Troubleshooting

Chapter 2 / Section 2: Troubleshooting

I. Diagnostic Center
The Diagnostic Center is located in the main electric box. The Diagnostic Center is easy to use
for troubleshooting electric and hydraulic problems. The Diagnostic Center can also be used for
adjustments — see chapter 2 procedure.
The Diagnostic Center has priority over loader controls (for example, switches and joysticks). If a
switch is used to control a function while the Diagnostic Center is in test mode, switch is dis-
abled temporarily while the Diagnostic Center is used.
Note: Loader must be in load mode (stabilizers down ↓ red load lamp lit), ignition switch
(starter) ON, and both emergency stop buttons pulled out to use Diagnostic Center.
WARNING: Make sure both decks are clear before pressing anything on the panel. Loader
functions can be test-run inadvertently and cargo can be transferred off the deck.
WARNING: Make sure all personnel are clear of loader before using the Diagnostic Center.
Loader functions can be test-run inadvertently and cause serious injury or death.

Diagnostic
Center

Figure 35: Main Electric Box

I.A. What the Diagnostic Center Can Do

Loader Operation:
• Auto-scan: When ignition switch (starter) is ON, the Diagnostic Center automatically
scans every loader circuit. Auto-scan is performed continuously when ignition switch is ON.
• Short and open wires: The Diagnostic Center identifies short and open wires during
auto-scan, even “remembering” an intermittent short or open wire. When a problem is
found, a red error light will stay lit as long as ignition switch stays ON.
Test Modes:
• Start-up Light Check: When ignition switch is turned ON, before auto-scan begins.
• Total System Self-test: The center checks for continuity of all electric circuits (inputs and
outputs) on the loader. A short or open wire is identified with a red error light.
Note: To perform a total system self-test, ignition switch must be ON.
• Individual Test-run: It is possible to operate any available loader function from the
Diagnostic Center, even if the corresponding control switch has failed.
Note: To use individual test-run, engine must be running.
Adjustments:
• Adjust cargo transfer speeds, elevator lift speeds, plus engine low and high demand
speeds from the Diagnostic Center — see chapter 2 procedure.

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 Troubleshooting
I.B. Two Separate Control Panels
The Diagnostic Center is divided into two panels which are independent:
• Cargo Control Panel: Use input selection and test modes from right side for diagnostics
of convey functions (for example, flat-top chains, side guides, cargo stops).
• Engine / Elevator Control Panel: Use input selection and test modes from left side for
diagnostics of lift and drive functions (for example, stabilizers, vehicle drive selection).
Note: In test mode, only one panel (one side) of the Diagnostic Center can be used at a time.
Note: During loader operation, both sides of Diagnostic Center function together, checking
continuity of all electrical circuits on the loader.
Engine / Elevator Cargo Control
Control Panel Panel

Figure 36: Two Separate Control Panels

I.C. Inputs and Outputs

The Diagnostic Center checks and displays inputs and outputs:
• Inputs are controls: For example, toggle switches, joysticks, proximity switches. An input is
an electric signal to start or stop action (loader function).
• Inputs are displayed as a letter: A through Z. There is one display on the cargo control
panel and a different display on the engine / elevator control panel.
Note: Do not confuse the two displays. An A on one display is a different input than an A on the
other display. See tables 1 and 2, chapter 2, for a list of input descriptions.
• Outputs are actions: For example, solenoid coil makes hydraulic valve open or close. An
output causes an action to function physically.
• Outputs are displayed as wire numbers: 1 yellow light = 1 output (showing corresponding
wire number). See table 5, chapter 2, for a list of wire numbers.

A Series of Inputs

Outputs =
Wire Numbers
Note: Engine / Elevator
Control Panel shown.

Figure 37: Inputs and Outputs

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Troubleshooting
I.C. Inputs and Outputs, continued
Display of inputs and outputs depends on operating mode of the Diagnostic Center:
• Auto-scan Mode: During loader operation, panel displays a letter only if input is activated.
If a switch is not in use, for example, corresponding letter will not display. Also, panel dis-
plays outputs (yellow lights with wire numbers) only if corresponding input is activated.
• Total System Self-test: Every available input on a loader displays in sequence. An option
must be installed on the loader to display. An input displays whether in use or not. As each
input displays, all corresponding outputs are displayed at the same time.
• Individual Test-run Mode: It is possible to operate only available loader functions. Some
functions (for example, a lock-out or a sensor/monitor) cannot be tested.
Note: See chapter 2 procedure for details on using different test modes.
I.C.1. Inputs
Sometimes, 1 switch > 1 input. For example, 1 joystick = 2 inputs, as shown below.
Note: the example below shows a 2-way joystick. Also, there are 4-way joysticks = 4 inputs.
Another example is a 3-way switch = 3 inputs.

NO INPUT
Cargo Transfer, Cargo Transfer,
Bridge, Reverse Bridge, Forward

Figure 38: Two Inputs from One Control

Note: Tables 1 and 2, chapter 2, show every possible input. Some inputs may not be available
on a loader. If a loader is not equipped with an option, input will be skipped.

Available Inputs for

Standard Bridge, 828

Cargo Transfer, Cargo Transfer,

Bridge, Reverse Bridge, Forward

Available Inputs for

Side Shift Option, 828
Standard Bridge, 929

Cargo Transfer, Cargo Transfer, Cargo Transfer, Cargo Transfer,

Bridge, Reverse Bridge, Left Bridge, Forward Bridge, Right

Note: Right side of loader = drive console side

(NOT to operator’s right, standing at load panel.

Figure 39: Example of “Available” Inputs

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 Troubleshooting
I.C.1. Inputs, continued
When a loader function is available for individual test-run from the Diagnostic Center, this is a
function that can be activated in two ways:
• Control Switch: Using a toggle switch or joystick.
• Diagnostic Center: Bypassing the control switch.
The Diagnostic Center has priority over loader controls (for example, switches and joysticks). If a
switch is used to control a function while the Diagnostic Center is in test mode, switch is dis-
abled temporarily while the Diagnostic Center is used.

Press Menu to
Make Selection

Control Switch Is
Temporarily Disabled Press Test to
While Diagnostic Center Test-run Function
Is Used to Test-run

Figure 40: Two Ways to Activate a Function

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Troubleshooting
I.C.2. Outputs
Many times, 1 input > 1 output. Auto-scan (during loader operation) displays each input being
used at the time, in sequence. As each input letter is displayed, one or more yellow lights will be
lit to show which wire numbers (outputs) correspond to that input.
Note: In example below, input A = wire 667, main deck bridge lift (828 UNI / 828 SUP / 929 / 929S)
only. Input B is available for side shift option, 828 / standard bridge, 929 only.
Note: In example below, wire 677 (high demand) is energized as needed for loader functions.
Wires 677 and 675 (low demand) are energized together when high demand is needed.
Note: Tables 3 and 4, chapter 2, show which outputs correspond to inputs.
Note: Table 5, chapter 2, shows wire numbers and associated solenoid valves.

Cargo Transfer, Cargo Transfer,

Bridge, Reverse Bridge, Left

Wire 65 SV-2 Flat-top Chains Wire 64 SV-3 Bridge MDW’s

Wire 667 SV-14 Front Cargo Stop Wire 673 SV-13 Flat-top Chains Down
Wire 675 Engine Low Demand Wire 675 Engine Low Demand
Wire 677 Engine High Demand Wire 677 Engine High Demand

Figure 41: Outputs and Corresponding Wire Numbers

The Diagnostic Center identifies short and open wires in two modes:
• Test Mode: Short and open wires must be in error condition while test is run. This does
not identify intermittent problems if they are OK when the test is run.
• Loader Operation: Auto-scan is performed continuously when the ignition switch is ON. If
an intermittent problem is identified during loader operation, a red error light is displayed as
long as the ignition switch stays ON — even if the error condition becomes OK again.
Note: If loader has intermittent problem, do NOT turn ignition switch off. Put loader in load mode
(stabilizers down ↓ red load lamp lit) and check Diagnostic Center to identify faulty wire number.
Note: See chapter 2 procedure for details on using different test modes.

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 Troubleshooting
I.D. Quick Reference Guide
Note: This figure provides quick information for the experienced user. For those not familiar
with the Diagnostic Center, read chapter 2, section 2, completely before using.

System Test Results System Test Results

System Test Results (Press Test to Start): (Press Test to Start):
(Press Test to Start): FAIL/OPEN light (red) + SHORT light (red) +
OKAY = No problems. Wire number light (yellow). Wire number light (yellow)
must be in same row.

Input Display
(Engine/Elevator Only):
Auto-scan loader functions
available and in use OR
Displays Input selected by
pressing Menu button.

Individual Test-run
(Engine/Elevator Only):
Press Menu to select input,
within 3 sec. press Test to
test-run specific function.
(Engine must be running).

Total System Self-test

(Engine/Elevator Only):
Press Test once, release
(ignition switch must be ON).

Tachometer: Displays
engine speed in RPM’s.

Feedback Transducers:
Failure light (red) signals
(1) check connections OR
(2) Replace transducer.
See chapter 2 procedure
to replace transducer.

Speed Adjustments: Engine Speed:

Press Menu to select input, Press Test and turn dial
within 3 seconds press Test while (CCW = slower ↓ ) — also
turning dial (CCW = slower ↓ ). check Engine RPM display.

Figure 42: Engine / Elevator Control Panel

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Troubleshooting
I.D. Quick Reference Guide, continued
Note: This figure provides quick information for the experienced user. For those not familiar
with the Diagnostic Center, read chapter 2, section 2, completely before using.

System Test Results System Test Results

System Test Results (Press Test to Start): (Press Test to Start):
(Press Test to Start): FAIL/OPEN light (red) + SHORT light (red) +
OKAY = No problems. Wire number light (yellow). Wire number light (yellow)
must be in same row.

Input Display
(Cargo Control Only):
Auto-scan loader functions
available and in use OR
Displays Input selected by
pressing Menu button.

Individual Test-run
(Cargo Control Only):
Press Menu to select input,
within 3 sec. press Test to
test-run specific function.
(Engine must be running).

Total System Self-test

(Cargo Control Only):
Press Test once, release
(ignition switch must be ON).

Speed Adjustments:
Press Menu to select input,
within 3 seconds press Test while
turning dial (CCW = slower ↓ ).

Figure 43: Cargo Control Panel

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 Troubleshooting
I.E. Tables: Inputs, Wire Numbers, Solenoids
These tables provide reference information for troubleshooting. For those not familiar with the
Diagnostic Center, read chapter 2, section 2, completely before attempting to locate problem.
TABLE 1: Inputs, Cargo Control Panel
Input Description Comments
A Joystick: Cargo Transfer, Bridge, Reverse
B Joystick: Cargo Transfer, Side Shift Bridge, Left • Side Shift Option for 828 / Standard for 929
C Joystick: Cargo Transfer, Bridge, Forward
D Joystick: Cargo Transfer, Side Shift Bridge, Right • Side Shift Option for 828 / Standard for 929
E Joystick: Cargo Transfer, Elevator, Reverse
F Joystick: Cargo Transfer, Elevator, Left • Front Side Load Option for 828 / Standard for 929
G Joystick: Cargo Transfer, Elevator, Forward
H Joystick: Cargo Transfer, Elevator, Right • Front Side Load Option for 828 / Standard for 929
I Elevator Rotate, Front, Counterclockwise • Triple Rotate Option for 828 / 929
J Elevator Rotate, Front, Clockwise • Triple Rotate Option for 828 / 929
K Joystick: Cargo Transfer, Elevator, Reverse
L Joystick: Cargo Transfer, Elevator, Left • Rear Side Load for 828 / 929
M Joystick: Cargo Transfer, Elevator, Forward
N Joystick: Cargo Transfer, Elevator, Right • Rear Side Load for 828 / 929
O Elevator Rotate, Rear, Counterclockwise • Rear Container Rotate for 828 / 929
P Elevator Rotate, Rear, Clockwise • Rear Container Rotate for 828 / 929
Q Arctic Kit Switch: Hydraulic Recirculation • Arctic Kit Option for 828 / 929
R Switch: Elevator Rear Cargo Stop Down
S Proximity: Elevator Near Frame • Option for 828 / 929
T High Deck Switch: Bridge Front Cargo Stop • 828 UNI and 828 SUP / Not on 929
U Proximity: Elevator Near Bridge
V Lock-out: Elevator Rear Cargo Stop • Option for 828 / 929
W Switch: Elevator Side Guide, Right, Down
X Switch: Elevator Side Guide, Left, Down
Y Spare
Z Spare

Note: On dual-rotate (option for 828 / standard for 929) OR on triple-rotate (option for 828 and
929), there is pallet rotate at center of elevator. This combination of 2 inputs is not on input list.

Rear, Left Rear, Right

Front, Right Front, Left

Figure 44: Pallet Rotate, Center Elevator

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Troubleshooting
I.E. Tables: Inputs, Wire Numbers, Solenoids, continued
These tables provide reference information for troubleshooting. For those not familiar with the
Diagnostic Center, read chapter 2, section 2, completely before attempting to locate problem.
TABLE 2: Inputs, Engine / Elevator Control Panel
Input Description Comments
A Accelerator Pedal Activated
B Accelerator Pedal Not Activated
C Drive Selector Switch – Forward
D Drive Selector Switch – Reverse
E Proximity: Elevator Up Slow • Option for 828 / 929
F Proximity: Elevator Up
G Proximity: Elevator Down Slow • Option for 828 / 929
H Proximity: Elevator Down
I Vehicle Drive Switch – Fast Mode • Standard for 828 Only / Not on 929
J Elevator Level With Bridge • Option for 828 / 929
K Lock-out: Elevator & Vehicle Drive • Option for 828 / 929
L Load Mode – Stabilizers Down
M Drive Mode – Stabilizers Up
N Proximity: Elevator Near Frame
O Proximity: Elevator Fully Down
P Monitor: Engine Lugging • Option for 828 / 929
Q Engine High Demand
R Engine Low Demand
S Monitor: Engine > 625 RPM
T Monitor: No Drive Pressure
U Spare
V Spare
W Spare
X Spare
Y Spare
Z Control Module Fan Check

Chapter 2 Operation / Maintenance

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 Troubleshooting
I.E. Tables: Inputs, Wire Numbers, Solenoids, continued
Each input corresponds to specific outputs. When an input letter is displayed, corresponding
outputs (yellow lights/wire numbers) are displayed. The following table shows corresponding
outputs — energized (and in some cases, inhibited) when given input is activated.
TABLE 3: Corresponding Outputs, Cargo Control Panel
Input Description Wire # Corresponding Outputs

Cargo Transfer, Bridge, Reverse 65 SV-2 Bridge Cargo Transfer – Reverse

Note: For 828 UNI / 828 SUP only, wire 667 / SV-14 667 SV-14 Bridge Front Stop (828 UNI / 828 SUP only)
A
is always on with SV-2 (low deck setting) OR on with 62 EP-1 Bridge Cargo Transfer Speed Control
SV-2 only when platforms NOT interfaced (high deck). 675 Low Demand [ + 677 High Demand, if needed ]
64 SV-3 Bridge MDW (828 Side Shift / 929) – Left
673 SV-13 Bridge Flat-top Chain – Down
B Cargo Transfer, Side Shift Bridge, Left
62 EP-1 Bridge Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]

Cargo Transfer, Bridge, Forward 66 SV-1 Bridge Cargo Transfer – Forward

Note: For 828 UNI / 828 SUP only, wire 667 / SV-14 667 SV-14 Bridge Front Stop (828 UNI / 828 SUP only)
C
is always on with SV-1 (low deck setting) OR on with 62 EP-1 Bridge Cargo Transfer Speed Control
SV-1 only when platforms NOT interfaced (high deck). 675 Low Demand [ + 677 High Demand, if needed ]
63 SV-4 Bridge MDW (828 Side Shift / 929) – Left
673 SV-13 Bridge Flat-top Chain – Down
D Cargo Transfer, Side Shift Bridge, Right
62 EP-1 Bridge Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
664 SV-32 Elevator Front Cargo Transfer – Reverse
E Cargo Transfer, Elevator, Reverse 648 EP-31 Elevator Front Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
663 SV-34 Elevator Front MDW (Side Load) – Left
671 SV-51 Elevator Front Flat-top Chain – Down
F Cargo Transfer, Elevator, Left 648 EP-31 Elevator Front Cargo Transfer Speed Control
652 SV-37 Elevator Side Rollers – Left
675 Low Demand [ + 677 High Demand, if needed ]
665 SV-31 Elevator Front Cargo Transfer – Forward
G Cargo Transfer, Elevator, Forward 648 EP-31 Elevator Front Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
662 SV-35 Elevator Front MDW (Side Load) – Right
671 SV-51 Elevator Front Flat-top Chain – Down
H Cargo Transfer, Elevator, Right 648 EP-31 Elevator Front Cargo Transfer Speed Control
651 SV-38 Elevator Side Rollers – Right
675 Low Demand [ + 677 High Demand, if needed ]
663 SV-34 Elevator Front MDW (Side Load) – Left
659 SV-33 Elevator Front Pivot (Container Rotate) – Up
661 SV-36 Elevator Front Rotate
I Elevator Rotate, Front, Counterclockwise
671 SV-51 Elevator Front Flat-top Chain – Down
648 EP-31 Elevator Front Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
662 SV-35 Elevator Front MDW (Side Load) – Right
659 SV-33 Elevator Front Pivot (Container Rotate) – Up
661 SV-36 Elevator Front Rotate
J Elevator Rotate, Front, Clockwise
671 SV-51 Elevator Front Flat-top Chain – Down
648 EP-31 Elevator Front Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]

