Wheel Loader Training Manuel

WHEEL LOADER
”SERIE 21 C’’
TRAINING MANUEL
ENGLISH VERSION
09/ 2000 Training Center
21C SERIES WHEEL LOADERS 1 - INTRODUCTION
TRAINING MANUAL
INTRODUCTION
page
“21C SERIES” WHEEL LOADERS PRESENTATION ............................................1.02.00
GENERAL SPECIFICATIONS................................................................................1.04.00
DESIGN..................................................................................................................1.05.00
DRIVING POSITION ..............................................................................................1.06.00
CONTROLS AND SAFETY FEATURES ..............................................................1.08.00
CHECKING THE GENERAL CONDITION OF THE MACHINE ............................1.10.00
MAINTENANCE TABLE..........................................................................................1.11.00
SERVICING PRODUCT GUIDE ............................................................................1.12.00
Training Center 1.1.00

1 - INTRODUCTION 21C SERIES WHEEL LOADERS
TRAINING MANUAL
“21C SERIES” WHEEL LOADERS PRESENTATION
1.2.00 Training center

TRAINING MANUAL
“21C SERIES” WHEEL LOADERS PRESENTATION

POWER UNIT
The “21C Series” wheel loaders are powered by 6 cylinder in-line turbo- Case 6T830
diesel engines of the following types.
✸ On 621 C : Case 6T590 99 kW (135 hp) at 2000 rpm.
✸ On 921 C : Cummins M11C 270 201kW (274 hp) at 1800 rpm.
TRANSMISSION:
Power on these machines is transmitted by a “power-shift” transmission,
with 4 forward speeds and 3 reverse of the following types:
✸ On 621C "4WG160 ZF" ✸ on 721C "4WG190 ZF"
✸ On 821C "4WG210 ZF" ✸ on 921C "4WG260 ZF"
The ”fully powershift” transmission allows automatically the gear
shifting from 1 rst to 4 th according the load on the transmission and
on the engine .
An electronic controler controles the gear shiftings and protects the
machine and the operator from incorrect operations; (over speed).
Downshift function"
In automatic mode every time the button is pressed this feature kicks
down one gear.
In manual mode this function enables the transmission to pass from
second to first speed simply by pressing the button located on the
button located on the attachment control lever knob.
ATTACHMENTS
Two types of attachment geometry are offered :
✸ on 621C - 721C - 821C -921C "Z" bar geometry

✸ on 621C XT- 721C XT parallel geometry
✸ on 621C XR- 721C XR - 821C XR -921C XR
extended "Z" bar geometry
STABILITY AND MANOEUVRABILITY
The perfect balance of these machines is due to a long wheel base and
also a good combination between, on the one hand, the tipping load
and the break-out force, and on the other hand, the lifting capacity.
Add to this:
Steering by central pivot at 40°.
A rear axle mounted on an articulated cradle, enabling the machines to
cross uneven ground without twisting the chassis.
COMFORT AND SIMPLICITY
These machines are fitted with ROPS and FOPS standard cabs which
give the driver maximum comfort inside, due to high standard
soundproofing, and adjustable suspended seat, total visibility and
carefully positioned and efficient controls..
Training center 1.3.00

TRAINING MANUAL
GENERAL SPECIFICATIONS
The data shown below are with 20.5 x 25 XHA tyres for 6/7/821C and
26.5 x 25 XHA for 921C.
Standard attachments, ROPS and FOPS cabs, driver, standard counterweight and full
tanks.
The dimensions and specifications are to ISO 8313, 5998, 7546 and for EN 474-3.
MACHINE TYPE 621C 721C 821C 921C
TYPE OF BUCKET (SAE capacity with dome) . . . . . . . . . m3 1,70 2,10 2,80 4,10
Bucket width ....................................................m 2,50 2,50 2,75 3,20

Bucket weigt ....................................................kg 740 835 1260 2140
Overall dimensions: :
A Maximum unloading height with bucket at 45°..............................m 2,87 3,01 2,891 2,83
B Reach at maximum height with bucket at 45° ..............................m 1,00 0,95 1,18 1,39
C Reach at 2.13 m height with bucket at 45° ..................................m 1,48 1,54 1,73 1,90
D Overall length ....................................................m 6,83 6,89 7,56 8,99
E Overall height ....................................................m 4,81 5,03 5,39 5,81
F Digging depth ..................................................mm 57 71 89 45
G Wheel base ....................................................m 2,90 2,90 3,20 3,40
H Length of pivot on front axle ....................................................m 1,45 1,45 1,60 1,70
J Ground clearance ....................................................m 0,42 0,42 0,40 0,44
K Maximum height of cab ....................................................m 3,26 3,26 3,34 3,57
L Maximum height at bucket pin ....................................................m 3,70 3,81 3,95 4,28
Track ....................................................m 1,88 1,89 2,08 2,21
Width tyre outer ....................................................m 2,43 2,44 2,70 2,95
Turning diameter at bucket ....................................................m 11,53 11,62 12,61 13,91
Break-out force ................................................daN 10780 14970 15225 20300

Tipping load in line ....................................................kg 9770 10441 14010 20515
Tipping load turned to 40° ....................................................kg 8330 8706 11530 16645
All up weight ....................................................kg 12630 13900 17520 24212

TRAINING MANUAL
DESIGN
CHASSIS
The undercarriage is made from two welded box sections.

1. Front box section
2. Rear box section
They are connected by a pivot which enables the machine to be
steered.
The front axle (4) is fitted rigidly to the front box section.
The rear axle (5) is fitted on a pivoting cradle (3) with an oscillation of
maximum 24 o, enables the machine to cross uneven ground up to an
uneven level of
❍ 621C : 391 mm ❍ 721C : 412 mm

❍ 821C : 442 mm ❍ 921C : 470 mm
TRAVEL SPEEDS
2 1
The power of the engine is transmitted to the front and rear axles via a 5 4 6
torque converter and a “Power-shift” type gearbox (4 forward speeds
and 3 reverse speeds).
1SRT 2ND 3RD 4TH

FW / RV FW / RV FW / RV FW
621C 7,0 / 7,4 13,5 / 14,2 23,6 / 24,9 37,4

721C 8 / 8,4 14 / 14,8 26,1 / 27,5 39,0
3
821C 7,8 / 8,6 13,8 / 15,8 25,4 / 26,8 37,9
921C 8,2 / 8,2 14,5 / 14,5 26,7 / 26,7 38,8
TRAVEL SPEEDS
The engine power is transmitted to the front and rear axles via a
torque converter and a fully powershift transmission (4 forward speeds
and 3 reverse speeds).
ATTACHMENTS
The Z geometry of the loader arm (6) gives the machines fitted with
loader bucket high break-out force.
The “parallel arm” version is used for special attachments.

TRAINING MANUAL
DRIVING POSITION
CONTROLS ON STEERING COLUMN
1. Speed change and direction change lever (SP3)

Front : forward drive
N : neutral position 1
Rear : reverse drive
Selecting the 4 forward speeds and 3 reverse speeds is done by
turning the handle (see Chapter 6 - TRANSMISSION)
2. Combination lever with four functions:
✸ right-hand and left-hand flashers.
✸ high and low beam head lamps.
✸ head lamp flash.
✸ horn.
3. Parking brake control switch

Brake engaged the light is on
Brake released the light is off
9
FLOOR CONTROLS
4. Engine accelerator pedal.

5. Right-hand and left-hand brake pedal with stop lamp switch
The switches are on the left side of the left pedal.
ATTACHMENTS CONTROL LEVERS
6 Cross-pattern control lever 2

The detent solonoids are located inside this control
(B3-B4-B5)
1 Bucket unloading 3
2 Digging or return to level of the bucket
3 Lowering the arms or “floating” position of arms.
4 Raising arms 3
4
2 1
5
4
5
7. Option control lever
5 4 in 1 bucket opening
8
6 4 in 1 bucket closing
6
8. Quick Downshift switch 7
9. Hydraulic locking switch (road safety)
This switch enables hydraulic flow to be cut off to the control levers
(6) and (7) of the attachments. With the light on, the pilot pressure is
off

TRAINING MANUAL
DRIVING POSITION
ATTACHMENT AUTOMATIC CONTROLS
18. Transmission cut-out selector switch (ST4). ST4 ST1 ST2
The transmission cut-out enables all the power of the engine to be
applied to the hydraulics when the “digging” and “lifting” functions
are being used.
The switch (ST4) turns the transmission cut-out function on or off.
When on the cut-out is controlled by the switch (SD5) located under
the left-hand brake pedal.
19. Detent switch (ST1)

This switch turns on the detent solonoids located in control lever 18 19 20
(14) which enables the following functions to be used:
✸ Bucket return to dig
The control is cancelled by the proximity detector (SD1).
✸ “Floating arm” position.
✸ Bucket return to transport position. SD1 SD3
✸ Lifting the bucket to the controlled unloading height.
SD2
20. Automatic functions switch (ST2)
Position A “Floating arm” position and return to transport position
Position B “Floating arm” position alone.
21. Bucket quick hitch locking switch (ST3).

Only on 621C XT and 721C XT.
22
22. Four position starting key switch (SP2)
ACC Supply goes to radio only.
ON Supply goes to all electrical circuits.
START Turns on the engine starter motor.
OFF Stops the engine.
2
VARIOUS CONTROLS
23 Air conditioning system control.

24 Blower control.
25 Heater mechanical control.
26 Lighting switch.
27 Front washer and wiper switch.
28 Transmission mode switch (auto / manual) 27
29 Ride control switch.
30 Rear washer and wiper switch.
31 Rotating beacon switch. 28 29
32 Rear fog light switch. 25
23 31
30 32
26
24

TRAINING MANUAL
DRIVING POSITION - INSPECTIONS AND SAFETY ITEMS
33 34 35 36
43 44
41 42 45
40 46
39 47
38 48
49
37
58 50
51 54
52
55
56
53
57
59
Switches
33 Hazard switch. 34 Pilot pressure control switch.
35 Up / Down count switch 36 Program / Reset switch.
Lights and bar graph lights

37 Rear Fog light 38 Beacon indicator.
39 Work lights indicator 40 Pilot control actuator
41 Low coolant indicator 42 Brake pressure indicator
43 Stop master indicator (Stop the engine) 44 Caution master indicator
45 Secondary steering indicator 46 Parking brake indicator
47 Air conditioning pressure indicator 48 Air filter indicator
49 Hydraulic oil filter indicator 50 Transmission oil filter indicator
51 Engine coolant gauge 52 Engine oil pressure gauge
53 Fuel level gauge 54 Transmission temperature gauge
55 Hydraulic oil temperature gauge 56 Volt meter gauge
57 High beam lights indicator. 58 Information center display.
59 Transmission display.
CAUTION when :
Stop master indicator 43 is on : stop the machine and the engine.
Caution master indicator 44 is on : A service or a fault diagnosis must be done.

TRAINING MANUAL

TRAINING MANUAL
CHECKING THE GENERAL CONDITION OF THE MACHINE

To the check the general condition of a SERIES 21C machine without disassembling any parts, the “STALL” or “STALLING POINT” tests
should be made.
For this, first bring the engine and transmission up to normal operating temperatures..
■ CHECK THE ENGINE SPEED
621C & 621CXT 721C & 721CXT 821C 921C
Idling speed : 950 - 1050 950 - 1050 950 - 1050 950 - 1050 RPM
Full no load speed : 2375 - 2460 2375 - 2460 2375 - 2460 2200 - 2300 RPM
■ PERFORM “STALL” TEST

❒ Combined “STALL” (Torque converter + hydraulic loader)
On 621C : 1490 to 1720 RPM
On 621C XT : 1490 to 1720 RPM
On 721C : 1490 to 1720 RPM
On 721C XT : 1490 to 1720 RPM
On 821C : 1700 to 1925 RPM
On 921C : 1400 to 1650 RPM
a - Disengage the parking brake and select the transmission manual mode.
b - Immobilise the machine using the right-hand brake pedal and do not select the declutch mode.
c - Select fourth gear in forwards direction
d - Maintain the hydraulic control “loader arm raise” at maximum position forcing the main relief valve to open.
e - Read the revolution counter.
If the result is correct, this shows that the engine and hydraulic power are both correct and that the drive train is in good condition.
If the result is not correct, conduct the two individual "STALL" tests.
❒ “STALL” test for torque converter only: (proceed as for steps a b c and e)
On 621C : 2040 to 2240 RPM
On 621C XT : 2040 to 2240 RPM
On 721C : 2070 to 2240 RPM
On 721C XT : 2070 to 2240 RPM
On 821C : 2045 to 2225 RPM
On 921C : 1900 to 2100 RPM
If the result is not correct, this shows a defect in the torque converter or the transmission.
If the result is correct, conduct the hydraulic "STALL" test.
❒ Hydraulic “STALL” test for hydraulic system only: (proceed as for steps d and e)
On 621C : 2110 to 2250 RPM
On 621C XT : 2110 to 2250 RPM
On 721C : 2110 to 2250 RPM
On 721C XT : 2130 to 2250 RPM
On 821C : 2250 to 2310 RPM
On 921C : 2100 to 2200 RPM
❒ STALL results”
If the result is not correct, this indicates a defect in the hydraulic circuit (pressure or flow).
If the results of the separate “STALL” two tests are correct, but the “Combined STALL” test is not, this indicates a lack of power

TRAINING MANUAL
MAINTENANCE OPERATIONS ON 21C SERIES WORKING HOURS MAINTENANCE INTERVALS

10 50 100 200 250 500 1000 2000 NEEDS
Check the engine oil level.................................................... ●

Check the fan belt condition ................................................ ●
Check for any leaks ............................................................. ●
Check hydraulic oil level ...................................................... ●

Check coolant liquid level .................................................... ●
Check transmission oil level ................................................ ●
Check fuel circuit filter bowl ................................................. ●
Lubricate bucket pins........................................................... ●
Lubricate steering cylinder pivots ........................................ ●
Lubricate universal joint intermediate bearings ................... ●
Lubricate rear axle pivot beam ............................................ ●
Lubricate loader pivots......................................................... ●

Lubricate rear universal joint slider...................................... ●
Drain the axles and transmission, replace its filter (1st 100h) ........ ●
Change engine oil................................................................ ●

Change engine oil filter ........................................................ ●
Check axle oil levels ............................................................ ●
Check batteries liquid level.................................................. ●
Clean cab air filters .............................................................. ●
Calibrate the transmission clutches(1st 250h)....................... ●
Change cooling circuit water filter (7-8-921C) ..................... ❍
Lubricate cab door hinges ................................................... ●
Lubricate accelerator pedal bearing .................................... ●
Change the fuel filter............................................................ ●

Bleed water from the fuel tank............................................. ●
Change the hydraulic filters ................................................. ●
Lubricate universal joint and centre bearing ....................... ●
Check the cab mounting...................................................... ●
Adjust valve rockers............................................................. ●

Change hydraulic oil ............................................................ ●
Clean hydraulic tank and screen ......................................... ●
Change transmission oil ...................................................... ●
Change transmission oil filter............................................... ●
Clean transmission and axle breather ................................. ●
Lubricate both chassis pivot points...................................... ●
Calibrate the transmission clutches ..................................... ●
Change axle oil .................................................................... ●

Drain and clean the cooling circuit and refill ........................ ●
Change the cooling system load filter (921C)...................... ●
Change engine air filters...................................................... ●
Clean engine air filter........................................................... ●

Change hydraulic filter (when warning light is on) ............... ●
Tighten wheel nuts to torque ............................................... ●

TRAINING MANUAL
SERVICING PRODUCTS
CAPACITiES
COMPONENTS RECOMMENDED PRODUITS
621C 721C 821C 921C
Fuel tank 193 l. 204 l. 272 l. 394 l No 2 diesel fuel
Cooling system 26,5 l. 32,2 l. 32,2 l. 47,3l 50% ethylene glycol + 50% water (above)- 37°C)
Engine oil :
with filter change 15,1 l. 20,8 l. 20,8 l. 36,9 l Engine oil : (SAE 10W30)
Hydraulic oil :
- Complete circuit 153,1 l. 153,1 l. 174,2 l. 232 l CASE trans fluid XHD or Dexron 3
- Tank only 90,1 l. 90,1 l. 90,1 l. 125 l
Transmission 6-7-821C:
Gear box + filter 19 l 22,7 l 27,5 l 27,5 CASE Number One (SAE 15W40)
Complete transmission circuit 25 l. 35 l. 35 l. 47 (See service buletin FAR 6014)
Axles (old type) ZF AP ZF AP ZF AP GKN

- Front differential 8,5 l. 13,7 l. 18,9 l. 36,3 l CASE fluid 135-HEP (SAE 85W140)
1,0 l. 1,4 l. 1,9 l. 0l + additive (réf : B 91246)
- Rear differential 8,5 l. 8,5 l. 13,7 l 36,3 l CASE fluid 135-HEP (SAE 85W140)
1,0 l. 1,0 l. 1,4 l. 0l + additive (réf : B 91246)
- Front planetary 5,7 l. 5,7 l. 6,2 l. 13,6 l CASE fluid 135-H EP (SAE 85W140)
- Rear planetary 5,7 l. 5,7 l. 5,7 l. 13,6 l CASE fluid 135-H EP (SAE 85W140)
Axles (new type)

MT-L Multitrac serie 3000
- Front 24 l. 30 l. 30 l. 51 l CASE fluid 135-HEP (SAE 85W140)
Rear 24. 24 l. 30 l. 51l with 6% of additive (réf : B 91246)
Batteries As As As As
required required required required Add distilled water
Grease fittings As As As As
required required required required Molybdenum bisulphide grease
A/C circuit 1,6 kg 1,6 kg 1,6 kg 1,6 kg Fluide HFC134a

4 - ELECTRICS 21C SERIES WHEEL LOADERS
TRAINING MANUEL
ELECTRICS
Pages
ELECTRICAL COMPONENT LAYOUT IN THE RIGHT SIDE OF THE CAB ............................................................................ 4.02.00
FUSES, RELAYS, AND OTHER ELECTRONIC COMPONENTS (DESCRIPTION / SPECIFICATION).................................. 4.03.00
ELECTRICAL SCHEMATIC ....................................................................................................................................................... 4.04.00 to 4.17.00

- Rotating beacon, stop switch, hazard switch, turn signal / HI-LOW beam /horn switch, flasher module ................. 4.04.00
- External lights and signals, rotary lamp switch and cab light (European models) ................................................... 4.05.00
- Fog light, LOW-HI beam lights and cab lights........................................................................................................... 4.06.00
- 621C 721C 821C power control and distribution, fuel shut off, charge , starter motor, ............................................ 4.07.00
- 921C power control and distribution, fuel shut off, charge , starter motor, ignition switch ...................................... 4.08.00
- Ignition relay, accessory relay, voltmeter relay, starter motor, ignition switch ........................................................... 4.10.00
- Transmission solenoid, sensor and switches, contriol modul, shifter, back-up alarm ............................................... 4.11.00
- Senders, indicators, program reset, park brake switches - IDC pilot control & Up/Down count switches ................ 4.12.00
- Engine oil pressure sender, pilot control, parking brakerelays and solenoid, redundant brake switches ................. 4.13.00
- Bucket controls and secondary steering ................................................................................................................... 4.13.00
- Quick coupler control and ride control circuit ............................................................................................................ 4.14.00
- Wiper / Washer,n air suspension seat, horn ............................................................................................................ 4.15.00
- Cab blower, air conditioning...................................................................................................................................... 4.16.00
- Cigar lighter, power converters, radio and speakers................................................................................................. 4.17.00

TRAINING MANUEL
FUSES, RELAYS AND COMPONENTS
2
A
L
X
B M
3 Y
1 N
1 C
Z
P
D A’
R
4
E B’
F S
C’
G T
D’
7
R13
5 H U E’
6 J V F’
2
R7
K W G’
R8
R1 R9 C1 C5
C6
R2
C7 C11 C12
3
R3 R10
C13
R4 R11 C18
R5 R12 C15 C16

C17
R6

TRAINING MANUEL
FUSES, RELAIS and COMPONENTS
COMPONENTS FUSES
1 Transmission electronic control module (TECM) A 7,5A Transmission control module

2 Time delay module B 5A Flasher unit
3 Flasher unit C 5A Ride control and pilot pressure
4 Charging resistor (75 OHM) D 5A Parking brake
5 12,5 A circuit breaker E 10A Ether start
6 12,5 A circuit breaker F 5A Automatic engine shutoff
7 Suppression diode module G 15A Cab blower
C1 24Volts connector H 5A Back up alarm
C5 Radio connector J 10A Wiper and washer (front)
C6 12 Volts connector K 10A Wiper and washer (rear)
C7 24 Volts connector L 7,5A Radio converter
C11 Convertor connector M 7,5A Auxiliary steering
C12 12 Volts connector N 10A Air suspension seat
C13 24Volts connector P 7,5A Quick coupler
C15 Not used R 7,5A Emergency steering
C16 Cigar lighter connector S 5A Information center
C17 24 Volts connector T 7,5A Transmission control module
C18 12 Volts connector U 7,5A Engine compartment light
V 7,5A Volmeter relay
RELAYS W 15A Cigar lighter
R1 Ignition relay X 7,5A Rotating beacon
R2 Ignition relay Y 7,5A Fog light
R3 Accessory relay Z 10A Work light (front)
R4 Ride Control relay A’ 10A Work light (rear)
R5 Horn relay B’ 5A High beam light (left)
R6 Ether start relay (US) C’ 5A High beam light (right)
R7 Back up alarm relay D’ 5A Low beam light (left)
R8 Neutral start relay E’ 5A Low beam light (right)
R9 Parking brake relay F’ 5A Tail light (left)
R10 Pilot pressure relay G’ 5A Tail light (right)
R11 Automatic engine shutoff relay
R12 Volmeter relay
R13 Low / high beam relay

TRAINING MANUEL
ROTATING BEACON FLASHER MODULE

1 CAB POSITIVE STUD 1
2 CAB SWITCHED POWER 2

3 INSTRUMENT ILLUMINATION 3
O (19X) 1.0
30
SPLICE WITH TIME DELAY FLASHER MODULE
CIRCUIT BREAKER B 12 A MODULE GROUND SHEET 10 101
PED CAB
R (1B) 0,8
R (1B) 0.8
R (1B) 0.8 1 POWER IN
TO SPLICE 4 B (1B) 0.8 65
SHEET 8 DBr (45N) 0.8 2 FLASHER OUT
1 B (0) 1.0 3 GROUND
B (0) 1.0 B (0) 1.0 4 GROUND
Gy (49) 0.8P
Gy (49) 0.8
R (1B) 0.8 S 13 5 NC
13 6 NC
CAB FRONT
PED DBr/LG (45R)) 0.8 7 R TURN LIGHT OUT
DBr/Y (45L) 0.8 8 L TURN LIGHT OUT

TO PILOT CONTROL 15 CAB
96 SWITCH SHEET 16
HAZARD SWITCH DBr/LG (45B) 0.8 9 RIGHT TURN SWITCH
2 DBr/Y (45A) 0.8 10 LEFT TURN SWITCH
R (1B) 0,8
2 D Br (45H) 0.8 DBr (45H) 0.8 11 HAZARD SWITCH
67
Gy (49) 0,8 O (19B) 0.8 DBr (45N) 0.8 12 OPPOSITE SIDE CONTROL
66
TO BACK-UP ALARM TO FUSE B PAGE 8
6
DISEMABLE
TO BACK-UP ALARM SWITCH, SHEET 12 5
6 64 62
DISEMABLE B (0) 0.8
5 B (0) 1.0
SWITCH, SHEET 12 4
TO PILOT CONTROL NOT CONNECTED ON EUROPEAN MODELS
4 71 SWITCH SHEET 16
BEACON SWITCH
99
42 4
2 TO CLUSTER CAVITY 35 PAGE 16
P (46) 1.0
4 31
1
NC 1 32
3 C 4 T (44) 1,0
O (19B) 0,8
CAB FRONT
TO INSTRUMENT CLUSTER NO 2 T (44) 1,0 X
CAVITY 13 SHEET 14
98 DBr/Y (45L) 0.8 A DBr/Y (45L) 1,0
STOP LAMP SWITCH DBr/LG (45R) 0.8 C DBr/LG (45R) 1,0
P (46) 0,8
CAB 94
23 21
CAB
ROOF 10 DBr/Y (45L) 1.0 9
TO RR WIPER DBr/Y (45L)) 1.0 33
MOTOR GROUND 12 DBr/LG (45R) 1,0 11 DBr/LG (45R)) 1,0
SHEET 25
34
T (44) 1,0 8 T (44) 1,0 7 T (44) 1,0
CAB REAR REAR REAR LIGHT

PED CAB 35
DBr/LG (45B) 0,8 70
P (46) 1,0
B (0) 1,0
TO CLUSTER CAVITY 17 SHEET 17
DBr/Y (45a) 0,8 69
13
A B DBr/Y (45L) 0.8 TO CLUSTER CAVITY 18 SHEET 17
B (0)1 0.0
85 TURN SIGNAL
HI/LOW BEAM
ROTATING BEACON & HORN SWITCH
H
4 B (0) 0.8
B (0)1 0.0
R
M
5 13
L
68
H/L A4 O/LB (64D) 0,8 55 O/LB (64D) 0,8 36
42 O/LB (64C) 0,8 TO HORN RELAY 5 SHEET 26
100 41 B (0) 0.8
97 66 67
B (0) 0.8 PED CAB
O/LB (64C) 0,8
4 CAB NEGATIVE STUD 4
SHEET 1 SHEET 2
ABBREV. COLOR ABBREV. COLOR ABBREV. COLOR

LEGEND
B BLACK DG DARK GREEN O/R ORANGE/RED CIRCUIT TAG WIRE SIZE
BR BROWN Gy GRAY O/W ORANGE/WHITE
BR/W BROWN/WHITE LBe LIGHT BLUE P PINK Y (35R) 1.0 MALE TERMINAL FEMALE
RED COLOR INDICATES INLINE TERMINAL
BR/Y BROWN/YELLOW LGe LIGHT GREEN R
CONNECTION X
DBe DARK BLUE O ORANGE T TAN
WITH TERMINALS
DBr DARK BROWN O/Be ORANGE/BLUE V VIOLET (PURPLE) CAB|FRONT
XXX CONNECTOR NO.
DBr/LG DARK BROWN/LT GREEN O/G ORANGE/GREEN W WHITE CAVITY INDICATES
DESIGNATION INTERFACE
DBr/Y DARK BROWN/YELLOW O/LB ORANGE/LT BLUE Y YELLOW

TRAINING MANUEL
EXTERNAL EUROPEAN LIGHTS
2 CAB SWITCH POWER 2

O (19X) 1,0 30
30
LEFT FRONT LEFT HEAD LAMP RIGHT HEAD LAMP RIGHT FRONT
LOW:HIGH BEAM RIGHT SIDE TURN RIGHT FRONT MARKER LAMP
LEFT FRONT LEFT SIDE TURN (ITALY) COMBINATION LAMP LOW/ HIGH BEAM COMBINATION LAMP
(ITALY)
MARKER LAMP
TURN MARKER LOW HIGH HIGH LOW MARKER TURN
119 123 124 120

125 129 130 126
B (0) 1,0
DBr (45) 1,0
BLACK 0.8
DBr (45) 1,0
RED 0,8
RED 0.8
B (0) 1,0
BLACK 0,8
B (0) 1,0
O (18D) 1,0
O (18B) 1,0
O (18G) 1,0
B (0) 1,0
B (0) 1,0
O (18F) 1,0
DBr (45) 1,0

B (0) 1,0
B (0) 1,0
DBr (45) 1,0
D (18C) 1,0
B (0) 1,0
O (18E) 1,0
A B B A
A B B A
129 131 132
131
DBr/Y (45) 1.0
B (0) 1.0
B (0) 1.0 B (0) 1.0
O (18F) 1.0 O (18G) 1.0
B C A
A C B
121 124
A C B B C A FRONT / CAB
31 DBr/Y (45L) 1.0 122 123 37
1
32 DBr/G (45R) 1.0 38
O (18E) 1.0 P 39
O (18C) 1.0 Q
O (18G) 1.0 E 40
O (18B) 1.0 G
O (18D) 1.0 O 41
O (18F) 1.0 F
42
B (0) 2.0
33 DBr/Y (45L) 1.0
94
34 DBr/LG (45R) 1.0 DBrLG (45R) 1.0
T (44) 1.0 T (44) 1.0 REAR LIGHT / REAR

35
O (18G) 1.0 6 43
B (0) 2.0 8
O (18F) 1.0 17 44
P (41F) 1.0 10
45
P (18F) 1.0
125 D C A B 126 126 127

P (18G) 1,0
B (0) 0.8 132 B A C D
119 A B
R (0) 0.8 ENGINE A B
COMPARTIMENT 120
B (0) 1,0
A
O (18F) 1,0
B
137 LAMP
P (41F) 1,0
B (0) 1,0
P (41T) 1,0
DBr (45) 1,0
T (44) 1,0
B A
P (41TF) 1,0
B (0) 1,0
DBr (45) 1,0
T (44) 1,0
B (0) 1,0
P (41T) 1,0
B (0) 1,0
RED 0.8
BLACK 0.8
128
RED 0,8
133 ENGINE
B (0) 1,0
BLACK 0,8
COMPARTIMENT
LAMP SWITCH
121 127 REAR B A
LICENCE LAMP 135 BROUIL. VEIL. STOP CLIG.
128 122
LEFT REAR TURN. STOP MARKER. FOG. TO REAR CAB
O (19U) 1.0
MARKER LAMP CONNECTOR RIGHT REAR
131 SHEET 3 MARKER LAMP
RIGHT REAR COMBINATION LAMP
B (0) 1,0
LEFT REAR COMBINATION LAMP

SHEET 3A

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.
Centre de formation
4.5.00
TRAINING MANUEL
LIGHT SWITCH, LOW/ HIGH BEAM RELAY, AND WORKING LAMPS

2 CAB SWITCH POWER 2

RIGHT FUSES
30 O (19X) 1.0 FUSE X BEACON (7,5)

R (19Y) 1,0 FUSE Y FOG LIGHTS (7,5A)
TO CLUSTER CAVITY 15 FUSE Z FRONT FLOOD LIGHTS AND ILLUMINATION (10A)
SHEET 15 O (18C) 0.8
FUSE A REAR FLOOD LIGHTS (10A) LEFT FRONT LEFT REAR RIGHT REAR RIGHT FRONT
FUSE B LEFT HIGH BEAM (5A) WORKING LAMP WORKING LAMP WORKING LAMP WORKING LAMP
FUSE C RIGHT HIGH BEAM (5A)
FUSE D LEFT LOW BEAM (5A)
FUSE E RIGHT LOW BEAM (5A)
113 114 115 116
FUSE F LEFT MARKER LIGHTS (5A)
R (1) 3,0
R (1) 3,0
FUSE G RIGHT MARKER LIGHTS (5A)
NO CONNECTION
18 ON EUROPEAN MODELS
P (41L) 0.8 P (41J) 0.8 117
DBe (42C) 1,0

DBe (42R) 1,0
CAB DOME LIGHT B (0) 1,0
B (0) 1,0
DBe (42R) 1,0
B (0) 1,0
DBe (42C) 1,0
B (0) 1,0
O (18E) 0,8
O (18D) 0,8
O (18B) 0,8
O (18A) 2,0
O (19Z) 1,0
Gy (49) 0,8
O (18F) 0,8
O (18B) 0,8
O (18F) 0,8
COURTESY
O (18G) 0,8
111 LOW / HIGH BEAM RELAY B A B A A B A B LIGHT
118 79 83 80
78
8 TO ENGINE COMPARTIMENT LIGHT DBe (42R) 1.0
30
ON SHEET 3 (6- 7 - 821C ONLY) B (0) 1.0
P (41H) 2.0 4
56a
1 DBe (42C) 1.0
56 7
37 P (41L) 2.0 3
O (18G) 0,8
56b
38 21 B (0) 1.0 B A
O/LB (64D) 0.8 6 59
S
39
B (0) 0.8
40 Gy (49) 0.8
77
41 P (41J) 2.0 O (19U) 1.0
42 23 24
P (41T) 1.0
TO FUSE U SHEET 10
O (19U) 1.0
CONNECTED O (19U) 0.8
ON EUROPEAN
O (18A) 2.0 MODELS
43 TO CAB/PED CONNECTEOR
CAVITY 12 SHEET 14
DBe (42R) 0.8
B (0) 1,0
B (0) 1,0
B (0) 1,0
O (19Z) 1.0
Gy (49) 0,8
44 DBe (42R) 0.8

Gy (49) 0.8
45 P (41F) 1.0
TO RETURN Gy (49) 0.8
TO CLUSTER CAVITY 14 TO TRAVEL
SHEET 14
P (41T) 1.0
SWITCH SHEET 19
DBe (42C) 1.0

TO BEACON SWITCH
SHEET 1
Gy (49) 1.0
LIGHTS - LAMPS
FOG
34 SWITCH
2
LIGHT 32 LOW WORKING
33 POSITION MARKER INSTRUMENT
SWITCH BEAM LAMPS
25 ILLUMINATION
TO BEACON SWITCH
110 6 SHEET 1 HD TL F4 81 IL F1 83 F3 F2 82
B (0) 1.0
1 OFF OFF OFF OFF
36 5 3
4 2 3 4 2 4
2 3 2 ON OFF OFF OFF
1 5 5 5
4 1 1
112 3 ON ON OFF ON
4 ON ON ON ON
43 5 ON OFF ON ON
5 POSITION ROTARY LAMP SWITCH
SHEET 4 SHEET 5

LEGEND
CONNECTION X
DBeDARK BLUE O ORANGE T TAN
WITH TERMINALS
DBrDARK BROWN O/Be ORANGE/BLUE V VIOLET (PURPLE) CAB|FRONT
XXX CONNECTOR NO.

