Case W26 User manual
W26
Loader
Service Manual
9-78236
IReprinted I
TABLE
OF
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications,
Serial
Number,
RH
and
LH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Combined
Converter
-
Equipment
Hydraulic
Stall
Test
• • • • • . . • . • • • • • • . • . . . 4
Converter Stall
Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Equipment
Hydraulics
Stall
Test
. . . . • . • • . . . . . • • . • • • . • . • • . • . • . . • • • • . 5
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTING
IDLE
SPEEDS
AND
THROTTLE
CONTROLS • • • . • . • • . • • • • • • • • . • . • 7
2
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INTRODUCTION
NOTE:
This
manual
does
not
cover
the
Detroit
Diesel
engine,
excepting
routine
main-
tenance
items,
removal
and
installation,
and
adjustmentofthe
throttle
linkage
and
idle
speeds.
Service
problems
relating
to
the
engine
should
be
referred
to
a
Detroit
Diesel
service
center.
Specifications
Make
and
model
. • . . . . • . • . • • . • • • • • . • • • • • • . • . • . • . • • . • •
Detroit
Diesel
6V53
Recommended
fuel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel
No. 2
Type
. . • . . . . • . . . . . . . • . • . . . • . . • . . • • • . 6
cylinder,
2
stroke
cycle,
valve-in-head
Piston
displacement
. . . . . . . . • . . . . . • . • . • . . . . . . . • . • • • . . . • . •
318.6
cu.
inches
Air
cleaner
..................••...............•.
Dry
type,
oil
bath
optional
Idle
speeds
No
load
governed
speed
(high idle) . • . • . . • . . . . . . . . . . . . . . . . . . 2660 + 25
RPM
Low
idle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 + 25 RPM
Governor
. . . . . . . . . . . . . . . . . • . . . • • . . • . . • • . . • . .
Variable
speed,
mechanical
Engine
lubrication
Filter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Full
flow type
Oil
pressure
..•.•.••..•.•.....•••••.•.•..•.•.•••
40-50
PSI
at
high
idle
Cooling
system
Pressurized
to
.............................................
7 PSI
Thermostat
(2
used)
...•...•.•••.•••.•.
Starts
to
open
at
175°, fully
open
at
190°
Fluid
capacities
..........•.•••••.•.•.•••••......
Refer
to
Section
IX,
Page
5.
Serial
Number
The
serial
number
plate
is
located
on
the
right
hand
side
at
the
front
of
the
engine.
See
Figure
1,
Section
IX.
3
Righi
Hand
and
Left
Hand
The
terms
"right
hand"
(RH)
and
"left
hand"
(LH),
used
throughout
this
manual,
are
determ_ined
by
standing
at
the
rear
of
the
unit
and
facing
the
direction
of
forward
travel.
This
places
the
engine
at
the
REAR
of
the
unit.
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ST~LL
CHECKS
TO
TEST
CONDITION
OF
ENGINE,
TORQUE
CONVERTER
AND
EQUIPMENT
HYDRAULIC
SYSTEMS
During
these
tests,
engine
speed
will
be
recorded
at
full
throttle
(2660 RPM) when
the
converter
and/or
equipment
hydraulic
sy-
stems
are
stalled.
The
results
of
these
tests
can
help
determine
whether
wear
or
other
faults
exist
in the
engine,
converter,
or
equip-
ment
hydraulic
system.
Test
1 -
Combined
Converter
-
Equipment
Hydraulic
Stall
Test
1.
Apply
parking
brake.
With engine
at
low
idle,
shift
into
forward.
2.
Increase
engine
speed
to
full
throttle.
Tilt
bucket
back
and hold
lever
back
to open
the
main
relief
valve.
Record
the
engine RPM.
Test
Summary
Engine
speed
shouldbe 1700 to 1800 RPM.
If
engine
speed
is
below 1700
RPM
or
if
the
engine
quits,
it
may
be
due to:
a.
Engine
worn
or
out
of
tune.
b.
Excessive
hydraulic
pressures
or
mechanical
faults
in the
converter
and/or
equipment
hydraulic
system.