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Troubleshooting
Input Description Wire # Corresponding Outputs
657 SV-41 Elevator Rear Cargo Transfer – Reverse
K Cargo Transfer, Elevator, Reverse 646 EP-32 Elevator Rear Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
656 SV-43 Elevator Rear MDW (Side Load) – Left
666 SV-50 Elevator Rear Flat-top Chain – Down
L Cargo Transfer, Elevator, Left 646 EP-32 Elevator Rear Cargo Transfer Speed Control
652 SV-37 Elevator Side Rollers – Left
675 Low Demand [ + 677 High Demand, if needed ]
658 SV-40 Elevator Rear Cargo Transfer – Forward
M Cargo Transfer, Elevator, Forward 646 EP-32 Elevator Rear Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
655 SV-44 Elevator Rear MDW (Side Load) – Right
666 SV-50 Elevator Rear Flat-top Chain – Down
N Cargo Transfer, Elevator, Right 646 EP-32 Elevator Rear Cargo Transfer Speed Control
651 SV-38 Elevator Side Rollers – Right
675 Low Demand [ + 677 High Demand, if needed ]
656 SV-43 Elevator Rear MDW (Side Load) – Left
654 SV-42 Elevator Rear Pivot (Container Rotate) – Up
653 SV-45 Elevator Rear Rotate
O Elevator Rotate, Rear, Counterclockwise
666 SV-50 Elevator Rear Flat-top Chain – Down
646 EP-32 Elevator Rear Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
655 SV-44 Elevator Rear MDW (Side Load) – Right
654 SV-42 Elevator Rear Pivot (Container Rotate) – Up
653 SV-45 Elevator Rear Rotate
P Elevator Rotate, Rear, Clockwise
666 SV-50 Elevator Rear Flat-top Chain – Down
646 EP-32 Elevator Rear Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
65 SV-2 Bridge Cargo Transfer – Reverse
62 EP-1 Bridge Cargo Transfer Speed Control
665 SV-31 Elevator Front Cargo Transfer – Forward
Q Arctic Kit Switch: Hydraulic Recirculation 648 EP-31 Elevator Front Cargo Transfer Speed Control
658 SV-40 Elevator Rear Cargo Transfer – Forward
646 EP-32 Elevator Rear Cargo Transfer Speed Control
675 Low Demand [ + 677 High Demand, if needed ]
R Elevator Rear Cargo Stop Down 669 SV-48 Elevator Rear Cargo Stop – Down (* see note)
S Proximity: Elevator Near Frame —— Information N/A
T High Deck: Bridge Front Cargo Stop 667 Energize / Inhibit SV-14 Bridge Front Stop (828 Option)
667 Inhibit SV-14 Bridge Front Stop (828 UNI / 828 SUP only)
669 Inhibit SV-48 Elevator Rear Cargo Stop – Down
U Proximity: Elevator Near Bridge
674 Inhibit SV-46 Elevator Right Side Guide – Down
659 Inhibit SV-47 Elevator Left Side Guide – Down
667 Inhibit SV-14 Bridge Front Stop (828 UNI / 828 SUP only)
669 Inhibit SV-48 Elevator Rear Cargo Stop – Down
V Lock-out: Elevator Rear Cargo Stop
674 Inhibit SV-46 Elevator Right Side Guide – Down
659 Inhibit SV-47 Elevator Left Side Guide – Down
W Switch: Elevator Side Guide, Right, Down 674 SV-46 Elevator Right Side Guide – Down (* see note)
X Switch: Elevator Side Guide, Left, Down 659 SV-47 Elevator Left Side Guide – Down (* see note)

* Note: Controls for side guides / rear cargo stop may be “locked out” depending on position of elevator platform.
Chapter 2 Operation / Maintenance
Page 42 October 2002
 Troubleshooting
I.E. Tables: Inputs, Wire Numbers, Solenoids, continued
Each input corresponds to specific outputs. When an input letter is displayed, corresponding
outputs (yellow lights/wire numbers) are displayed. The following table shows corresponding
outputs — energized (and in some cases, inhibited) when given input is activated.
TABLE 4: Corresponding Outputs, Engine / Elevator Control Panel
Input Description Wire # Corresponding Outputs
531 SV-68 Drive Selector – Reverse
Accelerator Pedal Activated OR
529 SV-67 Drive Selector – Forward
Note: Wire 531 / SV-68 OR wire 529 / SV-67 may be
A 540 * SV-73 Main Pump Enable
activated, depending on drive setting, when loader is
in Drive Mode (stabilizers up) with elevator down. 532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)

Accelerator Pedal Not Activated 531 SV-68 Drive Selector – Reverse

OR
Note: Wire 539 (stop lights) automatically activated 529 SV-67 Drive Selector – Forward
B
when accelerator pedal released, with loader in 539 Stop Lights
Drive Mode (stabilizers up) with elevator down. 524 Inhibit EP-61 Elevator / Drive Control (Engine RPM)
529 SV-67 Drive Selector – Forward
Drive Selector Switch – Forward
Note: Wire 539 (stop lights) automatically activated 539 Stop Lights
OR
C when accelerator pedal released OR wire 532 (throttle) 532 Throttle
activated when accelerator pedal pressed. Loader 540 * SV-73 Main Pump Enable
must be in Drive Mode / elevator fully down.
524 Energize / Inhibit EP-61 Elevator / Drive Control
531 SV-68 Drive Selector – Reverse
Drive Selector Switch – Reverse
Note: Wire 539 (stop lights) automatically activated 539 Stop Lights
OR
D when accelerator pedal released OR wire 532 (throttle) 532 Throttle
activated when accelerator pedal pressed. Loader 540 * SV-73 Main Pump Enable
must be in Drive Mode / elevator fully down.
524 Energize / Inhibit EP-61 Elevator / Drive Control
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only
528 SV-66 Elevator Lift – Up
Option: Elevator Up Slow 525 Inhibit Elevator Up Stop
E
Note: This option not yet implemented. 540 * SV-73 Main Pump Enable
532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only

Elevator Up (Normal Speed) 528 SV-66 Elevator Lift – Up

Note: When cargo stops engage (platforms interfaced), 525 MUST BE OFF Elevator Up Stop
F
wire 525 is activated and wire 528 / SV-66 is inhibited. 540 * SV-73 Main Pump Enable
Loader must be in Load Mode (stabilizers down). 532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only
527 SV-65 Elevator Lift – Down
Option: Elevator Down Slow
G 540 * SV-73 Main Pump Enable
Note: This option not yet implemented.
532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only
Elevator Down (Normal Speed) 527 SV-65 Elevator Lift – Down
Note: When elevator is at frame (input O is on)
H 540 * SV-73 Main Pump Enable
wire 527 / SV-65 is inhibited. Loader must be in
Load Mode (stabilizers down). 532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)

* Note: Pump enable (SV-73) is energized whenever a function is activated requiring increased hydraulic pressure.
Pump enable is also energized at low ambient temperatures (-5˚C / +20˚F) to heat hydraulic fluid. When SV-73 is
enabled, the pump should deliver 207 bar / 3000 psi (for 828’s) or 245 bar / 3600 psi (for 929 vehicle drive and elevator
lift only). When SV-73 is not enabled, the pump idles at 20 to 40 bar / 300 to 600 psi.

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October 2002 Page 43
Troubleshooting
Input Description Wire # Corresponding Outputs
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only
527 SV-65 Elevator Lift – Down
Elevator Level With Bridge 52 Elevator Up Slow
J Note: Loader must be in Load Mode (stabilizers 525 Elevator Up Stop
down), input O (elevator at frame) must be off. 540 * SV-73 Main Pump Enable
532 Throttle
524 EP-61 Elevator / Drive Control (Engine RPM)
538 Inhibit EP-62 Elevator / Drive Control – 828 Turbo & 929
531 Inhibit SV-68 Drive Selector – Reverse
Lock-out: Hydraulic Fluid Low 529 Inhibit SV-67 Drive Selector – Forward
Note: Vehicle drive functions and elevator lift
K 528 Inhibit SV-66 Elevator Lift – Up
functions automatically “locked out” when
hydraulic fluid is low. 540 * Inhibit SV-73 Main Pump Enable
532 Inhibit Throttle
524 Inhibit EP-61 Elevator / Drive Control (Engine RPM)
538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only
531 Inhibit SV-68 Drive Selector – Reverse
529 Inhibit SV-67 Drive Selector – Forward
Load Mode – Stabilizers Down
528 SV-66 Elevator Lift – Up
L Note: Vehicle drive functions “locked out” when
527 SV-65 Elevator Lift – Down
loader is in Load Mode (stabilizers down).
540 * Energize / Inhibit SV-73 Main Pump Enable
532 Energize / Inhibit Throttle
524 Energize / Inhibit EP-61 Elevator / Drive Control
538 Inhibit EP-62 Elevator / Drive Control – 828 Turbo & 929
531 SV-68 Drive Selector – Reverse
529 SV-67 Drive Selector – Forward
Drive Mode – Stabilizers Up 528 Inhibit SV-66 Elevator Lift – Up
M Note: Elevator & cargo transfer functions “locked out” 527 Inhibit SV-65 Elevator Lift – Down
when loader is in Drive Mode (stabilizers up). 539 Stop Lights
540 * Energize / Inhibit SV-73 Main Pump Enable
532 Energize / Inhibit Throttle
524 Energize / Inhibit EP-61 Elevator / Drive Control
538 Inhibit EP-62 Elevator / Drive Control – 828 Turbo & 929
Proximity: Elevator At Frame 527 Inhibit SV-65 Elevator Lift – Down
O Note: Elevator “locked out” when loader is in 540 * Inhibit SV-73 Main Pump Enable
Drive Mode (stabilizers up). 532 Inhibit Throttle
524 Inhibit EP-61 Elevator / Drive Control
Q Engine High Demand 524 EP-61 Elevator / Drive Control (Engine RPM)
R Engine Low Demand 524 EP-61 Elevator / Drive Control (Engine RPM)
526 Engine Running
S Monitor: Engine > 625 RPM
540 * SV-73 Main Pump Enable
531 SV-68 Drive Selector – Reverse
T Monitor: No Drive Pressure 529 SV-67 Drive Selector – Forward
524 EP-61 Elevator / Drive Control (Engine RPM)

* Note: Pump enable (SV-73) is energized whenever a function is activated requiring increased hydraulic pressure.
Pump enable is also energized at low ambient temperatures (-5˚C / +20˚F) to heat hydraulic fluid. When SV-73 is
enabled, the pump should deliver 207 bar / 3000 psi (for 828’s) or 245 bar / 3600 psi (for 929 vehicle drive and elevator
lift only). When SV-73 is not enabled, the pump idles at 20 to 40 bar / 300 to 600 psi.

Chapter 2 Operation / Maintenance

Page 44 October 2002
 Troubleshooting
TABLE 5: Wire Numbers and Coil Resistances (ohms Ω)
Manifold Wire # Solenoid Function / Description Check Ω Valve P/N Coil P/N Voltage
66 SV-1 Bridge Cargo Transfer – Forward
Bridge 19.2 Ω 032316 032254 24V DC
65 SV-2 Bridge Cargo Transfer – Reverse
64 SV-3 Bridge MDW (Side Shift) – Left
Bridge 19.2 Ω 032316 032254 24V DC
63 SV-4 Bridge MDW (Side Shift) – Right
911 SV-7 Bridge Side Guides – Left
Bridge 19.2 Ω 032611 032155 24V DC
912 SV-8 Bridge Side Guides – Right
913 SV-9 Bridge Tilt (left side) – Up
Bridge 19.2 Ω 032611 032155 24V DC
914 SV-10 Bridge Tilt (left side) – Down
73 SV-11 Bridge Tray (249 cm/98”) – Up
Bridge 19.2 Ω 032611 032155 24V DC
74 SV-12 Bridge Tray (249 cm/98”) – Down
Bridge 673 SV-13 Bridge Flat-top Chain – Down 28.8Ω 032610 032155 24V DC
Bridge 667 SV-14 Bridge Front Stop (828 Main Deck Only) 19.2 Ω 032611 032155 24V DC
701 SV-15 Bridge Outer Trays (325 cm/128”) – Up
Bridge 19.2 Ω 032611 032155 24V DC
702 SV-16 Bridge Outer Trays (325 cm/128”) – Down
665 SV-31 Elevator Front Cargo Transfer – Forward
Front Elev 19.2 Ω 032316 032254 24V DC
664 SV-32 Elevator Front Cargo Transfer – Reverse
Front Elev 659 SV-33 Elevator Front Pivot (Container Rotate) – Up 28.8Ω 032610 032155 24V DC
663 SV-34 Elevator Front MDW (Side Load) – Left
Front Elev 19.2 Ω 032316 032254 24V DC
662 SV-35 Elevator Front MDW (Side Load) – Right
Front Elev 661 SV-36 Elevator Front Rotate 28.8Ω 032610 032155 24V DC
652 SV-37 Elevator Side Rollers – Left
Front Elev 19.2 Ω 032316 032254 24V DC
651 SV-38 Elevator Side Rollers – Right
658 SV-40 Elevator Rear Cargo Transfer – Forward
Rear Elev 19.2 Ω 032316 032254 24V DC
657 SV-41 Elevator Rear Cargo Transfer – Reverse
Rear Elev 654 SV-42 Elevator Rear Pivot (Container Rotate) – Up 28.8Ω 032610 032155 24V DC
656 SV-43 Elevator Rear MDW (Side Load) – Left
Rear Elev 19.2 Ω 032316 032254 24V DC
655 SV-44 Elevator Rear MDW (Side Load) – Right
Rear Elev 653 SV-45 Elevator Rear Rotate 28.8Ω 032610 032155 24V DC
Rear Elev 674 SV-46 Elevator Right Side Guide – Down 28.8Ω 032610 032155 24V DC
Rear Elev 659 SV-47 Elevator Left Side Guide – Down 28.8Ω 032610 032155 24V DC
Rear Elev 669 SV-48 Elevator Rear Cargo Stop – Down 28.8Ω 032610 032155 24V DC
Rear Elev 668 SV-50 Elevator Rear Flat-top Chain – Down 28.8Ω 032610 032155 24V DC
Front Elev 671 SV-51 Elevator Front Flat-top Chain – Down 28.8Ω 032610 032155 24V DC
Front Elev 672 SV-52 Elevator Center Pivot (Pallet Rotate) – Up 28.8Ω 032610 032155 24V DC
85 SV-61 Stabilizers Down (Load Mode)
Chassis 19.2 Ω 032611 032155 24V DC
83 SV-62 Stabilizers Up (Drive Mode)
94 SV-63 Bridge Lift – Down
Chassis 19.2 Ω 032611 032155 24V DC
91 SV-64 Bridge Lift – Up
527 SV-65 Elevator Lift – Down
Drive 19.2 Ω 030084 032392 24V DC
528 SV-66 Elevator Lift – Up
529 SV-67 Drive Selector – Forward
Drive 19.2 Ω 030084 032392 24V DC
531 SV-68 Drive Selector – Reverse
67 SV-69 Rear Adjust – Up
Chassis 19.2 Ω 032611 032155 24V DC
68 SV-70 Rear Adjust – Down
Chassis 94 SV-71 Bridge Lift – Down Fast 19.2 Ω 033547 032155 24V DC
Drive 537 SV-72 Drive Speed – Fast Mode (828 Only) 30.8 Ω 032535 033601 24V DC
Pump 540 SV-73 Main Pump Enable 19.2 Ω 033547 032155 24V DC
Chassis 92 SV-75 Bridge Lift – Up Fast 19.2 Ω 032316 032254 24V DC
Bridge 62 EP-1 Bridge Cargo Transfer Speed Control 4.7 Ω 030515 032156 12V DC
Front Elev 648 EP-31 Elevator Front Cargo Transfer Speed Control 4.7 Ω 030515 032156 12V DC
Rear Elev 646 EP-32 Elevator Rear Cargo Transfer Speed Control 4.7 Ω 030515 032156 12V DC
Drive 524 EP-61 Elevator / Drive Control (Engine RPM) 8.6 Ω 030080 032202 12V DC
Drive 538 EP-62 Elevator / Drive Control – 828 Turbo & 929 Only 8.6 Ω 030080 032202 12V DC

Operation / Maintenance Chapter 2

October 2002 Page 45
Troubleshooting
I.F. Locations of Manifolds/Solenoid Valves & Coils
The figure below shows the location of hydraulic manifolds. See TABLE 5 on the preceding
page to match wire numbers and solenoids to manifolds.
Pump
Manifold
Front Elevator Bridge
Manifold Manifold
Rear Elevator
Manifold

Pre-Big-Block
Loaders
828’s with S/N 9019
and below
929’s with S/N 903
and below

Axle Chassis
Drive Manifold Manifold
Accessory
Manifold
Manifold

These 3 Manifolds = Pre-Big-Block Loaders ONLY

(Replaced by the BIG BLOCK MANIFOLD)

Figure 45: Location of Solenoid Valve / Manifolds

Note: Components may vary according to loader configuration and options (inputs, outputs,
wire numbers, solenoid valves, manifolds). See electric / hydraulic schematics provided in the
manual for each loader — OR check each valve / manifold to identify actual wire numbers.
Note: The bridge, front elevator, rear elevator manifolds are the same for all loaders. Actual
solenoids installed in each manifold vary according to configuration.
Note: Above, drive and axle manifolds (also accessory on 828 turbo and 929’s) for pre-big-
block loaders. Below, these have been replaced by the Big Block manifold for Big Block loaders.
Big Block (Drive)
Manifold

828’s Only: Chassis

SV-72 Fast-speed Manifold Big Block
Loaders
828’s with S/N 9020
and above
929’s with S/N 904
and above

Pump
Manifold

Note: Bridge and Elevator Manifolds are The Same As Shown Above.

Chapter 2 Operation / Maintenance

Page 46 October 2002
 Troubleshooting
II. Test Modes
Note: Loader must be in load mode (stabilizers down ↓ red load lamp lit), ignition switch
(starter) ON, and both emergency stop buttons pulled out to use Diagnostic Center.
The Diagnostic Center performs the following tests:
• Start-up Light Check: When ignition switch is turned ON, before auto-scan begins, all
panel lights are tested. This test is fully automated and cannot be run manually.
• Total System Self-test: The center checks for continuity of all electrical circuits (inputs
and outputs) on the loader. A short or open wire is identified with a red error light. This test
is fully automated and must be started manually by pushing test once.
Note: To perform a total system self-test, ignition switch must be ON.
• Individual Test-run Mode: It is possible to operate any available loader function from the
Diagnostic Center, even if the corresponding control switch has failed. This test is not fully
automated and must be run manually. Press menu to select desired input and then push
test within 3 seconds to test-run an individual loader function.
Note: To use individual test-run, engine must be running.