TRAINING MANUEL
BATTERIES ,POWER CONTROL & DISTRIBUTION, ALTERNATOR, STATER MOTOR, IGNITION, FUEL SUTOFF 821C
R (1) 13.0 CAB POSITIVE STUD 1

R (1) 3.0
CAB POWER STUD
TO 19A SPLICE
RESISTOR ON SHEET 12 5
TO ENGINE SHUTDOWN
75 OHM
RELAY #11 ON SHEET 18 R (1A) 0.8 6
SPLICE #4
LG (14) 0.8 O (19A) 0.8
+ 7
TO CIRCUIT
POS CAB BREAKER B 8
2 R (1) 3.0
NEG 22 ON SHEET 1 R (1) 3.0
ENG
O (13C) 0.8
- CIRCUIT BREAKER A
R (1) 3.0
R (1A) 0.8
22 12.5 AMP IGNITION

R (1) 1.0 TO DIODE MODULE
1 RELAY BOX 21 W (21C) 0.8 ON SHEET 24 13
R (1) 2.0
12 SWITCH
CAB 1 JUNCTION
REAR|CAB
ENG R (1A) 0.8 62
BATTERIES BLOCK 21
IGN BAT.
B-62.0
93 87 R (1A) 0.8 56 O (13K) 0.8
W (21C)1.0 11 W (21C) 0.8
LG (14) 1.0
W (21C) 1.0 ST
W (21K) 0.8 64 W (21K) 0.8
30
+ TO CAB|PED 11
A CONNECTOR 87a R (1A)
R-8.0
POS REAR ON SHEET 12
10 ACC
63 O (12K) 0.8
NEG RELAY BOX LBe (25T) 0.8 9
R-13.0
85 86
86
87
- 6 CAB|PED
D+ 54
O (13C) 1.0
LBe (25T) 0.8
4 69
30
R
85
+
65 NEUTRAL 10
- TO TRANS SHIFTER O (13P) 1.0 11
NEUTRAL POSITION START
W (21C) 0.8
ALTERNATOR ON SHEET 12 ETHER START B (0) 0.8
STARTER RELAY TO SPLICE AT T.E.C.A. TO RELAY #7
B-62.0
RELAY AND SWITCH ON SHEET 12 ON SHEET 12
RELAY
R-19.0
R-8.0
87
9 B (0) 0.8
A FUEL 87 B (0) 0.8 30
W (21C) 1.0
R-62.0
RELAY 12
O (19A) 0.8 87a
B S 30 O (19A) 0.8
PED 52
TO SECONDARY 87a 13
STEERING PUMP/ CAB TO TURN SIGNAL 85 86
86
87
MOTOR ON SHEET 21 R-50.0 M CAB|PED SPLICE
2 W (28C) 0.8 ON SHEET 1
85 86
6A
30
85
TO RIDE CONTROL|CAB PED 13
B 133 5 M SPLICE ON SHEET 15 IGNITION O (13K) 1.0
O (13P) 1.0
LEFT 13 47
MASTER RELAY
52 TO PILOT CONTROL,
O (19E) 1.0
B (0) 0.8
FUSES
B (0) 0.8
W (28P) 0.8
DISCONNECT A RELAY #10 ON SHEET 15
SWITCH STARTER FUSE A TRANS CTRL (7.5A)
O (19B) 0.8
139 TRANS|REAR MOTOR TO PARKING BRAKE, FUSE B FLASHER MODULE (5A)
1 CAB 103 O (19C) 1.0
RELAY #9, ON SHEET 18
B (0) 1.0
B (0) 1.0
FUSE C RIDE AND PILOT CTRL (5A)
W (23F) 2.0
21 REAR
94 O (19C) 1.0
O (19D) 1.0 FUSE D PARKING BRAKE (5A)
W (28P) 1.0 2 W (28P) 1.0 A B FUSE E ETHER START (10A)
TO ENGINE SHUTDOWN,
B (O) 2.0
O (13M) 1.0
W (23F) 2.0
RELAY #11, SHEET 18
RELAY REAR ETHER 14
B C BOX TO RIDE CONTROL LIGHT 8 SOLENOID O (19F) 1.0 FUSE F ENGINE SHUTDOWN (5A)
RELAY #4 TO BLOWER SWITCH
ON SHEET 23 ON SHEET 26 O (19G) 2.0 FUSE G BLOWER SWITCH (15A)
1 2
REAR
O (19H) 1.0 FUSE H BACK-UP ALARM (5A)
W (23F) 2.0 TO BACK-UP ALARM
W (28T) 1.0
93 RELAY #7, SHEET 12 O (19J) 1.0 FUSE J FRONT WIPER AND WASHER MOTOR (10A)
B-62.0
97 ENG|REAR 94
O (19K) 1.0 FUSE K REAR WIPER AND WASHER MOTOR (10A)
134 TO ROTARY WIPER &
B A W (28T) 1.0 A W (28T) 1.0 1 WASHER SWITCH ON SHEET 24
3 C TRESSE
BOBINE BOBINE REAR|REAR LT TO REAR WIPER/WASH 18
92 MOTOR ON SHEET 25
DE MAINTIEN D'APPEL
B (0) 5.0
CAB 7 15
FUEL COLD START
SOLENOID TEMP. SWITCH 16
B (0) 13.0
B (0) 62.0
B (0) 1.0
B (0) 2.0
B (0) 62.0
B (0) 62.0
RR CHASSIS FRT CHASSIS CAB NEGATIVE STUD 4
4A 821C ENG BLOCK 4A
SHEET 6 SHEET 7 SHEET 8

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
BATTERIES ,POWER CONTROL & DISTRIBUTION, ALTERNATOR, STATER MOTOR, IGNITION, FUEL SUTOFF 921C
R (1) 13.0 CAB POSITIVE STUD 1

R (1) 3.0
CAB POWER STUD
TO 19A SPLICE
RESISTOR ON SHEET 12 5
TO ENGINE SHUTDOWN
75 OHM
RELAY #11 ON SHEET 18 R (1A) 0.8 6
SPLICE #4
LG (14) 0.8 O (19A) 0.8
+ 7
TO CIRCUIT
POS CAB BREAKER B 8
2 R (1) 3.0
NEG 22 ON SHEET 1 R (1) 3.0
ENG
O (13C) 0.8
- CIRCUIT BREAKER A
R (1) 3.0
R (1A) 0.8
22 12.5 AMP IGNITION

R (1) 1.0 TO DIODE MODULE
1 RELAY BOX 21 W (21C) 0.8 ON SHEET 24 13 12 SWITCH
CAB 1 JUNCTION
REAR|CAB
ENG R (1A) 0.8 62
BATTERIES BLOCK 21
IGN BAT.
B-62.0
93 87 R (1A) 0.8 56 O (13K) 0.8
W (21C)1.0 11 W (21C) 0.8
LG (14) 1.0
W (21C) 1.0 ST
W (21K) 0.8 64 W (21K) 0.8
30
+ TO CAB|PED 11
A CONNECTOR 87a R (1A)
R-8.0
POS REAR ON SHEET 12
10 ACC
63 O (12K) 0.8
NEG RELAY BOX LBe (25T) 0.8 9
R-13.0
85 86
86
87
- 6 CAB|PED
D+ 54
O (13C) 1.0
LBe (25T) 0.8
4 69
30
R
85
+
65 NEUTRAL 10
- TO TRANS SHIFTER O (13P) 1.0 11
NEUTRAL POSITION START
W (21C) 0.8
ALTERNATOR ON SHEET 12 ETHER START B (0) 0.8
STARTER RELAY TO SPLICE AT T.E.C.A. TO RELAY #7
B-62.0
RELAY AND SWITCH ON SHEET 12 ON SHEET 12
RELAY
R-19.0
R-8.0
87
9 B (0) 0.8
A
87 B (0) 0.8 30
R-62.0 O (19A) 0.8 87a
12
B S 30 O (19A) 0.8
PED 52
TO SECONDARY 87a 13
STEERING PUMP/ CAB TO TURN SIGNAL 85 86
MOTOR ON SHEET 21 R-50.0 M CAB|PED SPLICE
2 W (28C) 0.8 ON SHEET 1
85 86
TO RIDE CONTROL|CAB PED 13
B 5 M SPLICE ON SHEET 15 IGNITION O (13K) 1.0
O (13P) 1.0
LEFT 13 47
MASTER RELAY
52 TO PILOT CONTROL,
O (19E) 1.0
B (0) 0.8
FUSES
B (0) 0.8
W (28P) 0.8
DISCONNECT RELAY #10 ON SHEET 15
SWITCH STARTER FUSE A TRANS CTRL (7.5A)
O (19B) 0.8
139 MOTOR TO PARKING BRAKE, FUSE B FLASHER MODULE (5A)
1 CAB 103 O (19C) 1.0
RELAY #9, ON SHEET 18
B (0) 1.0
21 94 O (19C) 1.0 FUSE C RIDE AND PILOT CTRL (5A)
REAR
O (19D) 1.0 FUSE D PARKING BRAKE (5A)
W (28P) 1.0 2 W (28P) 1.0 A B FUSE E ETHER START (10A)
TO ENGINE SHUTDOWN,
O (13M) 1.0
RELAY #11, SHEET 18
RELAY REAR ETHER 14
C BOX TO RIDE CONTROL LIGHT 8 SOLENOID O (19F) 1.0 FUSE F ENGINE SHUTDOWN (5A)
RELAY #4 TO BLOWER SWITCH
ON SHEET 23 ON SHEET 26 O (19G) 2.0 FUSE G BLOWER SWITCH (15A)
1
REAR
O (19H) 1.0 FUSE H BACK-UP ALARM (5A)
TO BACK-UP ALARM
W (28T) 1.0
93 RELAY #7, SHEET 12 O (19J) 1.0 FUSE J FRONT WIPER AND WASHER MOTOR (10A)
B-62.0
97 ENG|REAR 94
FUEL O (19K) 1.0 FUSE K REAR WIPER AND WASHER MOTOR (10A)
TO ROTARY WIPER &
SOLENOID B A W (28T) 1.0 A W (28T) 1.0 1 WASHER SWITCH ON SHEET 24
3 TRESSE
REAR|REAR LT TO REAR WIPER/WASH 18
92 MOTOR ON SHEET 25
B (0) 5.0
CAB 7 15
COLD START
TEMP. SWITCH 16
B (0) 13.0
B (0) 62.0
B (0) 1.0
B (0) 2.0
B (0) 62.0
RR CHASSIS FRT CHASSIS CAB NEGATIVE STUD 4
4A 921C ENG BLOCK 4A

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.
Training center
4.8.00
TRAINING MANUEL
IGNITION RELAY, ACCESSORY RELAY, VOLMETER RELAY & TIME DELAY MODULE
VIA SPLICE #3
1 CAB POSITIVE STUD

1
CAB SWITCHED POWER 2
2
O (13K) 0.8 TO RESET SWITCH ON
5 SHEET 15, PIN 25
6
7 2 POWER IN
8 R (1A) 0.8
V (37R) 0.8 4 PROGRAM RESET
TO RIDE CONTROL
B (0) 0.8 RELAY #4 ON SHEET 23 B (0) 0.8 3 GROUND
O (13D) 1.0 1 DELAY POWER

17
O (13K) 0.8 5 IGNITION SWITCH
R (1) 3.0
87 15 6 PLUG
30 63 TIME DELAY
R (1) 3.0
MODULE
85 86 TO RELAY SOCKET #11

O (13K) 1.0
ON SHEET 18
R (1) 1.0
TO PROGRAM RESET
9 R (1A) 0.8 SWITCH, ON SHEET15 ACCESSORY 49
RELAY O (19L) 1.0 TO FUSE BLOCK
CONNECTOR #C5, C11, C17
10
O (12K) 0.8
O (19M) 1.0 TO CAB/REAR CONN. CAVITY 23
11 ON SHEET 22
87
O (19N) 1.0 TO SEAT COMPRESSOR
ON SHEET 6
30
14 O (19N) 1.0 TO FUSE BLOCK
CONNECTOR #C1, C7, C13
12 85 86 87
16
O (19P) 1.0 TO PIN ENGAGE
SWITCH, SHEET 22
30
O (13K) 1.0
IGNITION O (19R) 1.0 TO CONNECTOR CAVITY 22
48 87a ON SHEET 22
RELAY
O (13K) 0.8
13 85 86
O (19S) 0.8 TO INSTRUMENT CLUSTER

TO RELAY SOCKET #1 CAVITY 2 ON SHEET 17
ON SHEET 18
VOLTMETER 58
RELAY O (19T) 0.8 TO TRANS ELECTRONIC CONTROL
B (0) 0.8 MODULE CAVITY 23, SHEET 11
O (12P) 1.0 CENTER

FUSES
O (13R) 1.0
O (19T) 0.8 TO TRANS ELECTRONIC CONTROL
MODULE CAVITY 68, SHEET 11
RADIO (7.5A) FUSE L
14 SECONDARY STEERING (7.5A) FUSE M
COMPRESSOR (SEAT) (10A) FUSE N TO HORN RELAY #5
COUPLER (7.5A) FUSE P ON SHEET 25
SECONDARY STEERING (7.5A) FUSE R
INSTRUMENT CLUSTER (5A) FUSE S TO CAB ROOF SPLICE
TRANSMISSION CONTROL (7.5A) FUSE T ON SHEET 5
DOME LAMP, ENGINE COMP. AND HORN (7.5A) O (19U) 1.0
FUSE U
VOLTMETER (7.5A) O (19U) 1.0
FUSE V TO INSTRUMENT CLUSTER
O (19V) 0.8
CIGARETTE LIGHTER (15A) FUSE W CAVITY 1, SHEET 14
15 O (13V) 1.0 18 O (19W) 1.0 TO FUSE BLOCK

CONNECTOR C16
R (1) 3.0
16
SPLICE WITH FLASHER
MODULE GROUND ON SHEET 2
SHEET 9 SHEET 10

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
TRANSMISSION, TRANSMISSION CONTROL, BACKUP ALARM

1 1
CAB POSITIVE STUD
TO FUSE A
PAGE 8
VIA LA COMMANDE D'AUTOMATISME
DE BRAS PAGE 5
31 DIAGNOSTIC VIA LA COMMANDE
TRANS. FILTER PAR LA COMMANDE DE RIDE CONTROL PAGE 22
A Y (32F) 1.0 DE FEU ROTATIF
SWITCH PAGE 1
CONNECTOR 27
O (19A) 0.8
22 B V (36R) 1.0
O (19A) 0.8 1
O (19A) 0.8
142 V (37D) 0.8 2 108
TORQUE CONVERTER A V (36G) 1.0 B (0) 0.8 3 TRANSMISSION
21A 22
B V (36R) 1.0 V (37E) 0.8 4
OUTPUT TEMP. SENSOR AUTO SWITCH
100 31 Y (32F) 0.8 17 66
Gy (49) 1.0
O (19A) 0.8
O (19A) 1.0 29 O (19A) 0.8 45 15
C TO PARKING BRAKE SWITCH TO PARKING BRAKE SWITCH
B (0) 1.0 28 B (0) 0.8 4 18 ON SHEET 15 2
OUTPUT 18 ON SHEET 15 29
A LBe (25D) 1.0 10 LBe (25D) 0.8 62
SPD. SENSOR B LBe (25A) 1.0 7 LBe (25A) 0.8 19 1
B (0) 1.0 11 B (0) 0.8 3 TRANS.

101 O (19A) 0.8 6
LBe (25C) 1.0 9 LBe (25C) 0.8 42 26
ENG. SPD. 70 SHIFTER 5
A LBe (25B) 1.0 8 LBe (25B) 0.8 41
SENSOR 19 B 13 V (36G) 1.0 49 13 4
A B
CAB|PED LBe (25W) 0.8 B G
95 LBe (25Z) 0.8 O (19A) 0.8
41
65 LBe (25W) 0.8 48 C Be
B (0) 1.0
63 LBe (25Z) 0.8 49 LBe (25Y) 0.8 D
INTERMEDIATE B
20 22 LBe (25Y) 0.8 LBe (25Y) 0.8 50
A
SPD. SENSOR 43 O (19A) 0.8 A R
43 LBe (25F) 0.8 44 LBe (25F) 0.8 B Y
96 TRANSMISSION
64 LBe (25R) 0.8 45 LBe (25R) 0.8 C P
B (0) 1.0
67 LBe (25T) 0.8 LBe (25T) 0.8 46 LBe (25T) 0.8 D Gy
KICK-DOWN
TURBINE B
SWITCH
21 A LBe (25T) 0.8
SPD. SENSOR
70
B (0) 1.0 24 SPARE 28 20
B (0) 1.0 25 SPARE TO ETHER SWITCH
Gy (49) 1.0
ON SHEET 7 TO ETHER SWITCH

1 LBe (25K) 1.0 16 LBe (25K) 0.8 56 ON SHEET 7
921C 2 LBe (25L) 1.0 17 LBe (25L) 0.8 10
LBe (25Y) 0.8
3 LBe (25M) 1.0 18 LBe (25M) 0.8 32 1 2
O (19A) 0.8
4 LBe (25N) 1.0 19 LBe (25N) 0.8 55

LBe (25H) 0.8
23 5 LBe (25P) 1.0 20 LBe (25P) 0.8 9 TO NEUTRAL START RELAY #8 SITUE DANS LE MANIPULATEUR
6 LBe (25J) 1.0 21 LBe (25J) 0.8 51 LBe (25T) 0.8 ON SHEET 7
102 7 LBe (25S) 1.0 22 LBe (25S) 0.8 12 LBe (25G) 0.8
8 V (36T) 1.0 5 13
9 V (36R) 1.0 12 Y (36T) 0.8 39
Y (36R) 0.8 46 29
TRANS. SOLENOID V (36R) 1.0 ENGINE/CAB
VALVE & TEMP. 87 32
FROM FUSE T PAGE 10 O (19T) 0.8 2
SENSORS O (19H) 1.0 FROM FUSE H
30 PAGE 8
1 LBe (25K) 1.0 1
23 87a
O (19A) 0.8
LBe (25L) 1.0 O (19T) 0.8

6/7/821C 2 FROM FUSE T PAGE 10 68 FROM FUSE A 30
3 LBe (25M) 1.0 Y (35C) 0.8 O (19A) 0.8 6
85 86 PAGE 8
24 4 LBe (25N) 1.0 5
102A 5 LBe (25P) 1.0 53 BACK-UP
7 4
6 LBe (25J) 1.0 ALARM
1 BACK-UP ALARM RELAY 38
7 LBe (25S) 1.0 TO PARKING BRAKE RELAY W (52P) 0.8 21 2 AND ALARM DISABLE
#9 ON SHEET 17
Gy (49) 1.0
33
Y (35A) 0.8
8 V (36T) 1.0
9 V (36R) 1.0 34 DECLUTCH
TO RR WIPER SWITCH
Gy (49) 1.0 ON SHEET 25 SWITCH
27
+
G (50L) 0.5 26 2
TO RR WIPER SWITCH -
Y (50H) 0.5 25 B (0) 1.0
LBe (25G) 0.8
1
ON SHEET 25 31
25 NC 4 1
C
6
B (0) 1.0
Y (35R) 1.0
B/R (50G) 0.5 94

5 1 LBe (25G) 1.0 B
94 NO O (19A) 1.0 D
TO MAIN CAB HARNESS Y (35R) 0.8 6 Y (35R) 1.0 4 3
ON SHEET 17 4
B (0) 0.8
B (0) 0.8
TRANSMISSION 19 21 FRONT|CAB
TO MAIN CAB HARNESS 15
ON SHEET 17 ELECTRONIC REAR|REAR REAR DECLUTCH
LIGHT LIGHT
CONTROL CAB |REAR
BRAKE SWITCH
TO MAIN CAB HARNESS REAR
Y (35A) 0.8
ON SHEET 17 118
B (0) 1.0
B (0) 1.0
B (0) 1.0
Y (35R) 0.8
MODULE NAO-JUMPER CONNECTED VIA DETENT SWITCH

EURO-JUMPER OPEN ON SHEET 19
B (0) 1.0

VIA BEACON SWITCH
VIA RIDE CONTROL SWITCH
SHEET 11 ON SHEET 1 SHEET 12 SHEET 13 ON SHEET 19

LEGENDE
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
INFORMATION CENTER
REAR|CAB 13 43A INSTRUMENT DBr/LG (45R) 0.8 17

94 21 CAB|PED 76 76 PED|CAB
CLUSTER
REAR LIGHT|REAR Y (33P) 1.0 4 Y (33P) 0.8 3 Y (33P) 0.8 3 RIGHT TURN LIGHT 17 DBr/LG (45R) 0.8 17
BRAKE PRESSURE SWITCH
Y (31D) 1.0 3 Y (31D) 1.0 3 Y (31D) 0.8 4 Y (31D) 0.8 4 COOLENT LEVEL LEFT TURN LIGHT 16 DBr/Y (45L) 0.8 16 DBr/Y (45L) 0.8 18
V (36F) 1.0 16 V (36F) 0.8 19 V (36F) 0.8 19 FUEL LEVEL SENDER TRANS. OIL TEMP. SENDER 21 B (50T) 0.8
88 Y (35X) 1.0 20 Y (35X) 0.8 5 Y (35X) 0.8 5 STEERING PRESSURE SWITCH PILOT LOCKOUT SWITCH 29 Y (31L) 0.8 13
TO SECONDARY
STEERING SWITCH V (36H) 1.0 13 V (36H) 0.8 20 V (36H) 0.8 20 HYDRAULIC OIL TEMP. SENDER CAN BATTERY 33
A OPEN AT B (0) 0.8
ON SHEET 22 Y (31H) 1.0 14 Y (31H) 0.8 7 Y (31H) 0.8 7 HYDRAULIC FILTER RESTR. SWITCH SIGNAL GROUND 38 B (0) 0.8 38 B (0) 0.8 19
11,724 kPa
V (36C) 0.8 18 V (36C) 0.8 18 ENGINE COOLENT TEMP. SENDER ENGINE OIL PRESSURE SENDER 22 V (36P) 0.8 22 V (36P) 0.8 20
22 Y (31F) 0.8 6 Y (31F) 0.8 6 AIR FILTER RESTR. SWITCH REDUNDANT BRK. SWITCH 28 Y (33R) 0.8 28 Y (33R) 0.8 21
35 MOTEUR / CABINE
B (0) 0.8 8 B (0) 0.8 8 ANALOGUE GROUND FUEL SOL. OUT (RELAY #12) 23 W (23C) 0.8 23 W (23C) 0.8 22
A
136 V (36C) 1.0 4 W (53C) 0.8 W (53C) 0.8
BRAKE O (19V) 0.8 1 O (19V) 0.8 1 POWER MAIN PILOT PRESSURE SOL. OUT 36 36 23
Y (31F) 1.0 3 O/R (61R) 0.8 10 W (52C) 0.8 W (52C) 0.8
WARNING O/R (61R) 0.8 10 A/C - H/L PRESSURE SWITCH PARK BRAKE SOL. OUT 30 30 24
B (0) 1.0 30 T (44) 0.8 T (44) 0.8
PRESSURE N.C. 11 SPARE INDICATOR SWITCH SERVICE BRK. FOOT SWITCH 35 35 25
B SWITCH 38 Y (18G/42R) 1.0 12 Y (18G/42R) 0.8 12 WORK LIGHT SWITCH CAN LOW 31 G (50L) 0.5 31 G (50L) 0.5
P (46) 0.8 13 P (46) 0.8 13 BEACON LIGHT SWITCH CAN HIGH 32 Y (50H) 0.5 32 Y (50H) 0.5 26
TO FUSE V
HYDRAULIC OIL ON SHEET 10 P (41F) 1.0 14 P (41F) 0.8 14 REAR FOG LIGHTS SWITCH CAN GROUND 34 B/R (50G) 0.5 34 B/R (50G) 0.5
RELIES
TEMP. SENDER O (18C) 0.8 15 O (18C) 0.8 15 HIGH BEAM LIGHTS SWITCH SEAT SWITCH 37 37
B TO TRANSMISSION/ENGINE B (0) 0.8 39 B (0) 0.8 39 SIGNAL GROUND 2 2 O (19S) 0.8 27
POWER DELAYED
HARNESS CAVITY, SHEET 26
Y (33U) 0.8 9 PARK BRAKE SWITCH SHIELD GROUND 40 B (0) 0.8 40
104 B (0) 0.8
A V (37P) 0.8 24 PROGRAM IN UP COUNT IN 26 28
TO ROTARY LAMP B (0) 0.8
FERME A SWITCH ON SHEET 4 25 25 RESET IN DOWN COUNT IN 27
3,1 BAR
29
36 TO CAB ROOF SPLICE
P 39 ON SHEET 1 Gy (49) 0.8 PEDESTAL CONNECTION PEDESTAL CONNECTION
COOLANT O (19S) 0.8
HYDRAULIC FILTER TO FOG LAMP SWITCH TO TIME DELAY V (37R) 0.8 TO HAZARD SWITCH
O (19S) 0.8
V (37R) 0.8
LEVEL SPLICE ON SHEET 3 MODULE, SHEET 10 ON SHEET 1
RESTRICTION SWITCH 2
B SENDER 2
43 Gy (49) 0.8
TO FUSE C
ON SHEET 3
6
6
2 5
5 B (0) 0.8
1 PARK
4
4 BRAKE
A 141 A 138 A
117 PILOT
SWITCH
5 6 UP/DOWN
B (0) 1.0
CLOSE AT 44 CONTROL
6.4 kPa 72 37 SWITCH TO HAZARD SWITCH COUNT
Gy (49) 0.8
O (19A) 0.8
ON SHEET 1
V (37R) 0.8
4
O (19A) 0.8
B (0) 0.8 SWITCH
94 37 40 V
41 22 CAB|PED CONN.
ON SHEET 12
ENG. COOLANT AIR FILTER 75 42 2
REAR FUEL
B (0) 0.8
V (31L) 0.8
V (37D) 0.8
CAB 1
B (0) 0.8
13 LIGHT B B TEMP. SENDER B RESTRICTION TO TRANS. SHIFTER
LEVEL ENG ON SHEET 12 13
SWITCH 23 PROGRAM
R (1A) 0.8
REAR SENDER
RESET SWITCH CAB|PED 5 6
B (0) 0.8
TO FUSE C
13 ON SHEET 8 O (19C) 1.0 O (19C) 0.8 68 O (19C) 0.8
4
PED TO IGNITION SWITCH TO RIDE CONTROL
O (19C) 1.0 SWITCH ON SHEET 22 CAB FLOOR
ON SHEET 8
53 B (0) 0.8 WELD STUD
CAB
Gy (49) 0.8 74 45
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
4 4
CAB NEGATIVE STUD
4A ENGINE BLOCK 4A
VIA GROUND SPLICE ON 6/7/821C

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
PARKING BRAKE SOLENOID - PILOT PRESSURE SOLENOID - EMERGENCY RELAY SOCKET
17 TO RIGHT TURN LIGHT

CAVITY 17 ON SHEET 2
O (13C) 0.8
O (13K) 0.8
TO ENG|CAB CONN. O (13C) 0.8
TO LEFT TURN LIGHT ON SHEET 6
18 O (13K) 1.0 TO IGNITION RELAY #2,
CAVITY 16 ON SHEET 2 22 ON SHEET 9
TO DIODE MODULE O (13C) 0.8
ON SHEET 24
CAB|ENG
O (13K) 1.0 TO VOLTMETER RELAY #12
19 15 ON SHEET 9
20 6
21 O (19F) 1.0 TO FUSE F, SHEET 8
22 RELAY
23 SOCKET 52
24 #11 57
25 TO STOP LAMP SWITCH
ON SHEET 2 CAB|REAR
26 TO TRANS. ELECTRONIC TO TRANS. ELECTRONIC CONTROL 15 Y (33R) 1.0

CONTROL MOD. ON SHEET 11 MODULE ON SHEET 11, CAVITY 21
V (36P) 1.0
19
27 TO TRANS. ELECTRONIC
B (0) 1.0
CONTROL MOD. ON SHEET 11 W (52P) 0.8 18
28 TO TRANS. ELECTRONIC
CONTROL MOD. ON SHEET 11 21
87
W (52P) 0.8
TO FUSE S
29 ON SHEET 10 O (19D) 1.0 TO FUSE D, SHEET 8
30
W (53P) 1.0
W (52P) 1.0
87a
W (53P) 0.8
O (19D) 1.0
85 86
55
C B A
87
B (0) 1.0
PARKING
Y (33R) 1.0
Y (33R) 1.0
48 BRAKE
87
RELAY 86 86
O (19C) 1.0 TO FUSE C
W (53P) 0.8 ON SHEET 8
SHEET 19 30
A A
87a
CLOSE AT
6200 kPa
85 86
46 49 B (0) 1.0
O (19C) 1.0 51 P P
PILOT REDUNDANT
ENGINE OIL
CONTROL PARKING C B A
REDUNDANT
PRESSURE 47 56
RELAY BRAKE BRAKE B B
SENDER
SOLENOIDS SWITCH
89
B (0) 1.0
B (0) 1.0
PILOT
50 PRESSURE
SOLENOID
B (0) 1.0
B (0) 1.0

4A ENGINE BLOCK 4A
SHEET 17 SHEET 18

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
BUCKET CONTROL EMERGENCY STEERING

VIA LIGHT SWITCH ON SHEET 1
3 3
INSTRUMENT ILLUMINATION
Gy (49)1.0 Gy (49)1.0 RETURN TO 21
90
B (0) 1.0
TRAVEL/FLOAT
SWITCH REAR|CAB
TO FUSE M
O (19M) 1.0 C O (19M) 1.0 23 O (19M) 1.0
2 B (0) 1.0
2 ON SHEET 10
TO DECLUTCH SWITCH 1 O (19R) 1.0
Gy (49)1.0 B (0) 1.0 ON SHEET 13
6 6 5
5 5 8
TO DECLUTCH
SWITCH ON 6
SHEET 13 4 39 4
W (53P) 0.8 4
36 1
53 55 TO FUSE R
TO PILOT 3
CONTROL D O (19R) 2.0 22 O (19R) 1.0 ON SHEET 10
RELAY #10,
DETENT
V (35X) 1.0
SHEET 17 SWITCH 7 2
W (56) 0.8
SECONDARY
W (51P) 1.0
59 STEERING
TO REAR|CAB
BUCKET CONTROL W (56) 0.8 RELAY WITH Y (35X) 1.0 A Y (35X) 1.0 CONNECTOR ON SHEET 14
VALVES DETENT LOCKOUT B
W (56) 0.8 1
W (55B) 0.8
ELECTROMAGNETS
B/W-1.0
CAB|FRONT STEERING|REAR TO B+ FROM CRANKING
MODULE MOTOR BATTERY TERMINAL
RETURN ON SHEET 6
TO DIG
W (53B) 0.8 M
P
HEIGHT 54
CONTROL 5
8
RETURN W (55A) 0.8
TO TRAVEL 6
T W (51) 1.0
W (54B) 0.8 L
4
W (56) 0.8 SECONDARY
1
17 61 STEERING
3
K SWITCH
R-50.0
W (56) 1.0
W (55B) 1.0
W (54B) 1.0
W (53B) 1.0
7 2
B (0) 1.0 W (54B) 1.0
W (56) 1.0
W (53B) 1.0
SECONDARY SECONDARY
W (56) 1.0 W (56) 1.0
60 STEERING STEERING
B (0) 1.0
B (0) 1.0
B (0) 1.0 RELAY WITH PUMP/MOTOR

B (0) 1.0 LOCKOUT
12
B A C B A C M
B (0) 1.0 B/O-50.0
B A C 11 10 W (56) 1.0
B (0) 2.0
57 C
+
58 C 56 -
+
- 62
C
+
- RETURN
RETURN PROXIM. PROXIM.
SWITCH HEIGHT SWITCH TO WITH LOCKOUT/RELAY
B (0) 1.0
PROXIM. TO VIA ASSEMBLY
SWITCH
B (0) 1.0
CONTROL DIG GROUND

TRAVEL SPLICE
4 CAB NEGATIVE STUD CAB NEGATIVE STUD 4

4A ENGINE BLOCK ENGINE BLOCK 4A
SHEET 19 SHEET 21

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
QUICK COUPLER CONTROL RIDE CONTROL
B (0) 1.0
Gy (49) 1.0 W (58H) 0.8
W (58H) 0.8
TO TRANS./AUTO
SWITCH, SHEET 13 W (58S) 0.8
62A 63
Gy (49) 0.8
3 87
2
Gy (49) 1.0 TO ACCESORY
1 RELAY #3 30
40 ON SHEET 9
6 B (0) 0.8
6 87a
5 5
O (19C) 1.0
85 86
4 44 4
TO ETHER START B (0) 0.8
RELAY #6
TO SPLICE ON COMMANDE ON SHEET 7
PIN ENGAGEMENT SHEET 15 RIDE
DU RIDE CONTROL 50 65
SWITCH CONTROL
w (57) 0.8
O (19P) 1.0
RELAY
W (58S) 0.8 W (58H) 0.8
TO TRANS./AUTO
SWITCH ON SHEET 13 B (0) 1.0
A 15
TO FUSE P
16 OPENS AT
SHEET 10 625 kPa
FERME A
CAB A 17,25 BAR
P
FRONT U P
64 B 66
BUCKET DUMP
1 AND
B ROLL BACK
HOIST UP PRESSURE SWITCHES
PRESSURE
w (57) 1.0
SWITCH
W (58D) 0.8
W (58H) 0.8
A
67
107
62B OPENS AT
625 kPa
P
A
B W (58) 1.0
PIN ENGAGEMENT 14
SOLENOID CAB|FRONT
A
W (58) 0.8 V
B
(6/7/821C/CE 1
ONLY)
RIDE ENGAGE 68
SOLENOID
B
VIA GROUND SPLICE
B (0) 1.0
5
B (0) 1.0
B (0) 1.0
4 4
4A 4A
VIA GROUND SPLICE
SHEET 22 SHEET 23