If
engine
speed
is
above 1800
RPM,
it
indicates
inefficiency in
the
converter
and/or
equipment
hydraulic
system.
Possi-
ble
sources
of
the
trouble
are:
a.
Leakage.
b. Worn
charging
or
equipment
pump.
c.
Low
main
relief
valve
setting.
To
narrow
down
the
problem
area,
con-
duct
Tests
2 and
3.
If
one
system
tests
satis-
factory
and the
other
system
tests
unsatis-
factory,
it
shows
that
the
engine
is
O.K.
If
both
systems
test
unsatisfactory,
the
cause
of
the
trouble
is
very
likely
the
engine.
Stall
Speed
and
Engine
Performance
Stall
speed
will
decrease
as
engine
performance
falls
off
from
wear
or
need
of
a tune up.
Test
2 -
Converter
Stall
Test
1.
Apply
parking
brake.
With engine
at
low
idle,
shift
into
forward.
2.
Increase
engine
speed
to full
throttle.
Record
the engine RPM.
Test
Summary
Engine
speed
should be 2200 to 2400
RPM.
If
engine
speed
is
below 2200
RPM,
indications
are
that
either
the engine
is
worn
4
or
there
are
hydraulic
or
meohanical
trou-
bles
in
the
transmission.
Checkoutthetrans-
mission
as
instructed
on page 33 and 34 in
Section
III,
Transmission.
Make
repairs
or
adjustments
as
required.
Repeat
Test
2.
If
engine
speed
is
still
low,
the
engine
is
the
faulty
component.
If
engine
speed
is
above 2400
RPM,
the
converter
system
is
inefficient.
This
may
be
caused
by
leakage
of
oil,
wear
in
the
charging
pump
or
faulty
regulator
valve.
SeeSectionIII.
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Test
3 -
Equipment
Hydraulics
Stall
Test
1.
Place
bucket
on ground.
Operate
engine
at
2660
RPM
(full
throttle).
2.
Tilt
bucket
back
and hold
lever
in
power
position
to
open
the
main
relief
valve.
Record
the
engine RPM.
Test
Summary
Engine
speed
should
be
2500 to 2600
RPM.
If
engine
speed
is
below 2500 RPM,
it
indicates
engine
wear
or
excessive
pres-
5
sure
or
restriction
somewhere
is
the
system.
Check
main
relief
valve
pressure
setting.
If
faulty,
repair
or
adjust.
Repeat
Test
3.
If
engine
speed
is
still
low,
the
engine
is
likely
at
fault.
If
engine
speed
is
above 2600 RPM,
the
equipment
hydraulic
system
is
inefficient,
indicating
leakage,
pump
wear,
or
a low
main
relief
valve
setting.
Further
testing
of
the
equipment
pump
can
be
done
with
a
flowmeter
as
described
in
Section VI,
Hydraulic
System.
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REMOVING
THE
ENGINE
NOTE
1: Right
hand
(RH)
side
and
left
hand
(LH)
side
are
determined
by standing
at
the
rear
of
the
machine
and
facing
the
forward
direction
of
travel.
NOTE
2:
Repair
parts,
service,
and
informa-
tion
for
the
engine on
this
machine
are
avail-
able
at
an
authorized
Detroit
Diesel
service
center.
1.
Remove
sheet
metal
parts
to gain
access
to
the
engine and
radiator.
This
includes
the
grille,
hood, and engine
side
panels.
2.
Remove
the
air
cleaner
and
brackets,
mufflers,
and
exhaust
pipes.
Seal
the
openings
against
entry
of
dirt
with
clean
rags,
aluminum
foil,
etc.
3.
Drain
the
engine coolant.
4.
Drain
the
engine
oil.
A
drain
hose
runs
from
the
engine to the
RH
side
of
the
chassis
under
the hold down. Remove
the
plug
at
this
point and allow the
oil
to
drain.
After
draining,
disconnect
or
re-
move
this
hose.
Close
openingswith
clean
caplugs.
5.
Remove
the
radiator
and
shroud
(wrap
around):
a.
Disconnect
transmission
oil
cooler
hoses
on
RH
side
of
engine.