Engine / Elevator:
Push Menu to Select
Input, then Push Test to
Test-Run a Function

Engine / Elevator:
Push Test to Run
Fully Automated
System Self-test

Cargo Control: Cargo Control:

Push Test to Run Push Menu to Select
Fully Automated Input, then Push Test to
System Self-test Test-Run a Function

Figure 46: Test Modes

II.A. Total System Self-test

Start troubleshooting by running a total system self-test. Run this test before trying to locate a
problem by individual test-runs (see next article). The results of this test will identify short or
open wire(s), if there are any, throughout the entire electrical system. An error light indicates a
problem with output(s). Check solenoid valve associated with wire number on.
Note: Before running a system self-test, have pen or pencil and paper handy to write down
wire numbers, in case short or open wire(s) are identified.
Note: For details on how to read error lights, see chapter 2, Short and Open Wires.
Note: For wire numbers and associated solenoids, see table 5, chapter 2.
Note: For details on checking solenoids, see chapter 2, Solenoid Valves and Coils.
Run the Test: Press test on cargo control panel (right side). Write down information because
results display for only a few seconds. Press test on the engine / elevator control panel. Again,
write down results before Diagnostic Center returns to the auto-scan mode.
The system self-test lasts a few seconds. Results are displayed immediately after. If all electrical
circuits are continuous, test results are indicated with a green OK light.

Operation / Maintenance Chapter 2

October 2002 Page 47
Troubleshooting
II.B. Individual Test-run
When running a total system self-test (see previous article), perhaps no errors are identified.
The next thing to try, if a loader function fails to operate, is to test-run that individual function to
determine whether the malfunction is an input (switch or joystick) problem.
WARNING: Make sure both decks are clear before pressing anything on the panel. Loader
functions can be test-run inadvertently and cargo can be transferred off the deck.
WARNING: Make sure all personnel are clear of loader before using the Diagnostic Center.
Loader functions can be test-run inadvertently and cause serious injury or death.
Note: To use individual test-run, engine must be running.
Note: For details on input problems, see chapter 2, Switches and Controls.
Run the Test: Determine whether desired loader function is on the engine / elevator control
panel or the cargo control panel. Press menu on desired control panel until input is displayed.
Press test within 3 seconds to test-run individual loader function. Hold test during test-run.
III. Troubleshooting Strategy
Troubleshooting is simple using the Diagnostic Center. Start by checking outputs:
• Run a total system self-test. If red error lights indicate short or open wire(s), check solenoid
associated with wire number.
• If solenoid resistance does not check out, determine whether the valve cartridge is bad or
the coil is bad. Replace component as needed.
• If solenoid resistance is OK, check mechanism. Check moving parts to determine if there is
interference or if a part is broken or jammed.
• If solenoid is OK and moving parts are OK, check to determine if problem is hydraulic (for
example, motor, relief valve, cylinder, counterbalance valve).

OKAY:
Green Light

Figure 47: Test Results OK

The system self-test lasts a few seconds. Results are displayed immediately after. If all electrical
circuits are continuous, test results are indicated with a green OK light. If the total system self
test does not identify a problem with the outputs:
• Test-run the individual function which has failed to operate. If the system operates from the
Diagnostic Center, there is a problem with the input.
• If there is a problem with the input, check the electrical connections to the associated
switch, joystick, or proximity switch.
• If all connections are secure, but loader function still fails to operate when the control is
engaged, replace switch, joystick, or proximity switch as needed.

Chapter 2 Operation / Maintenance

Page 48 October 2002
 Troubleshooting
III.A. Short and Open Wires
If all circuits are NOT continuous, an error will be indicated with a flashing yellow light for the wire
number and a red error light to indicate a short or open wire. If the problem is a short to ground,
the red short light will be lit on the same row as the flashing yellow output light. If the problem is
an open circuit, the red fail light will be lit, along with the flashing yellow output light.
Open: Short:
Red Error Light Red Error Light on
Along With Flashing Same Row as Flashing
Yellow Output Light Yellow Output Light

Figure 48: Error Indicators

Auto-scan is performed continuously when the ignition switch is ON. If an intermittent problem is
identified during loader operation, a red error light is displayed as long as the ignition switch
stays ON—even if the error condition becomes OK again during operation. That is to say, the
Diagnostic Center “remembers” intermittent short and open wires.
Note: If loader has intermittent problem, do NOT turn ignition switch off. Put loader in load mode
(stabilizers down ↓ red load lamp lit) and check Diagnostic Center to identify wire number.
III.B. Electrical Switches and Controls (Inputs)
If the total system self-test shows no errors, all outputs are usually OK. To check input, test-run
the individual function which has failed to operate. If the system operates from the Diagnostic
Center, there is a problem with the input.
If there is a problem with the input, check the electrical connections to the associated switch,
joystick, or proximity switch. If all connections are secure, but loader function still fails to operate
when the control is engaged, replace switch, joystick, or proximity switch as needed.
Individual Function Fails to Individual Function Operates
Operate Using Control from Diagnostic Center

Press Menu to
Make Selection

Press Test to
Test-run Function

Figure 49: Input Problem

Operation / Maintenance Chapter 2

October 2002 Page 49
Troubleshooting
III.C. Solenoid Valves and Coils (Outputs)
If total system self-test indicates short or open wire(s), check solenoid valve. When a solenoid
fails, it shows up as a short. If the error indicates an open wire, check connections.
Note: See table 5, chapter 2, to identify solenoid valve by wire number and to identify in which
manifold to find each valve.
Note: See figure 45 to locate each manifold on the loader.
• If the Diagnostic Center indicates a short, disconnect wire from solenoid and run system
self-test again. If the same wire number now shows up as open, wire is good and not
shorted to ground.
• If wire is good, check resistance of solenoid for value recommended in table 5, chapter 2.
Use a digital multimeter to get a reliable reading on solenoids with very small resistances.
• If solenoid has failed, remove cartridge and check for debris or jammed parts. If it is not
possible to unclog or free the cartridge, replace as needed.
• If cartridge is OK, check coil. Replace as needed.
III.D. Feedback Transducers
Check indicators for feedback transducers in main electric box. When red error light is lit on the
Diagnostic Center:
• Check for a secure connection to transducer.
• Turn off loader to reset error.
• Turn on loader and check again for red error light.
• Replace feedback transducer as needed, if light stays lit.

RFT-1 Bridge Stop, Right

RFT-2 Bridge Stop, Left
RFT-3 Accelerator Pedal
LFT-4 Throttle Actuator
LFT-5 Spare, Not Used

Figure 50: Feedback Transducer Error Lights

Chapter 2 Operation / Maintenance

Page 50 October 2002
 Troubleshooting
III.D.1. Accelerator Pedal
If red light stays lit for RFT-3, accelerator pedal:
• Order TLD part number 032908 to replace transducer.
• No adjustment is needed because this transducer is pre-calibrated.
• Follow instructions in package for installation.

Transducer on
Accelerator Pedal

Figure 51: Accelerator Pedal

III.D.2. Engine Throttle Actuator

IMPORTANT: Correct adjustment of throttle actuator includes calibration of transducer AND
making sure linkage is adjusted correctly. Linkage adjustment follows calibration procedure.
If red light stays lit for LFT-4, throttle actuator:
• Order TLD part number 029698 to replace transducer.
• Locate throttle actuator on the engine.
Note: Location of transducer varies according to engine installed in the loader.

Transducer

Transducer

Front of
Rear of Perkins Engine
Deutz Engine

Figure 52: Throttle Actuator (Engine)

• Push emergency stop button for safety.

• Remove and discard existing feedback transducer.
• Install replacement transducer.
• Fasten, but do NOT tighten hardware.
• Secure electrical connector to transducer.
• Pull out emergency stop button.
• Turn ON ignition (starter) switch. Do NOT start engine.

Operation / Maintenance Chapter 2

October 2002 Page 51
Troubleshooting
III.D.2. Engine Throttle Actuator, continued
• Open main electric box.
• Locate transducer test points as shown below.

Main
Electric
Box
Transducer
Test Points

Figure 53: Transducer Test Points

• For digital voltmeter being used, switch to DC (if applicable).

• Connect ground (common) probe to TP-6 (black).
• Connect positive probe to TP-5 (white).

Test Points
for Feedback
Transducers

V( ↓)

TP-6 (Black): TP-5 (White):

Ground / Common Throttle Actuator
V( ↑)

Figure 54: Test Points for Throttle Calibration

• Rotate transducer on throttle actuator. At the same time, check voltmeter for a reading of
1.60V (range: 1.58V to 1.62V). Turn transducer clockwise to reduce ( ↓ ) voltage reading.
• When transducer is in position for desired voltage reading, fasten securely in this position.
CAUTION: Do NOT tighten one fastener completely before tightening the other. This will alter
voltage reading and impair correct functioning.
• Tighten each fastener a little at a time. Go back and forth—from one fastener to the other.
Bring transducer down into a secure position EVENLY. Be careful not to nudge it while
tightening fasteners.
• After transducer is tightened down in position, check voltage again.
Note: Feedback transducer for engine actuator should be checked regularly (every 300 hours
of operation or every six months).
• Proceed to next page to perform adjustment of actuator linkage, as required.

Chapter 2 Operation / Maintenance

Page 52 October 2002
 Troubleshooting
III.D.3.a. Engine Throttle Actuator Linkage Adjustment
PERKINS ENGINES
Note: Engine throttle actuator kit (TLD part number 030332) supplies several different lengths
of threaded rods for the common engines. On the current Perkins 1004-42, use the 25,41 cm
(10”) long threaded rod (same for earlier Perkins 1004-4 engine). For the very early Perkins
4.236 engine (G1 828’s) use 5,1 cm (2”) long threaded rod).
• For Perkins 1004-42 engine, start with 7th slot (A) on the lever, counting out from center
(1st slot) of the actuator, to locate the rod eye on the actuator lever.
• Start with center mounting hole (B) on the lever to locate the other end of the threaded rod
on the fuel distributor (using threaded rod with approximate length of 29, 22 cm / 11.50”
rod eye to rod eye distance).
• Make adjustments, as needed, to get 15-degree motion in either direction, from center of
actuator stroke.
• Adjust engine idle to 950 rpm. Turn rod eye clockwise to increase idle speed (shorter
threaded rod = more rpm) or counterclockwise (longer threaded rod = less rpm).
• Tighten all locknuts to secure. Make sure actuator mounting is secure on engine, not loose.
For loaders with earlier Perkins 1004-4 engine, start with 6th slot (A) . . . and use eye-to-eye dis-
tance of 30,19 cm (11.88”). For very early Perkins 4.236 engine, start with 7th slot (A) . . . and use
eye-to-eye distance of 8,74 cm (3.44”).

Perkins Deutz

B B

A A

DEUTZ AND CUMMINS ENGINES

Note: Engine throttle actuator kit (TLD part number 030332) supplies several different lengths of
threaded rods for the common engines. On Deutz BF4M and BF6M engines, use the 21,6 cm
(8.50”) long threaded rod. On the Cummins 6BT, use the 36,84 cm (14.50”) long.
• For Deutz engines, start with 3th slot (A) on the lever, counting out from center (1st slot) of
the actuator, to locate the rod eye on the actuator lever.
• Start with center mounting hole (B) on the lever to locate the other end of the threaded rod
on the fuel distributor (using threaded rod with approximate length of 24, 14cm / 9.50” rod
eye to rod eye distance).
• Make adjustments, as needed, to get 15-degree motion in either direction, from center of
actuator stroke.
• Adjust engine idle to 1100 rpm (for Deutz BF4M) or 900 rmp (for Deutz BF6M). Turn rod eye
clockwise to increase idle speed (shorter threaded rod = more rpm) or counterclockwise
(longer threaded rod = less rpm).
• Tighten all locknuts to secure. Make sure actuator mounting is secure on engine, not loose.
For loaders with Cummins 6BT engines, start with 3rd slot (A) . . . and use eye-to-eye distance
of 40,66 cm (16.00”) with idle speed of 1000 rpm).
IMPORTANT: In all cases, make sure grease fittings are located AWAY from engine block.
With linkage adjusted and engine idle rpm’s at recommended target, use Diagnostic Center to
dial in engine rpm for low demand (1600 for Deutz/Perkins or 1300 for Cummins) and high
demand (2450 for all engines).

Operation / Maintenance Chapter 2

October 2002 Page 53
Troubleshooting
III.D.3. Bridge Rear Cargo Stops
If red light stays lit for RFT-1 and / or RFT-2, bridge cargo stop transducer(s):
• Order TLD part number 029698 to replace transducer.
• Locate transducer on right side (operator’s console side) if RFT-1 stays lit.
• Locate transducer on left side if RFT-2 stays lit.
• Pull out both emergency stop buttons. Start loader.
• Raise elevator ( ↑ ) until flush with bridge. Elevator must be fully interfaced with bridge for
correct adjustment of replacement transducer. Install elevator safety supports.

Elevator MUST Be
Flush With Bridge
Adjustment Will
For CORRECT
Be WRONG
Adjustment
With Cargo Stops
In This Position

Figure 55: Cargo Stop Position to Calibrate

• Stop loader. Push emergency stop button for safety.

• Remove and discard existing feedback transducer.
• Put replacement transducer on shaft — at first, in approximate position shown below.
Looking Toward Rear of Loader

Approximate Position Approximate Position

for Installing Right Side for Installing Left Side

Figure 56: Transducer Position to Install

• Rotate transducer counterclockwise to the approximate position shown below before

starting adjustment procedure.
Looking Toward Rear of Loader

Approximate Position Approximate Position

for Adjusting Right Side for Adjusting Left Side

Figure 57: Transducer Position to Calibrate

• Fasten, but do NOT tighten hardware with transducer in position shown above.
• Secure electrical connector to transducer.
• Pull out emergency stop button. Turn ON ignition (starter) switch. Do not start engine.

Chapter 2 Operation / Maintenance

Page 54 October 2002
 Troubleshooting
III.D.3. Bridge Rear Cargo Stops, continued
• Open main electric box. Locate transducer test points as shown below.
• For digital voltmeter being used, switch to DC (if applicable).
• Connect ground (common) probe to TP-6 (black).
• Connect positive probe to TP-2 (green) for cargo stop on right side.
• OR connect positive probe to TP-3 (yellow) for cargo stop on left side.

TP-2 (Green): TP-3 (Yellow):

Right Side Left Side

Test Points
for Feedback
Transducers

V(↓)

TP-6 (Black):
Ground / Common
V( ↑)

Figure 58: Test Points for Cargo Stop Calibration

• Rotate transducer on shaft. At the same time, check digital voltmeter for a until a reading of
1.74V (range 1.71V to 1.77V) is obtained. Turn transducer clockwise to reduce ( ↓ ) voltage
reading.
• When transducer is in position for desired voltage reading, fasten securely in this position.
CAUTION: Do NOT tighten one fastener completely before tightening the other. This will alter
voltage reading and impair correct functioning.
• Tighten each fastener a little at a time. Go back and forth—from one fastener to the other.
Bring transducer down into a secure position EVENLY. Be careful not to nudge it while
tightening fasteners.
• After transducer is tightened down in position, check voltage again.
• Pull out emergency stop, start loader, lower elevator ( ↓ ). Stop loader.
• Rotate cargo stop manually to check for full range of motion.
• With elevator down ( ↓ ), check test points for a reading of 4.35V (range: 4.30V to 4.40V).
Note: Feedback transducers for bridge rear cargo stops should be checked regularly (every
300 hours of operation or every six months).

Operation / Maintenance Chapter 2

October 2002 Page 55
 Troubleshooting
Localización y corrección de averias
IV. Troubleshooting Flowcharts
Description (Descripción) Page (Página)

FIGURE 61: Cargo System: Flat-top chains or MDW’s won’t operate in one direction 57
(GRÁFICO 61: Las bandas transportadoras planas o los rodillos MDW no funcionan en una dirección)

FIGURE 62: Cargo System: Flat-top chains or MDW’s won’t operate in both directions 58
(GRÁFICO 62: Las bandas transportadoras planas o los rodillos MDW no funcionan en ninguna de las dos direcciónes)

FIGURE 63: Cargo System: Flat-top chains or MDW’s slow drastically with a load 59
(GRÁFICO 63: La velocidad en las bandas transportadoras planas o en los rodillos MDW disminuye drasticamente con la carga)

FIGURE 64: Main Hydraulic System: Pump does not generate 3000 psi (828) / 3600 to 3700 psi (929) 60
(GRÁFICO 64: La bomba hidraulico no genera 3000 psi – por modelo 828 / 3600 a 3700 psi – por 929)

FIGURE 65: Main Hydraulic System: Excessive heat in hydraulic oil (in excess of 180˚F / 80˚C) 61
(GRÁFICO 65: El flúido hidraulico se sobrecalienta – por encima de los 180˚F / 80˚C)

FIGURE 66: Vehicle Drive: No movement in forward or reverse 62

(GRÁFICO 66: El mecanismo de conducción – para desplazamiento horizontal – no funciona: ni en avance, ni en reversa)

FIGURE 67: Vehicle Drive: Movement in one direction, but not the other 63
(GRÁFICO 67: El mecanismo de conducción – para desplazamiento horizontal – funciona en una sola dirección)

FIGURE 68: Platform Lift: Elevator will not go up or down 64

(GRÁFICO 68: El elevador no sube ni baja)

FIGURE 69: Platform Lift: Elevator will go down, but it will not go up 65
(GRÁFICO 69: El elevador desciende pero no asciende)

FIGURE 70: Platform Lift: Transducer error – for elevator at bridge 66

(GRÁFICO 70: Esta un error en el transductor – por el elevador al puente)

FIGURE 71: Platform Lift: Elevator will go up, but it will not go down 67
(GRÁFICO 71: El elevador asciende pero no desciende)

FIGURE 72: Platform Lift (828 Turbo & 929 Only): Elevator lift operates slowly 68
(GRÁFICO 72: El ascenso y el descenso del elevador son muy lentos – modelos 828 turbo y 929 únicamente)

FIGURE 73: Platform Lift / Vehicle Drive: Replace proportional valve? 69

(GRÁFICO 73: La sistema del elevador / conducción – ¿Cambie la valvula de proporción?)