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
WIPER & WAHER SEAT COMPRESSOR & HORN

VIA BACK-UP ALARM DISABLE
SWITCH ON SHEET 12
REAR WIPER/WASH O (19U) 1.0
87
FRONT ROTARY OFF 5-4
WIPER AND WASHER TO FUSE U
70 ON SHEET 10
Gy (49) 1.0
SWITCH ON 5-6 30
87a
WASH 2-3, 5-6
O/LB (64C) 0.8 TO HORN SWITCH
46 86 85 ON SHEET 1
O (19U) 2.0
RESISTOR 51
3
O/LB (64) 0.8
75
2 73 HORN CAB
N
1 TO FUSE K RELAY 1
ON SHEET 8 FRONT
6 O (19K) 1.0
5
TO FUSE J
ON SHEET 8 O (19J) 1.0 45 4
FRONT REAR WIPER

` ` ` ` ` `
WIPER 35 AND WASHER
MOTOR TO FUSE N
61 SWITCH ON SHEET 2
O (19K) 1.0
COLONNE / CABINE
O/G (63W) 0.8 O/G (68W) 1.0
O/G (68C) 1.0

53B C O (19J) 0.8 60 B (19J) 0.8
31P D O/G (63C) 0.8 59 O/G (63C) 0.8 O/G (68L) 1.0
M 53 B O/G (63L) 0.8 58 O/G (63L) 0.8 CAB
53D A O/G (63H) 0.8 57 O/G (63H) 0.8 CAB 23
O (19N) 1.0
61 B (0) 0.8 ROOF

69 B (0) 0.8
O/Be (64) 1.0
25 24 CAB
13 A
60 REAR 46
1
O/G (68L) 1.0

O/G (68C) 1.0
O (19K) 1.0
28
81 C B D HORN
DIODE REAR AIR SEAT
MODULE F E D C B A 77
O/G (68L) 0.8

O/G (63W) 1.0
140 WIPER M 74 OPTION ONLY
O/G (68W) 1.0

CAB 2 3
MOTOR M
O/G (63L) 0.8 76
A A
M B
M 82
O/G (63H) 0.8 B
TO NEUTRAL
START RELAY #8 W (21C) 0.8 SEAT
ON SHEET 7
TO ROTATING BEACON B COMPRESSOR
72 GROUND SPLICE
B (0) 0.8
71 ON SHEET 1 B (0) 1.0
TO RELAY SOCKET #11 O (13C) 0.8
ON SHEET 17 FRONT WASHER
B (0) 1.0
REAR WASHER
PUMP MOTOR PUMP MOTOR VIA BACKUP ALARM DISABLE
SWITCH ON SHEET 12
B (0) 1.0
B (0) 1.0
B (0) 1.0
CAB FLOOR
B (0) 1.0
B (0) 1.0
WELD STUD

4A ENGINE BLOCK 4A

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
CAB BLOWER AIR CONDITIONING & CONDENSER FAN
REAR|A/C CONDENSOR
27
83
R (1) 2.0 A R(1) 2.0
A THERMOSTAT
3 SWITCH
CAB|REAR
P 81
O/R (61M) 0.8 17 O/R (61M) 1.0 F O/W (61M) 2.0
1 2
B LOW
O/R (61R) 0.8

PRESSURE 21 91
SWITCH O/W (61R) 2.0 O (12) 2.0
92 CIRCUIT BREAKER U & V
O/W (61R) 2.0 10.0 AMP
O/R (61A) 0.8

CAB|ENG
86
ENGINE / REAR
TO PEDESTAL HARNESS 26 O/R (61A) 1.0 O/R (61A) 1.0 B O/R (61A) 1.0 B O/W (61A) 2.0 87 87
INSTRUMENT CLUSTER
CAVITY 10, SHEET 15 O/R (61R) 0.8 27 O/R (61R) 1.0 O/R (61R) 1.0 D O/R (61R) 1.0
D
30 30
22 C
TO FUSE G E 87a 87a
BLOWER
SHEET 8
SWITCH CAB
86 85 86 85
O/R (61A) 1.0

B O (19G) 2.0
C O/R (61T) 1.0 98
84
COMPRESSOR CONDENSER
L O/R (62L) 1.0 W A
1 2 CLUTCH LOCKOUT
M O/R (62M) 2.0 R FAN #1
H O/R (62H) 2.0 B
RELAY RELAY
3 82 P O/W (61C) 2.0
O/R (61R) 1.0

B (0) 2.0
30 BLOWER HIGH
O (19U) 2.0
B (0) 2.0
O (19V) 2.0
78 SWITCH CAB 79 PRESSURE B

SWITCH
BLOWER
RESISTOR
B
SWITCH 29
Br
O/R (61C) 1.0
BOARD
B B
CONDENSER
B (0) 2.0
80 FAN #1 AND #2 M M
M B (0) 2.0 MOTORS
A A
BLOWER
MOTOR
C REAR
92 ENG 88 89
O/R (61C) 1.0 B (0) 2.0

COMPRESSOR
CLUTCH 85
B (0) 2.0
99
MASSE DE L'ENSEMBLE
DU CONDENSEUR DE CLIMATISATION
4A ENGINE BLOCK 4A

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
CIGAR LIGHTER, 12V POWER CONVERTER, RADIO AND SPEAKERS
TO FUSE W TO FUSE L TO FUSE L

TO FUSE L
SHEET 2
93 93A
R (1) 5.0
24V RADIO RADIO 12V
POWER CONVERTER
24V / 12V
B (0) 0.8
B (0) 0.8
O/W (65C) 0.8
B (0) 0.8
O/W (65L) 0.8

O/W (65R) 0.8
O (19L) 1.0
O (19L) 1.0
O (19L) 1.0
B (0) 0.8
O (19W ) 3.0
B (0) 0.8
O/W (45L) 0.8
B (0) 0.8
O/W (65L) 0.8

O/W (65R) 0.8
CIGAR RADIO POWER CONVERTER

90 LIGHTER 91 24V TO 12V
FUSE BLOCK 6 3 1 2 5 4 93B 6 3 1 2 5 4
C6, C12, C18
24V ING
12V A O/W (65C) 0.8 A A O/W (65C) 0.8
GND R (12V) 5.0 24V 12V
B B (0) 0.8 B B B (0) 0.8
B (0) 0.8
B (0) 0.8
O/W (65L) 0.8

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

O/W (65R) 0.8
R (12V) 3.0
A B
A B
POWER LEFT SPEAKER LEFT SPEAKER

SUPPLY (12V)
94 94
A B
A B
B (0) 5.0
B (0) 1.0
B (0) 5.0
B (0) 1.0
RIGHT SPEAKER RIGHT SPEAKER
B (0) 3.0
95 95

LEGEND
CONNECTION X
WITH TERMINALS
XXX CONNECTOR NO.

TRAINING MANUEL
ADDITIONAL NOTES

21C SERIE WHEEL LOADERS 4A - INFORMATION CENTER
TRAINING MANUAL
INFORMATION CENTER
page
LAYOUT AND FEATURE .......................................................................................4A.02.00

INSTRUMENT CLUSTER LAYOUT.......................................................................4A.03.01
PROGRAMMING THE INFORMATION CENTER .................................................4A.09.00
Programming the gauge display....................................................................4A.12.00
Display of the induvidual functions & Setting display center light .................4A.12.00
Testing the parking brake , Transmission clutch calibration ..........................4A.13.00
Testing system voltage, Alarm check, Coolant check level ...........................4A.15.00
Brake pressure switch check.........................................................................4A.15.00
Park brake information center output check..................................................4A.16.00
Pilot lockout information output check...........................................................4A.16.00
Hydraulic and air filter restriction switch checks............................................4A.17.00
Work light check, fog lig check, A/C switch check.........................................4A.18.00
Transmission filter restriction switch check ..................................................4A.18.00
Requested gear check, Actual gear status, Master indicator status .............4A.19.00
Master Reset, Park brake and redundant brake pressure switch checks .....4A.20.00
Service brake foot pedal switch check, pilot lock-out switch check...............4A.21.00
Minimum and maximum gear selection, Service interval hours ...................4A.22.00
Reset the service hour interval location, fault code status ............................4A.23.00
ADVANCED PROGRAMMING FUNCTIONS ........................................................4A.24.00
Programming the information center (transmission identificartion number) ..4A.26.00
Resatable fault codes....................................................................................4A.29.00
Fault code read out and diagnostics .............................................................4A.29.00
Erasing fault codes........................................................................................4A.30.00
Main fault codes ............................................................................................4A.31.00
INFORMATION CENTER ELECTRICAL SYSTEM ...............................................4A.34.00
INFORMATION CENTER ELECTRICAL CIRCUIT................................................4A.36.00
Centre de formation 4A.1.00

4A - INFORMATION CENTER 21C SERIE WHEEL LOADERS
TRAINING MANUAL
INSTRUMENT CLUSTER LAYOUT

Layout and Features
The new 21 ìCî series wheel loaders incorporates a new information center as part of the system monitoring and
operational design. The information center is a solid state electronic design that is designed into the instrumentation
cluster located under the steering wheel. The cluster is designed to monitor all functions of the machine and inform
the operator if a problem has been detected. The instrument cluster is a digital readout that can be programmed by
the operator to monitor specific machine operations as requested.
At initial start up of the machine all LEDís and LCDís on the instrument cluster will light up and the audible alarm will
sound for a period of three seconds. This is a system check which tests out all of the LEDís and LCDís to see if they
are faulty At the same time the information center is testing all of the wiring and sensors being monitored for open
circuits.
The ìCî series wheel loaders also incorporate a power down time delay module. This timer keeps power to the
information center and transmission controller for a period of ten seconds after the key switch is turned off. This allows
the entire machine to power down before cutting power to the information center and transmission controller. It also
allows the controllers to store all shutdown data in the appropriate memory locations. The time delay module is a
digital circuit board located under the right hand access door outside the cab.
33 34 35 36
43 44
41 42 45
40 46
39 47
38 48
49
37
58 50
51 54
52
55
56
53
57
59
Instrument Cluster Layout

At the top of the Instrument cluster are a series of operation and warning lights. They are identified as follows
4A.2.00 Centre de formation

TRAINING MANUAL

37 Rear Fog Lights
- Fitted only on European models
38 Beacon Indicator - This indicator will illuminate when the beacon is turned to the on position.
39 Work Lights Indicator - This indicator illuminates when the work lights on turned on.
40 Pilot Control Actuator - This indicator illuminates when the pilot lockout is actuated.
41 Low Coolant Indicator - This indicator illuminates when the engine coolant is low. The alarm will sound
continuously and the stop master indicator lamp will also be red.
42 Brake Pressure Indicator - This indicator illuminates when the brake system pressure is too low. Th alarm
will sound continuously and the stop master indicator lamp will be red.
43 Stop Master Indicator - When this indicator illuminates it is informing the operator that a major system
malfunction has been detected. Action must be taken to correct the problem immediately. The machine must
be stopped and the engine shut down. The stop light will illuminate if one or more of the following
circumstances exists:
Low engine oil pressure
Low brake pressure
Low steering pressure
Low engine coolant level
High engine coolant temperature
High hydraulic oil temperature
High transmission oil temperature
44 Caution Master Indicator - When this indicator illuminates it is informing the operator that a system
malfunction has been detected. Action must be taken to correct the problem. The caution light will illuminate
if one or more of the following circumstances exists:
Parking brake engaged and forward or reverse selected.
High engine coolant temperature
High hydraulic oil temperature
High transmission oil temperature
Low engine oil pressure
Air filter restriction switch activated
Transmission filter restriction
Alternator malfunction
Low fuel level
Hydraulic oil filter restriction
45 Secondary Steering Indicator (If Equipped) - This indicator illuminates when the primary steering pressure
is low. The alarm will sound continuously and the stop master indicator will illuminate.
46 Parking Brake Indicator - This indicator illuminates when the parking brake is applied. When the parking
brake is applied and the machine is shifted into forward or reverse the alarm sounds for 3 seconds and the
caution master indicator turns yellow.
47 Air Conditioner Indicator - This indicator illuminates when the air conditioner has stopped due to refrigerant
pressures that are too high or too low. The alarm sounds for 3 seconds and the caution master indicator turns
yellow. This light may also light if the outside air temperature is too cool for the system to operate.
48 Air Filter Indicator - This light illuminates when the air filter is restricted and requires service. The alarm
sounds for 3 seconds and the caution master indicator turns yellow.
49 Hydraulic Oil Filter Indicator - This light illuminates when the hydraulic filters are restricted and require
changing. The alarm sounds for 3 seconds and the caution master indicator turns yellow.
50 Transmission Oil Filter Indicator - This indicator illuminates when the transmission filters are restricted and
require changing. The alarm sounds for 3 seconds and the caution master indicator turns yellow
The Instrument Cluster also contains six individual 12 bar graph liquid crystal diode (LCD) displays. These are located
in the following positions on the instrument cluster and serve the following functions.

TRAINING MANUAL
54 Transmission Oil Temperature Gauge
When the transmission oil temperature is in the normal operating zone a green LCD will be illuminated The
information center monitors the transmission oil temperature with two sensors, one located at the torque converter
output and one located in the sump of the transmission. The information center compares the two readings and
monitors both temperatures to determine if the transmission has overheated. As the temperature starts to increase
the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds and the caution
indicator turns yellow. When the transmission oil temperature continues to increase the bars move into the red
zone and continue to flash, the warning alarm sounds continuously and the stop indicator turns red. When the
temperature decreases the LCDís move back into the yellow zone and the red warning light goes out and the yellow
caution light turns on. If the temperature falls to bar 10 in the green zone the yellow caution light goes out. If the
temperature rises back into the yellow zone the caution light turns back on, however, the alarm does not sound.
The temperature must fall to bar 9 in the green zone and then increase to the yellow zone again to sound the alarm
for three seconds again. The following table lists the relative temperatures for each of the 12 LCD display bars.
Bar number Temperature (°F) Temperature (°C) Indicator color
12 257 125 Red

11 248 120 Yellow
10 239 115 Green
9 230 110 Green
8 212 100 Green
7 194 90 Green
6 176 80 Green
5 158 70 Green
4 140 60 Green
3 104 40 Green
2 68 20 Green
1 <68 <20 Yellow
55 Hydraulic Oil Temperature Gauge

When the hydraulic oil temperature is in the normal operating zone the green LCD will be illuminated As the
temperature starts to increase the bars move into the yellow zone and begin to flash, the warning alarm sounds for
three seconds and the caution indicator turns yellow. When the hydraulic oil temperature continues to increase the
bars move into the red zone and continue to flash, the warning alarm sounds continuously and the stop indicator
turns red. When the temperature decreases the LCDís move back into the yellow zone and the red warning light
goes out and the yellow caution light turns on. If the temperature falls to bar 10 in the green zone the yellow
caution light goes out. If the temperature rises back into the yellow zone the caution light turns back on, however,
the alarm does not sound. The temperature must fall to bar 9 in the green zone and then increase to the yellow
zone again to sound the alarm for three seconds again. The following table lists the relative temperatures for each
of the 12 LCD display bars.
Bar number Temperature (°F) Temperature (°C) Indicator color
12 230 110 Red

11 221 105 Yellow
10 212 100 Green
9 203 95 Green
8 194 90 Green
7 185 85 Green
6 176 80 Green
5 158 70 Green
4 140 60 Green
3 104 40 Green
2 68 20 Green
1 <68 <20 Yellow
TRAINING MANUAL
56. Voltmeter gauge

The amount of voltage is shown with the indicator bars. Normal operating range is in the green zone. When
the voltage increases or decreases the bars move into the yellow zone and begin to flash, the warning alarm sounds
for three seconds and the caution indicator turns yellow. If the system voltage falls below 18 volts the transmission
will shift into neutral and operation of the unit will cease
Bar number Tension (Volt) Indicator color
12 >36 Yellow
11 32 Yellow
10 30 Green
9 29 Green
8 28 Green
7 27 Green
6 26 Green
5 24 Green
4 22 Green
3 18 Green
2 14 Yellow
1 <14 Yellow
53 Fuel level gauge

The fuel level is shown on the indicator bars. Normal operating range is in the green zone. When the tank is
almost empty bars move into the yellow zone and begin to flash, the alarm sounds for three seconds, and the
caution master indicator turns yellow.
Bar numbers % Full Resistance (Ohm) Indicator color
12 95 <39 Green
11 86 49 Green
10 77 60 Green
9 68 70 Green
8 59 84 Green
7 50 103 Green
6 41 120 Green
5 32 145 Green
4 23 163 Green
3 14 192 Green
2 5 225 Green
1 <5 >225 Yellow

TRAINING MANUAL

52. Engine oil pressure
The engine oil pressure is shown with indicator bars. Normal operation is in the green zone. As the engine oil
pressure increases or decreases the bars move into the yellow zone and begin to flash, the warning alarm sounds
for three seconds and the caution indicator turns yellow. When the engine oil pressure continues to increase or
decrease the bars move into the red zone and continue to flash, the warning alarm sounds continuously and the
stop indicator turns red.
Bar number Pressure (bar) Pressure (PSI) Indicator color
12 5,20 75 Yellow
11 4,80 70 Green
10 4,30 62 Green
9 3,80 55 Green
8 3,40 49 Green
7 3,00 44 Green
6 2,60 38 Green
5 2,20 32 Green
4 1,80 26 Green
3 1,40 20 Green
2 1,00 14,5 Yellow
1 <1,00 <14,5 Red
51. Engine coolant temperature

The engine coolant temperature is shown with indicator bars. Normal operation is in the green zone. As the
temperature starts to increase the bars move into the yellow zone and begin to flash, the warning alarm sounds for
three seconds and the caution indicator turns yellow. When the engine coolant temperature continues to increase
the bars move into the red zone and continue to flash, the warning alarm sounds continuously and the stop
indicator turns red.
Bar number Temperature °F Temperature en °C Indicator color
12 230 110 Red

11 221 105 Yellow
10 212 100 Green
9 203 95 Green
8 194 90 Green
7 185 85 Green
6 176 80 Green
5 158 70 Green
4 140 60 Green
3 104 40 Green
2 68 20 Green
1 <68 <20 Yellow

TRAINING MANUAL
Information center layout
Located directly between the engine coolant temperature gauge and the transmission temperature gauge is a large
digital readout screen. This is the information center portion of the information cluster. This is where the operator will
monitor critical machine functions, program the information center, and receive diagnostic information related to
servicing the machine. At the top of the information center are five seven-segment LCD displays with a decimal point
between the fourth and the fifth digit.
Information Center Display
Here is a list of the functions that the operator can choose to see on the information center.:
Hourmeter
Displays the accumulated running time of the engine in hours and tenths of an hour with an hour glass symbol
illuminated below the five digit display.
Tachometer
Displays the engine speed in revolutions per minute along with an ìn/minî symbol located below the five digit
display.
Speedometer
Displays the ground speed in either kilometers per hour (km/h) or miles per hour (mph) along with either an ìkm/h
or mphî symbol illuminated below the five digit display.
Engine Coolant Temperature

Displays the engine coolant temperature in Celsius with the engine coolant temperature bar graph flashing.
Engine Oil pressure

Displays the engine oil pressure in Kilopascals (Kpa) with the engine oil pressure bar graph flashing.
Fuel Level
Displays the fuel level in percent (%) remaining from a full tank with the fuel level bar graph flashing.
Transmission Oil Temperature

Displays the transmission oil temperature in Celsius with the transmission oil temperature bar graph flashing.
Hydraulic Oil Temperature

Displays the hydraulic oil temperature in Celsius with the hydraulic oil temperature bar graph flashing.
Voltmeter
Displays the electrical system voltage level in volts with the voltmeter bar graph flashing.

TRAINING MANUAL
Afficheur de la transmission
Located directly below the instrument cluster display is the transmission display. It acts as a
readout for the transmission controller, which is located behind the access door outside on the
right hand side of the cab. The transmission display serves the following four functions
- Direction selected
At the top of the display are three letters (F), (N), and (R). Which ever position the gear
selection forward-neutral-reverse (FNR) selector lever is in will be shown at the top of
the display. If the (F) or (R) is flashing, then it is an indicator to the operator that the
forward or reverse direction has been selected, however, for some reason the
transmission did not engage. This could be evident if the transmission is shifted into forward or reverse and the
transmission oil is not up to operating temperature. If the display shows a flashing (N), it is informing the
operator to put the FNR lever into the neutral position.
- Requested gear
In the center of the gear symbol on the display will be a number 1 ñ 4 displayed. It shows the requested gear
selected on the shift lever.
- Actual gear engaged

To the right of the gear symbol will be four LCD bars. The number of bars illuminated indicates the gear the
transmission is actually in. This may vary from the requested gear if the transmission is in the automatic mode
- Transmission mode
In the lower left hand corner of the display is a gear symbol with an ìAî in the middle. If the transmission is
operating in the automatic mode the symbol will be displayed. With the transmission in the manual mode no
symbol will be displayed.
NOTE: The actual gear may be different than the selected gear if operating in the automatic mode.
Programming the information center

The software inside of the information center is designed to provide many spaces or slots of information that are
available to the operator and service technician. Each space of information is given a three digit number starting
with 000 and continuing up to 199. These spaces are called Display Field Numbers. Machine operators will
only have access to positions 000 through 099 in the software logic. Any numbers beyond 099 will require a
password to obtain access. This information will be covered in greater detail in the Advanced Setup section of
this manual.
Up/Down Count & Program/Reset Switch Locations
To access the information you must use the two switches located at Up count Programme
the upper right corner of the instrument cluster. The switch located in
the far right position is the Program/Reset switch and the one located
directly to the left of it is the Up/Down Count switch. The switches are
three position rocker switches. The center position is the neutral or
off position. To enter the programming mode press the left side of the Down count Reset
Program/Reset switch, for resetting the information center press the
Program/Reset switch to the right. For an up count press the Up/Down Count switch to the left, for a down
count press the Up/Down Count switch to the right. The picture below shows where the switches are located
NOTE: To enter into the programming modes the key switch must be in the on position.
The operator can also display the current gauge status of the information center without the key by pushing the
reset button. This will display gauges and hour meter for ten seconds and all of the indicator lights will light up
on the instrument cluster. The alarm will not sound unless the lights have been left in the on position.

TRAINING MANUAL
PROGRAMMING THE INFORMATION CENTER

NOTE: To enter into the programming modes the key switch must be in the on position.
To get into the programming of the instrument cluster you must
perform the following steps: Up count Programme
1 Turn the key switch to the on position, however, do not start the
machine.
2 Put the information center into the program mode by pressing the
Program/Reset switch to the left.
Down count Reset
3 Press the Up/Down Count switch to the right until the desired Display
Field Number is on the display screen.
4 Push the Program/Reset Switch to the center position. This will display the current value stored in that program
location.
5 Push the Up/Down Count switch to the right or left until the desired setting is obtained.
6 Push the Program/Reset switch to the right to store the value in the information center memory. This will also
exit you from the programming mode. If you do not wish to change any of the values and only wish to read the
information stored in that field display number location you do not need to press the Program/Reset switch to the
Reset position, by going back to the Program position you can move to other display field number locations
without starting at location 000.
7 Turn the key switch to the off position.
Display field number and description
Field
dnumber Items Status
000 Engine Hoursr

001 Engine Tachometer
002 Speedometer in Miles Per Hour
003 Speedometer in Kilometers Per Hour
004 Engine Coolant Temperature in Degrees Celsius
005 Engine Oil Pressure in Kilopascals
006 Fuel Level in Percent of Fuel Tank
007 Transmission Oil Temperature in Degrees Celsius
008 Hydraulic Oil Temperature in Degrees Celsius
009 Voltmeter Reading (Continuous)
010 Gauge Display Selection
011 Parking Brake Test / Clutch Calibration
012 Information Center Light Setting ñ Work Lights Off.
013 Information Center Light Setting ñ Work Lights On
014 Voltmeter Reading at Key-on
015 Alarm Status 00 = Off 01 = On
016 Coolant Level Status 00 = normal level
01 = low level
017 Brake Pressure Status 00 = Switch closed
01 =Switch opened
opened = pressure OK
018 Steering Pressure Status 00 = Switch closed

01 = Switch opened
opened = pressure OK
019 Present Park Brake Output from Information Center Status 00 = Off
01 = On

TRAINING MANUAL

Données et champs correspondants
Field Item
number Status
020 Present Pilot Lock-out Status Output from Information Center 00 = Off
01 = On
021 Hydraulic Filter Restriction Switch Status. 00 = Closed
01 = Opened
ouvert = Filter OK
022 Air Filter Restriction Switch Status. 00 = Switch Closed
01 = Switch opened
ouvert = Filter OK
023 Present Work Lights Status 00 = Off
01 = On
024 Present Fog Lights Status 00 = Off
01 = On
025 Air Conditioning High/Low Pressure Switch Status 00 = Switch opened
01 = Switch closed
opened= OK
026 Transmission Filter Restriction Switch Status (not fittedon 621C) 00 = switch openedt
01 =switch closed
oopened = pres OK
027 Present Status Of High Beam Lights 00 = Off
01 = On
028 Requested Gear Status 101:F1, 102: F2, 103: F3
104:F4, 201: N1, 202: N2
203:N3, 204: N4, 301: R1
302: R2, 303: R3
029 Status of Transmission Operation Indicator In Transmission Display 00 : Always
030 Actual Gear Status 101:F1,102:F2,103:F3
104:F4, 115 = limp home
301:R1, 302:R2,303:R3
315: =limp home
031 Shift status
First digit 000: Shift not in process
001:Shift in process
Driveline status
second digit 001: Transmission not engaged
010: Transmission engaged
Work mode status(Normal, Substitute tion Limp home)
Third digite 010: normal
110: substitution
210: limp home
300:Transmission shut down
400: ECM shut down
032 Hourmeter Status 00 : Always
033 Tachometer Status 00 :Always
034 Current Status of Service Indicator for Normal Operating Mode 00 = Off
(Book with the wrench) 01 = On
035 00 : Always
036 Beacon Statusf 00 =: Off
01 = On
037 Left Turn Indicator Status 00 = Off
01 = On
038 Right Turn Indicator Status 00 = Off
01 = On
1.10.01 Centre de formation

TRAINING MANUAL
Données et champs correspondants
Numéro
du champ Donnée Etat du code
039 Current Status Master Indicator (Red) 00 = Off

01 = On
040 Current Status of Diagnostic Indicator 00 – Always

(Book without the wrench - Operators Manual)
041 Current Status Master Indicator (Yellow) 00 = Off
01 = On
042 Master Reset
043 Park Brake Switch Status 00 = Switch opened
01 =Switch closed
(closed =brake engaged)
044 Redundant Brake Pressure Switch 00 = switch closed

Closed = Normal Operation) 01 = switch oened
045 Service Brake Foot Switch Status 00 = switch openedt

01 = switch closed
(closed actuated)
046 Pilot Lock-out Switch Status 00 = switch openedt

01 = switch closed
(closed =control locked)
047 Spare
050 Minimum Gear SelectionRange Range – 1st or2nd
051 Maximum Gear SelectionRange Range – 2nd, 3irdet 4th
052 Minimum Gear Read Only

053 Maximum Gear Read Only
055 Resettable faults
061 à 070 Service Hour Interval Selection #1 -10
071 à 090 Fault Code #1 Through Fault Code #10

Hour Code #1 Through Hour Code #10.
Hour Codes Follow Fault Codes Respectively
091 1st Portion Of Transmission ECM Part Number (ZF) 5 digits from 0 to 9
092 2nd Portion Of Transmission ECM Part Number (ZF) 5 digits from 0 to 9
093 Cluster Software Revision Number

094 Light Emitting Diode (LED) Duty Cycle
095 Liquid Crystal Display (LCD) Duty Cycle

TRAINING MANUAL

Programming the Gauge Display
The C series wheel loaders give the operator the ability to program the instrument cluster to display options that they
wish to view. There are five options available in this category.
They are as follows:
01 Scrolls through Hourmeter, Tachometer, and Speedometer (km/h).

02 Scrolls through Hourmeter, Tachometer, and Speedometer (mph).
03 Scrolls through Hourmeter (at startup), Tachometer (in 1st ñ 3rd gears), and Speedometer (km/h) (in 4th gear).
04 Scrolls through Hourmeter (at startup), Tachometer (in 1st ñ 3rd gears), and Speedometer (mph) (in 4th gear).
05 Scrolls through Hourmeter, Tachometer, and Speedometer (mph), Speedometer (km/h), Engine Coolant
Temperature (Celsius), Engine Oil Pressure (Kpa), Fuel Level, Transmission Oil Temperature (Celsius), Hydraulic
Oil Temperature (Celsius), and Voltmeter.
Two of the options are automatically scrolling displays and three of the options are manual scrolling displays.
Options 03 and 04 are automatic scrolling and options 01, 02, and 05 are manual scrolling. In order to advance the
display readings during normal machine operation in the manual scrolling mode the operator must hit the Up/Down
Count switch in either the up or down position to scroll through the display readings. Pressing the Up/Down Count
switch while in the automatic mode will have no effect on the display.
NOTE: 05 is the setting from the factory.
Displaying Individual Functions
It is also possible to see each of the display functions individually at anytime, regardless of the gauge display youíve
chosen. The following program locations are available to view at anytime by selecting each display field number one
at a time using the programming entry procedure listed previously.
000 Hourmeter
001 Tachometer
002 Speedometer (mph)
003 Speedometer (kph) Up count Program
004 Engine Coolant Temperature
005 Engine Oil Pressure
006 Fuel Level
007 Transmission Oil Temperature
008 Hydraulic Oil Temperature Down count Reset
009 Voltmeter
When a display option that has a display gauge associated with it is selected the display gauge will flash while the
actual value is being displayed on the display screen.
Setting Display Center Light
The operator can set the brightness of the display for two separate conditions. The first is with the work lights off and
the second is with the work lights on. To change the brightness of the display for each location select the display
field number desired and press the Up/Down Count switch until the desired brightness setting is obtained. The
setting can be varied between 001 ñ 100 with 100 being the brightest. The machine is shipped from the factor with a
brightness setting of 070 for work lights off and 020 for work lights on. If the display brightness is set to low it may not
be possible to read the instrument cluster in bright sunlight.
012 Display brightness for work lights off

013 Display brightness for work lights on

TRAINING MANUAL

Testing the Park Brake
The operator can test the park brake by using the diagnostics built into the Up count Program
information center. The transmission must be in 3rd gear manual mode to
perform the test. If the transmission is left in any other gear during the test
the transmission will be disconnected from the engine. To perform the test
use the following procedure: Down count Reset
1 Start the machine.
2 Make sure the transmission selector switch is in 3rd neutral, the automatic switch is in the manual position,and
the park brake switch is on.
3 Select the display field number 011 using the programming entry procedure listed previously.
4 Press the up count switch once so the display reads 01.
5 Shift the transmission selector into 3rd forward and slowly increase the engine RPM's. The park brake should
hold the machine at full throttle.
6 Reduce the engine RPMís and shift the machine into neutral.
7 Press the reset switch to exit the test mode.
8 Turn off the machine.
If the park brake does not hold the machine at full throttle refer to the brakes section of this manual for troubleshooting
procedures.
Transmission Clutch Calibration
The 21 C series wheel loaders have the ability to adjust the clutch modulation between shifts to allow for smooth
shifting between gears. This procedure should be done after the first 250 hours of operation and after every 1000
hours of operation after that. For more information on why and how this occurs refer to the transmission section of
this manual.
5th digit 4th digit 3rd digit 2 nddigit 1st digit
Before adjusting the clutch calibration it is important to understand how the controller communicates to you while the
calibration is taking place. In the main instrument cluster display window there are five digits that will be displayed to
the operator. They are numbered 1 - 5 starting at the left with the 5th position and continuing to the right with the 1st
position. The calibration Main Code status will be displayed in the 3rd and 4th spaces and the 1st and 2nd digits will
display the calibration ìSub Codeî
The calibration Main Code will inform you where the machine is in the process of calibration, or where the machine
was in the process when the calibration was aborted due to a malfunction. The calibration Sub Code will inform you
why the process was aborted.
The meanings of the Main and Sub Codes are listed in the following tables
The 5th digit shows 2 during calibration process.