Dis-
connect
tubing
from
clamps
under
the
radiator.
Close openings with
clean
caplugs.
b.
Remove
the
twoupperradiatorhoses
and the
lower
hose.
c.
Attach
a
hoist
to the
radiator
and
shroud
assembly.
d.
Remove
all
the
bolts,
nuts
and
wash-
ers
attaching
the
shroud
to
the
chassis.
Remove the
radiator-to-
chassis
mounting
bolts.
e.
It
is
recommended
that
the
fan
be
re-
removed
to
prevent
possible
damage
when
the
radiator
and
shroud
assem-
bly
is
lifted
out.
f.
Carefully
lift
the
radiator
and
shroud
from
the
machine
as
an
assembly.
6
Use
care
not
to
damage
the
oil
cooler
tubes
during
removal
process.
6. Open the
drain
cock
on
the
bottom
of
the
main
air
reservoir
and
depressurize
the
air
system.
Then
remove
the
air
lines
from
the
governor
and
compressor
to
the
main
air
reservoir.
7.
Disconnect
the
engine
from
the
electrical
system:
a.
Tag
and/or
mark
wires
and
cables
and
their
terminals
which
will
have
to be
disconnected
for
correct
rein-
stallation.
b.
Disconnect
the
battery
cables.
Dis-
connect
the
ground
cable
first.
c.
Disconnect
wires
from
the
alterna-
tor,
regulator,
starter,
switches,
sending
units,
etc.
as
required
to
free
the
engine
from
the
electrical
system.
d. Remove
clamps
as
required.
8.
Disconnect
the
fuel
lines
from
the
RH
side
of
the
engine.
Close
openings
with
clean
caplugs.
9.
Disconnect
the engine fuel and
air
shut-
off
controls
from
the
top
of
the
engine.
10.
Remove
or
disconnect
the
driveshaft
to
the
transmission.
11.
Two
lift
lugs
are
provided
on
the
engine.
Attach
a
hoist
and
take
out
the
slack.
Hoist
capacity
should
be
at
least
oneton.
12.
Remove
the
front
mounting
bolt,
nut, and
lockwashers.
13.
Remove
two
bolts,
nuts,
andlockwashers
from
the
mounting
bracket
on
each
side
at
the
rear
of
the
engine.
14.
Thoroughly
inspect
the engine
to
see
that
wll
necessary
items
have
been
removed
or
disconnected.
When
all
is
clear,
carefully
lift
out
the
engine.
NOTE:
Engine
overhaul
and
repairs
other
than
routine
maintenance
(
oil
changes,
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filter
service,
etc.)
should
be
done
at
an
authorized
Detroit
Diesel
service
center.
INSTALLING
THE
ENGINE
1.
The
engine
should
be
installed
in
the
reverse
order
of
the
instructions
under
"Removing
the
Engine" above,
2, In
addition,
the
following
illustrations
will
be
helpful
during
the
installation:
Electrical
wiring
-
Figure
1, SectionII
Air
system
diagram
-
Figure
1,
Section
V
Transmission
cooler
hydraulics
-
Figure
2,
Section
III.
3,
Install
oil,
fuel,
and
engine
coolant
as
follows:
a.
Replace
engine
oil
filter.
Add 19
U.S.
quarts
of
SAE 30
(MIL-L-
2104B),
Series
1,
heavy
duty
lubri-
cating
oil.
NOTE:
The
above
oil
is
recommend-
ed
for
year
round
use
except
where
extreme
cold
prevents
starting.
b.
Fill
fuel
tank
with
No, 2
diesel
fuel.
Capacity
is
85 U.S.
gallons.
c.
Fill
thecoolingsystemwith33
quarts
of
coolant-1/2
water,
1/2
permanent
anti-freeze.
4,
Pressurize
the
air
system
as
described
under
"Pressurizing/Depressurizing
the
Air
System",
Section
V.
5,
Adjust
the
engine
idle
speeds
and
throttle
controls
as
described
in
this
section
starting
below.