FIGURE 74: Platform Lift: Elevator rear cargo stop or side guide (s) will not lower 70
(GRÁFICO 74: La barra contenedora de carga o las guias laterales en el elevador no descienden

FIGURE 75: Stabilizers: Will not go down – load mode 71

(GRÁFICO 75: Los estabilizadores no se despliegan)

FIGURE 76: Stabilizers: Will not go up – drive mode 72

(GRÁFICO 76: Los estabilizadores no se repliegan)

FIGURE 77: Vehicle Drive: No movement in fast speed and movement in slow speed (828 only) 73
(GRÁFICO 77: El mecanismo de conducción – para desplazamiento horizontal – no funciona en moda rapido – 828 únicamente)

Operation / Maintenance Chapter 2

October 2002 Page 56
 Troubleshooting
Localización y corrección de averias

Cargo System
(El Sistema de Carga) Run Self-test for Cargo Haga una autoverificación
Control System using por el sistema de carga,
Diagnostic Center in en el Tablero del Centro OPEN DETECTED.
Problem: main electric box. de Auto-diagnóstico. (DETECTA LA ABERTURA).
Flat-top chains
or MDW’s won’t ELECTRIC SYSTEM SHORT DETECTED.
TESTS “OK”. (DETECTA UN
operate in one CORTO CIRCUITO).
(“OK” – NO HAY
direction. PROBLEMAS EN EL
SISTEMA ELECTRICO). Check resistance Check continuity
of solenoid coil. of solenoid coil.
Problema:
Las bandas transportadoras Verifique la resistencia Verifique la continuidad
planas o los rodillos MDW de la bobina solenoide. de la bobina solenoide.

no funcionan en una RESISTANCE OK. CONTINUITY OK.

dirección. (LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA).

Inspect cable from Revise el cable que va

main electric box de la caja electrica
to solenoid valve. principal a la valvula.

RESISTANCE IS LOW. NO CONTINUITY.

(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).

Cambie la bobina.

Test Individual Pruebe el función

Function using individual desde el
Diagnostic Center, Tablero del Centro
main electric box. de Auto-diagnóstico.

FUNCTION OPERATES. FUNCTION DOES NOT OPERATE.

(SÍ FUNCIONA). (NO FUNCIONA).

Check joystick(s) Verifique la palanca Remove and Quite y revise la

at load panel and de control y las inspect directional valvula direcciónal
check joystick conexiónes de la (SV) valve. Replace, (SV). Cambiela
connections. palanca de control. if needed. cuando se requiera.
JOYSTICK IS BAD. JOYSTICK AND CONNECTIONS
(LA PALANCA DE CONTROL ARE GOOD.
ESTÁ DEFECTUOSO). (LA PALANCA DE CONTROL
Y LAS CONEXIÓNES ESTÁN
EN BUENAS CONDICIÓNES).

Replace joystick. Inspect cable Revise el cable que va

from main de la caja electrica
Cambie la electric box to principal a el tablero de
palanca de control. operator’s console. control de operaciónes.

Figure 61: Cargo Transfer System

Operation / Maintenance Chapter 2

October 2002 Page 57
Troubleshooting
Localización y corrección de averias

Cargo System
(El Sistema de Carga) Run Self-test for Cargo Haga una autoverificación
Control System using por el sistema de carga,
Problem: Diagnostic Center in en el Tablero del Centro OPEN DETECTED.
main electric box. de Auto-diagnóstico. (DETECTA LA ABERTURA).
Flat-top chains
or MDW’s won’t
ELECTRIC SYSTEM SHORT DETECTED.
operate in both TESTS “OK”. (DETECTA UN
directions. (“OK” – NO HAY CORTO CIRCUITO).
PROBLEMAS EN EL
SISTEMA ELECTRICO).
Problema:
Check resistance Check continuity
Las bandas transportadoras of solenoid coil. of solenoid coil.
planas o los rodillos MDW
Verifique la resistencia Verifique la continuidad
no funcionan en ninguna
de la bobina solenoide. de la bobina solenoide.
de las dos direcciónes.
RESISTANCE OK. CONTINUITY OK.
(LA RESISTENCIA (LA CONTINUIDAD
Test Individual Pruebe el función ES LA CORRECTA). ES LA CORRECTA).
Function using individual desde el
Diagnostic Center, Tablero del Centro Inspect cable from Revise el cable que va
main electric box. de Auto-diagnóstico. main electric box de la caja electrica
to solenoid valve. principal a la valvula.
FUNCTION OPERATES. FUNCTION DOES
(SÍ FUNCIONA). NOT OPERATE.
(NO FUNCIONA). RESISTANCE IS LOW. NO CONTINUITY.
(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
Check joystick(s)
at load panel and Cambie la bobina.
check joystick
connections.
Test MDW’s corresponding Pruebe rodillos MDW correspondiente
Verifique la palanca to flat-top chains with a las bandas transportadoras planas con
de control y las problem — or test flat-top problema — o pruebe las bandas
chains corresponding to transportadoras planas correspondiente
conexiónes de la
MDW’s with problem — at a la problema — desde el Tablero del
palanca de control.
the Diagnostic Center. Centro de Auto-diagnóstico.
JOYSTICK IS BAD. JOYSTICK AND
(LA PALANCA DE CONNECTIONS ARE GOOD.
CONTROL ESTÁ (LA PALANCA DE CONTROL
DEFECTUOSO). CORRESPONDING CARGO TRANSFER OPERATES.
Y LAS CONEXIÓNES ESTÁN
(EL SISTEMA DE TRANSFERENCIA CORRESPONDIENTE FUNCIONA).
EN BUENAS CONDICIÓNES).

Remove and Quite y revise la

Inspect cable inspect directional valvula direcciónal
from main (SV) valve. Replace, (SV). Cambiela
electric box to if needed. cuando se requiera.
operator’s console.
CORRESPONDING CARGO TRANSFER DOES NOT OPERATE.
Revise el cable que va (EL SISTEMA DE TRANSFERENCIA CORRESPONDIENTE NO FUNCIONA).
de la caja electrica
principal a el tablero de
Remove and Quite y revise la valvula
control de operaciónes.
inspect proportional de proporción (EP) y
valve (EP) and el regulador de presión.
pressure compensator. Cambielos cuando
Replace joystick. Replace if needed. se requiera.

Cambie la
palanca de control.
Figure 62: Cargo Transfer System

Chapter 2 Operation / Maintenance

Page 58 October 2002
 Troubleshooting
Localización y corrección de averias

Cargo System
(El Sistema de Carga)

Problem: Test MDW’s corresponding Pruebe rodillos MDW correspondiente

Flat-top chains to flat-top chains with a las bandas transportadoras planas con
or MDW’s slow problem — or test flat-top problema — o pruebe las bandas
chains corresponding to transportadoras planas correspondiente
drastically with MDW’s with problem — at a la problema — desde el Tablero del
a load. the Diagnostic Center. Centro de Auto-diagnóstico.

Problema:
La velocidad en las bandas CORRESPONDING CARGO TRANSFER CORRESPONDING CARGO TRANSFER
transportadoras planas o ALSO SLOWS DOWN WITH A LOAD. DOES NOT SLOW WITH A LOAD.
(LA VELOCIDAD EN EL SISTEMA DE (LA VELOCIDAD EN EL SISTEMA DE
en los rodillos MDW TRANSFERENCIA CORRESPONDIENTE TRANSFERENCIA CORRESPONDIENTE
disminuye drasticamente DISMINUYE CON LA CARGA, TAMBIEN). NO DISMINUYE CON LA CARGA).

con la carga.

Remove and inspect Rebuild or replace

pressure compensator worn or damaged
cartridge. Replace, hydraulic motor.
as needed.

Quite y revise el Reconstruya o

cartucho regulador de cambie el motor
presión. Cambielo si hidraulico se encuentra
se requiere. desgastado o dañado.

Figure 63: Cargo Transfer System

Operation / Maintenance Chapter 2

October 2002 Page 59
Troubleshooting
Localización y corrección de averias

Hydraulic Pump
(La Bomba Hidraulica)
Does engine bog ¿Se atora el motor Go to page 61.
down when at cuando funciona en
Problem: idle speed? marcha lenta? YES Va a página 61.
(SÍ)
Main hydraulic pump
NO
does not generate
3000 psi (828) or
3600 to 3700 psi (929). Run Self-test for Engine Haga una autoverificación
Elevator Control System por el sistema de dinamico,
Note: on Diagnostic Center in en el Tablero del Centro
If main electric box main electric box. de Auto-diagnóstico.
is above 80˚F / 25˚C
ELECTRIC SYSTEM SHORT DETECTED OPEN DETECTED
pump turns on only as TESTS “OK”. IN WIRE 540. IN WIRE 540.
needed for functions. (“OK” – NO HAY (DETECTA UN CORTO CIRCUITO (DETECTA LA ABERTURA EN
PROBLEMAS EN EL EN EL ALAMBRE NUMERO 540). EL ALAMBRE NUMERO 540).
SISTEMA ELECTRICO).
Problema: Check resistance of pump Check continuity of pump
La bomba hidraulica enable solenoid coil (SV-73). enable solenoid coil (SV-73).
no genera 3000 psi
Verifique la resistencia de la bobina Verifique la continuidad de la bobina
(por modelo 828) o
acciónadora de la bomba (SV-73). acciónadora de la bomba (SV-73).
3600 a 3700 psi (por 929).
RESISTANCE OK. CONTINUITY OK.
Nota: (LA RESISTENCIA (LA CONTINUIDAD
Si la caja electrica se ES LA CORRECTA). ES LA CORRECTA).

encuentra por encima

de los 80˚F / 25˚C, la Inspect cable from Revise el cable que va
bomba solo arranca main electric box de la caja electrica
cuando se pone en to solenoid valve. principal a la valvula.
operación alguna de
las funciónes. RESISTANCE IS LOW. NO CONTINUITY.
(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).

Turn pressure compensator Cambie la bobina.

on pump clockwise to increase
pressure (see page 24).
PRESSURE IS ADEQUATE.
(PRECIÓN ESTA ADEQUADO).
Job complete.
Gira el regulador de presión
a las manecillas del reloj a Termina la
PRESSURE IS NOT ADEQUATE.
aumentar presión (página 24). (PRECIÓN NO ESTA ADEQUADO). reparación.

Remove and inspect Quite y revise la

pump enable solenoid valvula acciónadora
VALVE IS OK. VALVE IS NOT OK.
(NO HAY PROBLEMAS valve (SV-73). de la bomba (SV-73). (HAY PROBLEMAS
CON LA VALVULA). CON LA VALVULA).

Rebuild or replace pump. Replace valve.

Reconstruya o cambie Cambie la valvula.

la bomba.

Figure 64: Hydraulic Pump

Chapter 2 Operation / Maintenance

Page 60 October 2002
 Troubleshooting
Localización y corrección de averias

Hydraulic System
(El Sistema de Hidraulica)
¿Es el derivación Close it.
Is towing
de remolque se
bypass closed? NO
Problem: encuentra cerrado? Lo cierre.
Excessive heat in
YES (SÍ)
hydraulic fluid Note: Towing bypass valve (to
(in excess of freewheel front drive wheels) is
180˚F / 80˚C) red knob located on left side of
Let loader idle for 10 minutes. Then Big Block manifold for 828’s with
Problema: trace heat back from return filter to S/N 9020 and above; 929’s with
locate which manifold is heat source. S/N 904 and above.
El flúido hidraulico
se sobrecalienta For pre-big-block loaders, towing
Opere la maquina en marcha lente durante
(por encima de 10 minutos. Localice el calor recorriendo bypass valve is located in front of
los 180˚F / 80˚C) hacia atras el trayecto desde el filtro de the right front wheel.
retorno hasta la entrada que genera el calor.

HEAT SOURCE: MANIFOLD HEAT SOURCE: MANIFOLD

FOR DRIVE/ELEVATOR OR FOR CHASSIS, FOR BRIDGE, OR
FOR FRONT AXLE. FOR ELEVATOR – FRONT OR REAR.
(QUE GENERA EL CALOR: LA ENTRADA (QUE GENERA EL CALOR: LA ENTRADA
CONDUCCIÓN / ELEVACIÓN O DEL CHASIS, DEL PUENTE, O DEL
DEL EJE EN FRENTE). ELEVADOR – AL FRENTE O FONDO).

Trace the heat from the manifold

Use drive circuit pressure to the component. Replace
setting procedure. component with internal leakage.

Utilice el procedimiento Localice el calor recorriendo el

de ajuste de preción del trayecto desde la entrada hasta la
circuito en el mecanismo pieza que genera el calor. Cambie
de conducción. la pieza que tiene la fuga interna.

HEAT SOURCE: MANIFOLD

FOR PUMP / ENGINE.

(QUE GENERA EL CALOR: LA ENTRADA

DE LA BOMBA / EL MOTOR).

Check pressure at pump manifold.

Verifique la presión hidraulica

a la entrada de la bomba.

≤ 3000 PSI (828). ≥ 3500 PSI (828).

≤ 3200 TO 3600 PSI (929). ≥ 3700 PSI (929).

System relief is too low. Pressure compensator on pump is set

Replace relief valve. too high. Reduce setting by turning
counterclockwise (see page 24).
La descompresión del
sistema es demasiado El regulador de presión en la bomba tiene
baja. Cambie la valvula una graduación demasiado alta. Reduzcalo
de descompresión. a girando contrario a las manecillas del
reloj (página 24).

Figure 65: Hydraulic System

Operation / Maintenance Chapter 2

October 2002 Page 61
Troubleshooting
Localización y corrección de averias

Vehicle Drive
Put elevator down
(Conducción) and stabilizers up.
Is a green light ¿Se enciende una luz
ON (drive panel) verde en el tablero de Ponga el elevador
Problem: NO
for drive mode? control de conducción? abajo y ponga los
Vehicle drive will estabilizadores arriba.
YES (SÍ)
not function, in
either forward
or reverse. Run Self-test for Engine Haga una autoverificación
Elevator Control System por el sistema de dinamico,
Problema: on Diagnostic Center in en el Tablero del Centro
El mecanismo de main electric box. de Auto-diagnóstico.
ELECTRIC SYSTEM
conducción (para TESTS “OK”.
desplazamiento (“OK” – NO HAY SHORT DETECTED OPEN DETECTED
PROBLEMAS EN EL IN WIRE 529 OR 531. IN WIRE 529 OR 531.
horizontal) no SISTEMA ELECTRICO). (DETECTA UN CORTO CIRCUITO EN (DETECTA LA ABERTURA EN EL
funciona en EL ALAMBRE NUMERO 529 O 531). ALAMBRE NUMERO 529 O 531).
ninguna de las
dos direcciónes: Check resistance of solenoid coil, SV-67 Check continuity of solenoid
ni en avance, (forward) or SV-68 (reverse) = 19.2 Ω? coils (SV-67 or SV-68).
ni en reversa.
Verifique la resistencia de la bobina del solenoide Verifique la continuidad de las bobinas
SV-67 (avance) o SV-68 (reversa) ¿ = 19.2 Ω? de los solenoides (SV-67 o SV-68).

RESISTANCE OK. CONTINUITY OK.

(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA).

Inspect cable from Revise el cable que va

Does elevator lift system main electric box de la caja electrica
operate correctly? to solenoid valve. principal a la valvula.

¿Funciona correctamente RESISTANCE IS LOW. NO CONTINUITY.

el sistema del elevador? (LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
NO YES (SÍ)
Cambie la bobina.

Go to page 67. Does the letter “T” show ¿Aparece una letra “T” como
as an “Input” on Engine “Input” on al lado por sistema
Va a página 67.
/ Elevator Control side de dinamico en el Tablero del
of Diagnostic Center? Centro de Auto-diagnóstico?

NO YES (SÍ)

Note: Pressure switches are

Inspect pressure switches Rebuild or replace forward
located on top of Big Block (normally closed) and (SV-67) or reverse (SV-68)
manifold for 828’s with S/N cables to switches. directional valve, as required.
9020 and above; 929’s with
S/N 904 and above. For
Revise los interruptores Reconstruya o cambie la
pre-big-block loaders, the de presión (cerrado normal) valvula direcciónal avance
pressure switches are located y los cables que van a los (SV-67) or reversa (SV-68).
above the front axle at the interruptores de presión.
front of the axle manifold.

Figure 66: Vehicle Drive

Chapter 2 Operation / Maintenance

Page 62 October 2002
 Troubleshooting
Localización y corrección de averias

Vehicle Drive
(Conducción)
Run Self-test for Engine Haga una autoverificación
Elevator Control System por el sistema de dinamico,
Problem: on Diagnostic Center in en el Tablero del Centro
Vehicle drive main electric box. de Auto-diagnóstico.
ELECTRIC SYSTEM
functions in one TESTS “OK”.
direction, but (“OK” – NO HAY SHORT DETECTED OPEN DETECTED
PROBLEMAS EN EL IN WIRE 529 OR 531. IN WIRE 529 OR 531.
not the other. SISTEMA ELECTRICO). (DETECTA UN CORTO CIRCUITO EN (DETECTA LA ABERTURA EN EL
EL ALAMBRE NUMERO 529 O 531). ALAMBRE NUMERO 529 O 531).
Problema:
El mecanismo de Check resistance of solenoid coil SV-67 Check continuity of solenoid
conducción (para (forward) or SV-68 (reverse) = 19.2 Ω? coils (SV-67 or SV-68).
desplazamiento
Verifique la resistencia de la bobina del solenoide Verifique la continuidad de las bobinas
horizontal) SV-67 (avance) o SV-68 (reversa) ¿ = 19.2 Ω? de los solenoides (SV-67 o SV-68).
funciona en una
sola dirección. RESISTANCE OK. CONTINUITY OK.
(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA).

Inspect cable from Revise el cable que va

main electric box de la caja electrica
to solenoid valve. principal a la valvula.

RESISTANCE IS LOW. NO CONTINUITY.

(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).

Cambie la bobina.

Do letters “C” and “D” (forward ¿Aparece las letras “C” y “D” (avance
and reverse) show as “Inputs” y reversa) como “Inputs” on al lado Rebuild or replace forward
on Engine / Elevator Control por sistema de dinamico en el Tablero YES (SÍ) (SV-67) or reverse (SV-68)
side of Diagnostic Center? del Centro de Auto-diagnóstico? directional valve, as required.