TRAINING MANUAL
CLUTCH CALIBRATION MAIN CODES
Main codes Meaning Main codes Meaning
00 Clutch calibration was not initiated

because a requirement was not met
07 Calibration completed 08 Operator aborted calibration procedure
01 1st gear calibration 09 Aborting while adjusting 1st gear
02 2nd gear calibration 10 Aborting while adjusting 2nd gear
03 3rd gear calibration 11 Aborting while adjusting 3rd gear
04 4th gear calibration 12 Aborting while adjusting 4th gear
05 FW gear calibration 13 Aborting while adjusting FW gear
06 RV calibration gear 14 Aborting while adjusting RV gear
CLUTCH CALIBRATION SUB CODES
Sub codes Meaning Sub codes Meaning
00 Calibration in process 05 Low transmission oil temperature

01 Fault present 06 High transmission oil temperature
02 Shifter not in neutral 07 Low engine RPM
03 Park brake not engaged 08 High engine RPM
04 Output speed not 0 Km/h
The transmission oil temperature must also be heated above 50o C in the sump before the test can be
performed. If the transmission is not heated to the required temperature you will get 2 00 05 in the display. The 05
sub code is telling you that the transmission oil is not up to temperature. You must use the stall test procedure to
raise the oil temperature above 50o C in the transmission valve.
Up count Program
Clutch calibration procedure

2 Use the stall test procedure listed in the hydraulics section of this training Down count Reset
manual to warm the transmission oil above 50 C. o
3 Make sure the transmission selector switch is in 3rd neutral, the automatic switch is in the manual mode, and the
park brake switch is on.
4 Select the display field number 011 using the programming entry procedure listed previously
5 Press the up count switch once so the display reads 02. At this time you will see 2 00 00 flashing in the display.
Approximently one second later the calibration Main Code will be displayed in the 3rd and 4th spaces and the
calibration Sub Code will be displayed in the 1st and 2nd spaces. During the calibration sequence random
numbers will flash on the screen to inform you that the calibration is taking place. If an error occurs the code will
show continuous on the display.
NOTE: The calibration sequence may take up to 5 minutes to complete.

6 When the calibration procedure is completed you will see 2 07 00 in the display. Press the reset switch to exit the
calibration mode.
7 Turn off the machine..

TRAINING MANUAL

Testing System Voltage
The information center has the ability to allow you to view the system Up count Program
voltage without using a digital volt meter (DVM). The information center
operates on a system voltage of 24 volts supplied by the two batteries
located in the battery compartment. This will inform you of the condition
of the batteries at initial power up of the information center This figure
can be compared to the system voltage present on the guage display to Down count Reset
decide if the problem exist with the batteries or the altenator. To test
the system voltage do the following:
1 Turn the key switch to the on position, do not start the machine.
2 Advance to display field number 014 using the programming entry procedure listed previously.
3 Press the Program/Reset switch back to the center position. The system voltage will be displayed.
4 Press the Program/Reset switch to the Reset position to exit the monitoring mode.
Alarm Check
The alarm can be checked to make sure that it is operating correctly.
To check the alarm:
2 Advance to display field number 015 using the programming entry procedure listed previously. The alarm will
begin to sound intermittently.
3 Press the Program/Reset switch back to the center position. The display will read 00 and the alarm will sound
while the information center checks to see that all systems are normal. If an error is detected the display will read
01. The alarm will still sound intermittently.
Coolant Level Check

The machine coolant level can be checked by using the information center.
To check the machine coolant level:
2 Advance to display field number 016 using the programming entry procedure listed previously
3 Press the Program/Reset switch back to the center position. The display will read 00 if the coolant level is normal.
If the coolant level is low the machine will read 01 in the display.
Brake Pressure Switch Check

This will check the brake pressure switch to make sure that it is functioning properly. This same check will also
show if the brake pressure indicator light is functioning. This test checks the wiring from the information center to
the pressure switch. It does not check the wiring from the information center to the park brake pedal switch located
on the brake pedal under the cab.
To check the brake pressure switch:
1 Start the machine and allow it to run for 30 seconds to make sure the accumulators are fully charged.
3 Advance to display field number 017 using the programming entry procedure listed previously. The brake
pressure light will flash intermittently.
4 Press the Program/Reset switch back to the center position. You should see 01 in the display if the brake
pressure is normal.
5 Cycle the brake pedal several (30 ñ 40) times. You should see the 01 change to a 00 in the display indicating that
the pressure is below normal.
7 Turn the key switch to the off position

TRAINING MANUAL

Secondary Steering Pressure Switch Check Up count Program
This will check the secondary steering pressure switch to make sure that
it is functioning properly. This same check will also show if that the
secondary steering pressure indicator light is functioning. This check only
applies to machines equipped with secondary steering. Reset
Down count
To check the secondary steering pressure switch:

2 Advance to display field number 018 using the programming entry procedure listed previously. The secondary
pressure light will flash intermittently.
3 Press the Program/Reset switch back to the center position. You should see a 01 in the display if the secondary
steering is not activated.
4 Turn the key switch off and back on very quickly. You should hear the secondary motor kick in and the display
should read 00, indicating that the switch is activated. To test the secondary steering steer the machine from left
to right. NOTE: Do not turn the wheel until the unit hits the steering stops, if you do the steering wheel may kick
back.
Park Brake Information Center Output Check
This will check the wiring from the information center to the park brake relay to make sure that it is functioning
properly. This same check will also show if the park brake indicator light is functioning. This check does not
check the wiring from the information center to the park brake switch located in the cab.

2 Advance to display field number 019 using the programming entry procedure listed previously. The park brake
light will flash intermittently.
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the information
center is not activating the park brake relay and the park brake is in the on position.
4 Turn the park brake switch in the cab to the off position, place or foot on the service brake and shift the FNR lever
to either forward or reverse. You should see the display read 01 when the park brake releases.
5 Place the FNR lever back in neutral, place the park brake switch in the on position.
Pilot Lock-Out Information Output Check

This will check the wiring from the information center to the pilot lock-out relay to make sure that it is functioning
properly. This same check will also show if the pilot lock-out indicator light is functioning. This check does not
check the wiring from the information center to the pilot lock-out switch located in the cab.

2 Advance to display field number 020 using the programming entry procedure listed previously. The pilot lock-out
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the information
center is not activating the pilot lock-out relay and the pilot lock-out is in the off position.
4 Turn the pilot lock-out switch in the cab to the on position. You should see the display read 01 when the switch is
flipped.

TRAINING MANUAL

Hydraulic Filter Restriction Switch Check Up count Program
This will check the wiring from the information center to the hydraulic
filter restriction switch in the head of the filter base to make sure that it
is functioning properly. The information center monitors the
temperature of the hydraulic oil and if the temperature is below 20o C it
Down count Reset
will not activate the warning indicator. This same check will also show
if the hydraulic filter restriction switch indicator light is functioning.
2 Advance to display field number 021 using the programming entry procedure listed previously. The hydraulic
filter restriction light will flash intermittently.
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display. This is
indicating that the switch is not being activated. If you see a 01 in the display with the machine off this indicates
a short in the wiring. If the test is performed with the machine running the reading on the display will depend on if
the filter is bypassing.
Air Filter Restriction Switch Check
This will check the wiring from the information center to the air filter restriction switch in the air cleaner to make
sure that it is functioning properly. This same check will also show if the air filter restriction switch indicator light
is functioning.
2 Advance to display field number 022 using the programming entry procedure listed previously. The air filter
restriction light will flash intermittently.
indicating that the switch is not being activated. If you see a 00 in the display with the machine off this indicates
a short in the wiring. If the test is performed with the machine running the reading on the display will depend on if
the filter is plugged.

TRAINING MANUAL

Work Lights Check
Up count Program
This will check the wiring from the information center to the machine
work lights to make sure that it is functioning properly. This same
check will also show if the work lights indicator light is functioning. It
does not check the wiring from the information center to the work
lights switch located in the cab. Down count Reset
2 Advance to display field number 023 using the programming entry procedure listed previously. The work lights
indicator light will flash intermittently.
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display with the work
lights off. Turn the work lights switch to the on position. You should see the display reading change to 01 and
the work lights should operate normally.
Fog Lights Check
This option is not available on North American units.
Air Conditioning Switch Check
This will check the wiring from the information center to the air conditioning high/low pressure switch to make sure
that it is functioning properly. This same check will also show if the air conditioning pressure indicator light is
functioning. It does not test the wiring from the air conditioning switch to the information center in the cab.
2 Advance to display field number 025 using the programming entry procedure listed previously. The air
conditioning switch light will flash intermittently.
indicating that the switch is not being activated. If you see a 01 in the display with the machine off this indicates a
short in the wiring or the switch is being activated.
4 Start the machine and turn the air conditioning on. You should still see 00 in the display indicating everything is
functioning normally. If you see 01 that tells you that the switch is being activated and there is a problem with the
system.
Transmission Filter Restriction Switch Check
This will check the wiring from the information center to the transmission filter restriction switch in the head of the filter
base to make sure that it is functioning properly. The information center monitors the temperature of the transmission
oil and if the temperature is below 20o C it will not activate the warning indicator. This same check will also show if
the transmission filter restriction switch indicator light is functioning.
2 Advance to display field number 026 using the programming entry procedure listed previously. The transmission
hydraulic filter restriction light will flash intermittently.
indicating that the switch is not being activated. If you see a 01 in the display with the machine off this indicates a
short in the wiring. If the test is performed with the machine running the reading on the display will depend on if
the filter is bypassing.

TRAINING MANUAL

Requested Gear Check Up count Program
This test is designed to test the FNR/Shifting lever to see that it is
functioning normally. It tests to see that the information center is
reading the same gear that the lever is requesting.
2 Advance to display field number 028 using the programming entry
Down count Reset
procedure listed previously.
3 Press the Program/Reset switch back to the center position. You should see the appropriate code in the table
below for the requested gear. The display should also flash the appropriate direction selected and gear number
in the transmission display window.
4 Cycle through all gears in all directions(FNR) using the shifter lever and make sure the appropriate code is
shown on the display for each gear requested. The correct codes are listed in the table below
Forward 1 - Code 101 Neutral 1 – Code 201 Reverse 1 – Code 301
Forward 4 - Code 104 Neutral 4 – Code 204
Actual Gear Status

This test will check to determine that the actual gear the transmission is in, is the same as the gear that the
information center is reading. It does not test the readings that the information center is receiving from the
FNR/Shifter lever. To perform this test the operator must have the transmission in the manual mode and drive
the machine while performing the test.
3 Press the Program/Reset switch back to the center position. You should see the appropriate code in the table
below for the requested gear the transmission is in. The display should also flash the appropriate direction
selected and gear number in the transmission display window.
4 Cycle through all gears in all directions(FNR) using the shifter lever while driving the machine and make sure the
appropriate code is shown on the display for each gear requested. The correct codes are listed in the table
below.
Forward 4 - Code 104 Neutral 4 – Code 200
Limp homemode – 115 Limp home mode - 315
6 Stop the machine, place it in neutral and apply the park brake.
Master Indicator Status

This test is used to check the master indicator lights in the instrument cluster to make sure that the are functioning
properly.
2 Advance to display field number 039 using the programming entry procedure listed previously. The red warning
indicator light will begin to flash.
3 Press the Program/Reset switch back to the center position. If everything is functioning normally in the
information center the display will show 00 and the warning indicator will flash. If there is an error the display will
show 01. The indicator will still flash.
4 Advance to display field number 041 using the programming entry procedure listed previously. The yellow
caution indicator light will begin to flash.
5 Press the Program/Reset switch back to the center position. If everything is functioning normally in the
information center the display will show 00 and the caution indicator will flash. If there is an error the display will
show 01. The indicator will still flash.

TRAINING MANUAL

Master Reset Up count Program
This feature will reset the information center values back to the original
factory settings for the following features:
Gauge Display
Information Center Lighting Work Lights Off
Information Center Lighting Work Lights On
Minimum Gear Selection Down count Reset
Maximum Gear Selection
To set the features back to their original settings:

3 Press the Program/Reset switch back to the center position.
4 Press the Up/Down Count switch to the up position twice to change the reading from 00 to 01.
5 Press and hold the Program/Reset switch to the momentary position for 0.25 seconds.
Park Brake Switch Check

This will check operation of the park brake switch to make sure that it is functioning properly. This same check
will also show if t the park brake indicator light is functioning. This check does not check the wiring from the
information center to the park brake pressure switch.
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the park brake
switch is in the on position.
4 Toggle the park brake switch to the off position. You should see a 01 in the display when the switch is activated.
Redundant Brake Pressure Switch Check

This check will check operation of the redundant brake pressure switch and the wiring from the switch to
information center to make sure that it is functioning properly. This same check will also check to see that the
park brake indicator light is functioning. This check does not check the wiring from the information center to the
park brake switch located in the cab.

3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the brake
pressure is in the normal operating range. The display will show 01 if the brake pressure is out of the normal
operating range.

TRAINING MANUAL

Service Brake Foot Switch Check
Up count Program
This test will check operation of the service brake foot switch to make sure
that it is functioning properly. This same check will also shown if the park
brake indicator light is functioning.
2 Advance to display field number 045 using the programming entry Down count Reset
procedure listed previously. The park brake light will flash intermittently.
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the service
brake pedals are not activated.
4 Step on the service brake pedal. You should see a 01 in the display when the switch is activated.
Pilot Lock-Out Switch Check

This will check operation of the pilot lock-out switch in the cab to make sure that it is functioning properly. This same
check will also show if the pilot lock-out indicator light is functioning.
2 Advance to display field number 046 using the programming entry procedure listed previously. The pilot lock-out
3 Press the Program/Reset switch back to the center position. You should see a 00 in the display if the pilot
lockout switch is in the off position.
4 Toggle the pilot lock-out switch to the on position. You should see a 01 in the display when the switch is
activated.

TRAINING MANUAL

Minimum Gear Selection
The 21 ìCî series wheel loaders have the option to start out in either 1st
Up count Program
or 2nd gear when operating in the automatic mode. The gear that is
selected will be the gear that the transmission is in when the machine
begins to move. Machines coming from the factory will be programmed
to begin in 1st gear. If the machine is programmed to start in 2nd gear
and the load under which the unit is operated becomes too great the
machine will automatically down shift to 1st gear. Down count Reset
To change the minimum gear selection:

3 Press the Program/Reset switch back to the center position. There will be either a 1 or 2 in the display window.
This represents which gear you wish the transmission to start in.
4 Press the Up/Down Count switch to the up count position until the desired gear is selected.
5 Press the Program/Reset switch to the Reset position hold it for 0.25 seconds to save the desired setting.
Maximum Gear Selection

The 21 C series wheel loaders have the option to limit the highest attainable gear when operating in the automatic
mode. The lowest gear that can be selected is 2nd gear. Machines coming from the factory will be have the
maximum gear set at 4th gear.
To change the maximum gear selection:

3 Press the Program/Reset switch back to the center position. There will be a 2, 3 or 4 in the display window. This
represents the maximum gear currently selected.
4 Press the Up/Down Count switch to the up count position until the desired gear is selected.
5 Press the Program/Reset switch to the Reset position hold it for 0.25 seconds to save the desired setting.
Service Interval Hours

Display field number 061 - 070 are reserved for recording service interval hours. It is up to the customer or
operator to assign each location a service item. For example; they may choose to use location 061 to represent
engine oil change. Slot 061 will log engine hours independently from the regular engine hour meter reading. The
operator can view each field individually to see how many hours have passed since the last engine oil change at
any time. When the engine oil is changed the operator can reset slot 061 to 0 hours and it will continue to log
engine hours from 0 independently from the regular engine hour meter.
To view the service hour interval locations:

2 Advance to display field number 061 - 070 using the programming entry procedure listed previously.
3 Press the Program/Reset switch back to the center position. The accumulated hours will show in the display
window.

TRAINING MANUAL

To reset the service hour interval locations: Up count Program
2 Advance to display field number 061 - 070 using the programming entry
3 Press the Program/Reset switch back to the center position. The
accumulated hours will show in the display window.
4 Press the Up/Down Count switch to the down position and hold it for 3 Down count Reset
seconds. The service interval hours will reset to 0.
Fault Code Status

The 21 C series wheel loaders have the capability to store error codes in memory. Display field numbers 071 ñ
090 have been reserved for this feature. The machine has the capability of storing ten error codes and log the
engine hours where the malfunction occurred. The odd numbered locations are for error codes numbers and the
even numbered locations are for engine hour locations. The hour reading for a given error code will directly follow
the error code reading. For example, 072 will display the hours on the machine when the fault code in location
071 occurred. The fault codes and diagnostics will be covered in greater detail in the diagnostics section of this
manual.
To view the fault codes and hours they occurred:

2 Advance to display field number 071 - 090 using the programming entry procedure listed previously.
3 Press the Program/Reset switch back to the center position. The error code stored or engine hours reading will
show in the display window.
Storing a Location in Memory

The information center gives the operator the ability to store the location of one display field number in the memory of
the controller.
This reading can be displayed at anytime during operation of the unit by pressing the "Program/Reset" to the reset
position
To store a location in memory:
2 Press the Program/Reset switch to the program position.
3 Press the Up/Down Count switch to the up position until the desired display field number is shown.
4 Return the Program/Reset switch to the center position.
5 Press the Program/Reset switch to the program position once again and wait 5 seconds.
The numbers on the display will change.
6 Return the Program/Reset switch to the center position.
7 Within 3 seconds, press the "Program/Reset" once to the Reset position.
Whenever the operator presses the reset button the value will be displayed.
Machines coming from the factory will be programmed to automatically display location 000, hour meter.
If the operator wishes to change the reading back to 000 simply press the "Program/Reset" to the reset position and
hold it for five seconds.

TRAINING MANUAL
Advanced Programming Functions Up count Program

The 21 C series wheel loaders has advanced programming
functions built into the information center. The advanced functions
are reserved for Display Field Numbers 098 ñ 199. The operator
does not have access to the advanced programming features, they
are password protected. To enter into the advanced programming Down count Reset
functions the service technician will use the Program/Reset and
Up/Down Count switch.
To enter into the advanced programming mode the service
technician must utilize Display Field Numbers 098 and 099. The
technician must enter 21 in both locations to get the information
center to go above location 99. To do this: 98 Go to field 98
3 Press the Up/Down Count switch to the down position until
location 098 is reached.
4 Press the Program/Reset switch to the center position.
5 Press the Up/Down Count switch to the up position until 21 is in 21 Display the code 21
the display
7 Press the Up/Down Count switch to the up position until
location 099 is reached.
8 Press the Program/Reset switch to the center position.
9 Press the Up/Down Count switch to the up position until 21 is in 99 Go to field 99
the display.
11 Press the Up/Down Count switch to the up position to continue
past location 099.
21 Display the code 21
100 Go to field 100

TRAINING MANUAL

Display field numbers and description
Field number Item StatusIndications possibles
100 Transmission ECM (EST 37) 62101 - 72101 - 82101 - 92101
Identification number
101 Transmission ECM (EST 37) 62101 - 72101 - 82101 - 92101

Identification number
102 Transmission ECM Identification Lock 000: Fields 100 and 101 are the same and are locked
and Reprogram Set 001: Fields 100 and 101 are unlocked (may be
changed)
010: Reprogram the transmission ECM
1xx: the 1ist1 shows that 100 and 101 are diffèrents
103 Transmission ECM Identification 0 - - = No data received from Transmission ECM

Reprogramming result 1 - - = Data received from Transmission ECM
100 = TECM Identification Numbers are the same.
101 = TECM Identification Numbers are different
110 = TECM ID.N have been successfully reprogrammed.
111 111 = TECM ID.Nrs not present as received
104 to 113 Reserved for future machine information
114 Beginning numbers of Case Cluster Part Number

115 Remaining numbers of Case Cluster Part Number
116 Cluster production date code (yr ñ day) Example: 96 135
117 to 120 Reserved for future use
130 Tire Size Calibration for speedometer

131 to 139 Dedicated to tire calibration numbers
140 to 160 Reserved for future use
171 to 190 Resettable Fault Code #1 Through Fault Code #10172, 174, 176, 178, 180, 182, 184, 186, 188,
190Hour Code #1 Through Hour Code #10. Hour Codes Follow Resettable Fault Codes
Respectively.
197 Input analogue data read by the microprocessor. Voltages read by the microprocessor will not
exceed 5 volts When “13” is entered in this location, the analogue data inputs to the microprocessor
will be displayed in location 000 to location 015. It is read as 0 = 0 volts and 1023 = 5 volts.
When the Information Center is turned off, location 197 will reset back to 0 and normal gauge
indications will be read in the display center in location 000 to location 015.
NOTE : In the fields 100 and 101 new codes ending per 02 may be shown. This is for future uses.

TRAINING MANUAL
Transmission Identification Numbers Program

Locations 100 and 101 will display the transmission electronic control
Up count
module(ECM) identification numbers. These numbers should match the
machine model that the transmission ECM is installed in. Both locations
must have the same numbers in them for the machine to function properly.
It is possible that a service technician may have to set these identification Down count Reset
numbers if a new ECM is installed on a machine. The actual storage of the codes is stored in positions 100 and 101,
however, you must use positions 102 and 103 to make the changes kept in 100 and 101.
You must also have the park brake engaged to change the transmission identification numbers.
The first step is to unlock positions 100 and 101 so that they can be changed. This is done in position 102.
1 Press the Up/Down Count switch to the up position until 102 is shown in the display.
NOTE: Locations 098 and 099 must be set to 21 before position 102 can be accessed.
3 Press the Up/Down Count switch to the up position until 001 is in the display.
The next step is to change the transmission ECM numbers

4 Press the Program/Reset switch back to the program position.
5 Press the Up/Down Count switch to the down position to display location 101.
7 Press the Up/Down Count switch to the up position until the appropriate code is in the display. Use the table on
page 4.A.25.00 to select the correct code for the machine model number.
8 Press the Program/Reset switch back to the program position
9 Press the Up/Down Count switch to the down position to display location 100
11 Press the Up/Down Count switch to the up position until the appropriate code is in the display. Use the table on
page 4.A.25.00 to select the correct code for the machine model number.
LThe next step in the process is to instruct the information center to reprogram the transmission controller.

15 Press the Up/Down Count switch to the up position until 010 is in the display.
18 Press the Program/Reset switch back to the center position. If the transmission ECM was successfully
programmed you should see a 110 in the display. If it was not successfully programmed refer to the table below
for interpretation of the code that is displayed and go back and fix the problem
The next step in the process is to lock the program numbers so that they cannot be changed.

20 Press the Up/Down Count switch to the down position until 102 is shown in the display.
21 Press the Up/Down Count switch back to the program position.
22 Press the Up/Down Count switch to the up position until 000 is in the display. This locks locations 100 and 101.
23 Press the Program/Reset switch to the reset position and hold for 0.25 seconds.
24 Turn the key switch to the off position and restart the machine within 10 seconds or the programming will not be
saved in the memory of the information center.

TRAINING MANUAL
621C Programmation flow chart
Go to field Go to field
102 102 102 102 RESET Hold 0,25 s
Display the code Display the code

001 001 to unlock the 010 010 for
fields 101 and 100 programmation
processing Switch of
the key
switch
101 Go to field Go to field103

101 103
Check if the code Restart the To

Select the 110 is displayed for engine before memorise
62101 appropriate mode 110
correct 10 s
code (ex: 62101) programmation
processing
Go to field Go to field
100 100 102 102
Programmation
achieved
Select the appropriate Display the code

62101 model code (same as 000 001 to lock the
the code of the field fields 101 and 100
101)
For 721C, 821C, 921C select the appropriate code in the fields 100 and 101.

TRAINING MANUAL

Tyre Calibration
If a dealer or customer changes the tyre sizes, the new tyre calibration will
Up count Program
have to be changed to match the information center and transmission
ECM to the new tyres. If the tyre code is not changed then the
speedometer reading will not be accurate. The operator does not have
access to be able to change the tyre calibration on the machines since this
is an advanced programming function. This feature was made an Down count Reset
advanced programming function because most customers do not change tyre sizes frequently by themselves.
To select the appropriate code refer to the table below for the given tyre size.
Tyre Calibration Codes
Machine Tyre Axle ratio Z = Tyre Rev/Km Calibration

code
621 w17.5 x 25 L2 21.88 259 5667

621 w/17.5 x 25 XTLA/XHA 21.88 245 5361
621 w/ 20.5 x 25 L2 21.88 235 5142
621 w/20.5 x 25 XTLA/XHA 21.88 225 4923
721 w/17.5 x 25 L2 21.37 259 5535
721 w/17.5 x 25 XTLA/XHA 21.37 245 5236
721 w/ 20.5 x 25 L2 21.37 235 5022
721 w/20.5 x 25 XTLA/XHA 21.37 225 4808
821 w/20.5 x 25 L2 23.51 220 5172

821 w/20.5 x 25 XTLA/XHA 23.51 218 5125
821 w/23.5 x 25 L2 23.51 208 4890
821 w/23.5 x 25 XHA 23.51 207 4867
921 w/ 26.5 x 25 L2 22.85 201 4593

921 w/ 26.5 x 25 XRD/XHA 22.85 193 4410
To change the tyre size calibration:

NOTE: Locations 098 and 099 must be set to 21 before position 130 can be accessed.
3 Press the Up/Down Count switch to the up position until the correct tyre code is in the display.
4 Press the Program/Reset switch to the reset position.
There may be instances when the customer chooses a tyre size that is not listed in the table. If this is the case you
will have to figure the Dynamic Rolling Radius for the tyre and use that figure. To do this you must find out what
the revolutions per kilometer is for the respective tyre and multiply it by the axle ratio for the model of the
machine. This information is usually available from the tyre manufacturer. If it is not do the following:
1 Place a mark on the bottom side of the tyre.

2 Drive the machine until the tyre makes ten full revolutions.
3 Measure the distance traveled in meters this gives you a value X.
4 Divide 1000 by the distance traveled X (m) to obtain a value Y. Y=1000/X
5 Multiply Y times 10 to obtain the number of tyre revolutions in 1 km this will be a value Z. Z= Yx10
6 Multiply Z times the axle ratio from the table above for the given model machine.
Zx axle ratio = tyre calibration code
7 Enter this code during the programming procedure listed above.

TRAINING MANUAL
Resettable Fault Codes
The information center has two locations where error codes are stored in memory. The first of which is locations 071
ñ 090, the second is in the advanced programming function in field display locations 171 ñ 190. The second set
of error codes is set up exactly like the first set except that they will clear when ever the key switch is turned off.
The odd numbered locations are for error code numbers and the even numbered locations are for engine hours
at which the error occurred.
Up count Program
To view the fault codes and hours they occurred:
1 Advance to display field number 171 - 190 using the programming
entry procedure listed previously.
2 NOTE: Locations 098 and 099 must be set to 21 before position 171 -
190 can be accessed. Down count Reset
3 Press the Program/Reset switch back to the center position. The
error code stored or engine hours reading will show in the display window.
Fault Code Readout and Diagnostics

The information center on the 21(C) series wheel loaders has built in diagnostic features. The diagnostics will help
service technicians diagnose and repair system malfunctions with greater ease and speed.
Fault codes in the (C) series wheel loaders consist of a five digit number. Each number has been assigned a
specific fault through the software programming of the information center. The five digit code has a specific definition
associated with it. The first digit displayed from the left represents each of the following systems:
1 Engine Coolant
2 Engine Lubricant
3 Engine Air and Fuel
1st digit 2nd digit 3rd digit 4 thdigit 5th digit
4 Transmission
5 Steering
6 Brakes
7 Hydraulic
8 Electrical
9 Accessories (i.e. ñ Air Conditioning)
The second digit from the left has the following definitions assigned:
1 Pressure (kPa)
2 Temperature (oC)
3 Level (% full)
4 Voltage (volts)
5 Filter Restriction
6 Malfunction
7 CAN Interface Data
The 3rd, 4th, and 5th digits displayed from the left represent the actual pressure, temperature, % of full or volts
reading that the information center is measuring.
When a fault occurs the information center recognizes it and logs it into the memory of the controller. It also logs the
engine hours when the fault occurred. When a fault is recorded in memory the center display will also show an open
book with a wrench in the middle. This will be shown on the display for 10 minutes. After ten minutes the wrench
symbol disappears until another fault is logged into the memory of the controller. Because the wrench symbol
disappears does not mean that the error is gone. It is still stored in the memory of the controller. The symbol will
reappear for ten minutes again if another fault is detected by the information center. This cycle will repeat every time
another error code is logged. The information center will continue to log duplicate codes once every hour.
The information center has the ability to store ten faults in memory. If an eleventh fault is detected the last fault stored
in memory will be erased and the new one will be logged at the beginning of the fault stack.

TRAINING MANUAL
DIAGNOSTIC CODES
Erasing Fault Codes
There are two locations for fault code storage in the information center. How to gain access to these locations and
read error codes and engine hours when the error occurred was discussed earlier in this section of the manual. The
first set of fault codes, stored in locations 071 ñ 090, will be stored in memory until they are erased by the operator or
service technician. The second set of fault codes, stored in locations 171-190, are erased every time the key switch
is turned to the off position. You should erase the error codes stored in memory after you have written all fault codes
down on a piece of paper. This will tell you whether or not you have any new codes occurring while you are trying to
fix the machine. To erase the fault codes stored in locations 071 ñ 090, do the following:
2 Advance to display field number 055 using the programming entry Up count Program
4 Press the Up/Down Count switch to the up position until the display
reads 21.
5 Press the Program/Reset switch to the reset position. This clears the Down count Reset
error stack.
FAULT CODES
Code Definition
86000 All 86000 codes are Information Center codes
86010 Corrupt engine hours, data lost
86011 Corrupt engine hours, data suspect
86012 Corrupt engine hours, data suspect
86020 The calibration number will default back to the number used at cluster shipment
86021 Corrupt tyre calibration number, data suspect
86022 Corrupt tyre calibration number, data suspect
86030 Information Center memory error
86040 Information Center memory error
86050 Information Center RAM failure
86060 Information Center Reset ñ This code is generated if the Information Center Program «goes astray».
The Information Center is reset. This code will also be generated if there is a brief intermittent open
between the time the engine is shut off and the Information Center shuts off
The following diagnostic codes will be written into memory if the engine is running faster than 500 RPM for 15 seconds..
Cluster Gauge Diagnostics
Code Definition
12900 Engine coolant short circuit measuring less than 50 ohms to the engine coolant temperature sensor
12901 Engine coolant open circuit measuring greater than 10,000 ohms to the engine coolant temperature
sensor with hydraulic oil temperature at 40o C (104o F)or more.
33900 Fuel level short circuit measuring less than 16 ohms to the fuel level sender.
33901 Fuel level open circuit measuring more than 270 ohms to the fuel level sender.
72900 Hydraulic oil temperature short circuit measuring less than 50 ohms to the hydraulic oil temperature
sensor
72901 Hydraulic oil temperature open circuit measuring greater than 10,000 ohms to the hydraulic oil
temperature sensor with the engine coolant temperature at 90o C (1940 F) or more.
21900 Engine oil pressure short circuit measuring less than 16 ohms to the engine oil pressure sensor.
21901 Engine oil pressure open circuit measuring more than 270 ohms to the engine oil pressure

TRAINING MANUAL
DIAGNOSTIC CODES
Cluster Input Diagnostics
Code Definition
61900 1700 PSI (11,721 kPa) Brake pressure switch has not cycled within 50 hrs. of operation time.
61901 900 PSI (6250 kPa) Redundant brake pressure switch has not cycled within 100 hrs. of operation time.
66900 Park brake switch has not cycled within 50 hrs of operation time.
66901 Service brake foot switch has not cycled within 50 hours of operation.
DiagnoCluster Output Diagnostics
Code Definition
34000 Fuel solenoid output short circuit.

64000 Park brake solenoid output short circuit
74000 Pilot pressure solenoid output short circuit..
Machine System Diagnostics
Code Definition
21100 Engine oil pressure is measured below 100 kPa (14.5 PSI)
21110 Engine coolant temperature is 110° C (230° F) or greater.
61000 Low brake pressure (1700 PSI / 11721 kPa) has been detected after a normal operating pressure has
been reached since start up
51000 Low steering pressure has been detected after a normal operating pressure has been reached since
start up
13000 Low engine coolant level - This code will not be generated if the engine coolant temperature is below
20° C (68° F)
42120 Transmission temperature measured above 120° C
72110 Hydraulic oil temperature is 110° C (230° F) or greater.
84016 System voltage is below 16 volts.
84018 System voltage is below 18 volts.
84032 System voltage is above 32 volts..
35000 High air filter restriction
75000 High hydraulic filter restriction when the hydraulic oil is above 20° C (68° F).
91000 Air Conditioning high or low pressure indication
45000 High transmission filter restriction when the transmission oil is above 20° C (68° F).

TRAINING MANUAL
DIAGNOSTIC CODES
Transmission Diagnostics
Code Definition
46018 Logical error at direction select signal

46020 Logical fault at Park Brake Status
46037 Short circuit to battery voltage or open circuit at temperature sensor input
46038 Short circuit to ground at temperature sensor input
46049 Short circuit to battery voltage or Open circuit at engine speed input
46050 Short circuit to ground at engine speed input
46051 Logical error at engine speed input
46052 Short circuit to battery voltage or Open circuit at turbine speed input
46053 Short circuit to ground at turbine speed input
46054 Logical error at turbine speed input
46055 Short circuit to battery voltage or Open circuit at intermediate speed input
46056 Short circuit to ground at intermediate speed input.
46057 Logical error at intermediate speed input
46058 Short circuit to battery voltage or Open circuit at output speed input
46059 Short circuit to ground at output speed input
46060 Logical error at output speed input.
46062 Output speed zero, does not match other speeds
46064 Invalid gear range restriction (CAN)
46065 Invalid declutch modulation selection (CAN.
46089 Invalid test mode signal (CAN).
46090 Invalid park brake status (CAN).
46091 Invalid shift quality selection (CAN
46113 Short circuit to ground at clutch K1
46115 Open circuit at clutch K1.
46116 Short circuit to battery voltage at clutch K2.
46118 Open circuit at clutch K2
46119 Short circuit to battery voltage at clutch K3.
46120 Short circuit to ground at clutch K3.
46129 Short circuit to battery voltage a clutch K4
46132 Short circuit to battery voltage at clutch KV
46133 Short circuit to ground at clutch KV
46134 Open circuit at clutch KV
46135 Short circuit to battery voltage at clutch KR
46136 Short circuit to ground at clutch KR
46137 Open circuit at clutch KR
46145 Short circuit to ground at reverse warning alarm relay
46146 Short circuit to battery voltage at reverse warning alarm relay
46147 Open circuit at reverse warning alarm relay
46148 Short circuit to ground at starter interlock relay
46149 Short circuit to battery voltage at starter interlock relay
46150 Open circuit at starter interlock relay .