ADJUSTING
IDLE
SPEEDS
AND
THROTTLE
CONTROLS
Specifications
Low
idle
speed
. . . • . . . . . 750 + 25
RPM
High
idle
speed
. ,
.•.••..
2660 + 25 RPM
Adiustment
Procedures
1.
Warm
engine
to
approximately
140°
F.
2.
Remove
throttle
and
fuel
shut
off
cables
from
speed
control
and
stop
lever,
Figure
1.
SPEED
CONTROL
LEVER
\
\
~
,/
~
BOOSTER
\ \"
SPRING \
RETAINING,
NUT
&
BOLT
Figure
1
OP
LEVER
------
~
UFFER
CREW
691597
7
High Idle
Speed
Adjustment
3.
Back
off
buffer
screw
four
(4)
turns,
Figure
1.
4.
Turn
on
the
engine
and
check
by
hand
the
maximum
no
load
speed.
It
should
be
2660 + 25
RPM.
Move
speed
control
lever
clockwise.
SPRING
HOUSIN
SHIMS
SPRING
RETAINER
SOLID
STOP
VARIABLE
SPEED
SPRING
Figure
2
O
691596
FER
SCREW
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5.
Adjust
as
follows:
a.
Disconnect
the
booster
spring.
b.
Remove
the
two
attaching
bolts and
remove
the
variable
speed
spring
housing
andthe
variable
speed
spring
retainer
located
inside
the housing,
Figure
2.
c.
If
required,
add
or
remove
shims
to
obtain
the
specified
speed
•.
010
11
in
shims
changes
the
speed
approxi-
mately
20
RPM.
NOTE:
Obtain
shims
at
an
authorized
Detroit
Diesel
service
center.
d.
Reassemble
the
spring
housing.
Re-
check
for
specified
speed.
If
requir-
ed,
repeat
steps
5b and 5c above.
Low
Idle
Speed
Adjustment
6. Check
for
low
idle
speed
of
750
±
25
RPM.
Adjust
as
follows:
a.
With
the
engine
operating,
loosen
the
lock
nut and
turn
the idle
speed
adjusting
screw,
Figure
3,
in
or
out
until
the
engine
idles
at
the
specified
speed.
b. Hold
the
idle
speed
adjusting
screw
and tighten the
lock
nut.
IDLE
SPEED
ADJUSTING
SCREW
Figure
3
8
Buffer
Screw
Adjustment
7. With
the
idle
speed
adjusted,
adjust
the
buffer
screw:
a. With
the
engine
running
at
low idle,
turn
the
buffer
screw
in
so
that
it
contacts
the
differential
lever,
Fig-
ure
2.
Raise
engine
idle
speed
not
more
than 15 RPM.
b. Hold
the
buffer
screw
and
tighten
the
locknut.
Booster
Spring
Adjustment
8. With the
idle
speed
adjusted,
adjust
the
booster
spring:
a.
Refer
to
Figure
1.
Loosen
the
booster
spring
retaining
nut
on
the
speed
control
lever.
Loosen
the
lock
nuts
on the
eye
bolt
at
the
other
end
of
the
spring.
b. Move
the
spring
retaining
bolt in
the
slot
of
the
speed
control
lever
until
the
center
of
the
bolt
is
on
an
im-
aginary
line
through
the
center
of
the
lever
shaft
and
eye
bolt. Hold the
bolt
and
tighten
the
locknut.
c.
Start
the
engine and
move
the
speed
control
lever
to
the
maximum
speed
position and
release
it.
The
speed
control
lever
should
return
to
idle
position.
If
it
does not,
reduce
the
tension
on
the
booster
spring.
If
it
does
return
to the
idle
position,
con-
tinue to
increase
the
spring
tension
until the
point
is
reached
that
it
will
not
return
to idle.
Then
reduce
the
tension
until
it
does
return
to
idle.
Speed
Control and
Stop
Lever
Controls
Check
9.
Push
or
pull
cable
ends
before
con-
necting
to
stop
lever
and
speed
control
lever.
Cables
should
slide
freely.
If
the
cables
bind,
check
Figure
4
for
proper
cable
installation
or
binding in
the
ac-
celerator
linkage.