NO Reconstruya o cambie la
valvula direcciónal avance
(SV-67) or reversa (SV-68).
Inspect drive switch (forward SWITCH IS BAD. Replace switch.
(EL INTERRUPTOR
/reverse) on drive panel and ESTA DEFECTUOSO).
check switch connections. Cambie el
interruptor.
Revise el interruptor avance y
reversa al tablero de control
de conducción y verifique las Inspect cable Revise el cable que va
conexiónes del interruptor. SWITCH AND CONNECTIONS from main de la caja electrica principal
ARE GOOD. electric box to a el tablero de control
(EL INTERRUPTOR Y
LAS CONEXIÓNES ESTAN
drive panel. de conducción.
EN BUENAS CONDICIÓNES).

Figure 67: Vehicle Drive

Operation / Maintenance Chapter 2

October 2002 Page 63
Troubleshooting
Localización y corrección de averias

Elevator Lift Is a red light ¿Se enciende una luz Put stabilizers down.
(Sistema del Elevador) ON (drive panel) roja en el tablero de
NO Ponga los
for load mode? control de conducción?
estabilizadores abajo.
Problem:
Elevator will not YES (SÍ)

go up or down. Run Self-test for Engine Haga una autoverificación

Elevator Control System por el sistema de dinamico,
Problema: on Diagnostic Center in en el Tablero del Centro
El elevador no main electric box. de Auto-diagnóstico.
va arriba o abajo. ELECTRIC SYSTEM
TESTS “OK”.
(“OK” – NO HAY SHORT DETECTED OPEN DETECTED
PROBLEMAS EN EL IN WIRE 527 OR 528. IN WIRE 527 OR 528.
SISTEMA ELECTRICO). (DETECTA UN CORTO CIRCUITO EN (DETECTA LA ABERTURA EN EL
EL ALAMBRE NUMERO 527 O 528). ALAMBRE NUMERO 527 O 528).

Check resistance of solenoid coil SV-65 Check continuity of solenoid

(elevator down) or SV-66 (up) = 19.2 Ω? coils (SV-65 or SV-66).

Verifique la resistencia de la bobina del solenoide Verifique la continuidad de las bobinas

SV-65 (abajo) o SV-66 (arriba) ¿ = 19.2 Ω? de los solenoides (SV-65 o SV-66).

RESISTANCE OK. CONTINUITY OK.

(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA).
Select letter “F” (elevator up) and
then “G” (down) as “Inputs” on Inspect cable from Revise el cable que va
Engine / Elevator Control side of main electric box de la caja electrica
Diagnostic Center for individual test-run. to solenoid valve. principal a la valvula.

Escoje la letra “F” (elevador arriba) y RESISTANCE IS LOW. NO CONTINUITY.

“H” (abajo) como “Inputs” on al lado por (LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
sistema de dinamico en el Tablero del
Centro de Auto-diagnóstico a probar. Cambie la bobina.

ELEVATOR FUNCTIONS AT DIAGNOSTIC CENTER.

(EL ELEVADOR FUNCIONA DESDE EL CENTRO DE DIAGNÓSTICO).
ELEVATOR DOES NOT FUNCTION
AT DIAGNOSTIC CENTER.
Check joysticks Verifique la palanca (EL ELEVADOR NO FUNCIONA DESDE
at load panel and de control y las EL CENTRO DE DIAGNÓSTICO).
check joystick conexiónes de la
connections. palanca de control. Put stabilizers up
JOYSTICK IS BAD. JOYSTICK AND CONNECTIONS to drive the loader.
(LA PALANCA DE CONTROL ARE GOOD.
ESTÁ DEFECTUOSO).
LOADER DRIVES OK.
(LA PALANCA DE CONTROL Ponga los estabilizadores (EL MONTACARGAS FUNCIONA
Y LAS CONEXIÓNES ESTÁN arriba a conducirlo. AL SER CONDUCIDO).
EN BUENAS CONDICIÓNES).
Replace joystick.
DOES NOT DRIVE OK.
(EL MONTACARGAS
Cambie la Inspect cable NO FUNCIONA AL Rebuild or replace elevator
palanca de control. from main SER CONDUCIDO). down (SV-65) or up (SV-66)
electric box to directional valve, as required.
operator’s console.
Go to page 69. Reconstruya o cambie la
Revise el cable que va valvula direcciónal por abajo
de la caja electrica Va a página 69. (SV-65) or arriba (SV-66).
principal a el tablero de
control de operaciónes.

Figure 68: Elevator Lift

Chapter 2 Operation / Maintenance

Page 64 October 2002
 Troubleshooting
Localización y corrección de averias

Elevator Lift Is a red light ¿Se enciende una luz Put stabilizers down.
(Sistema del Elevador) ON (drive panel) roja en el tablero de
NO Ponga los
for load mode? control de conducción?
estabilizadores abajo.
Problem:
Elevator goes down, YES (SÍ)

but won’t go up. Run Self-test for Engine Haga una autoverificación TRANSDUCER
ERROR DETECTED.
Elevator Control System por el sistema de dinamico,
Problema: on Diagnostic Center in en el Tablero del Centro
(DETECTA UN ERROR
EN EL TRANSDUCTOR
El elevador va abajo, main electric box. de Auto-diagnóstico.
pero no va arriba. ELECTRIC SYSTEM
TESTS “OK”.
(“OK” – NO HAY SHORT DETECTED OPEN DETECTED
PROBLEMAS EN EL IN WIRE 528. IN WIRE 528.
SISTEMA ELECTRICO). (DETECTA UN CORTO CIRCUITO (DETECTA LA ABERTURA EN EL
EN EL ALAMBRE NUMERO 528). ALAMBRE NUMERO 528).

Check resistance of solenoid coil Check continuity of

SV-66 (elevator up) = 19.2 Ω? solenoid coil SV-66.
Is yellow light ON (wire 525)
for Elevator Control side of Verifique la resistencia de la bobina del Verifique la continuidad de
Diagnostic Center, when solenoide SV-66 (arriba) ¿ = 19.2 Ω? la bobina del solenoide SV-66).
elevator is at bridge?
RESISTANCE OK. CONTINUITY OK.
¿Se enciende una luz amarilla (por (LA RESISTENCIA (LA CONTINUIDAD
el alambre numero 525) por el ES LA CORRECTA). ES LA CORRECTA).

sistema de dinamico en el Tablero

del Centro de Auto-diagnóstico, Inspect cable from Revise el cable que va
cuando el elevador esta al puente? main electric box de la caja electrica
to solenoid valve. principal a la valvula.
NO YES (SÍ)

RESISTANCE IS LOW. NO CONTINUITY.

(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).

Select letter “F” (elevator up) Cambie la bobina.

as “Input” on Engine / Elevator
Control side of Diagnostic Go to page 66.
Center for individual test-run.
Va a página 66.
Escoje la letra “F” (elevador arriba)
como “Input” on al lado por sistema
de dinamico en el Tablero del Centro
de Auto-diagnóstico a probar función. Check joystick Verifique la palanca
ELEVATOR FUNCTIONS AT
DIAGNOSTIC CENTER. at load panel and de control y las
ELEVATOR DOES NOT FUNCTION
(EL ELEVADOR FUNCIONA check joystick conexiónes de la
AT DIAGNOSTIC CENTER.
DESDE EL CENTRO connections. palanca de control.
(EL ELEVADOR NO FUNCIONA DESDE
DE DIAGNÓSTICO).
EL CENTRO DE DIAGNÓSTICO).
JOYSTICK IS BAD. JOYSTICK AND CONNECTIONS
(LA PALANCA DE CONTROL ARE GOOD.
Rebuild or replace ESTÁ DEFECTUOSO). (LA PALANCA DE CONTROL
elevator up (SV-66) Y LAS CONEXIÓNES ESTÁN
directional valve. EN BUENAS CONDICIÓNES).

Reconstruya o cambie Replace joystick. Inspect cable Revise el cable que va

la valvula direcciónal por from main de la caja electrica
elevador arriba (SV-66). Cambie la electric box to principal a el tablero de
palanca de control. operator’s console. control de operaciónes.

Figure 69: Elevator Lift

Operation / Maintenance Chapter 2

October 2002 Page 65
Troubleshooting
Localización y corrección de averias

Elevator Lift
(Sistema del Elevador) Run Self-test for Engine Is yellow light ON (wire 525)
Elevator Control System for Elevator Control side of
Problem: on Diagnostic Center in Diagnostic Center, when
main electric box. elevator is at bridge?
Transducer error NO ERROR
(for elevator
at bridge). Haga una autoverificación
¿Se enciende una luz amarilla (por
por el sistema de dinamico, el alambre numero 525) por el
en el Tablero del Centro sistema de dinamico en el Tablero
Problema: de Auto-diagnóstico. del Centro de Auto-diagnóstico,
Esta un error en cuando el elevador esta al puente?
TRANSDUCER ERROR DETECTED
el transductor FOR RFT-1 OR RFT-2.
(por elevador YES (SÍ) NO
(DETECTA UN ERROR EN EL
al puente). TRANSDUCTOR, RFT-1 O RFT-2).

Revise si se encuentra Go to page 65.

Inspect bridge rear
atorada las barras
cargo stops to see Va a página 65.
contenedoras de cargas
if they are stuck.
al fondo del puente.

NO YES (SÍ)

Check calibration of cargo Unjam cargo Desatore las barras

stop transducers using stops. Turn contenedoras. Apague
chapter 2 procedure. power off, then y encienda nuevamente.
on, and retry. Intentelo de nuevo.

Verifique la calibración de los

transductores para las barras
contenedoras utilizando el
procedimiento.
TRANSDUCERS CALIBRATE
CORRECTLY.
TRANSDUCERS WILL NOT
CALIBRATE CORRECTLY.
(TRANSDUCTORES CALIBRADOS
CORRECTAMENTE).
(TRANSDUCTORES NO
CALIBRADOS).
Run Self-test for Engine
Elevator Control System
on Diagnostic Center in
main electric box.
Replace transducer(s) and
do calibration procedure.
Haga una autoverificación
Cambie el o los transductores por el sistema de dinamico,
y calibrelos de nuevo. en el Tablero del Centro
de Auto-diagnóstico.

NO TRANSDUCER ERROR DETECTED

FOR RFT-1 OR RFT-2.
(NO DETECTA UN ERROR EN EL
Job complete. TRANSDUCTOR, RFT-1 O RFT-2).

Termina la
reparación.

Figure 70: Elevator Lift

Chapter 2 Operation / Maintenance

Page 66 October 2002
 Troubleshooting
Localización y corrección de averias

Elevator Lift Does the letter “O” show ¿Aparece una letra “O” como
Replace switch.
(Sistema del Elevador) as an “Input” on Engine “Input” on al lado por sistema
/ Elevator Control side de dinamico en el Tablero del
Cambie el interruptor.
Problem: of Diagnostic Center? Centro de Auto-diagnóstico?
Elevator goes up, NO YES (SÍ) YES (SÍ)
but won’t go down. Desconecte el conector desde
Unplug connector from elevator
el interruptor de proximidad
Problema: fully down proximity switch.
por elevador en el nivel mas
El elevador va arriba, Does elevator still go down? bajo. ¿Desciende el elevador?
pero no va abajo. NO

Run Self-test for Engine Haga una autoverificación Inspect cable from
Elevator Control System por el sistema de dinamico, main electric box
on Diagnostic Center in en el Tablero del Centro to proximity switch.
main electric box. de Auto-diagnóstico.
ELECTRIC SYSTEM
TESTS “OK”. Revise el cable que va
(“OK” – NO HAY SHORT DETECTED OPEN DETECTED de la caja electrica
PROBLEMAS EN EL IN WIRE 527. IN WIRE 527.
principal al interruptor.
SISTEMA ELECTRICO). (DETECTA UN CORTO CIRCUITO (DETECTA LA ABERTURA EN EL
EN EL ALAMBRE NUMERO 527). ALAMBRE NUMERO 527).

Check resistance of solenoid coil Check continuity of

Select letter “H” (elevator down)
as “Input” on Engine / Elevator SV-65 (elevator down) = 19.2 Ω? solenoid coil SV-65.
Control side of Diagnostic Verifique la resistencia de la bobina del Verifique la continuidad de
Center for individual test-run. solenoide SV-65 (abajo) ¿ = 19.2 Ω? la bobina del solenoide SV-65).
Escoje la letra “H” (elevador abajo) RESISTANCE OK. CONTINUITY OK.
como “Input” on al lado por sistema (LA RESISTENCIA (LA CONTINUIDAD
de dinamico en el Tablero del Centro ES LA CORRECTA). ES LA CORRECTA).
de Auto-diagnóstico a probar función.
Inspect cable from Revise el cable que va
ELEVATOR DOES NOT FUNCTION main electric box de la caja electrica
AT DIAGNOSTIC CENTER.
(EL ELEVADOR NO FUNCIONA DESDE to solenoid valve. principal a la valvula.
EL CENTRO DE DIAGNÓSTICO).
RESISTANCE IS LOW. NO CONTINUITY.
(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
Rebuild or replace
elevator down (SV-65)
Cambie la bobina.
directional valve. ELEVATOR FUNCTIONS AT
DIAGNOSTIC CENTER.
Reconstruya o cambie (EL ELEVADOR FUNCIONA
DESDE EL CENTRO Check joystick Verifique la palanca
la valvula direcciónal por DE DIAGNÓSTICO).
elevador abajo (SV-65). at load panel and de control y las
check joystick conexiónes de la
connections. palanca de control.

JOYSTICK IS BAD. JOYSTICK AND CONNECTIONS

Replace joystick. (LA PALANCA DE CONTROL ARE GOOD.
ESTÁ DEFECTUOSO). (LA PALANCA DE CONTROL
Cambie la Y LAS CONEXIÓNES ESTÁN
palanca de control. EN BUENAS CONDICIÓNES).

Inspect cable from Revise el cable que va de la caja

main electric box electrica principal a el tablero
to operator’s console. de control de operaciónes.

Figure 71: Elevator Lift

Operation / Maintenance Chapter 2

October 2002 Page 67
Troubleshooting
Localización y corrección de averias

Elevator Lift
(Sistema del Elevador) Run Self-test for Engine Haga una autoverificación
Elevator Control System por el sistema de dinamico,
Problem: on Diagnostic Center in en el Tablero del Centro
Elevator goes up main electric box. de Auto-diagnóstico.
and down slowly
ELECTRIC SYSTEM SHORT DETECTED OPEN DETECTED
(828 Turbo TESTS “OK”. IN WIRE 527 OR 528. IN WIRE 527 OR 528.
& 929 only). (“OK” – NO HAY (DETECTA UN CORTO CIRCUITO EN (DETECTA LA ABERTURA EN EL
PROBLEMAS EN EL EL ALAMBRE NUMERO 527 O 528). ALAMBRE NUMERO 527 O 528).
SISTEMA ELECTRICO).
Problema:
El ascenso y el Check resistance of solenoid coil, SV-65 Check continuity of solenoid
descenso del (elevator down) or SV-66 (up) = 19.2 Ω? coils (SV-65 or SV-66).
elevador son
muy lentos Verifique la resistencia de la bobina del solenoide Verifique la continuidad de las bobinas
(modelos 828 turbo SV-65 (abajo) o SV-66 (arriba) ¿ = 19.2 Ω? de los solenoides (SV-65 o SV-66).
y 929 únicamente). RESISTANCE OK. CONTINUITY OK.
(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA).

Inspect cable from Revise el cable que va

main electric box de la caja electrica
to solenoid valve. principal a la valvula.

RESISTANCE IS LOW. NO CONTINUITY.

(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).

Cambie la bobina.
Has dynamic control ¿Se ha reemplazado
module been recientemente el
replaced recently? controlador dinamico? LOADER DOES NOT
NO Put stabilizers up DRIVE OK.
to drive the loader. (EL MONTACARGAS
YES (SÍ)
NO FUNCIONA AL
Ponga los estabilizadores SER CONDUCIDO).
arriba a conducirlo.
Check setting of dip Verifique los interruptores poquitos,
rojos y blancos, en nuevo controlador. LOADER DRIVES OK.
switches – same as dip
¿Están en el mismo configuración (EL MONTACARGAS
switches on old module? que estos del controlador anterior? FUNCIONA AL SER
CONDUCIDO). Go to page 69.
NO YES (SÍ)
Va a página 69.
Reset dip switches. Reset threshold using
chapter 2 procedure.
Ajuste nuevamente WON’T ADJUST.
los interruptores. Ajuste el limite utilizando (EL AJUSTE
NO FUNCIONA).
el procedimiento.
Adjuste la velocidad
Adjust elevator (up
del sistema del elevador
& down) speeds at
utilizando el Centro
Diagnostic Center. de Auto-diagnóstico.

Job complete. SPEED OK.

(VELOCIDAD OK).
Termina la reparación.

Figure 72: Elevator Lift

Chapter 2 Operation / Maintenance

Page 68 October 2002
 Troubleshooting
Localización y corrección de averias

Elevator Lift &

Vehicle Drive
(Sistema del Elevador LOADER DRIVES OK.
Put stabilizers up
y Conducción) to drive the loader. (EL MONTACARGAS FUNCIONA
AL SER CONDUCIDO).
Problem: Ponga los estabilizadores
Replace arriba a conducirlo.
proportional
LOADER DOES NOT DRIVE OK. Adjuste la velocidad
valve? (EL MONTACARGAS NO Adjust elevator (up
del sistema del elevador
FUNCIONA AL SER CONDUCIDO). & down) speeds at
utilizando el Centro
Problema: Diagnostic Center. de Auto-diagnóstico.
¿Cambie la
valvula de Put stabilizers down. Check WON’T ADJUST – SPEED OK.
proporción? pressure at pump manifold 828 ONLY. (VELOCIDAD OK).
while elevator lift is operated (EL AJUSTE
from load control panel. NO FUNCIONA –
MODELO 828
UNICAMENTE).
Job complete.
Ponga los estabilizadores abajo.
Verifique la presión a la entrada Termina la reparación.
de la bomba, cuando sube el
elevador a el tablero de control
de operaciónes.

≤ 2600 PSI (828). 2600 - 3000 PSI (828).

≤ 3300 PSI (929). 3300 - 3700 PSI (929).

WON’T ADJUST –
Go to page 60. Replace proportional 828 TURBO & 929.
valve (EP-61). (EL AJUSTE
Va a página 60. NO FUNCIONA –
MODELOS 828 TURBO
Cambie la valvula de O 929 UNICAMENTE).
proporción (EP-61).