TRAINING MANUAL
DIAGNOSTIC CODES
Transmission Diagnostics
Code Définition
46177 Slippage at clutch K1

46181 Slippage at clutch KV
46182 Slippage at clutch KR
46183 Oil temperature is above limit
46211 Low voltage at battery
46212 High voltage at battery
46213 Error at switch 1 for solenoid power supply
46214 Error at switch 2 for solenoid power supply
46229 Error at communication on CAN
46230 Undefined VIN request via CAN
46241 General EEPROM fault
46242 Current ID not set or corrupt
46243 Application error (ZF internal)
46245 Clutch calibration fault
46246 Clutch fill calibration has not yet taken place
CAN (Controller Area Network) Interface Diagnostics
If the following data is missing, then the code will be generated
Code Définition
47000 No CAN connection for 1 second

47001 Engine speed is missing
47002 Output shaft speed is missing
47011 Transmission oil temperature is missing
47012 Transmission filter restriction information is missing
47013 Current Transmission identification code is outside of the range
47014 Incorrect programmation of the model number
Fault codes 61900, 61901, 66900, and 66901 are timed fault codes. They will be logged into memory if the switch
has not cycled within the given time window. It is possible to see these fault codes if the machine is operated for
several hours in a row without letting the hydraulic system pressure bleed off.

TRAINING MANUAL
INFORMATION CENTER ELECTRICAL SYSTEM
The information center is supplied with battery power coming from the junction stud, going through the voltmeter relay,
when the key switch is turned to the on or start position. The information center is also supplied with power from the
time delay module, if the program/reset switch is activated to the reset position. Power flows from the time delay
module, through fuse S, to the up/down switch, and into the information center terminal 2. The information center has
three grounds coming out of terminals 8, 38, and 39. The seat switch wire coming out of terminal 37 is constantly
grounded to complete the circuit and signal the information center that the switch is always closed. This is done
because we do not use the seat switch application on the C series wheel loaders.
The following sensors and senders are wired into the following respective terminals on the information center:
3 Brake Pressure Switch 4 Coolant Level
19 Fuel Level Sender 5 Steering Pressure Switch
20 Hydraulic Oil Temperature Sender 7 Hydraulic Filter Restriction Switch
18 Engine Coolant Temperature Sender 6 Air Filter Restriction Switch
10 A/C High/Low Pressure Switch 22 Engine Oil Pressure Sender
28 Redundant Brake Switch
The information center constantly sends out a 5 volts signal to each of the senders. The sensors operate off of 24 volts
of key switch power. If the sensor is activated it either completes the signal to ground or breaks the signal to ground
notifying the information center of a possible system problem. Some of the senders depend on a variable resistor to
send a variable voltage signal back to the information center to perform the measurements, one example of this is the
hydraulic oil temperature sender.
The following switches are wired into the following respective terminals.
12 Work Light Switch 17 Right Turn Light
13 Beacon Light Switch 18 Left Turn Light
14 Fog light 29 Pilot Lockout Switch
15 High Beam Lights Switch 35 Service Brake Foot Switch
9 Park Brake Switch
When any of these switches are activated they send a 24 volt signal into the information center telling it that the
particular function has been activated. The information center then responds by lighting the appropriate indicator light.
Terminals 24 and 25 are reserved for the Program/Reset switch in signals. The Program/Reset switch is provided 24
volts of power from the ignition switch. When the switch is activated in the program direction a 24 volt signal is sent
into terminal 24 of the information center calling for a programming request. When the switch is activated in the reset
direction a 24 volt signal is sent into terminal 25 of the information center calling for a reset function.
Terminals 26 and 27 are reserved for the Up/Down Count switch in signals. The Up/Down Count switch is provided 24
volts of power from the time delay module. When the switch is activated in the up direction a 24 volt signal is sent into
terminal 26 of the information center calling for an up count. When the switch is activated in the down direction a 24
volt signal is sent into terminal 27 of the information center calling for a down count.
Terminals 31 and 32 are reserved for the transmission ECM. The transmission ECM communicates to the information
center and visa versa through a can bus interface system. The can bus interface system is located between the
information center and the transmission ECM.
Terminal 23 of the information center is reserved for the input signal from the engine automatic shutdown relay. With
the key switch in the on or start position the controller always provides the ground for this relay. We do not use the
automatic shutdown feature so the controller will always provide the ground.
Terminal 30 is reserved for the park brake solenoid. When the park brake switch is turned off a signal is sent out of the
information center to the park brake relay. The park brake relay is energized and a signal is sent to the park brake
solenoid releasing the park brake.
Terminal 36 is reserved for the pilot pressure solenoid. When the pilot lockout is actuated a signal is sent out of the
information center to the pilot lockout relay. The pilot lockout relay is energized and a signal is sent to the pilot lockout
solenoid engaging the pilot lockout system. The hydraulic controls are now locked out and will not function.
The following Terminals are not used: 11, 21, 33, 34, 40..
TRAINING MANUAL
PROGRAMMATION DE L’AFFICHEUR NUMERIQUE

4A.36.00
PRESSION DE FREIN, NIVEAU RADIATEUR, COLMATAGE DES FILTRES, CONTROLE TEMPERATURES, AFFICHEUR, FREIN DE PARKING, PRESSION DE PILOTAGE
1 + 24 VOLT AVANT CONTACT 1
2 + 24 VOLT APRES CONTACT 2
3 ECLAIRAGE DES COMMANDES 3
94 21 13 76 43A AFFICHEUR 76 DBr/LG (45R) 0.8 17

AR / CABINE CAB / COLONNE COLONNE / CAB
FEUX AR / AR Y (33P) 1.0 4 Y (33P) 0.8 3 Y (33P) 0.8 3 ALARME DE PRESSION DE FREIN INDICATEUR GAUCHE DE DIRECTION 17 DBr/LG (45R) 0.8 17
Y (31D) 1.0 3 Y (31D) 1.0 3 Y (31D) 0.8 4 Y (31D) 0.8 4 NIVEAU DE LIQUIDE DE REFROIDISSEMENT INDICATEUR DROITE DE DIRECTION 16 DBr/Y (45L) 0.8 16 DBr/Y (45L) 0.8 18
V (36F) 1.0 16 V (36F) 0.8 19 V (36F) 0.8 19 NIVEAU DE CARBURANT TEMP. D'HUILE DE LA TRANSMISSION 21 B (50T) 0.8
4A - INFORMATION CENTER
88 Y (35X) 1.0 20 Y (35X) 0.8 5 Y (35X) 0.8 5 PRESSION DE DIRECTION PRESSION DE PILOTAGE 29 Y (31L) 0.8 13
AU CONTACTEUR V (36H) 1.0 V (36H) 0.8 20 TEMPERATURE DE L'HUILE HYDRAULIQUE CAN + 24 VOLT 33
DE DIRECTION DE 13 20 V (36H) 0.8
A OUVERT A B (0) 0.8
117 BAR SECOURS PAGE 22 Y (31H) 1.0 14 Y (31H) 0.8 7 Y (31H) 0.8 7 COLMATAGE DU FILTRE HYDRAULIQUE MASSE DES SIGNAUX 38 B (0) 0.8 38 B (0) 0.8 19
V (36C) 0.8 18 V (36C) 0.8 18 TEMP. LIQUIDE DE REFROIDISSEMENT PRESSION D'HUILE MOTEUR 22 V (36P) 0.8 22 V (36P) 0.8 20
22 Y (31F) 0.8 6 Y (31F) 0.8 6 COLMATAGE DU FILTRE A AIR PRESSION DES ACCU. DE FREIN 28 Y (33R) 0.8 28 Y (33R) 0.8 21
35 MOTEUR / CABINE
B (0) 0.8 8 B (0) 0.8 8 MASSE GENERALE RELAIS 52 D'ARRET MOTEUR (OPTION) 23 W (23C) 0.8 23 W (23C) 0.8 22
A
136 V (36C) 1.0 4 W (53C) 0.8 W (53C) 0.8
O (19V) 0.8 1 O (19V) 0.8 1 ALIMENTATION + 24 VOLT SIGNAL DE SORTIE DE PRES. PILOTAGE 36 36 23
ALARME Y (31F) 1.0 3
O/R (61R) 0.8 10 O/R (61R) 0.8 10 A-C - ALARME HAUTE/BASSE PRESSION SIGNAL DE SORTIE DU FREIN DE PARKING 30 W (52C) 0.8 30 W (52C) 0.8 24
PRESSION B (0) 1.0 30
N.C. 11 NON UTILISE SIGNAL DE LA PEDALE DE FREIN 35 T (44) 0.8 35 T (44) 0.8 25
B
DE FREIN 38 Y (18G/42R) 1.0 12 Y (18G/42R) 0.8 12 FEUX DE TRAVAIL CAN LOW - NIVEAU BAS DU CAN 31 G (50L) 0.5 31 G (50L) 0.5
P (46) 0.8 13 P (46) 0.8 13 FEU ROTATIF CAN HIGH - NIVEAU HAUT DU CAN 32 Y (50H) 0.5 32 Y (50H) 0.5 26
SONDE DE TEMP. AU FUSIBLE V B/R (50G) 0.5 B/R (50G) 0.5
PAGE 10 P (41F) 1.0 14 P (41F) 0.8 14 FEU ARRIERE DE BROUILLARD MASSE DU CAN 34 34
HYDRAULIQUE RELIES
O (18C) 0.8 15 O (18C) 0.8 15 FEUX DE ROUTE CONTACTEUR DE PRESENCE DU SIEGE 37 37
B B (0) 0.8 39 B (0) 0.8 39 MASSE DES SIGNAUX 2 2 O (19S) 0.8 27
AU CONNECTEUR 22 ALIMENTATION + 24 VOLT TEMPORISEE
TERMINAL 27 PAGE 26 Y (33U) 0.8 9 FREIN DE PARKING B (0) 0.8 40
104 MASSE CARCASSE 40
B (0) 0.8
A V (37P) 0.8 24 ENTREE "PROGRAM" ENTREE DU CONTACTEUR "UP COUNT" 26 28
A L'INTERRUPTEUR DE FEU B (0) 0.8
FERME A 25 25 ENTREE "RESET" ENTREE DU CONTACTEUR "DOWN COUNT" 27
3,1 BAR ROTATIF PAGE 4
29
36 P A L'EPISSURE DANS TOIT MASSES A LA COLONNE DE DIRECTION
39 DE CABINE PAGE 1 Gy (49) 0.8
O (19S) 0.8
NIVEAU A L'ALIMENTATION COMMANDE FEUX DE
TEMPORISEE PAGE 10 V (37R) 0.8 O (19S) 0.8
COLMATAGE DU A L'INTERRUPTEUR DE FEU
V (37R) 0.8
DETRESSE PAGE 1
RADIATEUR ARRIERE DE BROUILLARD PAGE 3 2
B FILTRE HYDRAULIQUE 43
2 Gy (49) 0.8
AU FUSIBLE C INTERRUPTEUR
PAGE 3
FREIN 6
6
2 PARKING 5
5 B (0) 0.8
1
4
141 117 4
A A 138 A COMMANDE DE
COMMANDE
5 6
B (0) 1.0
FERME A 44 PRESSION "UP /DOWN
TRAINING MANUAL
0,064 BAR 72 37 A LA COMMANDE DE FEUX

PILOTAGE DE DETRESSE PAGE 1 COUNT"
Gy (49) 0.8
O (19A) 0.8
V (37R) 0.8
4
O (19A) 0.8
37 40 V
B (0) 0.8
94 41 22 CONNECTEUR
NIVEAU /
CAB/COLONNE.
TEMP. DU LIQUIDE 75 42 PAGE 12 2
FEUX DE CONTACTEUR
B (0) 0.8
V (31L) 0.8
V (37D) 0.8
REFROIDISSEMENT 1
B (0) 0.8
13 ARRIERE B B B DE COLMATAGE CABINE AU SELECTEUR DE
GASOLE MOTEUR CONTACTEUR TRANSMISSION PAGE 12
13
ARRIERE 23
R (1A) 0.8
DU FILTRE A AIR MOTEUR PROGRAM/RESET
5 6
B (0) 0.8
CAB / COLONNE
AU FUSIBLE C O (19C) 1.0 O (19C) 0.8 68 O (19C) 0.8
13 PAGE 8
4
GOUJON SOUDE
COLONNE A LA CLE DE CONTACT CONTACTEUR DE RIDE CONTROL A LA CABINE
O (19C) 1.0 PAGE 22
PAGE 8
CABINE 53 B (0) 0.8
Gy (49) 0.8 74 45
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
B (0) 1.0
4 MASSE DE LA CABINE 4
4A MASSE MOTEUR 4A
VIA UNE EPISSURE EN 6/7/821C

PAGE 14 PAGE 15 PAGE 16
CODE DES COULEURS DES FILS LEGENDE

B NOIR DG VERT FONCE O/R ORANGE/ROUGE TERMINAL
BR MARON Gy GRIS O/W ORANGE/BLANC MALE NUMERO
BLEU CLAIR 55 DU
BR/W MARON/BLANC LBe P ROSE CONNECTEUR
Centre de formation
TERMINAL TERMINAL
BR/Y MARON/JAUNE LGe VERT CLAIR R ROUGE AVEC SON NUMERO XX FEMELLE
VOIR DETAIL
DBe BLEU FONCE O ORANGE T HAVANE IMPRESSION SUR LE FIL
DANS LE MANUEL
DBr MARON FONCE O/Be ORANGE/BLEU V VIOLET DE SERVICE SECTION EN
2 mm
COULEUR
DBr/LG MARON FONCE/VERT CLAIR O/G ORANGE/VERT W BLANC
O/LB (64D) 0,8
DBr/Y MARON FONCE/JAUNE O/LB ORANGE/BLEU CLAIR Y JAUNE
21C SERIE WHEEL LOADERS
RELAIS ET ELECTRO -VALVE DE FREIN DE PARKING ET DE PRESSION DE PILOTAGE
SUPPORT DE RELAIS D'ARRET AUTOMATIQUE
1 + 24V AVANT CONTACT 1
2 + 24V APRES CONTACT 2
Centre de formation
3 ECLAIRAGE DES COMMANDES 3
17 CLIGNOTANT DROIT
TERMINAL 17 PAGE 2
O (13C) 0.8
O (13K) 0.8
AU CONNECTEUR MOTEUR/CABINE. O (13C) 0.8
21C SERIE WHEEL LOADERS
CLIGNOTANT GAUCHE PAGE 6

18 O (13K) 1.0 AU RELAIS #2,
TERMINAL 16 PAGE 2 22 PAGE 9
AU MODULE DE DIODES O (13C) 0.8
PAGE 24
CAB|MOTEUR
O (13K) 1.0 AU RELAIS DE TENSION #12
19 15 PAGE 99
20 6
21 O (19F) 1.0 AU FUSIBLE F, PAGE 8
22 SUPPORT
23 DE RELAIS 52
24 #11 57
25 CONTACTEUR DE FEUX DE SOP
PAGE 2 CABINE|AR
AU CONTROLEUR
26 AU CONTROLEUR 15 Y (33R) 1.0
DE LA TRANSMISSIONPAGE 11, TERMINAL 21
DE LA TRANSMISSION PAGE 11
V (36P) 1.0
AU CONTROLEUR 19
27 DE LA TRANSMISSION PAGE 11
B (0) 1.0
W (52P) 0.8 18
AU CONTROLEUR
28 DE LA TRANSMISSION PAGE 11 21
87
W (52P) 0.8
AU FUSIBLE S
29 PAGE 10 O (19D) 1.0 AU FUSIBLE D, PAGE 8
30 MANOCONTACTS
W (53P) 1.0
W (52P) 1.0
87a D'ACCUMULATEUR
TRAINING MANUAL
W (53P) 0.8
O (19D) 1.0 DE FREIN
85 86
55
C B A
87
B (0) 1.0
RELAIS
Y (33R) 1.0
Y (33R) 1.0
48 DE FREIN
AU CONTACYEUR D'AUTOMATISME 87
PAGE 19
DE PARKING 86 86
O (19C) 1.0 AU FUSIBLE C
W (53P) 0.8 PAGE 8
30
A A
87a
FERME à
6200 kPa
85 86
49 B (0) 1.0
46 O (19C) 1.0 51 P P
R =1620 Ohms ELECTRO-VALVES
RELAIS
SONDE DE FREIN ELECTRO-VALVE
DE PRESSION 47 56 C B A
PRESSION DE PARKING DE COMMANDE B B
DE PILOTAGE
HUILE DE PILOTAGE
MOTEUR 89
B (0) 1.0
B (0) 1.0
50
B (0) 1.0
B (0) 1.0
4 MASSE CABINE 4
4A MASSE MOTEUR 4A
PAGE 17 PAGE 18
4A - INFORMATION CENTER
4A.37.00
TRAINING MANUAL
ADDITIONAL NOTES

21C SERIES WHEEL LOADERS 5 - STEERING
TRAINING MANUAL
STEERING CIRCUIT
page
STEERING HYDRAULIC CIRCUIT 621C 721C ...........................................................5.02.00
STEERING HYDRAULIC CIRCUIT 821C......................................................................5.04.00
STEERING HYDRAULIC CIRCUIT921C.......................................................................5.06.00
AUXILIARY STEERING PUMP 621C - 721C - 821C - 921C ........................................5.08.00
ELECTRICAL CIRCUIT OF AUXILIARY STEERING.....................................................5.10.00
FLOW DIVIDER 621C - 721C - 821C...........................................................................5.12.00
FLOW DIVIDER 921C....................................................................................................5.14.00
STEERING VALVE 621C - 721C - 821C - 921C ..........................................................5.16.00
STEERING CYLINDER 621C - 721C - 821C ................................................................5.18.00
STEERING CYLINDER 921C ........................................................................................5.20.00
STEERING PIVOT .........................................................................................................5.22.00

5 -STEERING 21C SERIES WHEEL LOADERS
TRAINING MANUAL
STEERING CIRCUIT - 621B - 721B (with emergency steering)
▲
2 SS2 SS1
▲
Q1
▲ Q2 11
9
▲
SD7
▲
25
▲
▲ 8
● ●
P2
●
▲
▲
S2 S3 Z2
T2
5
T1
P1
▲
▲
31
18
●
19
●

21C-SERIES WHEEL LOADERS 5 - STEERING
TRAINING MANUAL
STEERING CIRCUIT- 621C- 721C - 821C
Hydraulic components:
1 Hydraulic tank
2 General circuit hydraulic pump Q1 2 Q2
Q1 - Tostering and attachment
Q2 - To attachment function
5 Loader attachments control valves block
25 Flow divider
9 Hydraulic cooler
11 Hydraulic filters
18 Closed center steering valve
19 Steering cylinders
31 Emergency electric pump 31
32 Pressure selector block
Electrical components:
SD7 Emergency circuit electrical switch
SS1 Hydraulic oil temperature sensor
SS2 Hydraulic filter clogging contact switch 25
A Display center
Operation:
The STEERING function receives flow (Q1) continuously from the
hydraulic pump (2).
This flow (1) flows to the flow divider (25).
Depending upon the amount of flow which arrives at (P2) and the
requirements of the steering valve, the flow divider directs more or less
flow to the loaders control valve (5).
The flow returning from the steering control valve goes through the oil
cooler, then the hydraulic filters to tank.
If any problem should happen on the steering circuit hydraulic circuit Q1

(engines stopping, defect in main pump, burst hose, etc.) the pressure
drop is detected by contact switch (SD7) which starts up the electrical
emergency pump (31). The steering circuit continues to receive feed.
18 19
◆ Steering warning light lights up

◆ The audible warning sounds continuously
◆ The main warning light (RED) (H12) flashes.
9
STOP THE MACHINE IMMEDIATELY

TRAINING MANUAL
STEERING CIRCUIT - 821C (with emergency steering)
1 9
A 8
▲
▲ ▲ ▲
2 SS2 SS1
▲
▲
Q1 ▲ Q2 11
▲
27
32
SD7
● T8
▲ P8 S8
25
P2
S2 S3 Z2
T2
●
5
T1
● P1
▲
▲
▲
●
31
18
●
19
●

TRAINING MANUAL
CIRCUIT DE DIRECTION - 821C
1 Hydraulic tank
2 General circuit hydraulic pump
2
Q1 - To steering and attachment functions Q2
Q2 - To attachment function Q1
5 Loader attachments’ control valve block
8 Oil cooler by-pass
9 Hydraulic oil cooler
18 Steering valve
19 Steering cylinders
25 Flow control valve
27 Unloading valve 31
31 Emergency circuit electric pump
32 Emergency circuit pressure selector
SD7 Emergency circuit electric contact switch 25
SS1 Hydraulic oil temperature sensor
SS2 Hydraulic filters clogging contact switch
A Display center
Operation:
STEERING function receives the flow (Q1) from the hydraulic pump (2)
on a continuous basis.
This flow passes through the flow control valve and supplies the steering
unit (18).
Depending upon the amount of flow which arrives at (P2) and the
requirements of the steering valve, the flow control valve adjusts more or
less flow to the LOADER function at (S3).
Pressure acts on contact switch (SD7) and the steering light is turned off.
The steering return flow passes through the oil cooler, the filters and
returns to tank.
Safety:
If any problem should happen on the steering hydraulic circuit (engine
stopping, problem with pump body (Q1), bursting of a hose, etc.) the
pressure drop is detected by the contact switch (SD7) which turns on the
electric emergency pump (31). The steering continues to be fed.
18
19
◆ Steering warning light lights up

◆ The audible warning sounds continuously 9
◆ The main warning light (RED) is ON.

TRAINING MANUAL
STEERING CIRCUIT - 921C (With emergency steering pump)
1 9
A 8
▲
▲ ▲ ▲
2 SS2 SS1
▲
▲
Q1
▲ Q2 11
▲
SD7
▲ 25
P2
S2 S3 Z2
T2
●
5
T1
P1
▲
▲
31
18
●
19
●

TRAINING MANUAL
921C STEERING SYSTEM
Hydraulic components :
1 Hydraulic reservoir
2 Main hydraulic pump
Q1 - To Steering and Loader valve block
Q2 - To Loader valve block
4
5 Loader control valve block
9 Hydraulic oil cooler
18 Closed centre steering control valve
19 Steering cylinders Q2
25 Flow control valve
31 Emergency electric pump Q1
Electrical components
SD7 Emergency steering electric switch
SS1 Hydraulic fluid temperature sender
SS2 Hydraulic filter blocked sensor switch
A Display center
Operation :
The STEERING circuit receives flow continuously from the hydraulic pump
(Q1).
The flow passes the flow control valve (25)
Depending on the amount of flow arriving at (P2) and the demand from the
steering control valve, the valve directs more or less flow to the loader
valve block (5). 25 31
The pressure acts on the switch (SD7) and stops power to the steering
warning lamp.
The return flow from the steering is directed through the oil cooler and
hydraulic filters to tank.
If a problem occurs in the steering circuit, the pressure drop will be

detected by the switch (SD7). This switch will activate the emergency
pump (31) and provide an alternative flow to the steering.
26 19
◆ Steering light lights up

◆ The audible warning sounds continuously
◆ The main warning light (RED) (H12) flashes.
9

TRAINING MANUAL
621C- 721C - 821C - 921C ELECTRICAL AUXILIARY PUMP
Description
1 Pump assembly
1A. Electric motor
2 Solenoid
3 Earthing strip
4 Screw
5 Washer
6 Pump front bearing
7 Seal
8 Coupling sleeve
9 Gear
10 Gear
11 O-ring
12 Protector
13 Seal
14 Seal
15 Plate
16 Pump body
17 Assembly dowel
18 Rear bearing
19 Screw
20 Washer
Specifications
Scew item : 19 ............................................................................................................................................................= 2,1 à 2,4 mdaN

For disasembly and assembly see Service manuel : .................................................................................................. 5008

TRAINING MANUAL
ELECTRIC EMERGEBCY STEERING PUMP - 621C- 721C - 821C - 921C
This is a hydraulic gear pump, driven by an electric motor.
It feeds the steering circuit in the event of problems on that circuit (engine
stopping, problems with main hydraulic pump, defective hoses, etc.).
1
Contact switch (SD7) detects a minimum pressure in the steering circuit;
if this is abnormally low it turns on the emergency pump electric motor.
The steering circuit is in this case fed with flow, which enables the driver
to control the machine for a short time.
2 ▲
The auxiliary steering pump is protected by the relief valve (32) adjusted
at 105 bar.
For adjustement see service buletin EWL FAR 4008 ●
▲
Setting of the pressure switch SD7: 2,4 bar on decreasing pressure.
Q1
▲ Q2 ▲ ▲
SD7
▲
P2
S2 S3 Z2
T2
105 BAR
▲
◆ Steering light lights up

▲
◆ The audible warning sounds continuously 32
◆ The main warning light (RED) flashes.
● ●
STOP THE MACHINE IMMEDIATELY 31

TRAINING MANUAL
ELECTRIC CIRCUIT EMERGENCY STEERING
B (+) (DIRECT) ● B (+) (DIRECT) ●
● B (+) (Aprés contact) (From ignition) ● ● B (+) (Aprés contact) (From ignition) ●
B (+) (Accessoires) (From Accessorie position) ● B (+) (Accessoires) (From Accessorie position) ●
F -V F-M F-R F-V F -M
7,5 A 7,5 A 7,5 A 7,5 A 7,5 A F-R
7,5 A
O (19R)
O (19P)
O (19M)
O (19M)
5 Y(35X)
✕ 5 Y(35X)
TABLEAU DE BORD P G G P G
TABLEAU DE BORD A B G
B
CONTROL PANEL CONTROL PANEL
O (19M) C O (19M) O (19M) E O (19M)
O (19R) D O (19R) D
K14 K14
Y (35X)
R - 50.0
V (35X)
R/- 50.0
5 5
8 8
6
V (35X) ● A 6
V (35X) ● A
4 4
1 1
V (35X)
V (35X)
W (51P) 3
W (51P)
7 2 7 2
● ●
SD7
(19R)
SD7
O (19P)
B (0)
(19P)
O (19R)
B (0)
K15 P K15 P
B/W
B/W
● 5 ● 5
8 8
6 6
W (51) B W (51) W (51) B W (51)
4 4
O (19P)
1
O (19P)
B (19P)
O (19P)
3 K16 3 K16
7 2 7 2
B/W
M M
B/W
B (0) ● C M9 C M9
B (0) ●
B/O - 50.0
- ENGINE STOPPED
B/O - 50.0
1 - ENGINE STOPPED 2
B (0)
B (0)
- IGNITION SWITCH OFF - IGNITION SWITCH ON
● ● B (-) ● ● B (-)
B (+) (DIRECT) ● B (+) (DIRECT) ●

● B (+) (Aprés contact) (From ignition) ● ● B (+) (Aprés contact) (From ignition) ●
B (+) (Accessoires) (From Accessorie position) ● B (+) (Accessoires) (From Accessorie position) ●
F-V F-M F -V F-M
7,5 A 7,5 A 7,5A 7,5 A
F-R F-R
7,5 A 7,5 A
O (19R)
O (19R)
O (19M)
O (19M)
5 Y (35X)
✕ 5 Y (35X)
TABLEAU DE BORD P G G TABLEAU DE BORD P G G

CONTROL PANEL CONTROL PANEL
O (19M) E O (19M) O (19M) E O (19M)
O (19R) D O (19M) D
K14 K14
V (35X)
V (35X)
R - 50.0
R - 50.0
5 5
8 8
6 6
V (35X) ● A V (35X) ● A
4 4
1 1
V (35X)
V (35X)
3 3
W (51P) W (51P)
7 2 7 2
● ●
SD7 SD7
(19P)
O (19R)
(19P)
O (19M)
B (0)
B (0)
K15 P K15 P
B/W
B/W
O
● 5 ● 5
8 8
6 6
W (51) B W (51) W (51) B W (51)
4 4
O (19P)
O (19P)
1 1
O (19P)
O (19P)
3 K16 3 K16
7 2 7 2
B/W
M B/W
M
B (0) ● C M9 B (0) ● C M9
- ENGINE RUNNING 4 - ENGINE RUNNING

B/O - 50.0
B/O - 50.0
3
B (0)
B (0)
- STEERING PRESSURE - STEERING PRESSURE

ABOVE 3 BAR LESS THAN 3 BAR
● ● B (-) ● ● B (-)

21C- SERIES WHEEL LOADERS 5 - STEERING
TRAINING MANUAL

TRAINING MANUAL
FLOW CONTROL VALVE (25) - 621C - 721C - 821C
Description
1 Valve body
2 Spool
3 Return spring
4 Steering safety cartridge
5 O-ring
6 Union with restrictor
7 O-ring
8 Cap
9 O-ring
10 Screw with restrictor (D=0.61 to 0.66 mm)
11 Screw with restrictor (D=0.89 to 0.94 mm)
Specifications
Cartridge pressure setting (4):
621C - 721C : .....................................................163 bar
821C....................................................................181bar
Adjustment of cartridge by hollow screw (4a)
Diameter of restrictor screw (10): .......................0.61 to 0.66 mm
Diameter of restrictor screw (11): .......................0.89 to 0.94 mm
For disassembly and reassembly see Service Manual: 5004
S3 S2
10
7
9
6
8
Z2
12
T2
P2
5 1 4 3 2

TRAINING MANUAL
FLOW CONTROL VALVE (25) - 621C - 721C - 821C
It ensures that feed goes to the steering valve regardless of the speed
of the engine.
The remainder of the flow is directed to the loader control valve.
Operation:
Depending upon the amount of flow (Q1) which arrives at (P2) and the
requirements of the steering valve via (S2), spool (2) will open the
passage to the loader function more or less at (S3).
◆ When steering is not being used:
At start up, the pump flows at (P2).

Since the steering valve is of the “closed centre” type, the pressure
EQUIPEMENT
increases at (S2) and at (Z1) via the internal drillings in the spool, this CHARGEUR DIRECTION
causes the spool to be piloted to the left (see drawing).

S3 S2
➠
➠
A permanent leak in the steering box (S2) from (Z2) ensures that the
forces on the ends of the spool are equal.
➠
➠
In this case the flow (Q1) is directed to the loader attachments
➠
function by (S3). ➠
Z2 ➠
➠ Z1
➠ ➠
T2
P2
◆ When the steering is being used ▲

Q1
As soon as this steering is used, the pressure drops at (Z1), and

increases at (Z2), the spool is pushed to the right by the spring.
➠
An equilibrium of forces on the sections of the spool (Z1/Z2) will be EQUIPEMENT

CHARGEUR DIRECTION
created depending upon the amount of flow required by the steering.

S3 S2
In this case, part of the flow (Q1), required by the steering, is directed
➠ ➠
➠
to the function (S2) the remainder of the flow being directed to the
➠
loader function.
➠
Steering safety cartridge:

➠
Z2 ➠ ➠ ➠ ➠ Z1
The feed pressure on the steering is controlled by the safety cartridge (4).
This pressure is taken from the pilot circuit (Z2).
➠ ➠
➠
The flow released by the opening of the cartridge valve goes to the tank T2
at (T2). ➠ ➠
The maximum pressure at (Z2) is controlled by the safety catridge.