CONTROL
CABLE
MOUNTING
BRACKET
FUEL
SHUTOFF
CABLE
ACCELERATOR
CABLE
"'
SPACER
AIR
SHUTOFF
(EMERGENCY
STOP)
CABLE
691579
Figure
4 -
Cables
Installation
NOTE:
Have
as
few
bends
in
the
accelerator
cable
as
possible.
10.
If
above
linkage
is
free,
connect
cables
to
speed
control
and
stop
lever.
11.
Repeat
step
8c
if
the
speed
control
does
not
return
to
idle.
When
idle
is
attained,
9
Figure
5 -
Accelerator
Adjustment
tighten
the
lock
nut
on
the
eye
bolt.
12.
Adjust
accelerator
pedal
as
shown
in
Figure
5.
13.
Recheck
high
and
low
idle
speeds.
SECTION
II
ELECTRICAL
SYSTEM
SECTION
II
ELECTRICAL
SYSTEM
Burl.
Form
9-7823&
KFCAO
Printed
in
u.s.A.
SPECIFICATIONS
WIRING DIAGRAM
TABLE
OF
CONTENTS
3
4
TROUBLE
SHOOTING CHART . . • • . • • • • • • • • . • • • • . • • . . • . . • . • • • • • . • • • . . 6
TROUBLE
SHOOTING
THE
STARTING
CIRCUIT . • . . . • • • . • • . • • • . • • • • • • . • . . • 8
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STARTER
18
STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SOLENOID SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
TROUBLE
SHOOTING
THE
CHARGING CIRCUIT . . . . . . • • • • . • • . . . • . • • . • • • • • 27
Testing
Battery
Circuit
. . . . . . . . . . . . . . . . . • . . • . . . . • . . • . . . • • • . • . . . 27
Testing
Alternator
Output
on
Engine
• . • • . . . . . • . • . . . . . . . . . • • . • • • . . • . . 28
Testing
Alternator
Field
Circuit
on
Engine
. • . . • . . . . • • • . • . • • . • • . . • • • . • 30
Testing
Field
Control
Circuit
. . . . • • . • • • • . . • • • • • • • . • • • • • . • • • • • . . . •
32
Testing
Regulator
Voltage
Setting
• • • . . • • . . • • • • • . . . • . . . • • • • • • • . • • . .
34
Adjusting
Regulator
Voltage
Setting
• • • . • . . • • • • . . • • • • • . • . • • • • • • . • • • •
35
Testing
Oil
Pressure
Switch
and
Circuit
Breaker
. . • • . . • • • . • • • • • . • • • • • . • 36
SERVICING AND
TESTING
THE
ALTERNATOR.
• • • . • . . . • • • • • • • • • • • • • • • • • • •
37
ALTERNATOR
BELT
ADJUSTMENT
. • • • • • • • • • • . • • • • • • • . . • • • • • . . • • • . • . • 42
INSTRUMENT
PANEL
RESISTOR CHECKS • . • . • . • . • . • • • • • • • . . . • . • • • . . . • • 43
CHECKING AIR
PRESSURE
WARNING SYSTEM • • • • • . • . • . . . • . • . . . . . • • • . • • • 43
NEUTRAL
START
SWITCH ADJUSTMENT . . • • • . . . • . • • . • . . • . . . . • . • • • • • . .
44
BUCKET
HEIGHT CONTROL
ELECTRICAL
CHECKOUT . • • • • . • . . . • .
See
Section
VIII
RETURN
TO DIG
ELECTRICAL
CHECKOUT
See
Section
VIII
2
SPECIFICATIONS
Type of
system
. • • . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . 24 volt,
negative
ground
Batteries
. . . . . . . . . . . . . . 2-12 volt, negative ground 155
ampere
hour
rating,
21
plates.
Alternator
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt, 45
amperes
Regulator
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable,
transistorized
24
volt
Starting
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
volts
with
solenoid
switch
Circuit
break.er,
starting
circuit
Part
no. L11343
.....................