Replace proportional
valve (EP-62).
Reset threshold using
chapter 2 procedure. Cambie la valvula de
proporción (EP-62).
Ajuste el limite utilizando
el procedimiento.

Adjuste la velocidad
Adjust elevator (up
del sistema del elevador
& down) speeds at
utilizando el Centro
Diagnostic Center. de Auto-diagnóstico.

Figure 73: Elevator Lift & Vehicle Drive

Operation / Maintenance Chapter 2

October 2002 Page 69
Troubleshooting
Localización y corrección de averias

Elevator Lift Is elevator interfaced Does the letter “U” ¿Aparece una letra “U” como
(Sistema del Elevador) with the bridge? NO show as an “Input” “Input” on al lado por sistema
on Cargo Control side de carga en el Tablero del
¿Estan unidos al of Diagnostic Center? Centro de Auto-diagnóstico?
Problem: mismo nivel el
Elevator rear cargo elevador y el puente? NO YES (SÍ)

stop or side guide(s) YES (SÍ)

will not go down Revise si se encuentra
Inspect bridge rear
atorada las barras
(no 60” / 150 cm cargo stops to see
contenedoras de cargas
interlock). Lower elevator until if they are stuck.
al fondo del puente.
platforms are no
Problema: longer interfaced. YES (SÍ) NO
La barra contenedora
Haga descender el Unjam cargo Desatore las barras
de carga al fondo del elevador hasta que stops. Turn contenedoras. Apague
elevador o la o las las plataformas no power off, then y encienda nuevamente.
guias laterales no se encuentren unidas on, and retry. Intentelo de nuevo.
al mismo nivel.
descienden (sin
interconexión de
60” / 150 cm). Check calibration of cargo
stop transducers using
chapter 2 procedure.
Run Self-test for Cargo Haga una autoverificación
Control System using por el sistema de carga,
ELECTRIC SYSTEM Diagnostic Center in en el Tablero del Centro Verifique la calibración de los
TESTS “OK”.
main electric box. de Auto-diagnóstico. transductores para las barras
(“OK” – NO HAY contenedoras utilizando el
PROBLEMAS EN EL procedimiento.
SISTEMA ELECTRICO). SHORT DETECTED. OPEN DETECTED.
(DETECTA UN (DETECTA LA ABERTURA).
CORTO CIRCUITO).
Check pump pressure
while pressing low
demand test button Check resistance Check continuity
at Diagnostic Center. of solenoid coil. of solenoid coil.

Verifique la presión de la Verifique la resistencia Verifique la continuidad

bomba cuando empujado de la bobina solenoide. de la bobina solenoide.
“low demand” botón a
RESISTANCE OK. CONTINUITY OK.
examinar, en el Tablero del
(LA RESISTENCIA (LA CONTINUIDAD
Centro de Auto-diagnóstico.
ES LA CORRECTA). ES LA CORRECTA).

Inspect cable from Revise el cable que va

2600 - 3000 PSI (828). main electric box de la caja electrica
3300 - 3700 PSI (929). to solenoid valve. principal a la valvula.

Remove and
RESISTANCE IS LOW. NO CONTINUITY.
inspect directional (LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
(SV) valve. Replace,
if needed. Cambie la bobina.

Quite y revise la
≤ 2600 PSI (828).
valvula direcciónal ≤ 3300 PSI (929). Go to page 60.
(SV). Cambiela
cuando se requiera. Va a página 60.

Figure 74: Elevator Lift

Chapter 2 Operation / Maintenance

Page 70 October 2002
 Troubleshooting
Localización y corrección de averias

Stabilizers Is the drive selector YES (SÍ) Does engine speed ¿Se acelera el motor
(Los Estabilizadores) in neutral? increase when trying cuando se ponga los
¿Está el interruptor to put stabilizers down? estabilizadores abajo?
YES (SÍ)
Problem: conducción (avance NO
Stabilizers will y reversa) en neutral?

not go down. NO Inspect stabilizer switch

SWITCH IS BAD.
on drive panel and check (EL INTERRUPTOR
Problema: Put drive selector switch connections. ESTA DEFECTUOSO).
Los estabilizadores switch in neutral
Revise el interruptor de los Replace switch.
no va abajo. and try again. estabilizadores a el tablero
de control de conducción Cambie el
Ponga el interruptor
y verifique las conexiónes interruptor.
conducción (avance
del interruptor.
y reversa) en neutral
y intentelo otra vez. SWITCH AND CONNECTIONS
ARE GOOD.
(EL INTERRUPTOR Y
LAS CONEXIÓNES ESTAN
Run Self-test for Engine Haga una autoverificación EN BUENAS CONDICIÓNES).
Elevator Control System por el sistema de dinamico,
on Diagnostic Center in en el Tablero del Centro Inspect cable from
main electric box. de Auto-diagnóstico. main electric box
to drive panel.
SHORT DETECTED OPEN DETECTED ELECTRIC SYSTEM
IN WIRE 540. IN WIRE 540. TESTS “OK”. Revise el cable que va de
(DETECTA UN CORTO CIRCUITO (DETECTA LA ABERTURA EN (“OK” – NO HAY la caja electrica principal
EN EL ALAMBRE NUMERO 540). EL ALAMBRE NUMERO 540). PROBLEMAS EN EL a el tablero de control
SISTEMA ELECTRICO).
de conducción.
Check resistance of pump Check continuity of pump
enable solenoid coil (SV-73). enable solenoid coil (SV-73).
Check pressure at pump ≤ 2600 PSI (828).
Verifique la resistencia de la bobina Verifique la continuidad de la bobina manifold while operating ≤ 3300 PSI (929).
acciónadora de la bomba (SV-73). acciónadora de la bomba (SV-73). stabilizers down from
RESISTANCE OK. CONTINUITY OK.
load control panel.
(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA). Verifique la presión de la Go to page 60.
bomba cuando funciona
las estabilizadores abajo Va a página 60.
Inspect cable from Revise el cable que va
a el tablero de control
main electric box de la caja electrica
de operaciónes.
to solenoid valve. principal a la valvula.
2600 - 3000 PSI (828).
3300 - 3700 PSI (929).
RESISTANCE IS LOW. NO CONTINUITY.
(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
Check voltage
Cambie la bobina. (24V) at stabilizers
down coil (SV-61).

Verifique que haya 24V

Replace stabilizers RESISTANCE IS LOW. en la bobina por los
down valve (SV-61). (LA RESISTENCIA ES BAJA). estabilizadores abajo (SV-61).
Cambie la valvula por Check resistance of VOLTAGE OK.
los estabilizadores stabilizers down coil (SV-61).
abajo (SV-61).
Verifique la resistencia de la bobina
RESISTANCE OK.
por los estabilizadores abajo (SV-61).
(LA RESISTENCIA
ES LA CORRECTA).

Figure 75: Stabilizers

Operation / Maintenance Chapter 2

October 2002 Page 71
Troubleshooting
Localización y corrección de averias

Stabilizers
(Los Estabilizadores) Is the elevator Is the drive selector Is a red light ON
fully down? YES (SÍ) in neutral? YES (SÍ) elevator fully down
Problem: ¿Está el elevador ¿Está el interruptor proximity switch?
Stabilizers will abajo completamente? conducción (avance
not go up. y reversa) en neutral? ¿Se enciende una luz
NO NO
roja en el interruptor de
proximidad por elevador
Problema:
NO en el nivel mas bajo?
Los estabilizadores
no va arriba. YES (SÍ)

Put drive selector Inspect cable from Do LED’s (lights) on

switch in neutral main electric box elevator fully down
Lower elevator and try again. proximity switch flash
fully and try again. to proximity switch.
back and forth when
Ponga el interruptor elevator is lowered?
Ponga el elevador conducción (avance
Revise el cable que va
abajo completamente y reversa) en neutral de la caja electrica
¿Oscilan las luces LED
y intentelo otra vez. y intentelo otra vez. principal al interruptor.
en el interruptor de
CABLE OK. proximidad por elevador
YES (SÍ) en el nivel mas bajo
cuando se hace descender
el elevador?

NO
Does the letter “O” show ¿Aparece una letra “O” como
as an “Input” on Engine “Input” on al lado por sistema
/ Elevator Control side de dinamico en el Tablero del Do LED’s (lights) on
of Diagnostic Center? Centro de Auto-diagnóstico? elevator fully down
NO
proximity switch flash
YES (SÍ) NO
back and forth with
a metallic object placed
in front of switch?
Does engine speed ¿Se acelera el motor Replace proximity switch.
increase when trying cuando se ponga los
to put stabilizers up? estabilizadores arriba? Cambie el interruptor ¿Oscilan las luces LED
de proximidad. en el interruptor de
NO YES (SÍ) proximidad por elevador
en el nivel mas bajo
cuando un objeto metalico
Inspect stabilizer switch Go to page 73.
está en frente al interuptor?
on drive panel and check SWITCH IS BAD.
(EL INTERRUPTOR Va a página 73.
switch connections. YES (SÍ)
ESTA DEFECTUOSO).

Revise el interruptor de los

estabilizadores a el tablero Replace switch. Move proximity switch
de control de conducción closer to elevator.
y verifique las conexiónes Cambie el Inspect cable from
del interruptor. interruptor. main electric box Acerque el interuptor
SWITCH AND CONNECTIONS to drive panel. de proximidad mas cerca
ARE GOOD. del elevador.
(EL INTERRUPTOR Y Revise el cable que va de
LAS CONEXIÓNES ESTAN la caja electrica principal
EN BUENAS CONDICIÓNES). a el tablero de control
de conducción.

Figure 76: Stabilizers, 1 of 2

Chapter 2 Operation / Maintenance

Page 72 October 2002
 Troubleshooting
Localización y corrección de averias

Stabilizers
(Los Estabilizadores) From page 72.

Problem: Desde página 72.

Stabilizers will
not go up.
Problema: Run Self-test for Engine Haga una autoverificación
Los estabilizadores Elevator Control System por el sistema de dinamico,
no va arriba. on Diagnostic Center in en el Tablero del Centro
main electric box. de Auto-diagnóstico.

SHORT DETECTED OPEN DETECTED ELECTRIC SYSTEM

IN WIRE 540. IN WIRE 540. TESTS “OK”.
(DETECTA UN CORTO CIRCUITO (DETECTA LA ABERTURA EN (“OK” – NO HAY
EN EL ALAMBRE NUMERO 540). EL ALAMBRE NUMERO 540). PROBLEMAS EN EL
SISTEMA ELECTRICO).

Check resistance of pump Check continuity of pump

enable solenoid coil (SV-73). enable solenoid coil (SV-73).
Check pressure at pump
Verifique la resistencia de la bobina Verifique la continuidad de la bobina manifold while operating
acciónadora de la bomba (SV-73). acciónadora de la bomba (SV-73). stabilizers up from
RESISTANCE OK. CONTINUITY OK.
load control panel.
(LA RESISTENCIA (LA CONTINUIDAD
ES LA CORRECTA). ES LA CORRECTA). Verifique la presión de la
bomba cuando funciona
las estabilizadores arriba
Inspect cable from Revise el cable que va
a el tablero de control
main electric box de la caja electrica
de operaciónes.
to solenoid valve. principal a la valvula.
2600 - 3000 PSI (828).
3300 - 3700 PSI (929).
RESISTANCE IS LOW. NO CONTINUITY.
(LA RESISTENCIA ES BAJA). Replace coil. (NO HAY CONTINUIDAD).
Check voltage
Cambie la bobina. (24V) at stabilizers
RESISTANCE IS LOW.
down coil (SV-62).
(LA RESISTENCIA ES BAJA).
Verifique que haya 24V
Replace stabilizers en la bobina por los
down valve (SV-62). estabilizadores abajo (SV-62).

Cambie la valvula por VOLTAGE OK.

los estabilizadores
abajo (SV-62). Check resistance of
stabilizers down coil (SV-62). ≤ 2600 PSI (828).
RESISTANCE OK. ≤ 3300 PSI (929).
(LA RESISTENCIA Verifique la resistencia de la bobina
ES LA CORRECTA).
por los estabilizadores abajo (SV-62).
Go to page 60.

Va a página 60.

Figure 76: Stabilizers, 2 of 2

Operation / Maintenance Chapter 2

October 2002 Page 73
Troubleshooting
Localización y corrección de averias

Vehicle Drive
(Conducción)
¿Es el derivación Close it.
Is towing
de remolque se
bypass closed? NO
Problem: encuentra cerrado? Lo cierre.
No movement in fast YES (SÍ)
speed and movement Note: Towing bypass valve (to
in slow speed freewheel front drive wheels) is
Is the bridge red knob located on left side of
(828 only). fully down?
Big Block manifold for 828’s with
Problema: ¿Está el puente S/N 9020 and above; 929’s with
abajo completamente? S/N 904 and above.
El mecanismo de
conducción (para NO YES (SÍ) For pre-big-block loaders, towing
desplazamiento bypass valve is located in front of
horizontal) no funciona the right front wheel.
en moda rapido y funcíona Does the letter “I” show
as an “Input” on Engine
en moda despacio
/ Elevator Control side
(828 unicamente). of Diagnostic Center?
Lower bridge
fully and try again. Inspect bridge down proximity
¿Aparece una letra “I” como switch and cables to switch.
Ponga el puente “Input” on al lado por sistema
abajo completamente de dinamico en el Tablero del NO Revise el interruptor de proximidad
y intentelo otra vez. Centro de Auto-diagnóstico?
para el puente abajo y los cables
van a los interruptores.
YES (SÍ)
AS NEEDED
Replace brake
BRAKE NO BRAKE
valve at pedal. PRESSURE Disconnect brake lines at the PRESSURE
brake drums to check pressure Replace switch.
Cambie la valvula (do NOT press brake pedal).
por los frenos al pedal. Cambie el
interruptor.

VOLTAGE OK. AS NEEDED

Clean, rebuild, or replace
(VOLTAJE ES
Check for 24 volts at high speed high speed valve (SV-72) Inspect high / low speed
CORRECTA).
coil on front axle (SV-72). on front axle manifold. switch and cables to switch.

Verifique que haya 24V en la bobina Limpia, reconstruya, o SWITCH Revise el interruptor de moda
de moda rapido, eje en frente (SV-72). OK
cambie la valvula por rapido o moda despacio y los
moda rapido (SV-72). cables van a los interruptores.
NO VOLTAGE (NO VOLTAJE)
VALVE (VALVULA) OK.
Locate open wiring or short circuit.
Detecta la abertura o un corto circuito.
Check resistance of high speed
coil on front axle (SV-72).
See Troubleshooting Check pressure of Verifique la resistencia de la bobina
procedure for low LOW hydraulic system RESISTANCE OK. de moda rapido, eje en frente (SV-72).
hydraulic pressure. PRESSURE (PRESS brake pedal). (LA RESISTENCIA
ES LA CORRECTA). RESISTANCE IS LOW.
PRESSURE (LA RESISTENCIA ES BAJA).
OK
Remove brake drums
Replace coil.
and inspect. Replace
as needed. Cambie la bobina.
Figure 77: Vehicle Drive

Chapter 2 Operation / Maintenance

Page 74 October 2002
 Troubleshooting
V. Control Modules
V.A. Troubleshooting Dynamic Control Module
No Engine Throttle Advance
Broken Wire Check Wire #532 for damage. Repair as needed.
Transient Diode Test transient diode at throttle actuator by disconnecting diode wire
#532 from all other terminals. Test diode and replace, as needed.
Feedback Transducer Check test point voltage, TP5 (white) = 1.60V, at engine idle. Adjust
or replace transducer, as needed. Check wires.
Flywheel Sensor Check and adjust for correct operation (turn in by hand until slight
contact with flywheel – back out one revolution). Check for letter “S”
on Diagnostic Center display when engine is running.
Throttle Actuator Turn engine high rpm to max on Diagnostic Center. In LOAD mode,
press high rpm button and measure voltage at throttle actuator,
checking for 7.2V or greater. Replace dynamic module if low.
Replace actuator if voltage is correct.

Delay Before Vehicle Drive

Broken Wires Check wires and connectors to drive pressure switches (located on
top of Big Block manifold for 828’s with S/N 9020 and above; 929’s
with S/N 904 and above . . . for pre-big-block loaders, located on
top of front axle, at the front of axle manifold). Repair wires as
needed. In DRIVE mode, check for letter “T” on Diagnostic Center
display while drive selector is in neutral.
Pressure Switches In DRIVE mode, with engine OFF, ignition ON, check for letter “T” on
Diagnostic Center display. If not displayed, replace drive pressure
switch (see locations described in item above for Big Block loaders
and pre-big-block loaders) corresponding to forward or reverse
drive, as needed. If “T” is displayed, adjust hydraulic drive charge
pressure to be lower (it is too high).
Valve Threshold Adjust the threshold setup procedure at the end of chapter 2.

Vehicle Drive Slows, Then Speeds Up

Problem with EP-61 Block front wheels off the ground safely to perform the following
test. In DRIVE mode, forward mode, bridge UP, accelerator pedal
pressed fully, check voltage on wire #524 in main electric box. If volt-
age is stable, replace proportional valve EP-61 (located at rear of Big
Block manifold for 828’s with S/N 9020 and up; 929’s with S/N 904
and up . . . for pre-big-block loaders, located on drive manifold).
Dynamic Module Block front wheels off the ground safely to perform the following
test. In DRIVE mode, forward mode, bridge DOWN, accelerator
pedal pressed fully, check voltage on wire #524 for 8.50V or more
and steady. If voltage is not OK, replace dynamic control module.

Operation / Maintenance Chapter 2

October 2002 Page 75
Troubleshooting
V.A. Troubleshooting Dynamic Control Module, continued
Elevator Lift / Lower Speed Not Constant or Elevator will Not Raise
Feedback Transducer With elevator fully down, check voltage at TP2 (green) and TP3 (yel-
low) = 4.35 (range: 4.32 to 4.38). Adjust calibration of feedback
transducers for bridge cargo stops, using chapter 2 procedure. If
calibration does not reach correct range, replace transducers.
Proximity Switch For elevator slow down proximity switch, check for letter “N” on
Diagnostic Center display. Adjust sensing distance between switch
and elevator, if necessary. Replace switch, if necessary.
Dynamic Module Block front wheels off the ground safely to perform the following
test. In DRIVE mode, forward mode, bridge DOWN, accelerator
pedal pressed fully, check voltage on wire #524 for 8.50V or more
and steady. Ifthe voltage is OK, replace EP-61. If voltage is not OK,
replace dynamic control module.
Problem with EP-62 (For 828 Turbo or 929’s only) with loader in LOAD mode, be ready
to check wire #538 in the main electric box, while running elevator lift
to the maximum speed. Check voltage for 8.50V or more and
steady. Ifthe voltage is OK, replace EP-62. If voltage is not OK,
replace the dynamic control module.