Further pressure increase at (Z1) will cause the all flow at (P2) to be
directed to (S3). P2
▲
Q1

TRAINING MANUAL
FLOW CONTROL VALVE (25) - 921C
Description
4a
1 Valve body 4 5 7 3 12
2 Spool
3 Return spring
4 Steering relief valve
5 O-ring
6 Screw with restrictor
7 O-ring
8 Plug
9 O-ring
10 Screw with restrictor 6
11 Screw with restrictor
12 Washer
Spécifications
Relief valve pressure setting (4) : 179 to 182 bar
Adjustthe relief valve using hollow screw (4a)
Diameter of restrictor screw (10) : 0.61 to 0.66 mm
Diameter of restrictor screw (11) : 0.89 to 0.94 mm
Disassembly and assembly : See Service Manual : 5004 10 2 11 1 9 8
10
7
9
11
4a 5 4 3 1
2

21C- SERIES WHEEL LOADERS 5 - STEERING
TRAINING MANUAL
FLOW CONTROL VALVE (25) - 921C
It provides priority supply to the steering control valve, regardless of engine speed.
Any excess flow is directed to the loader control valve.
Operation :
Depending on amount of flow (Q1) arriving at (P2) and the demand from steering
control valve (S2), the spool (2) opens the passage to the loader circuit at (S3) to a
greater or lesser extent.
◆ Steering not used : EQUIPEMENT

As soon as the machine is running, the pump CHARGEUR DIRECTION
provides flow at (P2).
Because the steering control valve is of the
«closed centre» type, the pressure Z2 S3 S2
increases at (S2) and at (Z1) via the internal
➠ ➠
➠
➠ ➠
passages in the spool, this causes the spool
to move to the left (see drawing).
A leak-off in the steering control valve via
(S2) from (Z2) balances the forces acting T2
on the ends of the spool. In this case the ➠ ➠ Z1
➠ ➠
flow (Q1) is directed to the loader circuit
via (S3).
➠
◆ Steering used :
When the steering is operated, the pressure
falls at (Z1) and increases at (Z2). The P2
spool is pushed to the right by the spring.
4
A balance of the forces acting on the spool
sections (Z1/Z2) will be created
depending on the amount of flow required by
▲
the steering.
Q1
In this case, part of the flow (Q1) required by
the steering, is directed to that circuit
via (S2). The remaining flow is directed to the
loader circuit via (S3). EQUIPEMENT
CHARGEUR DIRECTION
Steering relief valve :
The supply pressure on the steering is Z2 S3 S2

controlled by the relief valve (4).
➠➠
➠
This pressure is sensed from the pilot circuit

(Z2).
The flow released by the opening of the relief
valve goes to tank at (T2). T2
➠
➠ ➠
The maximum pressure at (Z2) is controlled

➠ Z1
by the relief valve.
Further pressure increase at (Z1) will cause
all the flow at (P2) to be directed to (S3).
The pressure test port is located on the pump
(Q1).
P2
4
▲
Q1

TRAINING MANUAL
STEERING VALVE- 621C - 721C - 821C - 921C
Description
1 Seal
2 Seal-carrier flange Z2
3 Circlip
4 Thrust washer
5 Centring springs T
6 Distribution spool P
7 Steering control valve body A
8 Rotary spool B
9 Drive shaft
10 Retaining screw
11 Lower flange
12 Stator
13 Rotor
14 Distribution plate
15 Splined shaft
16 Pin
17 Thrust bearing
18 O-ring
19 Anti-extrusion ring
20 Back-up ring
21 O-ring
Port identification
P Inlet of flow coming from flow control valve

T Return to reservoir
A Steering cylinder LH feed
B Steering cylinder RH feed
Spécifications
............................................................................................................................................... TORQUE SETTING
- Retaining screw (Item 10)..................................................................................................................= 1st tightening 2 to 2.7 mdaN
- Retaining screw (Item 10)..................................................................................................................= 2nd tightening 10 mdaN
Disassembly and assembly see Service Manual : .............................................................................. 5004

TRAINING MANUAL
STEERING VALVE- 621C - 721C - 821C - 921C
On the 21C series the steering is a closed centre type.
T
In neutral position :
A
The control valve supply line (P) is not connected to the
reservoir return outlet (T).
A signal line from the steering control valve is connected to the

flow control valve via port (Z2)
Steering cylinder feed lines (Aand B) are locked.
P B

TRAINING MANUAL
STEERING CYLINDERS (19) - 621C - 721C
Description
1 Cylinder barrel
2 Articulated bushing
3 Stop ring
4 Threaded bearing
5 Seal
6 Seal
7 O-ring
8 Ring support
9 Bearer ring
10 Scraper seal
11 Stop screw
12 Cylinder rod
13 Cylinder piston
14 Composite seal
15 Piston seal
16 Carrier ring
17 Assembly screw
18 Washer
19 Grease fitting
STEERING CYLINDERS (19) - 821C
Description
1 Cylinder body
2 Articulated ring
3 Stop ring
4 Threaded bearing
5 Seal
6 Seal
7 O-ring
8 Seal support
9 Carrier ring
10 Scraper seal
11 Stop screw
12 Cylinder rod
13 Articulated bushing
14 Stop ring
15 Cylinder piston
16 Composite seal
17 Piston seal
18 Carrier ring
19 Assembly screw
20 Washer
21 Grease fittings

TRAINING MANUAL
STEERING CYLINDERS (19) - 621C - 721C - 821C

These cylinders are mounted on self-aligning knuckles.
◆ (2) for the (621C-721C)

◆ (2 and 13) for the (821C).
Spécifications
TIGHTENING TORQUE
- Assembly screw (Item 17).......................................................................................= 400 to 500 Nm
- Cylinder bearing (Item 4)........................................................................................= 135 to 504 Nm (for fitting the stop screw (11).
Disassembly and reassembly, see Service Manual.................................................. 5005

TRAINING MANUAL
STEERING CYLINDERS (19) - 921C
Description
1 Lock screw
2 Screw-in type gland
3 O-ring
4 Back-up ring
5 Bearing sleeve
6 Seal
7 Dust seal
8 Seal
9 Cylinder rod
10 Retaining screw
11 Washer
12 Cylinder piston
13 Carrier piston ring
14 Anti-extrusion ring
15 Seal
16 Snap ring
17 Pivot bearing
18 Cylinder barrel
These cylinders are mounted on

self-aligning ball-joints.
Spécifications
TORQUE SETTING
- Retaining screw (Item 10).............................................................................= 180 to 220 mdaN using blue Loctite 242
- Cylinder gland (Item 2).................................................................................= 13.5 to 50.4 mdaN (to assemble the lock screw (1)
Disassembly and assembly see Service Manual............................................ 5006

21C- SETIES WHEEL LOADERS 5 - STEERING
TRAINING MANUAL
STEERING PIVOT - 621C - 721C- 821C - 921C
Description
6 Grease fitting
7 Lock screw
8 Washer
9 Spacer
10 Articulating shaft
11 Lip seal
12 Flange
13 Retaining scre
14 Washer
15 Adjusting shims
16 Taper bearing
17 Lip seal
18 Articulating shaft
19 Lip seal
20 Spacer
21 Taper bearing
22 Adjusting shims
23 Flange
24 Retaining screw
25 Washer
26 Spacer
27 Lip seal
28 Adjusting shims
29 End plate
30 Retaining screw
31 Retaining screw
32 Washer
38 Grease fitting
Disassembly / Assembly, see Service Manual : 5008

TRAINING MANUAL
STEERING PIVOT - 621C- 721C - 821C- 921C
For disassembly and reassembly see Service Manual................................................... 5006

TRAINING MANUAL
STEERING PIVOT - 621C - 721C- 821C - 921C
Vis : CAS- 10592
Vis : CAS- 10592
Installing the upper pivot bearings
◆ Tooling (CAS 1960 and CAS 10592).

◆ Fit the bearing and spacer assembly (16).
◆ Fit the flange (12) hard against the bearings.
◆ Measure the play between the flange and the chassis (make two diametrically opposite measurements, and then take the average).
◆ Subtract 0.075 mm to 0.1 mm of the play noted in the preceding step.
◆ Disassemble the flange and fit it again using the necessary thickness of shims (15).
◆ Tighten the flange retention screws (13) to 125 Nm.
◆ Fit the pivot pin (10) and check that all the bearings turn with some resistence.
◆ Remove the pivot pin.
◆ Fit the two lip seals (11 and 17) as shown on the drawing opposite.
Note : carefully lubricate the bearings before fitting.
Installing the lower pivot bearings

The installation method is identical to that of the fitting of the upper pivot bearings.
ASSEMBLING THE FRONT AND REAR CHASSIS
Upper pivot
◆ Install spacer (20) for the lower pivot.
◆ Couple up and align the two parts of the machine.
◆ Fit pin (10) using grease.
◆ Install spacer (9) and tighten screw (7) to between 200 and 240 Nm. for 621B,
721B and 821B and between 30 and 36 mdaN for the 921B.
Lower pivot
◆ Make sure the two parts of the machine are correctly aligned.
◆ Fit spacer (26)
◆ Fit the pin using grease (18).
◆ Fit the lower flange (29)(without using shims).
◆ Tighten the flange retention screws (30) on the pin to 70 Nm.
◆ Measure the play between the flange and the chassis.
◆ Subtract 0.8 mm to 0.1 mm of the play noted in the preceding step.
◆ Untighten the flange and install the thickness of shims (28) necessa-
ry.
◆ Fit the flange retention screws (31) on the chassis and tighten the
screws to 17 mdaN for the 621C and 721C and to 30 mdaN for the
821C and to 50 mdaN for the 921C.
◆ Tighten the screws (30) to 17 mdaN.

5 - STEERING 21C SERIES WHEEL LOADERS
TRAINING MANUAL
COMPLEMENTARY NOTES

21C SERIES WHEEL LOADERS 6 - TRANSMISSION
TRAINING MANUAL
TRANSMISSION
CONTENT pages
TRANSMISSION LAYOUT............................................................................................. 6.02.00

GENERAL SPECIFICATIONS........................................................................................ 6.03.00
TORQUE CONVERTER................................................................................................. 6.04.00
GEAR BOX 4WG “ZF”
Présentation........................................................................................................... 6.05.00
Transmission hydraulic circuit................................................................................ 6.11.00
Torque converter circuit and cooler........................................................................ 6.13.00
Identification of pressure test point ports ............................................................... 6.15.00
Transmission control.............................................................................................. 6.16.00
Brake pedal switch and speed sensors.................................................................. 6.20.00
Other electrical components .................................................................................. 6.22.00
Control and diagnostic .......................................................................................... 6.23.00
Controler electrical circuit....................................................................................... 6.24.00
Connector 68 terminals of the controler................................................................. 6.25.00
Transmission electrical circuit ................................................................................ 6.26.00
"ZF" AP AXLES
Type AP 407 - CK (differential) .............................................................................. 6.28.00
Type AP 407 - CK (wheel reducer) ........................................................................ 6.30.00
Type AP 409 - DK (differential) .............................................................................. 6.32.00
Type AP 409 - DK (wheel reducer) ........................................................................ 6.34.00
Type AP 411 - HK (differentael) ............................................................................. 6.36.00
Type AP 411 - HK (wheel reducer)......................................................................... 6.38.00
"GKN" AXLES
Type RPS32S - 34 (differential) ............................................................................. 6.40.00
Type RPS32S - 34 (wheel reducer) ....................................................................... 6.42.00
REAR AXLE PIVOT........................................................................................................ 6.44.00
PARK BRAKE (towing and adjustment) ......................................................................... 6.45.00
COOLING 621C - 721C - 821C...................................................................................... 6.46.00
COOLING 921C ............................................................................................................. 6.47.00
"ZF" MULTITRAC AXLES............................................................................................. 6.48.00

6 - TRANSMISSION 21C SERIES WHEEL LOADERS
TRAINING MANUAL
TRANSMISSION LAYOUT
921C
621C
721C
821C
Description
1 Engine
2 Torque converter 21
3 “ZF” gear box types:
22 23
4 Front intermediate propeller shaft
5 Front propeller shaft
6 Rear propeller shaft 12
7 Front and rear axles fitted with: 18
- Limited slip differential on 6-7-821BE
Torque proportional differential on 921BE 20
- Planetary wheel reduction box
- Oil bath disc brakes
8 Parking brake (disc type) 16
9 Transmission oil cooler
10 Oil filter
11 Transmission oil temperature sender
12 Shifter
13 Electronic control box (EST 37).
14 Fuse box
15 Output speed sensor
16 Speed sensors (engine, intermediate and
turbine)
17 Transmission control valve
18 Declutch switch
19 .Brake declutch switch and stop switch 24
20 .Down shift button
21 Autoshift switch(auto / manual mode).
22 Display center
23 CAN BUS
19 13 14 10
24 Diagnostic connector (not used) 15 17 3
25 Filter transmission restriction switch (721C
821C).
6.2.00 Training Center

21C SERIE WHEEL LOADERS 6 - TRANSMISSION
TRAINING MANUAL
GENERAL SPECIFICATIONS
ENGINE STALL SPEED (RPM) after running in
MACHINE TYPE 621C & 621CXT 721C 721CXT 821C 921C
IDLING SPEED 950-1050 950-1050 950-1050 950-1050 950-1050

MAXIMUM NO LOAD SPEED 2375 to 2460 2375 to 2460 2375 to 2460 2375 to 2460 2200 to 2300
CONVERTER STALL SPEED(manual 4th) 2040 to 2240 2040 to 2240 2040 to 2240 1885 to 2065 1900 to 2100
HYDRAULIC STALL SPEED 2110 to 2250 2110 to 2250 2110 to 2250 2250 to 2310 2100 to 2200
CONVERTER AND HYDRAULIC STALL SPEED 1490 to 1720 1490 to 1720 1490 to 1720 1600 to 1825 1400 to 1650
TORQUE CONVERTOR
MACHINE TYPE 621C & 621CXT 721C & 721C T 821C 921C
TORQUE CONVERTER RATIO......................................... 2,83 to 1 2,87 to 1 2,79 to 1 3,08 to 1

CONVERTER TYPE........................................................... Fixe stator
INLET PRESSURE............................................................. 8,5 to 9,5 bar 8,6 to 10,6 bar
OUTPUT PRESSURE........................................................ 3,5 to 6,5 bar 3,5 to 6,6 bar
OIL TEMPERATURE.......................................................... 80°C to 90°C 80 to 100°C
GEAR BOX
MACHINE TYPE 621C & 621CXT 721C & 721C 821C 921C
TYPE : POWER SHIFT "ZF ERGO POWER"................. 4WG 160 4WG190 4WG 210 4WG 260
REDUCTION RATIO: 1st FORWARD / REVERSE........... 4,012 / 3,804 3,745 / 3,551 3,754 / 3,551 3,713 / 3,713
REDUCTION RATIO: 2nd FORWARD / REVERSE.......... 2,204 / 1,919 2,089 / 1,981 2,089 / 1,981 2,063 /2,063
REDUCTION RATIO: 3rd FORWARD / REVERSE .......... 1,088 / 1,031 1,072 / 1,017 1,072 / 1,017 1,065 / 1,065
REDUCTION RATIO: 4th FORWARD............................... 0,619 0,666 0,666 0,686
CLUTCH PRESSURE...................................................... 16 à 18 bar 16 à 18 bar 16 à 18 bar 16 à 18 bar
LUBRICATION PRESSUE............................................... 0,2 à 0,8 bar 0,2 à 0,8 bar 0,2 à 0,8 bar 0,02 à 1,2 bar
OIL CAPACITIES (oil drain / total) .................................. 19 / 25 l 22,7 / 35 l 27,5 / 35 l 27,5 / 47l
FRONT AND REAR AXLES
MACHINE TYPE 621C & 621CXT 721C & 721CXT 821C 921C
(For ZF Multitrac axles see pages 1.11.00 & 1.12.00)
FRONT AXLE “ZF” TYPE .................................................. "ZF" AP - 407 / CK "ZF" AP - 409 / DK "ZF"AP - 411 / HK "GKN"RP32S-34
REAR AXLE “ZF” TYPE ..................................................... "ZF" AP - 407 / CK "ZF"AP - 407 / CK "ZF" AP - 409 / DK "GKN" RP32S-34
DIFFERENTIAL REDUCTION RATIO FRT/REAR............. 3,44 3,363 3,70 4,625
WHEEL REDUCTION BOX REDUCTION RATIO.............. 6,353 6,353 6,353 4,94
TOTAL REDUCTION RATIO.............................................. 21,88 21,37 23,51 22,85
DIFFERENTIAL CAPACITY FRT/REAR ............................ 9,5 / 9,5 litres 15 / 9,5 litres 21 / 15 litres 36,3 /36,3 litres
WHEEL REDUCTION CAPACITY FRT/REAR................... 5,5 / 5,5 litres 5,5 / 5,5 litres 6 / 5,5 litres 13,6 /13,6 litres
TOTAL AXLE CAPACITY FRT/REAR................................ 20,5 / 20,5 litres 26 / 20,5 litres 33 / 26 litres 63,6 /63,6 litres
REAR AXLE OSCILLATION............................................... ± 12° ± 12° ± 12° ± 12
MAXIMUM MOVEMENT AT WHEEL ................................. 391 mm 411 mm 442 mm 470 mm
TRAVEL SPEEDS
MACHINE TYPE 621C & 621CXT 721C & 721CXT 821C 921C
1ST SPEED FWD/REV (KPH) .............................................. 7,1 / 8,4 7,9 / 8,4 7,9 / 8,2 8,2 / 8,2
2ND SPEED FWD/REV (KPH).............................................. 13,5 / 14,2 14 / 14,8 13,8 / 14,5 14,5 / 14,5
3RD SPEED FWD/REV (KPH).............................................. 23,5 / 25 26,1 / 27,5 25,4 / 26,7 26,7 / 26,7
4TH SPEED FWD (KPH)....................................................... 37,5 39 37,8 38,8
Training Center 6.3 00

TRAINING MANUAL
TORQUE CONVERTOR
Operational principle
Introduction
It acts instead of a clutch.
It connects the transmission to the engine via hydraulic fluid, it is therefore a
hydraulic coupling.
It gives automatic and continuous variation of engine torque which is
transmitted depending upon the resistant loads, within well-defined limits
(stalling ratio).
Description
1 Drive turbine, driven by the engine flywheel.
2 Stator or reactor (fixed) for torque multiplication.
3 Receiving turbine connected to the transmission.
4 Engine flywheel.
5 Coupling by flexible disc.
6 Gear box
Principe of operation
Driven by the engine flywheel (4), the drive turbine (1) propels the wheel,
using its vanes, against the vanes of the receiving turbine (3) which causes
the latter to turn.
In its turn the turbine propels the oil onto the stator (fixed) fins (2).
The stator (2) located between the drive turbine (1) and receiving turbine (3)
is used to recover the fluid leaving the receiving turbine, change its speed
and direction , then redirect towards the drive turbine.
It also absorbs the difference between the torques of the drive turbine and
the receiving turbine which enables torque to be multiplied.
Spécifications
COUPLE DE SERRAGE :
- Assembly screws for torque converter flexible discs NC mdaN
- Assembly screws for engine fly wheel flexible discs NC mdaN
- Assembly screws for rubber support NC mdaN

TRAINING MANUAL
4WG "ZF" GEAR BOX
5 1
3
7
4
KR
10
621C - 721C - 821C
KV
Description
1 Electro-hydraulically controlled valve 11
at the front of the transmission on 621C- 721C- 821C
and at the top on 921C
2 Suction filter 921C 6
3 Transmission
4 Fixed stator torque converter K2 12
5 Hydraulic filter 621C - 721C - 821C
6 Hydraulic pump with by-pass valve
7 Reverse clutch shaft
8 Front output shaft
K3
9 Rear output shaft 13
10 Main hydraulic circuit pump drive shaft
11 Forward clutch shaft
12 2nd gear clutch shaft
13 3rd gear clutch shaft
14 Output shaft
15 1rst gear clutch shaft
14
16 4th gear clutch shaft
17 Converter inlet valve
KV Forward drive clutch
KR Reverse drive clutch
K1 1st speed clutch 8
K2 2nd speed clutch K1 9
K3 3rd speed clutch
K4 4th speed clutch forward
15 621C - 721C- 821C
17
K4
16
921C

TRAINING MANUAL
WG160 - WG190 - WG210 TRANSMISSION DRIVE PATHS
Clutch control
Gear engaged Clutch supplied

1st FW KV + K1 KR
2nd FW KV + K2 KV
3rd FW KV + K3
IN
4th FW K3 + K4
1st RV KR + K1
2nd RV KR + K2 K2 K4
3rd RV KR + K3
K3 K1
OUT
1st FW
KR KR
KV KV
IN IN
K4 K2 K4
K2
K3 K1 K3 K1
OUT OUT
nd 3rd FW
2 FW

TRAINING MANUAL
WG160 - WG190 - WG210 TRANSMISSION DRIVE PATHS
KR KR
KV KV
IN IN
K2 K4 K2 K4
K3 K1 K3 K1
OUT OUT
4th FW 1st RV
KR KR
KV KV
IN IN
K2 K4 K2 K4
K3 K1 K3 K1
OUT OUT
2nd RV 3rd RV

TRAINING MANUAL
CLUTCH SHITTING and CLUTCH CALIBRATION
18 bar
FW (or RV)
ZF ERGOPOWER
SHUTTLE SHIFT RV (or FW)
Clutch filling Clutch slippage
VARIABLE GRADIENT
= f(engine RPM)
Fast fill
pressure
Power transfert point
determined during
Compensating clutch calibration
6 bar pressure
CAUTION
Can be only used for
didactic purpose by
CASE TRAINING CENTER
1 to 2 secondes
P TURBINE SPEED SENSOR

SIGNAL
ZF ERGOPOWER
COMPENSATING PRESSURE DETERMINATION
Clutch pressure CAUTION

Compensating didactic purpose by
pressure CASE TRAINING CENTER
0,1 bar increase

per step
0,2s T
2s
JLL/WL/CLUTCH PRES 2

TRAINING MANUAL
CLUTCH SHITTING and CLUTCH CALIBRATION
TURBINE SPEED SENSOR

SIGNAL
P
ZF ERGOPOWER
CLUTCH FAST FILLING TIME DETERMINATION
0,01 sec
CAUTION
didactic purpose by
6 bar
Clutch pressure
0,15 sec
T
ZF ERGOPOWER
P SHIFT FROM NEUTRAL INTO GEAR
DIRECTION AND GEAR
GEAR DIRECTIONNA
CLUTCH L CLUTCH
Clutch pressure
Fast filling
Fill compensation
CAUTION
didactic purpose by

TRAINING MANUAL
921CV WG260 TRANSMISSION
921C
Description
1 Coupling 1 2 3 4 5
2 Converter
3 Breather
4 Inlet pinion 6
5 Control valve
6 PTO
7 Pump
8 1st gear clutch 7
9 2nd gear clutch
10 3rd gear clutch 8
11 Front output shaft
12 Rear output shaft
13 Iddler
14 4th gear clutch 16 9
15 Forward clutch
16 Reverse clutch
15
14
10
13
11
12

TRAINING MANUAL
TRANSMISSION HYDRAULIC CIRCUIT

GENERAL INFORMATION
The new ZF transmissions use a new hydraulic system that is different than the “B” series wheel loaders. The
hydraulic system for the transmission is its own independent operating hydraulic system separate from the regular
hydraulic system on the machine. The transmission case serves as the hydraulic reservoir.
All transmission circuit receives SAE 15W40 ENGINE OIL.

The following table lists the fill capacities for the individual model machines
OIL CAPACITIES
621C 721C 821C 921C
Transmission System Capacity (litre 25 35 35 47
Transmission Refill Capacity (litres) 19 22,7 27,5 27,5
(with filter change).
The transmissions on the 6, 7, and 821C no longer use hoses to port the oil to the end of the shafts for clutch
engagement. The flow of oil on these three units is now ported through a valve plate that sits on the back of the
transmission. The 921C still uses external hoses.
TRANSMISSION PUMP
The transmission hydraulic pump is a gerotor type
hydraulic pump. It is mounted to the stator housing and
spins with the input shaft pump wheel drive assembly. It
is rated at 53 l/mn on the 621C, 80 l/mn on the 7 &
821C, and 114 l/mn on the 921C. These ratings are the
minimum acceptable flow ratings at low engine RPM’s.
Flows below these ratings could cause the transmission
to shift rough, have poor modulation, and possibly fail to
operate. The pump is rated high enough to supply
enough oil to operate the system even at lower idle
engine speeds. The pump draws oil out of the
hydraulic reservoir through a suction screen and
delivers it to the next component in the system, the
hydraulic oil filter.
621C - 721C - 821C
TRANSMISSION FILTER
The transmission hydraulic filter is located on the rear

outside cover of the transmission. It filters the oil down
to a rating of 10 micron. Oil and filter change interval is
set at every 1000 hours of operation or yearly. If the
machine is new the first oil and filter change should
occur after the first 100 hours of engine operation. The
921C has two hydraulic filters that must be changed at
every oil change or as required.
The filter incorporates a bypass that opens at ____ PSI

of differential oil pressure. It is located in the head of
the filter base. The bypass will also function if the oil is
cold. 921C

TRAINING MANUAL

TRANSMISSION CONTROL VALVE
The transmission control valve directs the flow of oil into
the appropriate clutches at the appropriate time to drive
the machine. The valve is located on the back cover of
the transmission on the 6, 7, and 821C series wheel
loaders. On the 921C series wheel loaders it is located
on the top of the transmission.
The transmission control valve consists of six solenoids

and 12 spools used to control the flow of oil into the
required clutches to drive the transmission. The six large
spools are control spools, directing the flow of oil into
each clutch pack. The six small spools are dampening 3 4 11
spools, used to modulate the shifting of the main control 12
spools to allow for smooth shifting between gears.
The control valve also has two more spools located

A A
inside of the assembly. The largest spool in the control
valve is the Main Pressure Spool. It sets the regulated
pressure at 16 to 18 bars. Main regulated pressure is
used to lock up the clutch packs inside the transmission.
The second smaller spool, is the Pressure Reducing B
Spool. It reduces the main regulated pressure down to 9
13
to 11 bars pilot oil. The pilot oil is used to shift the
spools inside the transmission control valve. There is no 11 14
adjustment for either the main or pilot control spools. If it
is not within the specification limits the spools and springs
must be replaced.
Description
3 Main pressure valve (16+2 bars) 3 14 4
4 Pressure reducing valve (9 bars)
11 PWM solenoid valve housing
12 Harness connector
13 Cover
14 Valve assembly
16 Intermediate plate
17 Plate (seal)
SECTION A-A
18 Clutch supply
19 Main pressure
20 To transmission housing
D Dumper spool
G Control spool
Y Proportionnal valve
D
SECTION B 20 18 19 G

TRAINING MANUAL
G G G G G G
3
CIRCUIT SHOWN 1ST FWD
5 2
8 1
9
1 Pump 53 Forward clutch pressure (16-18bar)

2 Filter 55 Reverse clutch pressure (16-18bar)
3 Main pressure valve (16-18bar) 56 1st gear clutch pressure (16-18 bar)
4 Pressure reducing valve (9bar) 57 2nd gear clutch pressure (16-18 bar)
5 Converter inlet relief valve 58 3rd gear clutch pressure (16-18 bar)
6 Converter 60 4th gear clutch pressure (16-18 bar)
7 Converter outlet relief valve 63 Converter oulet temperature (maxi 120C°)
8 Cooler 65 Main Pressure (16-18 bar)
9 Transmission lubrication G Clutch spool
15 Plug for output convertor temperature Y1 4th gear proportional solenoid valve
16 Plug for lubrication pressure test Y2 RV gear proportional solenoid valve
51 Converter inlet pressure Y3 1st gear proportional solenoid valve
52 Converter oulet pressure Y4 3rdgear proportional solenoid valve
Y5 FW gear proportional solenoid valve
Y6 2nd gear proportional valve

TRAINING MANUAL
CONVERTISSEUR AND COOLING CIRCUIT

CONVERTER INLET & OULET RELIEF
VALVES
Excess oil dumping over the main pressure
621C - 721C - 821C
spool, is ported through the transmission and
goes on to supply the torque converter with
oil. There is a bypass valve before the torque
converter, set at 9 bars, to dump off any
excess oil to the reservoir. It is located in the
transmission housing back cover. Return oil
from the converter goes through an inline
relief valve set at 3,5 bars. It is located in the
housing that bolts the converter to the
transmission. The purpose of this relief valve
is to keep enough back pressure on the
converter to prevent excess oil runoff. Both
of these pressure readings are the maximum
pressure readings that should ever be
present before and after the torque converter.
Under normal operating circumstances the
torque converter pressure after the torque
converter should be within 1,4 to 2 bars of the
pressure reading before the torque converter.
1 Inlet converter relief valve

2 Outlet converter relief valve
621C - 721C - 821C
COOLERS
921C
On the 621C 721C & 821C with European
specification, the oil cooler are a tube shell oil
cooler located inside of the left rear frame.
The 921C has the oil cooler incorporated into
the radiator.
The oil cooler does not incorporate an oil

cooler bypass.
Return oil from the oil cooler dumps back into

the transmission case and supplies lube to all
gears, clutches, and shafts.

TRAINING MANUAL
SPECIFICATIONS AND PRESSURE TEST PORTS

Spécification
Oil Type 621C - 721C- 821C - 921C CASE 15 W 40

Main(Regulated) Pressure 16 to 18 (bar)
Pilot Pressure (PWM solenoid) 9 to 11 (bar)
Lube Pressure 0,2 to 1,3 (bar)
Converter Pressure (Before) [Maximum acceptable reading] 9 (bar) (be increased at 11)
Converter Pressure (After) [Maximum acceptable reading] 3,5 (bar) be increased at 4,3)
Difference between inlet and outlet converter relief valve in normal operationl 1,2 to 1,8 (bar)
Clutch Lockup Pressure 16 to 18 (bar)
Oil Operating Temperature °C 80 to 100 degrés
Rep. Pressure ports

68
65 Main pressure (pump) (M10)
53 KV RV (M10)
55 KR FW (M10)
56 K1 1st (M10)
57 K2 2nd (M10)
58 K3 3rd (M10)
60 K4 4th (M10)
51 Converter inlet (M10)
52 Converter outlet (M14)
15 Cooler inlet (1 5/16”)
16 Cooler outlet (1 5/16”)
621C - 721C -821C
View Y

TRAINING MANUAL
4WG "ZF" TRANSMISSION CONTROL
The transmission (3) transmits the torque from the converter to the front
and rear axles. 21
It enables the machine’s direction of travel to be changed. 12
It offers a range of 4 forward and three reverse speeds. The selection of 18
the various forward and reverse speeds is by the manually controlled
electric rotary selector (12). 20
Direction of travel change and speed changes are obtained by means of
6 clutches (K1-K2-K3-K4-KV-KR). These are hydraulically controlled
multi-disc clutches with spring return and automatic wear compensation
without manual adjustment. 16
They are cooled and lubricated by oil.
They consist of externally toothed steel discs alternated with internally
toothed friction discs. 19
USE OF TRANSMISSION
In manual mode
You must always select the correct speed for the job to be performed.
If you work under overload conditions (when the engine is at full speed 13
but the wheels don’t turn), you must change down one or more gears (to
prevent the risk of over-heating the transmission)..
In autoshift mode
The controler will manage the shifting of the transmission without any operation of the operator.
The maximum gear can be selected in 2nd or 3 rd. (See section 4)
SHIFTER 12:
20
12
Ratios 1 to 4 are selected by a rotary movement and the direction of travel
(Forward - Neutral - reverse) by moving the lever (12). An electric safety device
prevents the engine being started if the gearshift lever is not in the neutral
position.
Changing the direction of the machine
It is possible to change the direction of travel of the machine, regardless of the
speed which has been selected. Nevertheless, to protect the operator and the
transmission, if the speed is too high the electronic controller (13) will select 2nd
speed and the direction of travel will be changed only when the speed of the
machine is sufficiently low.
MODE SELECTOR SWITCH 18

It selects the way in which gear-changes take place:
AUTOMATIC
- If the operator selects 4th gear with the gear lever, the ratio selected in the gearbox will depend on the real speed of the machine. The ratios
will therefore change between 1st gear and 4th gear, changing up or down depending on the load on the transmission.
If you release the accelerator pedal when travelling down a slope, the detector (19) will cause the transmission to stay in the ratio which has
been selected.
MANUAL
- When travelling in 1st or 2nd gear, if the operator directly selects 4 th gear, the ratios will change every 2.5 seconds until 4th gear is reached.
But the transmission will stay in 4th gear regardless of the real speed or the load on the transmission.
DOWN SWITCH BUTTON (20)

Switch (20) is located on top the loader lever.
IN AUTOSHIFT MODE
The transmission will down shift one gear each time the button is pressed.
IN MANUAL MODE
The operator must select 2 nd gear, using the gear lever 12 (SP3).
By pressing this button, the operator can change down automatically from 2nd to 1st gear.The transmission will automatically change up again to
2nd gear when you press the button a second time or if you change the direction of travel.
TRAINING MANUAL

TRANSMISSION CUT-OUT
This is mainly used to obtain total engine power on the hydraulics in
the "DIGGING" or "LIFTING" functions. 21
It also enables the machine to be stopped when loading a truck.
Switch (21)
It is used to select or deselect transmission cut-out.
Cut-out selected: 18
Press the upper part of the switch and then the left-hand brake pedal.
The system will automatically partially cut out the transmission. In this
case, the cut-out is controlled by the switch (19) located under the left-
hand brake pedal.
Cut-out not selected:
When the lower part of the switch is pressed, you can press on either
brake pedal and the transmission will remain engaged.
ELECTRONIC CONTROL MODULE 13:

This electronic unit (EST 37 microprocessor control unit) is located
under the right hand access door of the cab.
It is connected between the gearshift lever (12) and the "ZF" control
solenoid valves. The "ZF" control solenoid valves are controlled
directly from the electronic unit.
19
It manages the gears depending on the position selected at the gear
lever (12) and the position of the switches (21) and (18).
It continuously checks the condition of the circuit and the components
which are connected to it.
SPEED SENSORS (16): 13

They inform the electronic gear control box in the transmission of:
1 Engine speed
2 Converter turbine speed
3 Intermediate gear speed
4 Outlet speed (ground speed)
This enables changes up and changes down to be performed
correctly. If a speed sensor or its circuit has a defect, the electronic
control box will pass into substitution mode.
If two speed sensors have a defect the controler will pass

automatically in limp home mode, selecting the 2nd gear.