60
amperes
Pressure
switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
PSI
closing
range
Starter
solenoid
switch
. . . . . . . . . . . . . . . . . . • . . . . . . . . . 24
volts,
.83-.89
amperes
Front
flood
lights
.............................
,
Sealed
unit,
24
volts,
60
watts
Rear
work
lights
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealed
unit,
24
volts,
60
watts
Combination
stop
and
taillights
.............•.........
Single
contact
24
volt
bulb
Dash
lights
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
volt
bulb
Circuit
break.er,
light
circuit,
Part
no. A22877 . . . . . . . . . . . . . . . . . . . . 40
amperes
NOTE:
This
section
contains
wiring
diagrams,
trouble
shooting
charts,
and
other
information
necessary
to
locate
and
repair
most
troubles
in
the
electrical
system.
Whenever
testing
or
adjusting
the
elec-
trical
system,
use
proper
test
equipment
known to be
accurate.
The
major
components-alternator,
re-
gulator,
starter-are
supplied
by
Delco-
Remy.
If
detailed
information
is
required
or
tests
must
be
performed
which
are
beyond
the
scope
of
this
manual,
consult
a United
Delco
service
center
or
the
Delco-Remy
service
bulletin
for
the
component
being
serviced.
A
WARNING
Safety
Tips
For
Working
Around
The
Electrical
System
1. Always unhook
the
ground
cable
first-and
hook up
last.
2.
Never
smoke
near
batteries
that
are
being
charged
or
have
been
charged
recently.
3.
Never
wear
rings
or
metal
watch
bands
as
you
may
ground a
live
circuit.
4.
Think
out
the
circuit
before
making
or
breaking
a connection.
A
wrong
connection
can
be painful and
expensive.
3
HEADLIGHT
17B
BUCKET
LEVEL
LIMIT
SWITCH
FLOOD
LIGHT
LIFT
LEVER
ACTUATOR SWITCH '
,.
3
~23B
STOP
LIGHT SWITCH
r
(CONNECTS
TO
UPPER
O
8D
/
30
HARNESS
~
LH
BRAKE
ACTUATOR)
11A
INTERMEDIATE
I
11B
' " ' · .i,r
i.,,.,.
c.c:::o
~~~Tiiii"-lDH-=
c~
HEADLIGHT
FLOOD
LIGHT
Figure
1 - Wiring Diagram
4
ALSO
SEE
FIGURE 5
SECTION
VIII
----------
LIFT TILT
DIODE.
-
DIODE
111T
.-U-22A
l
OH
1
,1_22C
23A
lOJ~
V4'/23C
--
·
--·
.
'1'01~'''
·
,-~
1
lOK
LIFT SPOOL
~
SOLENOID
~
BUCKET HEIGHT
LIMIT
SWITCH
..
FRONT OF
TRACTOR
10K
\
691572
CONV,
~ENDER
4
REAR
HARNESS
REF.
2
3
4
5
6
BA
BB
BC
BD
BE
BF
9
l0A
l0B
l0C
10D
lOE
l0F
l0G
l0H
TEMP
WIRING CODE
COLOR
FROM
Brown
Cold
Weather
Start.
Aid
Lt.
Green
?uel
Level
Sender
Gray
Conv.
Temp.
Sender
Pink-Black
Eng.
Temp.
Sender
White Aux.
Start
"SOL"
Orange
Circuit
Breaker
(Charging)
60 Amps
Orange
Circuit
Breaker
(Lights)
40 Amps
Orange
Stop
Light
Switch
Orange
Stop
Light
Switch
Orange
Circuit
Breaker
(Charging)
Orange
Circuit
Breaker
(Charging)
60
Amps
Dk.
Green
Eng.
Oil
Press.
Sender
Purple
Key
Switch "IGN"
Purple
Key
Switch "IGN"
Purple
Eng.
Oil
Press.
Gauge
Res.
Purple
Eng.
Oil
Press.
Gauge
Res.
Purple
Coolant
Temp.
Gauge
Res.
Purple
Key
Switch
11
IGN
11
Purple
Conv.
Temp.
Gauge
Res.