Elevator Will Not Lower

Straddle Interlock Straddle interlock may be activated from operator or cargo mis-
judgement. Thorough operator training is required when this
optional interlock is being used. To disable the straddle interlock,
turn off dip switch #4 on the dynamic module. (Straddle interlock
causes the elevator to NOT continue travel in the DOWN direction if
the rear bridge cargo stops are prevented from going UP when the
elevator and the bridge are no longer interfaced).
Proximity Switch For elevator down stop proximity switch, check for letter “O” on
Diagnostic Center display. Adjust sensing distance between switch
and elevator, if necessary. Replace switch, if necessary.
Dynamic Module Block front wheels off the ground safely to perform the following
test. In DRIVE mode, forward mode, bridge DOWN, accelerator
pedal pressed fully, check voltage on wire #524 for 8.50V or more
and steady. Ifthe voltage is OK, replace EP-61. If voltage is not OK,
replace dynamic control module.
Problem with EP-62 (For 828 Turbo or 929’s only) with loader in LOAD mode, be ready
to check wire #538 in the main electric box, while running elevator lift
to the maximum speed. Check voltage for 8.50V or more and
steady. Ifthe voltage is OK, replace EP-62. If voltage is not OK,
replace the dynamic control module.

Chapter 2 Operation / Maintenance

Page 76 October 2002
Troubleshooting
V.C. Dip Switch Settings
Electric
Schematic

Figure 78: Switch Settings on Electric Schematic

• Push top latch DOWN and bottom latch UP—together—and pull carefully to remove.
• Before installing new module, set switches. Location of switches is shown below.
• To install module, align in top and bottom tracks before inserting into housing.
• Do not force module. If aligned correctly, module slides easily.
• With module aligned and inserted fully, push firmly until flush with face plate.
Dynamic Control Module

Switches
Unlatch
Top / Bottom
to Remove Top

Cargo Control Module Front

Bottom
Unlatch On Off
Top / Bottom
(1) (0)
to Remove

Figure 79: Setting Switches

Chapter 2 Operation / Maintenance
Page 78 October 2002
 Troubleshooting
V.C. Dip Switch Settings, continued
DYNAMIC CONTROL MODULE

1 2 3 4 5 6 7 8

Not Used
Not Used = 00
Deutz = 10 00 = 828
Perkins = 01 10 = 828 Turbo / 929
Cummins = 11 01 = 121
11 = Not Used
Proximity Switches Enabled OFF
LVDT Enabled (Elevator ON
Memory Option) Note: Straddle Interlock option is available on
any loader and requres thorough operator
NO Straddle Interlock OFF training (otherwise operators think something
Straddle Interlock Enabled ON is wrong with elevator because it won’t go
DOWN). With Straddle Interlock ENABLED,
elevator will STOP travelling down – IF, when
it begins to break away from bridge interface,
something (such as straddling cargo) prevents
rear cargo stops from going UP when elevator
goes DOWN.

CARGO CONTROL MODULE

1 2 3 4 5 6 7 8
End Load Elevator 000 ... 0
Single Rotate/Guides 100 ... 0 Not Used
Dual Rotate 828 010 ... 0
Used as 4th digit for cargo
Triple Rotate 110 ... 0 configuration (on the left)
Center Pallet Rotate 001 ,,, 0
Only (UPS Option) OFF = NO front pallet stop
Center Pallet Rotate 101 ... 0 ON = Main Deck Bridge with
Only, 929 & 121 front pallet stop (828 Only)
Dual Rotate 929 011 ... 0
OFF = End Load Bridge (828 Only)
Dual Rotate / Guides 111 ... 0
ON = Side Shift Bridge
Dual Rotate/Guides 000 ... 1
929 & 121
Not Used 100 ... 1
Not Used 010 ,,, 1
Not Used 110 ... 1
Not Used 001 ... 1
0 = OFF
Not Used 101 ... 1
Not Used 011 ... 1
1 = ON
Not Used 111 ... 1

Operation / Maintenance Chapter 2

October 2002 Page 79
Troubleshooting
V.D. Threshold Setup, Dynamic Control Module
Any time a new or different control module is installed in a loader, it is necessary to perform the
threshold setup before placing the loader back into service. Any time a drive proportional valve
is replaced (EP-61 for any 828 / 929 model, or EP-62 for 828 Turbo option, 929, or 929S), it is
also necessary to perform the threshold setup for the dynamic control module.
With Dynamic Control Module installed, close main electric box, pull emergency stop and start
loader. Leave loader in load mode — stabilizers down ( ↓ ). Go to load control panel on console
to operate the elevator lift through 5 cycles (up and down). Leave elevator 30 cm (12”) above
frame and let engine idle.
WARNING: Make sure there is no cargo on the decks and make sure all personnel are clear of
loader before using Test button on Diagnostic Center for any of the following procedures.
IMPORTANT: The next four steps must be performed in quick succession, one after another. If
Diagnostic Center resumes auto-scan before steps are completed, repeat steps #1 through #4.
Note: If loader has elevator proximity switches, perform steps 1 through 6, this page and
next page. If loader has LVDT elevator memory (one sensor mounted on elevator scissor),
skip steps 1 through 6 and go to procedure on page 82.
1. Turn off Dynamic Control Module by flipping circuit breaker CB-5 switch down ( ↓ ).

Main
Electric
Box

Turn Off ( ↓ )
1
Circuit Breaker CB-5

Figure 80: Turn OFF Circuit Breaker

2. On Engine / Elevator Control Panel side, press Menu and Test buttons (together).

Press Menu and

2
Test Together

Figure 81: Press Menu and Test Buttons

3. Turn circuit breaker CB-5 back on ( ↑ ) while still holding buttons in step #2.

Main
Electric
Box

Turn On ( ↑ )
3
Circuit Breaker CB-5

Figure 82: Turn ON Circuit Breaker

Chapter 2 Operation / Maintenance
Page 80 October 2002
 Troubleshooting
V.D. Threshold Setup, Dynamic Control Module, continued
4. Hold Menu and Test until a question mark (?) appears on the display. Release buttons.

Wait to See: ?
Release Menu 4
and Test

Figure 83: Wait for Question Mark to Appear

IMPORTANT: The next step must be performed within 3 seconds after the last step (#4). If
Diagnostic Center resumes auto-scan before steps are complete, repeat #1 through #4.
Within 3 seconds of releasing Menu and Test (step #4), press Menu once to select “1” (shown
on display). Within 3 seconds, press Test and hold during one of the next steps (#4 or #5).

Press Menu
Once to Select: 1

Figure 84: Press Menu Once

Elevator might be moving up ( ↑ ) slowly at this point. If so, proceed to step #5. If elevator is NOT
moving at all, skip step #5 and proceed to step #6.
5. If elevator is moving up ( ↑ ) slowly: Hold Test and use a small screwdriver to slowly reduce
elevator Up Speed until elevator movement is completely stopped. Release Test button.
Procedure is complete (skip step #6).
6. If elevator is NOT moving: Hold Test and use a small screwdriver to slowly increase elevator
Up Speed until movement up ( ↑ ) occurs. Now slowly back off (reduce) elevator Up Speed
until elevator movement is completely stopped. Release Test button. Procedure is complete.
IMPORTANT: Correct adjustment is the EXACT POINT where elevator movement stops.

Press Test, Rotate to Adjust

Hold While 5 6 Up Speed,
Adjusting Speed Pressing Test

Figure 85: Adjust Speed, if Necessary

IMPORTANT: After setting threshold, it is necessary to reset elevator speeds – up, down, and
down slow (see chapter 2 procedure).

Operation / Maintenance Chapter 2

October 2002 Page 81
Troubleshooting
V.E. Threshold Setup, LVDT Elevator Memory Option**
1. Turn off circuit breaker CB-4 by flipping switch down for the threshold setup procedure and raise
the bridge to the FULLY UP position.
** Make sure elevator is raised
120 cm high from ground with
potentiometers at diag. center
set to max values. Make sure
bridge pallet stops transducers
are properly set prior to perform
that procedure

Figure 86: Turn OFF Circuit Breaker

2. Turn off Dynamic Control Module by flipping circuit breaker CB-5 switch down. The next two
steps, #3 and #4, must be performed quickly. Otherwise, the controller will resume normal
operation. If this happens, repeat these steps again more quickly.
3. To enter the set-up menu, press Menu and Test buttons together (at the same time) on the left
side of the Diagnostic Center (Engine / Elevator Control), while switching CB-5 back ON at the
same time. Hold buttons during a short initialization sequence. Hold buttons until a question mark
(?) appears on the display. Release buttons.

Figure 87: Wait for Question Mark to Appear

IMPORTANT: The next step must be performed within 3 seconds after the last step (#3) If
Diagnostic Center resumes auto-scan before steps are complete, repeat steps #2 and #3.
Within 3 seconds of releasing Menu and Test (step #3), press Menu twice to select “3” (shown on
display). Within 3 seconds, press Test and hold it. The Dynamic Module will automatically find the
valve threshold without having to do anything at all except hold down the Test button. The elevator
will start moving down then up to the Bridge and stop. Do not release the Test button until
everything is finished AND the engine has returned to idle.

Figure 88: Press Menu Once

IMPORTANT: Threshold setup is stored in permanent memory. Turn on CB-4 and set elevator
speeds – up, down, and down slow (see chapter 2 procedure)
Chp 2.2 Maintenance Manual
Page82 REV: Aug 2003
 Troubleshooting
V.F. Threshold Setup, Cargo Control Module
Any time a new or different control module is installed in a loader, it is necessary to perform the
threshold setup before placing the loader back into service. In this case, ALL THREE thresholds
must be set: bridge, elevator front, and elevator rear (see list below).
Any time a conveyor proportional valve is replaced, it is also necessary to perform the threshold
setup for the cargo control module. In this case, only one threshold must be set, according to
the proportional valve that has been changed:
• Bridge: EP-1 (select “1” by pressing Menu once, between steps #4 and #5)
• Elevator Front: EP-31 (select “2” by pressing Menu twice, between steps #4 and #5)
• Elevator Rear: EP-32 (select “3” by pressing Menu 3 times, between steps #4 and #5)
With Cargo Control Module installed, close main electric box, pull emergency stop and start
loader. Leave loader in load mode — stabilizers down ( ↓ ). Go to load control panel on console
to operate the elevator lift through 5 cycles (up and down). Leave elevator 30 cm (12”) above
frame and let engine idle. Operate all cargo transfer conveyors for 3 minutes.
WARNING: Make sure there is no cargo on the decks and make sure all personnel are clear of
loader before using Test button on Diagnostic Center for any of the following procedures.
IMPORTANT: The next four steps must be performed in quick succession, one after another. If
Diagnostic Center resumes auto-scan before steps are completed, repeat steps #1 through #4.
1. Turn off Cargo Control Module by flipping circuit breaker CB-6 switch down ( ↓ ).

Main
Electric
Box

Turn Off ( ↓ )
1
Circuit Breaker CB-6

Figure 89: Turn OFF Circuit Breaker

2. On Cargo Control Panel side, press Menu and Test buttons (together).

Press Menu and

2
Test Together

Figure 90: Press Menu and Test Buttons

Operation / Maintenance Chapter 2

October 2002 Page 83
Troubleshooting
V.F. Threshold Setup, Cargo Control Module, continued
3. Turn circuit breaker CB-6 back on ( ↑ ) while still holding buttons in step #2.

Main
Electric
Box

Turn On ( ↑ )
3
Circuit Breaker CB-6

Figure 91: Turn ON Circuit Breaker

4. Hold Menu and Test until a question mark (?) appears on the display. Release buttons.

Wait to See: ?
Release Menu 4
and Test

Figure 92: Wait for Question Mark to Appear

IMPORTANT: The next step must be performed within 3 seconds after the last step (#4). If
Diagnostic Center resumes auto-scan before steps are complete, repeat #1 through #4.
Within 3 seconds of releasing Menu and Test (step #4), press Menu as follows:
• Bridge (EP-1): Press Menu once to select “1” (shown on display)
• Elevator Front (EP-31): Press Menu twice to select “2” (shown on display)
• Elevator Rear (EP-32): Press Menu 3 times to select “3” (shown on display)
Within 3 seconds, press Test and hold during one of the next steps (#4 or #5).

Press Menu to
Select: 1, 2, or 3

Figure 93: Press Menu Once

Cargo transfer conveyor (bridge, elevator front, or elevator rear, as selected above) might be
moving slowly at this point. If so, proceed to step #5. If cargo transfer conveyor is NOT moving
at all, skip step #5 and proceed to step #6.

Chapter 2 Operation / Maintenance

Page 84 October 2002
 Troubleshooting
V.F. Threshold Setup, Cargo Control Module, continued
5. If cargo transfer conveyor is moving slowly: Hold Test and use a small screwdriver to slowly
reduce Speed until conveyor movement is completely stopped. Release Test button.
Procedure is complete (skip step #6).
6. If cargo transfer conveyor is NOT moving: Hold Test and use a small screwdriver to slowly
increase Speed until movement occurs. Now slowly back off (reduce) Speed until conveyor
movement is completely stopped. Release Test button. Procedure is complete.
IMPORTANT: Correct adjustment is the EXACT POINT where conveyor movement stops.

Press Test, Rotate to Adjust

Hold While 5 6 Bridge Speed,
Adjusting Speed Pressing Test

Figure 94: Adjust Bridge Speed, if Necessary

IMPORTANT: After setting threshold, it is necessary to reset bridge cargo transfer conveyor
speed (see chapter 2 procedure).

Press Test, Rotate to Adjust

Hold While 5 6 Elevator Front Speed,
Adjusting Speed Pressing Test

Figure 95: Adjust Elevator Front Speed, if Necessary

IMPORTANT: After setting threshold, it is necessary to reset elevator front cargo transfer
conveyor speed (see chapter 2 procedure).

Press Test, Rotate to Adjust

Hold While 5 6 Elevator Rear Speed,
Adjusting Speed Pressing Test

Figure 96: Adjust Elevator Rear Speed, if Necessary

IMPORTANT: After setting threshold, it is necessary to reset elevator rear cargo transfer
conveyor speed (see chapter 2 procedure).

Operation / Maintenance Chapter 2

October 2002 Page 85
Troubleshooting
VI. Pump Setup Procedure and Drive Circuit Pressure Setting
VI.A. Pump Setup Procedure, Big Block Loaders
When the hydraulic pump has been removed and/or replaced — OR IF PUMP ADJUSTMENTS
HAVE BEEN TAMPERED WITH — perform the pump setup procedure, as follows. Make sure
hydraulic tank is filled with platforms fully down using hydraulic fluid which is adequate for typical
ambient temperatures in the operating environment.
Note: Pump setup for pre-big-block loaders (828’s S/N 9019 and below; 929’s S/N 903 and
below) can be found in chapter 3 under hydraulic start-up procedure.
Before starting loader for the first time, always make sure suction valve on hydraulic tank is fully
open. Handle should be aligned with (parallel to) suction hose to the main hydraulic pump on
the engine. Hydraulic pump will be damaged if loader is started and this valve is NOT open.

Front of
Loader For All Valves:

OPEN
Handle is Aligned
With Hose/Line

Suction Valve
(828 Shown)
Inside Engine
Module CLOSED
Handle and Line
are Perpendicular

Figure 97: Open Suction Valve

• Attach 0 to 350 bar / 0 to 5000 psi pressure gauge to test port of pump manifold. Check
system pressures, as described in the procedure, from this point.
• 929’s ONLY: Attach 0 to 350 bar / 0 to 5000 psi pressure gauge to test port of chassis
manifold. Check secondary pressures, as described in the procedure, from this point
Big Block Manifold
C.P. Test Port:
Big Block Check Drive Pressures
Loaders (828’s & 929’s)
828’s with S/N 9020 828’s Only:
and above Fast-speed Mode Chassis Manifold
929’s with S/N 904 Test Port:
and above Check Secondary System
Pressure – 929’s ONLY

Front of
Loader

Pump Manifold
Test Port:
Check System Pressure
(828’s & 929’s)

Figure 98: Location of Manifolds

Chapter 2 Operation / Maintenance

Page 86 October 2002
 Troubleshooting
VI.A. Pump Setup Procedure, Big Block, continued
Note: ONLY if pump has been removed or replaced, open bleeder vent on the pump to allow
hydraulic fluid to rise up inside and fill the pump. Close bleeder vent.
• Loosen jamnut on pressure compensator screw on pump. Turn adjustment screw clockwise
until it will no longer turn, then turn counterclockwise 4 full turns.

828
Rear of
Engine

Toward
Engine

Pressure Compensator:
Newer Loaders: Initially, Turn Clockwise Fully, then Turn
Pumps also feature Counterclockwise 4 Full Turns
Toward 929
adjustable differential.
Engine Front of
Torque (Away from Engine Side), Engine
HP Load: This will be adjusted last.

Big Block Pressure Compensator (Rear):

Loaders Initially, Turn Clockwise Fully, then Turn
Counterclockwise 4 Full Turns
828’s with S/N 9020
and above
929’s with S/N 904 Load Sense (Front):
and above DO NOT Change Torque (Away from Engine Side),
HP Load: This will be adjusted last.

Figure 99: Pump Pressure Compensator

• Disconnect electric lines to fuel shut-off solenoid (on engine) and pump enable (SV-73 on
pump manifold). Engage starter for 10 second intervals with 10 second rest periods — do this
6 times. System pressure at pump should be between 17,2 and 41,4 bar / 250 and 600 psi
during the last cranking. Turn the ignition (starter) switch off.
• Reconnect electric lines to fuel shut-off solenoid. Check hydraulic fluid level and refill, as
required. Start engine. Check system pressure (should be less than 41,4 bar / 600 psi).
Note: For newer loaders (featuring adjustable differential on pump – see figure above) if system
pressure is more than 41,4 bar / 600 psi at this point, loosen jam nut on adjustable differential.
Turn clockwise until system pressure is 31 to 34,5 bar / 450 to 500 psi at idle. Tighten jam nut
and paint exposed threads to mark correct setting.
• Stop Engine. Remove bleeder vent on pump and let air escape, until bubbles stop, then
replace screw.