TRAINING MANUAL
GENERAL INFORMATION
The new ZF transmissions have a new electrical system totally different from the “B” series wheel loaders. It
incorporates a new solid state Electronic Control Module(TECM). The TECM monitors system functions and controls
the shifting of the transmission. The following diagram o is a system flow chart illustrating inputs and outputs to and
from the transmission TECM.
The transmission TECM works together with the information center. The TECM uses the information center as a
communication mechanism to talk to the operator or service technician. The transmission TECM acts as the
computer and the information center acts as a readout device. By monitoring the transmission oil temperature and
varying the current that is applied to the electrical shift solenoids the transmission TECM can time the rate at which
the clutches engage and release. This provides for the smooth shifting while having constant control over the clutch
engagement. As the transmission changes gears, there is reduced hesitation from one gear to the next. This is
noticeable when going up a hill or charging a pile. When the transmission shifts gears the machine does not rock
back because it does not have to wait for the clutches to be emptied and filled.
Output speed Transmission Down shift

sensor shifter button
Torque Autoshift
convertor switch
temp. sensor
Filter Declutch
restriction switch
switch
Transmission
Oil Electronic Declutch
temperature
sensor in the
Control brake switch
valve Module
TCEM or TCM or ECU Engine speed

turbine speed EST 37 switch
sensor
Intermediate
speed sensor
CAN BUS
interface
Transmission Diagnostic
PWM connector
solenoids Information
center

TRAINING MANUAL

TRANSMISSION ELECTRONIC CONTROL MODULE
The transmission TECM is located under the right hand access door of the cab.
The transmission TECM carries out a variety of tasks in the overall system.
These tasks include:
Determining which clutches should be engaged in the transmission
Establishing the clutch modulation pressures with time during transmission transitions
Protecting the engine and transmission turbine from overspeed conditions during downshifting.
Receiving signals from the shifter, the automatic/manual rocker switch, the downshift button, the
parking brake control, the declutch control and the CAN interface. It uses these to determine
control under normal operating conditions.
Receiving speed information from the engine speed sensor, the turbine speed sensor, the
intermediate clutch speed sensor and the transmission output speed sensor. These sensors are
checked to determine if normal sensor operation is present. The data is also used to control
modulation during shifting and determine appropriate shift patterns.
Determines if there are any system failures and determines appropriate alternative actions.
Provides various diagnostic messages to the information center.
Provides other communication to the information center to inform the operator of engine speed,
wheel speed, gear shifter selection and actual gear selection.
Provides a method to calibrate the transmission clutch control.
The transmission TECM reads different RPM’s from four sensors.

It reads RPM’s from an engine speed sensor; a turbine speed sensor, a transmission intermediate
shaft speed sensor and an output shaft speed sensor. With this information, the transmission
TECM can accurately shift the transmission and determine if any clutches are slipping. The
shifting is based on the amount of load that is placed on the machine. If one of the sensors fails
the transmission will operate in a degraded mode. The shifting will be based on predetermined
time intervals that are programmed into the transmission TECM. The operator will complain of
rough shifting characteristics. A fault code will also be logged by the TECM. This is covered in
more detail under the transmission troubleshooting section of this manual.
The transmission TECM has the capability to find the optimal adjustment of the clutch filling
parameters for each individual transmission. This gives each transmission TECM the ability to
individually adjust the optimum fill time for the individual transmission in the machine. Clutch
filling parameter calibration is done to each machine at the plant. This should also be done at 250
hrs. and every 1000 hrs. after. This procedure takes around 4 minutes to complete. To perform
this procedure see the information center section of this training manual.

TRAINING MANUAL
BRAKE PEDAL SWITCH AND SPEED SENSORS

DECLUTCH BRAKE SWITCH
The declutch brake switch is located under the floor of the cab, connected to the left hand
brake pedal. When activated it sends a signal to the transmission ECM to declutch the
transmission (Except in 4th gear).
SPEED SENSORS
621C - 721C - 821C speed sensor layout

48 Engine Speed Sensor
47 Intermediate Speed Sensor
21 Turbine Speed Sensor
34 Output Speed Sensor
Résistance of the engine intermediate and turbine speed

sensors: 1050 +/- 10% Ohm at 20°C.
Engine Speed Sensor

The engine speed sensor is screwed into the front
housing for the torque converter pump wheel on the
transmission.
It sends an input signal into the transmission controller
so that it can monitor the current engine RPM’s to
determine the load on the engine for shift points. This
information is then relayed to the information center
where engine RPM’s are displayed on the instrument
cluster.
Turbine Speed Sensor

The turbine speed sensor is located on the upper right
side of the transmission and is the front sensor. It is
used to assist the engine speed sensor in determining
the load going into the transmission and to help
determine the appropriate shift points. 621C - 721C - 821C
Intermediate Speed Sensor

The intermediate speed sensor is located on the upper Test the Output speed sensor:
right side of the transmission and is the rear sensor. It is
- Disconnect the sensor from the wiring harness
used to determine differential gear speed in the - Place the positive lead of the DVM on the pin where the
transmission and to check for clutch slippage in the orange wire goes into the sensor, and the negative lead
transmission. on the pin where the black wire goes into the sensor.
- Turn the DVM on to the ohms scales
Output Speed Sensor - You should read OL.
The output speed sensor is located on the back of the - Place the positive lead of the DVM on the pin where the
transmission right behind the oil filter. It is used to orange wire goes into the sensor, and the negative lead
monitor the transmission output shaft speed to help on the pin where the blue wire goes into the sensor
determine the load on the transmission and assist in - You should read OL.
determining the appropriate shift points. This information - Place the positive lead of the DVM on the pin where the
is then relayed to the information center where the blue wire goes into the sensor, and the negative lead on
machine MPH / Km/h are displayed on the instrument the pin where the black wire goes into the sensor
cluster. - You should read approximently 18,000 ohms.
TRAINING MANUAL
WG 260 (921C) SPEED SENSORS

921C speed sensor layout
5 Intermediate Speed Sensor

9 Engine Speed Sensor
13 Output Speed Sensor
14 Turbine Speed Sensor
921C 921C

TRAINING MANUAL
OTHER ELECTRICAL COMPONENTS
Torque Converter Temperature Sensor
The torque converter temperature sensor is located in the cast housing that
fastens the torque converter to the transmission.
It is used to monitor the oil temperature coming out of the converter, because
this is the hottest oil generated by the transmission. 2
By monitoring this oil temperature the transmission TECM can light a warning
light in the instrument cluster and warn the operator of possible malfunctions
and prevent damage from occurring to the torque converter and transmission.
If the transmission oil temperature indicator light turns on the operator should
immediately shift the transmission into neutral and rev the engine up to 1500
RPM’s until the warning light goes out.
Resistance 800 to 1500 Ohms
1
Oil Temperature Sensor (1)
The transmission has a cold start protection system.
When the transmission sump temperature is below -10° C(14° F),
the transmission TECM will keep the transmission in neutral.
When the transmission sumptemperature warms up to -10° C(14° F), the
machine will operate in all gears.
Once the transmission temperature has been above -10° C(14° F),
it will not go back to a lower modeif the temperature decreases.
The oil temperature sensor is located in the transmission control valve.
Resistance 1000 to 1500 Ohms 3
Filter Restriction Switch
The ZF transmission hydraulic system has a filter restriction switch, located
behind the head of the filter base, to notify the operator if the transmission filter
needs to be changed.
Transmission Solenoids PWM. (2)
There are six transmission solenoidsscrewed into the transmission control
valve, located on the rear of the transmission.
They are used to direct the flow of oil to the designated clutch packs as the
gears are shifted.
The solenoids are always supplied with 24 voltsof power.
The transmission controller varies the amount of current going to the solenoids
to shift the spools inside the solenoids and redirect the flow of oil into or out of
the clutch packs.
The current that is applied to the solenoids varies from 100 mA to 500 mA;
100 mA when fully disengagedand
500 mA when fully engaged. Delay Power In (3)
If the transmission TECM detects a problem it will operate in one of the
Delayed power is sent into the transmission
degraded modes of operation, discussed in detail in the transmission TECM controller from the time delay module. This
troubleshooting section of this manual. If a major problem is detect which keeps power to the transmission TECM for 10
causes the transmission to go into Shutdown Mode and system voltage to the
seconds after the key switch is turned off. This
transmission solenoids is cut off by the transmission TECM. Résistance power is supplied through terminals 23 and 68.
17 to 21 Ohms Information Center
CAN BUS Interface
The information center is located in the
The CAN BUS interface is the circuitry that allows the Transmission TECM and instrument cluster. It is used as a systems
the information center to communicate. It is located in the wiring between the
monitoring tool for all 21 “C” series wheel
transmission TECM and the information center. It is an electronic circuit board loaders. It also acts as a readout device for any
that takes the information from the transmission TECM and converts it into a information that the transmission controller
format that the information center understands.
needs to communicate to the operator.
The information center will generate error codes if the CAN BUS is not
functioning properly.
6 - TRANSMISSION CHARGEUSE SUR PNEUS - SERIE 21C
TRAINING MANUAL
CHECK AND DIAGNOSTIC
Transmission Electronic Control Module
The transmission ECM also reviews voltage from the shifter and the transmission solenoids to determine if there are any short
circuits or open circuits in the system.
If the transmission ECM detects a problem in the transmission system, it will generate a service code in the information center
and enter one of three modes. These modes consist of; Clutch Modulation Substitute Mode, Limp-Home Mode and
Transmission/ Transmission ECM Shutdown Mode.
1 - Clutch Modulation Substitute Mode

The transmission clutch modulation is time dependant rather than load dependant.
If the output speed sensor is working and the transmission is in gear, the shifts points in automatic mode will be speed
dependant but the modulation will be a predetermined amount of time.
If the output speed sensor is not working and the transmission is in gear, the shift points will still be load dependant but
the modulation will be a predetermined amount time.
If the transmission is shifted from neutral into a direction in the clutch modulation substitute mode in automatic, the
transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.
The transmission will go into the clutch modulation substitute mode if any of the four speed sensors fail.
2 - Limp-Home Mode
The transmission will go into second gear forward or reverse no matter which speed is selected.
If second gear is not obtainable, the transmission ECM selects a series of prioritized gears until an operable gear is found.
The transmission will go into the limp-home mode if there is a fault on one clutch, a fault on one clutch valve or a fault on
more than more than speed sensor.
3 - Transmission / Transmission ECM Shutdown Mode
The transmission ECM has detected a severe failure that disables control of the transmission or system.
The transmission ECM will shut off all solenoid valves and the power supply.
The transmission shifts to neutral and stays in neutral.
The transmission will go into the shutdown mode if there is a fault on more that one clutch, a fault on solenoid power
supply, or invalid voltage.
System voltage to the transmission solenoids is cut off by the transmission ECM in this mode.
If the transmission ECM generates a code, the wrench over the service manual will appear on the display on the Information
Center.
If the transmission controller has an internal failure it will produce a fault code of 46241, which will be sent to the information
center where it is stored. If you access the fault codes and there is an 46241(general EEPROM fault) present you must
change the transmission ECM.
Transmission Shifter
To test the transmission shifter with a DVM use the following procedure:
1. Disconnect the transmission shifter at connector 70 on the machine.
2. Connect the positive and negative leads of the DVM to the appropriate
test points and you should read the following values
Directional selection - X1 Gear selection- X2

Forward A&B 0 ohm
Forwardt A&C Open 1st A&B Open
Forward A&D Open 1st A&C 0 ohm
Reverse A&B Open 2nd A&B Open
Reverse A&C 0 ohm 2nd A&C Open A BCD AB C D
Reverse A&D Open 3rd A&B 0 ohm
Neutral A&B Open 3rd A&C Open
Neutral A&C Open 4th A&B 0 ohm
X2 X1
Neutral A&D 0 ohm 4th A&C 0 ohm
If you do not get these readings replace the transmission shifter.

TRAINING MANUAL
CONTROLER ELECTRICAL CIRCUIT
ELECTRICAL SCHEMATIC
The transmission electronic control module(TECM) is supplied with 24 volts of key switch power through terminal 45. The same wire
coming into terminal 45 also supplies the output speed sensor and the diagnostic connector (which is not used) with 24 volts of key
switch power. When the key is turned to the on position the transmission TECM is powered up.
The transmission TECM is grounded to the cab negative stud through two wires coming out of terminals 1 and 2 of the TECM.
The transmission TECM communicates to the information center through a CAN Bus interface. The low signal information enters and
exits the transmission TECM through two terminals, 26 and 27. The high signal information enters and exits the transmission TECM
through terminal 25.
Transmission Shifter.
The transmission shifter is provided with 24 volts of power from the parking brake into terminal 2 of the shifter lever. When the
transmission lever is in neutral a signal is sent in to the controller through the ether start switch into terminal 67. When the transmission
is shifted into forward a 24 volt signal is sent into terminal 43 of the controller and when the transmission is shifted into reverse a 24 volt
signal is sent into terminal 64 of the controller.
When the transmission shifter lever if placed in 1st gear a 24 volt signal is sent into the controller terminal 63 to indicate 1st gear has
been selected. In 2nd gear no signal is sent into the controller. In 3rd gear a signal is sent into terminal 65 of the controller. In 4th gear
a signal is sent into both terminals 63 and 65 of the controller.
Terminal 10 on the shifter lever is not used, it is an option for a down shift button that can be placed on the end of the shifter lever. At
this time it is not available.
Down Shift Button

When the operator request the down shift function by pushing the button on the end of the control lever a 24 volt signal is sent into
terminal 22 of the transmission controller through the down shift button.
AutoShift Switch
When operating in the manual mode, switch off, a 24 volt signal is sent from the key switch through the autoshift switch out terminal 4
and into terminal 29 of the transmission controller. When the autoshift is selected the signal into the switch is sent out terminal 6 of the
switch, interrupting the signal from being sent to terminal 29 of the controller.
Declutch and Declutch Brake Switch

When the switch is in the “off” position, a 24 volt signal is sent form the key switch through the declutch switch out terminal four and into
terminal 66 of the transmission controller. When the switch is selected to the “on” position the signal is sent out terminal 6 of the switch,
however, a signal is still supplied to the controller terminal 66 from the key switch through the declutch brake switch. When the
operator steps on the brake the signal is no longer supplied to terminal 66 of the controller and the transmission goes into declutch
mode. When the operator lets up on the brake pedal the signal is again supplied to terminal 66 and the transmission functions
normally.
Temperature Sensor, Torque Converter Temperature Sensor, and Filter Restriction Switch
All three are sent a signal from the transmission controller. The temperature sensor signal is sent out terminal 39 of the controller, the
torque converter temperature sensor signal is sent out terminal 49 of the controller, and the filter restriction switch signal is sent out
terminal 17 of the controller. All three share a common ground through terminal 46 of the controller. As the temperature changes the
signal coming back to the controller changes through a variable resistor in the sensor. If the temperature gets too high or too low the
controller will sense the signal voltage change and the controller will send a signal to the information center to warn the operator.
If the filter restriction switch opens the signal is no longer sent back to the controller and it knows that it is time to change the filter, the
appropriate light is illuminated to warn the operator.
Output Speed Sensor

The output speed sensor is supplied with a 24 volt signal from the key switch. The returning signal changes from a high to a low
signal. The high signal returns to the controller through terminal 4, the low signal returns to the controller through terminal 62. When a
tooth moves in front of the sensor the signal returning changes from high to low. Based on how frequently this occurs this is how the
controller knows how fast the output shaft is turning.

TRAINING MANUAL
68 TERMINAL CONNECTOR OF THE CONTROLER

Engine Speed, Intermediate Speed, and Turbine Speed Sensors
These three sensors are have a high and a low side signal. When a gear tooth moves in front of them a pulse is
generated and flows back into the transmission controller. All three sensors share a common low signal which is sent
back to the controller through terminal 3. The high side for the engine speed sensor is terminal 19. The high side for
the intermediate speed sensor is terminal 42. The high side signal for the turbine sensor is terminal 41.
Terminal Description Comments

1 Control Ground 0V
2 Control Ground 0V
3 Common Signal Low (Turbine, Engine, Intermediate Sensor)
4 Output Speed Sensor Ground 0V
7 Backup Alarm Signal
9 Clutch KV Signal High 24 V
10 Clutch KR Signal High 24 V
12 Common Ground Signal LOW (PWM solenoid) 0V
13 Common Ground Signal LOW (PWM solenoid) 0V
15 Diagnostic Connector Signal
17 Filter Signal High
18 Diagnostic Connector Signal
19 Engine Speed Sensor Signal High
21 Park Brake Signal
22 Down Shift Switch Signal
23 Delay Power In (+)
25 CAN BUS Interface Signal High (+)
26 CAN BUS Interface Signal Low (-)
27 CAN BUS Interface Signal Low (-)
29 Autoshift Signal 24 V in autoshift
32 Clutch K1 Signal High 24V
39 Temperature Sensor Signal High
41 Turbine Speed Sensor Signal High
42 Intermediate Speed Sensor Signal High
43 Forward Signal
45 Cab Switched Power, Out speed Sensor Power (+)
46 Common Signal Low (Temperature, Torque Converter Output,
Temperature Sensor, Filter Restriction Switch) (-)
49 Torque Converter Output Temperature Sensor Signal High (+)I
51 Clutch K2 Signal High
62 Output peed Sensor Signal
63 Gear Selection Signal 24 V for 1rst et 4th
64 Reverse Signal
65 Gear Selection Signal 24 V for 3rd et 4th
66 Declutch Signal 24 V for driveline
67 Neutral Signal
68 Delay Power In (+) 24 V
NOTE : Not notified terminals are not used

TRAINING MANUAL
TRANSMISSION ELECTRICAL CIRCUIT

TRAINING MANUAL
TRANSMISSION ELECTRICAL CIRCUIT

Shift Solenoids
All shifts solenoids are supplied with 24 volts of power at all times.
The controller varies the current going to each solenoid to activate the solenoids and redirect the flow of oil.
They are sent a 24 volt power supply through the following designated terminals coming out of the controller:
621C – 721C – 821C 921C
Controler terminal Controler terminal PWM Solenoid Clutch
56 10 Y-1 K-4
10 56 Y-2 K-R
32 32 Y-3 K-1
55 55 Y-4 K-3
9 9 Y-5 K-V
51 51 Y-6 K-2
Delay Power In
Delayed power is sent into the transmission controller from the time delay module.
This keeps power to the transmission ECM for 10 seconds after the key switch is turned off.
This power is supplied through terminals 23 and 68.
Park Brake Signal

When the park brake is turned off a signal is sent into the controller through terminal 21 to tell the transmission ECM
that the park brake is off.
When the switch is turned on the signal is interrupted and the controller knows the park brake is on.
Diagnostic Connector
There is a high and a low signal coming into the controller from the diagnostic connector through terminals 15 and 18.
There is not a diagnostic connector on the 21 “C” series wheel loaders.
Backup Alarm
When the shifter lever is shifted into reverse the transmission controller sends a signal out terminal 7 to the backup
alarm relay to turn on the backup alarm.

TRAINING MANUAL
“ZF” AXLE (AP 407 - CK) - DIFFERENTIAL
Spécifications .................................................................................................. Tightening torques (pages 24 and 25)

- Nut item 13 ...................................................................................................................= 700 Nm
- Screw item 12 ..............................................................................................................= 260 Nm
- Screw item 18 ..............................................................................................................= 250 Nm
- Play between teeth of pinion ........................................................................................= 0.1 to 0.3 mm
- For disassembly and reassembly see Service Manual: ............................................... 6004

TRAINING MANUAL
“ZF” AXLE (AP 407 - CK) - DIFFERENTIAL
12
5
18
13
This type of differential is fitted in axles which are fitted on the following wheel loaders :
621C Front axle - rear axle

621C XT Front axle - rear axle
721C Rear axle
721C XT Rear axle
This limited slip differential enables tractive efforts to be spread equally automatically to all wheels, giving maximum adhesion for the machine
in difficult terrain.
Pinion bearing pre-load (5) and (6) = 1.10 to 2.30 Nm.

TRAINING MANUAL
“ZF” AXLE (AP 407 - CK) - WHEEL REDUCER
Spécifications
........................................................................................................................................Tightening torques (pages 26 and 27)
- Nut item 2 .....................................................................................................................= 800 to 1000 Nm
- Screw item 29 ..............................................................................................................= 50 Nm
- Disassembly - reassembly: see Service Manual: ......................................................... 6004

TRAINING MANUAL
“ZF” AXLE (AP 407 - CK) - WHEEL REDUCER
3 4
29
This type of wheel reduction box is fitted to axles on the following wheel loaders :
621C Front axle - rear axle

621C XT Front axle - rear axle
721C Rear axle
721C XT Rear axle
This wheel reduction box, with planetary gearing is fitted with an oil bath multi-disc brake (see Chapter 7 - BRAKING)
Pre-load on bearings (3) and (4) after nut (2) has been torque locked = 11 to 18 Nm (measured in the central axis of the reduction box).

TRAINING MANUAL
“ZF” AXLE (AP 409 - DK) - DIFFERENTIAL
Spécifications ................................................................................................. Tightening torques (pages 28 and 29)

- Nut item 11 ...................................................................................................................= 700 Nm
- Screw item 12 ..............................................................................................................= 90 Nm
- Screw item 13 ............................................................................................................... = 390 Nm
- Screw item 16 ............................................................................................................... = 250 Nm
- Play between pinion teeth ............................................................................................= 0.2 to 0.35 mm
- For disassembly - reassembly: see Service Manual:.................................................... 6004
TRAINING MANUAL
“ZF” AXLE (AP 409 - DK) - DIFFERENTIAL
12
7
13
11
This type of differential is fitted on axles on the followingwheel loaders :
721C Front axle

721C X Front axle
821 Rear axle
This limited slip differential enables tractive effort to be spread equally and automatically to all wheels, which ensures maximum adhesion of the
machine in difficult terrain.
Pre-load on the pinion bearings (4) and (7) = 1.50 to 3.0 Nm.
Pre-load on differential bearings (2) and (3) = 3 to 4 Nm.

TRAINING MANUAL
“ZF” AXLE (AP 409 - CK) - WHEEL REDUCTION BOX

- Nut item 2 .....................................................................................................................= 800 to 1000 Nm
- Screw item 29 ..............................................................................................................= 50 Nm
- Screw item 37 ..............................................................................................................= 180 Nm
- For disassembly - reassembly: see Service Manual : .................................................. 6004

TRAINING MANUAL
"ZF" AXLE (AP 409 - CK) - WHEEL REDUCER
29
This type of reduction box is fitted to axles which are fitted on the following wheel loaders :
721C Front axle

721C XT Front axle
821C Rear axle
This wheel reduction box with planetary gearing if fitted with an oil bath multi-disc brake (see Chapter 7 - BRAKING).
Pre-load on bearings (3) and (4) after locking the nut to torque (2) = 11 to 18 Nm (measured in the central axis of the reduction box).

TRAINING MANUAL
"ZF" (AP 411 - HK) - DIFFERENTIAL
12
13
21
14
Spécifications ................................................................................................... Tightening torque (pages 32 and 33)

...................................................................................................- Screw item 12 = 160 Nm
- Screw item 13 ..............................................................................................................= 390 Nm
- Nut item 14 ...................................................................................................................= 1200 Nm
- Screw item 21 ..............................................................................................................= 390 Nm
- Play between pinion teeth ............................................................................................= 0.1 to 0.3 mm
- For disassembly - reassembly: see Service Manua :: .................................................. 6004

TRAINING MANUAL
"ZF" AXLE (AP 411 - HK) - DIFFERENTIAL
21
12
13 5
14
This type of differential is fitted to axles which are fitted on the following wheel loader ::
821C Front axle
This limited slip differential enables tractive effort to be automatically and equally distributed to all wheels, which ensures maximum traction of
the machine in difficult terrain.
Pre-load on the pinion bearings (5) and (6) = 1.50 to 3.0 Nm.
Pre-load on differential bearings (2) and (3) = 3 to 4 Nm.

TRAINING MANUAL
"ZF AXLE (AP 411 - HK) - WHEEL REDUCER

- Nut item 2 .....................................................................................................................= 1300 to 1500 Nm
- Screw item 28 ..............................................................................................................= 50 Nm
- For disassembly - reassembly: see Service Manua : ................................................... 6004

TRAINING MANUAL
"ZF" AXLE (AP 411 - HK) - WHEEL REDUCER
6 4
28
This type of wheel reduction box is fitted to axles which are fitted on the following wheel loaders :
821C Front axle
This planetary gear reduction box is fitted with an oil bath multi-disc brake (see Chapter 7 - BRAKING).
Pre-load on bearings (4) and (6) after the nut has been locked to torque (2) = 11 to 18 Nm (measured in the central axis of the reduction box).

TRAINING MANUAL
"G.K.N." AXLE (RP32S - 34) - DIFFERENTIAL
Spécifications
TORQUE SETTINGS (pages 38 and 39)
- Nut Item 1............................................................................................................................= 108 to 120 mdaN
- Screw Item 3 ....................................................................................................................... = 15 mdaN
- Screw Item 23 .....................................................................................................................= 105 to 110 mdaN
- Nut Item32 and 49...............................................................................................................= 30 mdaN
- Screw Item 29 .....................................................................................................................= 40 mdaN
- Pinion backlash ...................................................................................................................= 0.2 to 0.3 mm
- Disassembly / Assembly , see Service Manual...................................................................6004

TRAINING MANUAL
"G.K.N." AXLE (RP32S - 34) - DIFFERENTIAL
49
23
14 29
9
1 3
17
32
27
This type of differential is housed in the front and rear axles of the 921C loader.
This torque proportional differential provides automatic, even distribution of tractive force to the wheels, giving better machine traction on
difficult ground.
Under extreme or very specific conditions, the differential, of the rear axle only, can be equipped with the «No-Spin» system (Items 42 to 46).
Pinion bearings pre-load (9) and (14) = 3.2 to 3.6 mdaN

If the crown wheel (17) has to be changed, the new crown wheel must be heated to 150°C for it to be installed on its support (27)

TRAINING MANUAL
"G.K.N." AXLE (RP32S - 34) - WHEEL REDUCER
Spécifications TORQUE SETTINGS (pages 40 and 41)

..........................................................................................................................................
- Nut item : 10 .........................................................................................................................................= 48 to 54 mdaN
- Screw Item : 1 and 2.............................................................................................................................= 56 to 63 mdaN
- Screw Item : 27 and 29.........................................................................................................................= 12 mdaN
- Screw Item : 31.....................................................................................................................................= 35 to 40 mdaN
- Disassembly / Assembly, see Service Manual : ...................................................................................6004

TRAINING MANUAL
"G.K.N." AXLE (RP32S - 34) - WHEEL REDUCER
5
31
2 4
6 mm
1
10
This type of reduction gear is housed in the front and rear axles mounted on the 921C loader.
This planetary type reduction gear is fitted with an oil bath multi-disc brake (See Chapter 7 - BRAKES)
To install bearing (5), special tool CAS-22 6-1 must be used for correct fitment in the reduction gear housing and on the shaft (4). Force
required : 50 tons.

TRAINING MANUAL
REAR AXLE PIVOT

Adjusting the lateral play of the beam pivot
Present and align the pivot to the chassis.

Place two shims (4) of 3.2 mm on the front side of the pivot.
Measure the remaining play on the rear side.
Fit shims so as to obtain a sideways maximum play of 3 mm.
Note: three thicknesses of shims are available:

3.2 mm
4.7 mm
6.4 mm
621C- 721C - 821C

921C
For 921C there is no setting, since rear axle mounting on the chassis is different.
The axle is held by 2 swing bars (2) and (3) which are fixed on the chassis and the joint is bumeans of bearing rings.
Spécifications
IGHTENING TORQUES:
- Pivot bearings retention screws (6) ..............................................................................................................................= 310 to 380 Nm.
- Axles retention screws (2X4) ........................................................................................................................................= 990 to 1000 Nm.
ON THE 921C
- Rear axle to chassis retaining screws ...........................................................................................................................= 56 to 59 mdaN
- Front axle to chassis retaining screws...........................................................................................................................= 207 to 221 mdaN

TRAINING MANUAL
PARK BRAKE
Towing the Machine

3
If you must tow the machine use the following
procedure:
1
1. Attach a rigid drawbar to the machine.
2. If the machine cannot be started to release the
parking brake do the following:
- Put blocks in front of and behind each tire.
- Remove the parking brake cover(1).
- Loosen the lock nut(2).
- Turn the adjusting screw counterclockwise
until the parking brake is released(3).
3. If the machine is to be towed more than 0.5_
mile (0,8 km) you must disconnect the front
and rear drive shafts. 2
4. Tow the disabled machine at a maximum
speed of 5MPH.
NOTE: Never tow the machine from the front.
Park brake adjustment

Park brake released
The gap between the disc and the brake shoes must be in
- 0,5 and 1,5 mm for 621C 721C and 821C
- between 1 and 3 mm for a 921C.
Parking brake check

See the procedure in section 4A.

TRAINING MANUAL
621C - 721C - 821C TRANSMISSION OIL COOLING

TRANSMISSION OIL TEMPERATURE
The transmission oil passes through the oil/water heat exchanger to be
cooled and then returns to the gear box to continue its lubrication.
The heat exchanger water is cooled by the engine radiator.
The temperature sensor (SS10) continuously checks the transmission oil
temperature. SS12
When the temperature reaches about 120°C: the red oil temperature
warning light lights up.
Oil level check
1 Place the machine on level ground.

2 Check the level every 50 hours.
3 Cold oil:
SS10
- the level should be at the arrow mark.
4 Hot oil:
- engine running at idle
- gear lever at neutral position
- the oil level should be between the minimum level “ADD”
and the maximum “FULL”.
- Top up if necessary via the filler plug
Maintenance
1 Replace the oil filter after the first 100 hours. then every
1000 hours.
2 Drain and replace the transmission oil and clean the breather
every 1000
hours (preferably with the gear box hot).

TRAINING MANUAL
921C OIL COOLING

TRANSMISSION OIL TEMPERATURE
On the 921C the transmission oil is cooled by passing through the oil
cooler which is attached to the engine radiator.
The oil cooler consists of two parts:
One for the loader / steering circuit
The other for the transmission oil.
The operation and the electrical safety components are the same as
the 621C - 721C - 821C described on the previous page.
Identification of ports
Loader / steering hydraulic circuit

A : Oil cooler outlet to filters and reservoir
B : Loader and steering flow return line A X Y
Transmission hydraulic circuit B
X : Torque converter outlet to oil cooler
Y : Oil cooler outlet to transmission lubrication circuit

TRAINING MANUAL
ZF AXLES - TYPE MULTITRAC ML T SERIE 3000
General purpose
Starting february 2000 all the models are equipped with new ZF MULTITRAC axles série 3000.
The new caracteristics are:
Only one oil housing for the center ball and the two reducers;
Disc brake fitted on the planetary
Automatic adjustment of the brake discs according the disc wear
Carrier bearings bigger
Internal chanel for brake oil circuit (very good protection)
On 921C : cooling of the axle oil by internal cooler cooled by hydraulic oil
All axles are eqquipped with a limited slip differential
See service bulletin EWL FAR 6015
Description of the cross section page 6.47.00
1 Hub/planetary nut 1500Nm on 921C7

2 Multi-lips oil seal
3 Shims
4 Limited slip differential
5 Vent
6 Chanel for brake circuit
7 Bleeder
8 Brake piston
9 Piston seal rings
10 Wear adjustment system
Capacities and maintenance

See page 1.11.00 and 1.12.00
Service
Differential backlash : from 0,25 to 0,34 mm

TRAINING MANUAL
10,5 mm
1 2
10
8 9
11
4
7

TRAINING MANUAL
621C - 721C - 821C 921C
1 Drain plug
2 Drain plug
3 Fill orifice
4 Bleeder acess
5 Vent
6 Cooling pipe with hydraulic oil flow on 921C axle
6
6

7 - BRAKE SYSTEM 21C SERIES WHEEL LOADERS
TRAINING MANUAL
621C - 721C - 821C - 921C HYDRAULIC BRAKE CIRCUIT
page
HYDRAULIC BRAKE CIRCUIT 621C - 721C - 821C - 921C ........................................7.02.00
COMBINATION VALVE....................................................................................................7.04.00
BRAKE HYDRAULIC PUMP............................................................................................7.05.00
ACCUMULATOR CHARGING VALVE ............................................................................7.06.00
BRAKE TREADLE PEDAL ................................................................................................7.8.00
BRAKE ACCUMULATOR ..................................................................................................7.9.00
DISC BRAKE "ZF"621C - 721C -821C ............................................................................7.10.00
DISC BRAKE" 921C ........................................................................................................7.11.00
DISC BRAKE "ZF" MULTITRAC 621C - 721C - 821 - 921C............................................7.12.00

21C SERIES WHEEL LOADERS
TRAINING MANUAL
11
X
▲ ● ● ●
1 ●
● P
X
● ● ●
Q ●
3
▲
T P
3
●
● ●
●
A
B
→
●
●
▲
)(
▲
13 13
●
33 ✕ )G
)(
D C
●
● ●
)( E P P
●
▲
● ●
)(
● Z SS4
SS5 P
● ●
●
● ●
●
+
▲
▲
▲
F
●
M5 M4
S1 S2
●
38
●
)(
●
●
●
●
● ●
+ +
S8
P1
●
●
●
S1 T1
●
P2
S2 37
●
T2
34
35 ● ● ● ● 36

21C SERIES WHEEL LOADERS 7 - BRAKE SYSTEM
TRAINING MANUAL
On these machines, the braking system is entirely hydraulic.
The flow necessary for braking is supplied by the pump (Q3).
This flow feeds the braking valve (33) at (P). The feed pressure is controlled by the safety valve (A).
Depending upon the requirements of the braking pedal via (S1) and (S2), the flow divides spool (B) of the valve opens and directs excess flow
to tank (T).
The purpose of the accumulators is to store a volume of oil which will be used, in event of a failure, by the brake pedal and by the pilot circuit
via the pressure reduction valve (12).
M7
Description:
1 Hydraulic tank M4
3 Hydraulic pump
12 Pilot pressure reducing valve M3
13 Hydraulic accumulators M5
33 Hydraulic brake valve
34 Hydraulic brake pedal
35 Front hydraulic brakes
36 Rear hydraulic brakes
S8Stop light contact switch on right-hand brake pedal
SS4 Transmission safety pressure contact switches (x 2).
SS5 Minimum braking pressure contact switch
M6
Spécifications
621C 7- 821C 921C
HYDRAULIC PUMP (3)

Flow (Q3) at 2200 RPM under 170 / 172 bar .................................................. 27,4 l/min 27,4 l/min 27,4 l/min
HYDRAULIC BRAKE VALVE(33) :

Safety valve setting......................................................................................... 185 to 207 bar 185 to 207 bar 185 to 207 bar
Cut out pressure ............................................................................................ 187 to 194 bar 187 to 194 bar 187 to 194 bar
Cut in pressure................................................................................................ 132 to 139 bar 132 to 139 bar 132 to 139 bar
ACCUMULATORS
Minimum pressure (nitrogen charged) ........................................................... 55 to 57 bar 55 to 57 bar 55 to 57 bar
BRAKING SYSTEM CONTROL PRESSURES

Low brake pressure switch on pressure (SS5) ............................................... 110 to 124 bar 110 to 124 bar 110 to 124 bar
Pressure controlled by transmission safety contact switches (SS4)............... 55 to 70 bar 55 to 70 bar 55 to 70 bar
BRAKE CIRCUIT PRESSURES

Brake pressure on front brakes M6................................................................. 52 / 59 bar 58 / 65 bar 69 / 76 bar
Brake pressure on rear brakes M7 ................................................................. 48 / 55 bar 55 / 62 bar 66 / 72 bar

TRAINING MANUAL
621C - 721C - 821C - 921C COMBINATION VALVE
ACF PS1F ACF ACR PS1R
● ●
PS1F
ACR +
PS1R
2
●
)(
PP
●
●
1 3
FB
● AUX
RB
T
PP
+ +
AUX
PB
PB
FB RB
Description
1 Park brake solenoid valve
2 Pilot pressure solenoid valve
3 Pressure reducing valve (37,2 to 42,7 bar)
T Tank
PB Park brake
FB Front brake
RB Rear brake
AUX Auxiliary supply (quick coupler for NAO)
PP Pilot presure
PS1F Front brake accumulator pressure switch (55 to 69 bar)
PS1R Rear brake accumulator pressure switch (55 to 69 bar)
ACF To front brake accumulator
ACR To rear brake accumulator

TRAINING MANUAL
HYDRAULIC BRAKE PUMP (3)
The brake pump is a Commercial Intertech gear pump driven by the engine PTO.
On 621C, 721C, 821C the pump rotates in a clockwise direction.