Purple
Key
Switch
"IGN"
FUEL
GAUGE
rr=======,GSENDING
UNIT
e
TO
Start
Aid
Switch
Fuel
Level
Gauge
Conv.
Temp.
Gauge
Eng.
Coolant
Temp.
Gauge
Neutral
Start
Switch N.O.
Key
Switch
"BAT"
Key
Switch
"BAT"
Key
Switch
"BAT"
Circuit
Breaker
(Charging)
60
Amps
Oil
Press.
Switch
(Field
Control)
Alternator
Output
"+"
Eng. Oil
Press.
Gauge
Hour
meter
Eng.
Oil
Press.
Gauge
Res.
Indicator
Lamp
"IGN"
Coolant
Temp.
Gauge
Res.
Fuel
Level
Gauge
Resistor
Conv.
Temp.
Gauge
Res.
Air
Press.
Warning
Switch
Lift
Arm
Diode
3------,
12
STARTING
AID
2==:::-0--,11,
ALTERNATOR
10A
HOURMETER~
12
VOLT
BATTERIES
(NEG,
GROUND)
60 AMP
O
a a
0
CIRCUIT
BREAKER
o
iJ
COOLANT
TEMP,
SENDER
ENG,
OIL.
PRESS,
SENDER
~'fss
CTE1
)tp9
SWITCHt[!aE
26
5
• FLOOD
11C
LIGHT
TAIL
LIGHT
FLOOD
LIGHT
691573
l0J
10K
l0L
lOM
llA
:).lB
UC
12A
12B
13
15
16A
16B
17A
17B
17C
lBA
lBB
lBC
22A
22B
22C
23A
23B
23C
24
25
26
30
31
32
33
34
35
36
37
3BA
3BB
39
39
Purple
Purple
Purple
Purple
Yellow
Yellow
Yellow
Blue
Blue
White
Red
&
Black
Black
Black
Pink
Pink
Pink
Dk.
Green
Black
Black
Black
White
White
White
Green
Black
Red
Black
White
Black
Black
Black
Black
Black
Orange
Red
Red
Black
BC
□
BA
□
9
□
10A
a
11A
a
12A
□
Lift
Arm
Diode
Lift
&
Tilt
Spool
Connector
Fuel
Level
Gauge
Res.
Voltmeter
11
IGN
11
Light
Switch
Resistor
Stop
Light
Switch
Left
Taillight
Light
Switch
"RL"
Left
Rear
Flood
Key
Switch
"SOL"
Light
Switch
11
BAT
11
Light
Switch
"INST"
Light
Switch
"INST"
Light
Switch
"HL"
RH &
LH
Connector
RH
&
LH
Connector
Light
Switch
"INST"
RH
&
LH
Flood
Lamp
Conn.
RH
&
LH
Flood
Lamp
Conn.
Lift
Lever
Actuator
Switch
11
COM
11
Lift
Lever
Actuator
Switch
"N.0."
Lift
Spool Solenoid
Tilt
Lever
Actuator
Switch
11
COM
11
Tilt
Lever
Actuator
Switch
"N.0."
Tilt
Spool
Solenoid
Regulator
Regulator
Regulator
Bucket
Level
Switch
11
COM
11
Buzzer
Buzzer
Inst.
Panel
Lights
Voltmeter
Ign.
Indicator
Lamp
Lift
Arm
Position
Cont.
Box
Term.
Aux. Solenoid
Starter
Solenoid
"B"
Starter
Solenoid
"B"
Aux. Solenoid
Bucket
Height Switch,
"COM"
INSTRUMENT
HARNESS
NEUTRAL
START
.
SWITCH
~:3~
Tilt
Arm
Diode
Tilt
Arm
Diode
Starting
Aid Switch
Eng.
Oil
Press.
Gauge
Res.
Stop
Light
Switch
Taillight
Right
Taillight
Left
Rear
Flood
Right
Rear
Flood
Neutral
Start
Switch
11
COM
11
Circuit
Breaker
(Lights)
Instr.
Panel
Lights,
L.H.
Instr.
Panel
Lights,
R.H.
RH
&
LH
Conn. (Head
Lamp)
RH
Head
Lamp
LH
Head
Lamp
RH
&
LH
Flood
Lamp
Conn.