Operation / Maintenance Chapter 2

October 2002 Page 87
Troubleshooting
VI.A. Pump Setup Procedure, Big Block, continued
• Reconnect pump enable (SV-73). Start engine, idle for 1 minute. Turn pressure compensator
screw on pump clockwise until system pressure reaches 103,5 bar / 1500 psi.
Pump
Manifold

828
Front of
Loader
Pump Enable
Solenoid (SV-73)

Pump
Manifold

929
Front of
Loader System
Relief Valve
Pump Enable
Solenoid (SV-73)

Figure 100: Pump Enable Solenoid (SV-73)

• Let loader idle for a few more minutes, checking for leaks around the pump and manifold.
• 929’s ONLY: Turn pressure compensator screw (on pump) clockwise until system
pressure (pump test port reading) = 230 bar / 3300 psi.
• 828’s ONLY: Turn pressure compensator screw clockwise until system pressure (pump
test port) = 210 bar / 3000 psi. Tighten jam nut and paint exposed threads to mark correct
setting. Proceed to next section of procedure: Setting Drive Pressures (next page).
• 929’s ONLY: Loosen jam nut on system relief valve (bottom of pump manifold, see figure
above). Turn relief screw clockwise until it no longer turns. Turn pressure compensator screw
clockwise until system pressure = 300 bar / 4300 psi.
• 929’s ONLY: Turn adjustment screw on relief valve counterclockwise until system pressure
= 295 bar / 4200 psi. Tighten jam nut and paint exposed threads to mark correct setting.
• 929’s ONLY: Turn pressure compensator screw (on pump) counterclockwise until system
pressure = 250 bar / 3600 psi. Tighten jam nut and paint exposed threads to mark setting.
• 929’s ONLY: Loosen jam nut on secondary relief valve (chassis manifold). Turn relief screw
counterclockwise until secondary pressure (chassis manifold test port) = 210 bar / 3000 psi.
Tighten jam nut and paint exposed threads to mark setting.
• Proceed to the next section of this procedure: Setting Drive Pressures (next page).

Chapter 2 Operation / Maintenance

Page 88 October 2002
 Troubleshooting
VI.B. Drive Circuit Pressure Setting, Big Block Loaders
When one or both motors have been removed and/or replaced on the front drive axle, set drive
circuit pressure as follows.
Big Block
Big Block Manifold
828’s Only:
Loaders Fast-speed Mode
828’s with S/N 9020
and above Note: For pre-big-block loaders,
929’s with S/N 904 see procedure on page 92.
and above Front of
Loader

Figure 101: Big Block Manifold

• Attach pressure gauge (0 to 70 bar / 0 to 1000 psi) to charge pressure test port (stamped
C.P.) on the rear of the Big Block manifold (see figure below).

Front of
Loader

Front of
Loader

Front of Large Pressure

Big Block Reducing Valve
Rear of
Big Block
Charge Pressure
(C.P.) Test Port 828’s Only:
Fast-speed Mode

Figure 102: Test Port and Large Pressure Reducing Valve

• Loosen jam nut on large pressure reducing valve (see figure above — part number 036425).
• Make sure both red emergency stop buttons are pulled out and start engine. Put loader in
load mode (stabilizers down). With the help of an assistant, go to the main electric box and
press Low Demand on engine/elevator side of Diagnostic Center.

Press Low
Demand

Figure 103: Diagnostic Center

Operation / Maintenance Chapter 2

October 2002 Page 89
Troubleshooting
VI.B. Drive Circuit Pressure Setting, Big Block, continued
• Turn adjusting screw on pressure reducing valve until gauge reads 22,4 bar / 325 psi. Tighten
jam nut and paint exposed threads to mark correct setting.
• Remove pressure gauge from Big Block manifold.
Note: Because 828 loaders have fast-speed mode, drive circuit pressure setting continues.
• Attach pressure gauge (0 to 70 bar / 0 to 1000 psi) to test port located on auxilliary valve
assembly with small pressure reducing valve and SV-72 (see figure below).

Big Block
Loaders
828’s with S/N 9020
and above
929’s with S/N 904
and above

Small Pressure
Reducing Valve

828’s Only: Front of

Fast-speed Mode Big Block Front of
Loader

Test
Port

Test Port and Small Pressure Reducing Valve

• Loosen jam nut on small pressure reducing valve (see figure above — part number 032532).
• Make sure both red emergency stop buttons are pulled out and start engine. Put loader in
load mode (stabilizers down). With the help of an assistant, go to the main electric box and
press Low Demand on engine/elevator side of Diagnostic Center.

Press Low
Demand

Diagnostic Center
• Turn adjusting screw on pressure reducing valve until gauge reads 22,4 bar / 325 psi. Tighten
jam nut and paint exposed threads to mark correct setting.
• Remove pressure gauge from valve assembly.
• Continue on with Pump Setup Procedure, next page.

Chapter 2 Operation / Maintenance

Page 90 October 2002
 Troubleshooting
VI.C. More on Pump Setup, Big Block Loaders
• With engine running and unit in load mode (stabilizers down), transfer a load of approximately
7 tonnes / 15,000 lbs onto the elevator.
• Loosen jamnut on torque screw (horsepower limiter) on the pump. Have a helper operate
the elevator lift up, while turning torque screw clockwise until engine just starts to bog down.
Note: This can be done at ground level (instead of using load panel on operator’s console) by
using test run feature, dialing in the letter F on the Diagnostic Center. (Use the letter H when it
comes time to lower the elevator again).
• Back out torque screw (on pump) slightly (counterclockwise) from the point where engine
just begins to bog while lifting a load on the elevator. Tighten jam nut and paint exposed
threads to mark correct setting.

828
Rear of
Engine

Toward
Engine

Pressure Compensator:
Newer Loaders: Adjust at beginning Toward 929
Pumps also feature of this procedure.
adjustable differential.
Engine Front of
Torque (Away from Engine Side): Engine
Adjust as described above.

Big Block Pressure Compensator:

Loaders Adjust at beginning
of this procedure.
828’s with S/N 9020
and above
929’s with S/N 904 Load Sense (Front):
and above DO NOT Change Torque (Away from Engine Side):
Adjust as described above.

Torque (HP Limiter) on Pump

• Lower elevator and transfer load from platform. Turn ignition (starter) switch off.
• Remove all gauges and cap test ports securely.
• Check oil level in hydraulic tank with platforms fully down and refill, as required.
• Adjust speed for engine RPM, low demand and high demand, as described in Operator’s
Manual. Adjust speed for bridge lift and/or elevator lift speed, as required. Set conveyor
speeds for bridge and elevator, as described in Chapter 2, using Diagnostic Center.
Note: Pump setup for pre-big-block loaders (828’s S/N 9019 and below; 929’s S/N 903 and
below) can be found in chapter 3 under hydraulic start-up procedure.

Operation / Maintenance Chapter 2

October 2002 Page 91
Troubleshooting
VI.D. Drive Circuit Pressure, Pre-big-block Loaders
When the hydraulic fluid is excessively hot (in excess of 180˚F / 80˚C), perform chapter 2 trouble-
shooting procedure. Let loader idle for 10 minutes. Then trace heat back from return filter to
locate which manifold is heat source. If the heat source is the drive/elevator manifold or the front
axle manifold, set drive circuit pressure setting as follows.

Front of
Loader
Pre-Big-Block
Loaders
828’s with S/N 9019
and below
929’s with S/N 903
and below

Front Axle
Manifold

Drive / Elevator
Lift Manifold

Accessory Manifold
(828 Turbo & 929 Only)

Figure 104: Drive/Elevator or Front Axle Manifolds

First, attach a pressure gauge (0 to 1000 psi) to one of the two test ports leading to the towing
bypass valve (in front of and to the inside of the front drive wheel, right side).
Front of Drive
Wheel, Right Side

Front of
Loader

Figure 105: Towing Bypass Valve

Locate the following valves, as shown in the figure on the following page:
1. Drive circuit relief valve (TLD part number 030113) located at the drive/elevator manifold.
2. Large pressure reducing valve (TLD part number 033019) located at the front axle manifold.
3. Small pressure reducing valve (TLD part number 032532) located as follows —
• 828 (not turbo) — separate valve to the rear of drive/elevator manifold (see next page)
• 828 turbo and 929 — accessory manifold (see figure at the top of this page).

Chapter 2 Operation / Maintenance

Page 92 October 2002
 Troubleshooting
VI.D. Drive Circuit Pressure, Pre-big-block, continued
Loosen the jam nuts on the three valves described at the bottom of the preceding page. Turn
the adjustment screw on the valves as follows:
1. Drive circuit relief valve: clockwise until it will no longer turn.
2. Large pressure reducing valve: counterclockwise until it will no longer turn.
3. Small pressure reducing valve: counterclockwise until it will no longer turn.
Drive Circuit
Pre-Big-Block 1
Relief Valve
Loaders
Small Pressure
828’s with S/N 9019 3 Reducing Valve
and below
929’s with S/N 903
and below

Note: For 828 turbo and 929,

small pressure reducing valve (#3)
is located at the bottom of the
accessory manifold (not a separate
valve, as shown below).
Large Pressure Small Pressure
2 3
Reducing Valve Reducing Valve
(Shown: 828 – not turbo)

Front of
Loader

Large Pressure
2
Reducing Valve

Drive Circuit
Relief Valve 1

Figure 106: Valves Used to Set Drive Circuit Pressure

Make sure both red emergency stop buttons are pulled out and start engine. Put loader in load
mode (stabilizers down). With the help of an assistant, go to the main electrical box and press
the Low Demand button on the engine/elevator panel side of the Diagnostic Center.

Press Low
Demand

Figure 107: Diagnostic Center

Operation / Maintenance Chapter 2

October 2002 Page 93
Troubleshooting
VI.D. Drive Circuit Pressure, Pre-big-block, continued
(As stated on the preceding page, start engine, and with loader running . . . )
While pressing the Low Demand button on the diagnostic panel, turn adjustment screw on the
small pressure reducing valve (#3) clockwise until gauge reads 31 bar / 450 psi.
Still pressing the low Low Demand, turn adjustment screw on the drive circuit relief valve (#1)
counterclockwise until gauge reads 29,3 bar / 425 psi. Tighten jamnut on this valve.
Continue to press Low Demand button and turn adjustment screw on small pressure reduc-
ing valve (#3) counterclockwise until gauge reads 20,7 bar / 300 psi. Tighten jamnut on valve.
Now, while pressing Low Demand button, turn adjustment screw on large pressure reducing
valve (#2) clockwise until the gauge reads 22,4 bar / 325 psi. Tighten jamnut on valve.
Release Low Demand button, stop engine, remove pressure gauge. Procedure done.
VI.E. Drive Circuit Pressure Setting, G0 Loaders
Note: Only a very few G0 loaders were built in 1996, all were 828’s, and these can be identified
with S/N starting with “6” and with elevator scissors located under the center of the bridge
(instead of outboard to either side of the elevator, as on loaders built after 1996).
Make sure towing bypass valve is closed – as with pre-big-block loaders, see figure on page 92,
located at the front of the right side front wheel. If valve will not close completely, check for dirt
or debris and clear, so valve will close.
Attach pressure gauge (0 to 70 bar / 1000 psi) to one of two test ports leading to towing bypass
valve on front axle.
Locate drive valve cluster as shown in the figure below.

Front of
Loader
Drive
Valves

Figure 108: Base of Elevator Scissors

Loosen jam nuts on the three valves shown in the figure on the next page.
1. Pressure reducing valve #1: Turn counterclockwise until it will no longer turn.
2. Pressure reducing valve #2: Turn counterclockwise until it will no longer turn.
3. Drive circuit relief valve: turn clockwise until it will no longer turn.

Chapter 2 Operation / Maintenance

Page 94 October 2002
 Troubleshooting
VI.E. Drive Circuit Pressure, G0 Loaders, continued
Follow three steps on previous page, regarding the three valves in the figure below.

Pressure
Reducing
Valve #‘1

At the rear of
valve housing:
Pressure
Reducing
Valve #2

Drive
Circuit
Relief

Figure 109: Adjust Valves

Make sure both emergency stop buttons are pulled out and start engine. Put loader in LOAD
mode (stabilizers down). With the help of an assistant, go to the main electric box and press the
Low Demand button on the Engine / Elevator side of the Diagnostic Center.
While pressing Low Demand:
4. Turn adjustment screw on pressure reducing valve #1 clockwise until gauge reads 31 bar /
450 psi.
5. Turn adjustment screw on on drive circuit relief counterclockwise until gauge reads 29,3 bar /
425 psi and tighten jamnut.
Continuing to press Low Demand:
6. Turn adjustment screw on pressure reducing valve #1 counterclockwise until gauge reads
20,7 bar / 300 psi and tighten jamnut.
7. Turn adjustment screw on pressure reducing valve #2 clockwise until gauge reads 22,4 bar /
325 psi and tighten jamnut.
Release Low Demand button on the Diagnostic Center, stop engine, remove pressure gauge.
Procedure is done.

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Troubleshooting
VII. Auto-Level Option Troublshooting
VII.A. Operation
This is intended to explain operating parameters of the auto-level option and to provide set-up
and troubleshooting suggestions. The auto-level design covered herein is the sensing clip and
cable type design, where the operator manually clips the cable to the aircraft doorsill.
The loader must be driven up to within several centimeters / inches of the aircraft and the bridge
must be at the optimum interface height. This is done using drive panel operating controls. The
auto-level cable is then clipped to the aircraft doorsill. The red switch cover over the On/Off
switch is lifted to turn the system ON and the green LED on the auto-level placard is lit. This
means the DC system is activated and ready.
With auto-level ON, bridge lift controls are dead and auto-level has priority over controlling
bridge height within a 1,3 cm / 0.5” range of motion. Elevator lift controls operate as usual
(although, if elevator is interfaced with bridge and bridge is adjusted down, elevator will also be
adjusted down automatically by auto-level). There is a stand-by feature which allows bridge
cargo transfer functions to be done before automatic bridge height adjustments are made.

VII.B. Reset Safety Shutdown

There are two safety shutdowns. If the cable is extended or retracted more than 2,6 cm / 1”
from starting position, bridge lift and cargo transfer functions will shut down to prevent damage
to the aircraft. A red, flashing LED: “Safety Shutdown” on the placard indicates the condition.
The second shutdown condition occurs after a timedown of 1.5 seconds. If auto-level cannot
find correct height adjustment in this time, the same shutdown described above occurs.
To reset auto-level after shutdown:
1. Turn auto-level system OFF.
2. Make sure sensing clip is secure.
3. Realign bridge and aircraft heights.
4. Turn ON auto-level system.

VII.C. LED Diagnostics on Auto-Level Board

The auto-level board, located in the load panel console, features LED diagnostics. These LED
indicators show which systems are currently being activated, as follows.
INPUTS (signals received by the board)
Yellow LED: Elevator and Bridge Interfaced
Green LED: Request for Bridge UP (from auto-level)
Yellow LED: Request for Bridge DOWN (from auto-level)
Amber LED: System Stand-by Mode
Red LED: Out of Bounds Cable Snagged
OUTPUTS (signals given by the board)
Green LED: Bridge UP command
Yellow LED: Bridge DOWN command
Yellow LED: Elevator DOWN command
SYSTEM STATUS LAMP (2-color LED)
Green = System activated and OK
Flashing Red = Safety shutdown mode

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 Troubleshooting
VII. Auto-Level Troublshooting, continued
VII.D. Checking Voltages and Currents
If it is necessary to check voltages and currents:
Supply voltage to circuit board = 11 to 17V DC
Supply voltage to rotary encoder = 5.0V DC
Supply current to circuit board = 31 mA max.
Supply current to rotary encorder = 26 mA max.
Output from rotary encoder = 2-bit grey code
400 Hz
–40˚C to 85˚C (–40˚F to 185˚ˆF)

VII.E. Test Setup Procedure

1. Start engine and put loader in LOAD mode. Raise bridge to a height to allow some movement
and to use a forklift at the front to “manipulate” the clip and cable by plus/minus 0,65 cm / 0.25”.
2. Bring loader and forklift “nose-to-nose” with fork directly over auto-level box, clip cable to
fork, and turn ON auto-level system. Check for green LED on auto-level placard on the console.
3. Check that bridge flat-top chains move in forward and reverse directions.
4. Lift fork by 0,65 cm / 0.25” and stop. The auto-level system should adjust bridge height.
Repeat this, up and down, nine times. Note that movement of the cable does NOT cause
instant movement of bridge height. Note that the distance between the fork and the bridge
should stay constant after every adjustment.
5. Now lift the fork by 3,2 cm / 1-1/4” to make sure auto-level system goes into safety shutdown
mode. Test bridge flat-top chains to make sure they do NOT move in forward or reverse. Check
for flashing red LED on auto-level placard on the console.
6. Turn OFF auto-level (see reset procedure on previous page). Readjust heights of fork and
bridge to allow for lowering by 3,2 cm / 1-1/4” for next step (#7). Turn auto-level system ON.
7. Now lower fork by 3,2 cm / 1-1/4” to make sure auto-level system goes into safety shutdown
mode. Test bridge flat-top chains to make sure they do NOT move in forward or reverse. Check
for flashing red LED on auto-level placard on the console.
8. Turn OFF auto-level (see reset procedure on previous page), readjust heights of fork and
bridge to starting point, and turn auto-level system back ON.
9. Lift and lower fork very, very slowly – up and down within the allowable 1,3 cm / 0.5” range of
motion – but not stopping for 2 seconds. This way, the safety shutdown is triggered because of
the timedown, but not because of the distance. Again, make sure auto-level system goes into
safety shutdown mode. Test bridge flat-top chains to make sure they do NOT move in forward
or reverse. Check for flashing red LED on auto-level placard on the console.
10. If everything checks out, auto-level system is in correct operating condition. Turn system
OFF, lower bridge, turn engine off. End of procedure.

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