RH
Flood
Lamp
LH
Flood
Lamp
Lift
Arm
Diode
Lift
Arm
Position
Control
Box
Lift
Arm
Diode
Tilt
Arm
Diode
Bucket
Level
Switch
"N.O."
Tilt
Arm
Diode
Alternator
F-1
Alternator
F-2
Oil
Press.
Switch
(Field
Control)
Ground
(Buzzer)
Air
Press.
Warning
Switch
Ground
Three
Way
Connector
Circuit
Breaker
(Lights)
Ground
Circuit
Breaker
(Lights)
Ground
Lift
Arm
Position
Cont.
Micro
Switch
"N.O."
Starter
Solenoid
11
SOL
11
Aux. Solenoid
60
Amp.
Circuit
Breaker
Ground
Ground
Figure
la
-
Instrument
Panel
Wiring
691574
WIRING
DIAGRAM
THIS
PAGE
FOLDS
OUT
PROBLEM
Starter
Not
Operating
Properly
Run
Do"rn
Batteries
TROUBLE
SHOOTING
CHART
POSSIBLE
CAUSE
1.
Discharged
batteries.
2.
Faulty
battery
ground
wire.
3.
Faulty
wiring
or
loose
con-
nections
from
starting
motor,
to
starter
solenoid,
to
key
switch.
4.
Faulty
key
switch.
5.
Engine
oil
too
heavy
for
out-
side
temperature.
6. High
resistance
in
starting
(insulated)
circuit.
7. High
resistance
in
ground
circuit.
8.
Worn
pinion
or
flywheel
ring
gear
teeth.
9.
Loose
starter
mounting.
10.
Faulty
or
improper
circuit
breaker.
11.
Defective
solenoid
(mag-
netic)
switch.
1.
Grounded
battery
cable.
2.
Loose
or
broken
battery
ground
cable.
3.
Key
switch
left
on
or
a
faulty
switch.
4.
Faulty
alternator
or
regulator
causing
insuf-
ficient
charging.
5.
Regulator
improperly
adjusted.
6. Grounded
wiring.
7.
Excessive
use
of
.
starting
motor
or
other
electrical
equipment.
8.
Faulty
starting
circuit.
6
REMEDY
1.
Test
batteries.
If
necessary,
place
on
slow
charger.
If
batteries
are
conti-
ually
discharged,
test
regulator
and
alternator.
2.
Check
for
looseness,
corrosion
or
breaks.
3.
Inspect
this
circuit
for
loose
con-
nections
at
terminals
or
connectors.
Also look
for
corrosion,
broken
or
shorted
wires.
4.
Replace
key
switch.
5.
Refer
to
Fuel
and
Lubricants
in
section
IX
Maintenance/Lubrication.
6.
Refer
to
Insulated
Circuit
Test,
page
8.
7.
Refer
to
Ground
Circuit
Test,
page
9.
8. Remove
starter
and
inspect
teeth.
9.
Inspect
and
tighten.
10. Connect
.jumper
to
circuit
breaker
terminals.
If
system
functions,
cir-
cuit
breaker
is
faulty
and
must
be
replaced.
Also
check
to
see
that
circuit
breaker
has
proper
capacity
(60
amperes).
11.
Replace
switch.
1.
Inspect
the
cable
from
the
battery
positive
post
to
the
starting
motor
and
tape
areas
of
worn
insulation
or
replace
cable.
2.
Inspect,
clean
and
tighten,
or
replace
if
necessary.
3. Check
key
switch.
Replace
if
faulty.
4. Any
of
reasons
under
Alternator
Fails
To
Charge
or
Low
or
Unsteady
Charging
Rate.
5.
Adjust
regulator
as
described
in
this
section.
6. Check
all
wiring
for
indication
of
a
ground
such
as
sparks,
heat,
smoke
or
discoloration.
7.
Recharge
batteries.
8.
Inspect
starting
circuit
wiring
for
ground.
Check
key
switch.
Check
solenoid
switch,
making
sure
switch
plunger
is
functioning.
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