On 921C the pump rotates in counter clockwise direction.
The pump delivers : 27,4 l /min at 2200 rpm
- Removal - Assembly : Service manual ................................................................................................... 7003

TRAINING MANUAL
TIGHTENING TORQUES
- Nut item (23) ................................................................................................................= 28 to 34 mN
- Disassembly - reassembly: Service Manual: ............................................................... 7007

TRAINING MANUAL
HYDRAULIC BRAKE VALVE (33)
It consists of:
A Safety valve
B Flow divider Z
C Filter C
D Non-return valve
E Engagement-disengagement
P
F Blocking valves
G Bleed tap
D
Purpose of components:
A - Safety valve:
It protects pump and circuit against too high E E
pressure due to a wrong function of the charging
valve.
B - Flow divider:
It is operated by the charging valve, it directs oil :
- to charge accumulators
- or to hydraulic tank
C - Filter:
It protects the braking circuit from impurities
contained in the hydraulic oil.
T
D - Non-return valve:
It holds the pressure in accumulators when the flow
divider is open to tank.
G
E - ON - OFF charging valve :
It is controls the maximuim braking pressure by T
piloting flow divider operation.
F - Blocking valve:
They block pressure in the two brake circuits if one
of them has a fault or if there is a failure between
pump and charging valve.
G - Bleed tap
It enables the braking system to be bled.
B

TRAINING MANUAL
BRAKE TREADLE VALVE (34)

Description
1 Tank
2 Tank
3 Front brake spool
4 Rear brake spool
5 Front brake
6 Rear brake
7 Pressure from front accumulator
8 Pressure from rear accumulator
Operation
More the spools 3 and 4 are pressed down the
3 more the pressure increased in the brakes and
the more the pedal reaction feeling increases.
1 5 The spool 4 has a smaller diameter than the

raise spool 3 to obtain a highier brake effort on
the front axle.
2 6
Spécifications
- Disassembly - reassembly: Service Manual:: .......................................................................................... 7005

TRAINING MANUAL
HYDRAULIC ACCUMULATOR (13)
These are piston accumulators
In case of engine failure or incidents in the hydraulic circuit, the accumulators provide a reserve of oil under pressure which is necessary to
operate the brakes and the pilot circuits of the attachments.
NOTE: Bigger accumulators have been intalled on models equipped with MULTITRAC axles.
Specifications
...........................................................................................................................
Inflation Pressure (NITROGEN) ....................................................................................................................= 55 to 57 bar
NOTA : NEVER INFLATE THE ACCUMULATORS USING AIR BECAUSE THERE IS A RISK OF AN EXPLOSION
- Disaembly reassembly : Service Manual : ............................................................................................. 7004

TRAINING MANUAL
DISC BRAKE ASSEMBLY - 621C - 721C - 821C
These are oil bath multi-disc brakes located in the wheel reduction boxes.
Each brake assembly consists of:

- A piston, fitted with seals which receives oil under pressure.
- Steel discs with external teeth alternating with friction discs with internal teeth.
- With a steel counter-plate.
- Return springs bring the piston back after braking.
Specifications
NUMBER OF DISCS AP 407 (CK) AXLE AP 409 (DK) AXLE AP 411 (HK) AXLE
STEEL 3 4 5
FRITION 2 3 4
Disassembly / Assembly : Service Manual : 6004

TRAINING MANUAL
DISC BRAKE ASSEMBLY 921C
These are the multi-disc oil-bath brakes housed in the wheel reduction gears.
Each assembly consists of :
- A piston, fitted with seals, which receives the oil under pressure.
- Externally toothed steel discs alternated with internally-toothed sintered discs.
- A steel counter-plate
- Return springs which return the piston after braking.
Specifications
NUMBER OF DISCS RPS32S-34 AXLE
STEEL 6
FRICTION 5
Disassembly / Assembly : Service Manual : 6004

TRAINING MANUAL
BRAKES OF ZF MT L MULTITRAC AXLES
Wear measurement of the disc brake
Measure the gap X once a year or before in severe usage

If «X» is lower than 4 mm when the brake pressure is
applied replace the lined discs both sides.
1 Automatic wear adjustement puller

2 Plug for wear measurement

TRAINING MANUAL
BRAKES OF ZF MT L MULTITRAC AXLES
6 4 3
8 7
11
10
12
13
14
15 5
1 Liner disc (inner)

2 Steel disc
3 Snap ring 3 6
4 Slotted pin (elastic pin)
5 Stnap ring
6 Support
7 Elastic washer (cup ring)
Y
8 Self adjustement puller 7
9 Snap ring
10 Brake piston
11 Carrier ring 9
12 Back seal
13 Oil seal 8
14 Oil seal
15 Back seal
Service
The measurement Y must be within 10,5 +/- 0,3mm
before disc reassembly.

21C SERIES WHEEL LOADERS 8 - HYDRAULICS
TRAINING MANUAL
HYDRAULICS CIRCUIT
page
HYDRAULIC CIRCUIT 621C - 721C .................................................................................... 8.02.00

HYDRAULIC COMPONENTS LOCATIONS 621C - 721C ................................................... 8.03.00
HYDRAULIC CIRCUIT 821C ................................................................................................ 8.08.00
HYDRAULIC COMPONENTS LOCATIONS 821C ............................................................... 8.09.00
HYDRAULIC CIRCUIT 921C ................................................................................................ 8.12.00
HYDRAULIC COMPONENTS LOCATIONS 921C ............................................................... 8.13.00
GENERAL SPECIFICATIONS .............................................................................................. 8.16.00
PRESSURE CHECKS ON 21C SERIES RANGE ............................................................... 8.18.00
HYDRAULIC TANK............................................................................................................... 8.19.00

HYDRAULIC PUMP .............................................................................................................. 8.20.00
UNLOADING VALVE 621C - 821C....................................................................................... 8.21.00
ATTACHMENT CONTROL BLOCK 621C - 721C - 821C - 921 ........................................... 8.23.00
ATTACHMENT CONTROL BLOCK 621C - 721C XT........................................................... 8.25.00
Inlet section 621C - 721C - 821C - 921C.................................................................... 8.27.00
Main relief valve.......................................................................................................... 8.29.00
Bucket and auxiliary section (all models).................................................................... 8.31.00
Bucket and arm sections 621C XT 721C XT ............................................................. 8.31.00
Arm section 621C - 721C - 821C - 921C.................................................................... 8.32.00
Secondary relief with anti-cavitation valve ................................................................ 8.33.00
Anti-cavitation valve 621C XT - 721C XT .................................................................. 8.34.00
BUCKET FUNCTIONS.......................................................................................................... 8.36.00
Bucket dump - Dumping speed .................................................................................. 8.36.00
Bucket roll back - Automatic return to dig ................................................................... 8.37.00
ARM FUNCTION................................................................................................................... 8.40.00
Arm up - Raising the arm to controlled height ............................................................ 8.40.00
Float position - Return to dig - controlled lowering ..................................................... 8.42.00
CYLINDERS.......................................................................................................................... 8.45.00
HYDRAULIC FILTERS.......................................................................................................... 8.48.00
HYDRAULIC OIL COOLER .................................................................................................. 8.49.00
OIL COOLER BY-PASS........................................................................................................ 8.50.00
COMBINATION VALVE ........................................................................................................ 8.51.00
HYDRAULIC REMOTE CONTROL VALVE.......................................................................... 8.52.00

8.2.00
●
+
1 X ● ● ● ● ●
▲
ST1
●
11
ST2
● ● ● 8
SS1
8 - HYDRAULICS
)( 14 ● ● ●
X ● ●
15
●
P ●
T° ● ● ● ● ●
●
● ● ●
●
M3 SS2
● ● ● ● 9
● ● ●
Q1 Q2 Q3
2 3 ● ●
▲ ▲ ▲
SD7 29 )( )( 30
M1 M2 ● ●
● ●
P
●
● ●
5 ZB1 ZA1 ZB2 ZA2 ZB3 ZA3
Q4
▲ M ● ● X ● X
P1
● ●
31 25
P2
●
● ● ● ●
32 T2 ● ● ●
)( Z
)(
)(
●
)(
●
Z1
)(
●
▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
●
●
)(
)(
● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
33 )( X X
▲
→ ● 19
● ● ● ● ● ●
●
13
●
✕ 13 B1 A1 B2 A2
X B3
A3X
41
● ●
TRAINING MANUAL
●
P P ● SS4
●
40
)( ●
)(
SS4
▲
●
●
●
18
HYDRAULIC CIRCUIT- 621C (before JEE0122501) and - 721C
●
●
SS5 + ● SD2
●
P B A T ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
+
●
●
●
M5 M4 38
SD1 SD3
● ●
●
●
●
● ● ●
●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
▲
● ●
●
●
▲
● ● ()
M6 M7 39
Training center
35 36 37
●
●
Z
12
HYDRAULIC CIRCUIT
14 06 1999 Centre de Formation CASE MONTHYON 621C / 721C

TRAINING MANUAL
HYDRAULIC COMPONENT LOCATION - 621C - 721C
36 31 25 1 11 19 35 17 34 7 6 5 7
14
9 3 33 13 36 38 19 35
15
Description
1 Hydraulic tank 27 Unloading valve (621C after JEE0122501)

2 Dual flow hydraulic pump 29 Oil flow restrictor
3 Hydraulic pump for brake and pilot pressure 30 Oil flow restrictor
5 Loader attachment control valve 31 Electric drived pump for auxiliary steering
6 Bucket cylinder 32 Auxiliary steering pup relief valve
7 Arm cylinder 33 Brake accumulator charging valve
9 Hydraulic oil cooler 34 Service brake pedal valve
11 Hydraulic oil filter 35 Hydraulic front dics brake
13 Hydraulic accumulators 36 Hydraulic rear disc brake
14 Pilot remote control (arm and bucketl 37 Parking brake piston
15 Pilot remote control (auxiliary) 38 Combination valve
18 Steering control valve 39 Ride control master solenoid valve
19 Steering cylinder 40 Ride control slave solenoid valve
25 Steering priority valve 41 Ride control accumulators

8.4.00
●
+
1 X ● ● ● ● ●
▲
ST1
●
11
ST2
● ● ● 8
SS1
)( ● ● ●
8 - HYDRAULICS
● ●
14 15
X
●
P ●
T° ●
● ● ● ● ●
● ● ●
●
M3 SS2
● ● ● ● 9
● ● ●
Q1 Q2 Q3
2 3 ● ●
▲ ▲ ▲
SD7 29 )( )( 30
M1 M2 ● ●
● ●
P
●
● ●
27
S8 5 ZB1 ZA1 ZB2 ZA2 ZB3 ZA3
Q4
●
M ● ● ●
●
▲ ● ● X X
●
P1
)(
● ●
25
●
31
▲
P2
●
● ● ● ●
32 T2 ● ● ●
●
●
)( Z ●
)(
)(
●
)(
T8
Z1
●
)(
●
●
▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
●
●
)(
)(
● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
33 )( X X
▲
→ ● 19
HYDRAULIC CIRCUIT - 621C (after PIN JEE0122501)
● ● ● ● ● ●
●
13
●
✕ 13 B1 A1 B2 A2
X B3
A3X
41
● ●
●
P P ●
TRAINING MANUAL
SS4
●
40
)( ●
)(
SS4
▲
●
●
●
●
● 18
SS5 + ● SD2
●
P B A T ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
+
●
●
●
M5 M4 38
SD1 SD3
● ●
●
●
●
● ● ●
●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
▲
● ●
●
●
▲
● ● ()
M6 M7 39
Training center
35 36 37
●
●
Z
12
HYDRAULIC CIRCUIT
621C AFTER JEE122501
03 11 1999 Centre de Formation CASE MONTHYON
TRAINING MANUAL
HYDRAULIC CIRCUIT - 621C (after PIN JEE0122501)

Hydraulic components
1 Hydraulic tank
2 Dual flow pump
Q1 Steering and loader functions
Q2 Loader function only
3 Brake and pilot pressure pump
5 Loader valve
5a Inlet plate
5b Main relief valve
5c Piloted back pressure valve
5d Bucket section Q2
5e Loader arm valve section with float positionl
5f Auxiliary circuit (4 in 1 bucket) Q1 2
5g End section
5h Secondary relief with anticavitation valve
6 Bucket cylinder
7 Arm cylinder
8 Cooler by-pass
9 Cooler
11 Hydraulic filter
13 Hydraulic accumulator
14 Dual remote control valve
15 Auxiliary remote control valve
18 Steering valve
25 Steering priority valve
27 Unloading valve
29 Oil flow restrictor
31 Auxiliary steering pump
32 Auxiliary steering relief valve
33 Brake accumulator charging valve 5d 5e
5f
34 Brake pedal valve
35 Service brake (front)
36 Service brake (rear)) 5a 5c
37 Parking brake) 5g
38 Combination valve
39 Ride control master valve
40 Ride control slave valve
41 Ride control accumulator
Electric components of the hydraulic functions

SD1 Bucket return to dig proximity switch
SD2 Maximum arm height control proximity switch
SD3 Return to travel proximity switchl
SS1 Hydraulic temperature sensor
SS2 Hydraulic filter restriction switch
SS4 Brake accumulator redundant pressure switches
SS5 Brake alarm pressure switch
SD7 Steering pressure switch
ST1 Detent switch
ST2 Float / return to travel switch
5
5b
5h 5h

8.6.00
●
+
1 X ● ● ● ● ●
▲
ST1
●
11
ST2
● ● ● 8
SS1
)( ● ● ●
8 - HYDRAULICS
● ●
14 15
X
●
P ●
T° ● ● ● ● ●
●
● ● ●
●
M3 SS2
● ● ● ● 9
● ● ●
2 Q1 Q2 Q3
3 ● ●
▲ ▲ ▲
SD7 29 )( )( 30
M M2 ● ●
1 ZB1 ZA1 ZB2
● ZA3
P ● ZA2 ZB3
●
●
●
5 X ● X
● ●
P1
Q4
▲ M ●
25 ●
●
P2 P2 ● ●
● ● ●
31
●
●
T2 ●
32 )(
)( Z
)(
●
)(
Z1
●
)(
● ●
●
▲
S2 S3
)(
T1
●
●
●
)(
)(
● ● ● ● ●
● ● ● ● ● ●
●
●
● ● ● ●
▲
)( 41
▲
→ ● 19 ● ● ● ● ● ●
●
33
● ● ● ● ●
13
●
✕ 13
X X
● ● B1 A1 B2 A2 B3 A3
●
P P ● SS4
TRAINING MANUAL
●
)( ●
)(
SS4
▲
●
●
●
●
● 18
SS5 + 40 ● SD2
●
P B A T ● ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
38
●
●
●
HYDRAULIC CIRCUIT 621C XT (before JEE0122501) and 721C XT
M5 M4 +
SD SD3
● ● 1
●
●
●
● ●
● ●
●
- C +
● ● ●
●
●
● + +
6 7 7
●
●
●
- C +
● 34
● ●
▲
● ●
●
●
▲
● ● () 39
M6 M7
37
Training center
35 36
●
●
Z
12
HYDRAULIC CIRCUIT
14 06 1999 Centre de Formation CASE MONTHYON 621C / 721C XT
●
+
1 X ● ● ● ● ●
▲
ST1
●
11
ST2
● ● ● 8
SS1
)( 14 ● ● ●
X ● ●
15
●
P ●
T° ● ● ● ● ●
●
Training center
● ● ●
●
M3 SS2
● ● ● ● 9
● ● ●
2 Q1 Q2 Q3
3 ● ●
▲ ▲ ▲
SD7 29 )( )( 30
M M2 ● ●
1 ZB1 ZA1 ZB2
● ZA3
P ● ZA2 ZB3
●
●
● 27
5 X ● X
S8
●
● ●
●
● ●
P1
●
Q4 ●
)(
▲ M
●
●
25 P2 ● ●
P2
●
▲
● ● ●
31
●
●
T2 ●
●
●
32 )(
)( Z ●
)(
●
)(
T8 Z1
●
)(
● ● ●
●
▲
S2 S3
)(
T1
●
●
●
)(
)( ● ● ● ● ●
● ● ● ● ● ●
●
HYDRAULIC CIRCUIT 621C XT (after JEE0122501)
●
●
● ● ● ●
▲
)( 41
▲
→ ● 19 ● ● ● ● ● ●
●
33
● ● ● ● ●
13
●
✕ 13
X X
● ●
TRAINING MANUAL
P P B1 A1 B2 A2 B3 A3
● ● SS4
●
)( ●
)(
SS4
▲
●
●
●
●
● 18
SS5 + 40 ● SD2
●
P B A T ● ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
38
●
●
●
M5 M4 +
SD SD3
● ● 1
●
●
●
● ●
●
●
- C +
● ● ●
●
●
● + +
6 7 7
●
●
●
- C +
● 34
● ●
▲
● ●
●
●
▲
● ● () 39
M6 M7
35 36 37
●
●
Z
12
HYDRAULIC CIRCUIT
621C XT AFTER JEE122501
8.7.00
8 - HYDRAULICS
8.8.00
●
+
1 X ● ● ● ● ●
▲
ST1
9
●
11
ST2
● ● ●
SS1
14 ● ● ●
●
15
8 - HYDRAULICS
X 8 ●
●
P ● ● ● ●
●
● ● ●
●
M3
● ● ● ●
● ● ●
Q1 Q3 ●
2 Q2 ●
T° ●
3 ● ●
▲ ▲ ▲
SS2 29 )( )(
SD7 30
M1 M2 ● ●
● ● ●
● P ● 27
HYDRAULIC CIRCUIT 821C
●
● ●
●
● X X
Q P8 P1
●
M
)(
▲
4 ● ●
25
●
▲
P2
31
●
● ● ● ●
T2 ● ● ●
32
●
●
)( Z
)(
)(
●
)(
T8
Z1
●
)(
●
● ● ▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
)(
)(
● ● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
)( X X
▲
→ ● 19
● ● ● ● ● ●
●
33
13
●
✕ 13 B1 A1 B2 A2
X B3 A3X
41
● ●
●
P P ● SS4
TRAINING MANUAL
●
40
)( ●
)(
SS4
▲
●
●
●
●
● 18
SS5 + ● SD2
●
P B A T ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
+
●
●
●
M5 M4 38
SD1 SD3
● ●
●
●
●
● ●
● ●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
▲
● ●
●
●
▲
● ● ()
M6 M7 39
35 36 37
●
●
Training center
Z
12
HYDRAULIC CIRCUIT

821 C
TRAINING MANUAL
HYDRAULIC COMPONENT LOCATION - 821C
36 19 35 18 34 7 6
31 27 1 11 5
15
3 33 36 14 19 35
4 13 38
Description
1 Hydraulic tank 27 Unloading valve

14 Pilot remote control (arm and bucket) 37 Parking brake piston

8.10.00
●
+
1 X ● ● ● ● ●
▲ ST1
9
●
11
ST2
● ● ●
SS1
14 ● ● ●
X ●
8 ●
15
●
P
8 - HYDRAULICS
● ● ● ● ●
● ● ●
●
M3
● ● ● ●
● ● ●
Q1 Q3 ●
2 Q2 ●
T° ●
3 ● ●
▲ ▲ ▲
SS2 29 )( )( 30
SD7
M1 M2 ● ●
● ● ●
● P ● 27
●
● ●
●
● X X
Q P8 P1
●
M
)(
▲
4 ● ●
25
●
▲
P2
31
●
● ● ● ●
T2 ● ● ●
32
●
●
)( Z
)(
)(
●
)(
T8
Z1
●
)(
●
● ● ▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
)(
)(
● ● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
)( X X
▲
→ ● 19
● ● ● ● ● ●
●
33
13
●
✕ 13 B1 A1 B2 A2
X B3 A3X
41
● ●
●
P P ● SS4
●
40
TRAINING MANUAL
)( ●
)(
SS4
▲
●
●
●
●
● 18
SS5 + ● SD2
●
P B A T ●
●
P
●
●
▲
●
- C +
▲
▲
●
●
)(
+
●
●
M5 M4 38
SD1 SD3
● ●
●
●
●
● ●
●
●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
▲
● ●
●
●
▲
● ● ()
M6 M7 39
35 36 37
●
●
Training center
Z
12
HYDRAULIC CIRCUIT
14 06 1999 Centre de Formation CASE MONTHYON 821 C

TRAINING MANUAL

1 Hydraulic tank
2 Dual flow pump
5 Loader valve
5a Inlet plate
5d Bucket section
Q2
Q1 2
5f Auxiliary circuit (4 in 1 bucket)
5g End section
6 Bucket cylinder
7 Arm cylinder
8 Cooler by-pass
9 Cooler
11 Hydraulic filter
18 Steering valve
25 Steering priority valve
27 Unloading valve
33 Brake accumulator charging valve 5e
34 Brake pedal valve 5d 5f
35 Service brake (front) 5a 5c
36 Service brake (rear))
37 Parking brake)
38 Combination valve
39 Ride control master valve 5g
40 Ride control slave valve
41 Ride control accumulator

SS4 Brake accumulator redundant pressure switches 5
ST1 Detent switch
5b
5h
5h
8.12.00
●
+
1 X ● ● ● ● ●
▲
ST1
11
ST2
● ● ●
SS1
14 ● ● ●
●
15
8 - HYDRAULICS
X
●
P ● ● ●
● M3 ●
● ● ●
● ● ● ●
● ● ●
Q1 Q3 ●
2 Q2 ●
T° ●
●
3 ● ●
▲ ▲ ▲
SS2 29 )( )(
SD7 30
M1 M2 ● ●
● ● ●
P
●
● ●

9
●
8
31 ● X ● X
P1
Q4 ● ● ● ●
▲ M 25 P2
P2
● ● ●
●
●
●
T2 ● ● ●
)( Z
)(
)(
32 ●
)(
Z1
●
)(
● ▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
)(
)(
● ● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
)( X X
▲
→ ●
19
● ● ● ● ● ●
●
33
13
●
✕ 13 B1 A1 B2 A2
X B3 A3X
● ●
●
P P ● SS4
TRAINING MANUAL
●
)( ●
)(
SS4
▲
●
●
●
● +
●
SS5 + ● SD2
●
P B A T 18 39 ●
●
P
●
●
▲
●
- C +
▲
●
▲
●
)(
●
38
●
●
M5 M4
SD1 SD3
● ●
●
●
● ●
●
●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
●
▲
● ●
●
●
▲
● ● ()
M6 M7
35 36 37
●
●
Training center
●
Z
41 40 HYDRAULIC CIRCUIT
14 06 1999 Centre de Formation CASE MONTHYON 921 C

TRAINING MANUAL
HYDRAULIC COMPONENT LAYOUT - 921C

18
8 14
11 34
31
2
5
3 25
38
33 37
13
Description
1 Hydraulic tank 27 Unloading valve

14 Pilot remote control (arm and bucket) 37 Parking brake piston

8.14.00
●
+
1 X ● ● ● ● ●
▲ ST1
11
ST2
● ● ●
SS1
14 ● ● ●
●
15
8 - HYDRAULICS
X
●
P ● ● ●
● M3 ●
● ● ●
● ● ● ●
● ● ●
Q1 Q3 ●
2 Q2 ●
T° ●
●
3 ● ●
▲ ▲ ▲
SS2 SD7 29 )( )( 30
M1 M2 ● ●
● ● ●
P
●
● ●

9
●
8
31 ● X ● X
P1
Q4 ● ● ● ●
▲ M 25 P2
P2
● ● ●
●
●
●
T2 ● ● ●
)( Z
)(
)(
32 ●
)(
Z1
●
)(
● ▲
S2 S3
●
)(
T1
●
●
● ● ● ● ● ● ●
)(
)(
● ● ● ●
● ● ● ●
●
●
● ● ● ● ● ● ● ●
▲
)( X X
▲
→ ●
19
● ● ● ● ● ●
●
33
13
●
✕ 13 B1 A1 B2 A2
X B3
A3X
● ●
●
P P ● SS4
TRAINING MANUAL
●
)( ●
)(
SS4
▲
●
●
●
● +
●
SS5 + ● SD2
●
P B A T 18 39 ●
●
P
●
●
▲
●
- C +
▲
●
▲
●
)(
●
38
●
●
M5 M4
SD1 SD3
● ●
●
●
● ●
●
●
●
- C +
●
- C +
● ●
●
●
● + +
6 7 7
●
●
●
● 34
● ●
●
▲
● ●
●
●
▲
● ● ()
M6 M7
35 36 37
●
●
Training center
●
Z
41 40 HYDRAULIC CIRCUIT

921 C
TRAINING MANUAL

1 Hydraulic tank
2 Dual flow pump
5 Loader valve
5a Inlet plate
5d Bucket section
5f Auxiliary circuit (4 in 1 bucket)
5g End section
6 Bucket cylinder
7 Arm cylinder
8 Cooler by-pass
9 Cooler
11 Hydraulic filter
Q1
18 Steering valve
25 Steering priority valve 2
30 Oil flow restrictor Q1
33 Brake accumulator charging valve Pressure test ports
34 Brake pedal valve
35 Service brake (front) M1 Steering and loader attachment
36 Service brake (rear)) M2 Loader pressure
37 Parking brake) M3 Pilot pressure
38 Combination valve M4 Front brake accumulator
39 Ride control master valve M5 Rear brake accumulator
40 Ride control slave valve M6 Front brake
41 Ride control accumulator M7 Rear brake

SS4 Brake accumulator redundant pressure switches
ST1 Detent switch

8 - HYDRAULICS 21C SERIES WHEEL LOADERS
TRAINING MANUAL
TECHNICAL SPECIFICATIONS
COMPOSNENTS ........................................... 621C 721C 821C 921C
HYDRAULIC TANK
Tank capacity ........................................... dcm3 90 90 90 125
Hydraulic circuit total capacity ........................................... dcm3 153 153 174 232
Tank pressurisation ........................................... bar 0,4 0,4 0,4 0,4
MAIN HYDRAULIC PUMP

Stage displacement Q1 ...................................... cm3 79,5 79,5 88,5 132,8
Stage displacement Q2 ...................................... cm3 34,1 34,1 56,6 73,8
Drive speed ........................................... RPM 2200 2200 2200 2100
Nominal flow at 2200 RPM Q1 .................................. l/mn 175 175 195 278
Nominal flow at 2200 RPM Q2 ................................... l/mn 75 75 124 155
STEERING PRIORITY VALVE

...........................................
Steering relief pressure ........................................... bar 165 / 186 165 / 186 183 / 193 183/193
UNLOADING VALVE
Valve setting ........................................... bar 145 / 158 //////////////////// 145 / 158 ////////////////////
LOADER CONTROL VALVE

Main relief valve ........................................... bar 158 / 165 177 / 184 189 / 199 189 / 199
621C if equipped ........................................... bar 165 / 186
Secondary relief valves for Z bar model (with hand pum):
- Bucket dump (rod end ) ........................... bar 193 / 221 193 / 221 193 / 221 193 / 221
- Bucket roll back (piston end) ........................ bar 193 / 221 193 / 221 193 / 221 193 / 221
- Arm lowering (rod end) ............................ bar //////////////////// //////////////////// //////////////////// ////////////////////
- Arm up (piston end) ........................ bar //////////////////// //////////////////// //////////////////// ////////////////////
- 4 in 1 bucket (rod end) ........................... bar 193 / 221 193 / 221 193 / 221 ////////////////////
- 4 in 1 bucket (piston end) ....................... bar 193 / 221 193 / 221 193 / 221 ////////////////////
LOADER CYLINDERS
- Arm ........................................... mm 76 x 127 x 833 76 x 127 x 833 76 x 152 x 806 101x178x868
- Bucket ........................................... mm 76 x 152 x 544 76 x 165 x 544 89 x 178 x 579 101x203x745
- 4 in 1 bucket ........................................... mm 51 x 101 x 254 51 x 101 x 254 63 x 127 x 355 ////////////////////
STEERING CONTROL VALVE

Type : wide angle (flow amplifyer) ........................................... Closed center Closed center Closed center Closed center
Capacity ........................................... Cm3 573 / 983 573 / 983 737 / 1180 1129 / 1968
Secondary relief valve setting ........................................... bar 224 / 231 224 / 231 224 / 231 228
Steering cylinders ........................................... mm 44 x 76 x 443 44 x76 x 443 44 x 89 x 435 51x102x517
Numbers of steering wheel turn at stop to stop ........................ Rev 3,3 à 5,3 3,3 à 5,3 3,3 à 5,3 3,3 à 5,3
Maximum steering angle ........................................... ±° 40 40 40 40
Time from lock to lock (full RPM) ........................................... sec. 3,3 3,3 2,5
PRESSURE REDUCING VALVE

Setting ........................................... bar 36 / 40 36 / 40 36 / 40 36 / 40
HYDRAULIC FILTER
Clogging indicator pressure .......................................... bar 2,7 2,7 2,7 2,7
By-pass pressure setting ........................................... bar 3,4 3,4 3,4 3,4
COOLER BY-PASS
Pressure setting ........................................... bar //////////////////// //////////////////// 1,7 / 4,1 1,7 / 4,1

TRAINING MANUAL
TECHNICAL SPECIFICATIONS
COMPONENTS 621C 721C 821C 921C
HYDRAULIC BRAKE PUMP

Pump displacement Q3 ................................ Cm3 14 14 14 14
Drive speed ..................................... rpm 2200 2200 2200 2200
Nominal flow Q3 ................................ l/mn 29 29 29 29
BRAKE ACCUMULATOR CHARGING VALVE

Main relief ..................................... bar 185 / 207 185 / 207 185 / 207 185 / 207
Cut out pressure ..................................... bar 190 / 196 190 / 196 190 / 196 190 / 196
Cut in pressure ..................................... bar 134 / 140 134 / 140 134 / 140 134 / 140
SS5 alarm pressure switch ..................................... bar 117 117 117 117
BRAKE ACCUMULATORS
Nitrogene inflation pressure ..................................... bar 55 55 55 55
SS4 redundant accumulator brake pressure ............................ bar 62 62 62 62
RIDE CONTROL ACCUMULATOR

Nitrogene inflation pressure ..................................... bar 31 31 31 31
PEDALE DE FREINAGE
Front service brake pressure (fully actuated)............................. bar 52 / 59 58 / 65 58 / 65 69 / 76
Rear service brake pressure (fully actuated) ............................. bar 48 / 55 55 /62 55 /62 65 / 72
Cycle time with empty bucket

Arm up ..................................... Sec. 5,4 5,4 5,9 6,2
Float position arm lowering .................................... Sec. 4,4 4,6 4,1 3,7
Bucket dump ..................................... Sec. 1,5 1,8 1,6 1,5
Bucket roll back ..................................... Sec. 2,5 2,7 2,1
Cycle time with full bucket

Arm up ..................................... Sec. 5,7 5,9 6,2 6,2
Bucket dump ..................................... Sec. 1,5 1,8 1,6 1,5
COMPONENTs 621CXT 721C XT //////////////////// ////////////////////
CONTROL VALVE on C XT MODELS

Main relief valve (w/o unloading valve) ..................................... bar 155 186 //////////////////// ////////////////////
Main relief valve (w/o unloading valve) ..................................... bar 172
Secondary relief valve with hand pump:
- Bucket dump (piston end).................. bar 103 / 117 103 / 117 //////////////////// ////////////////////
- Bucket roll back (rod end) ...................... bar 193 / 221 193 / 221 //////////////////// ////////////////////
- 4 in 1 bucket (piston and rod end)..... bar 193 / 221 193 / 221 //////////////////// ////////////////////
Empty bucket cycle time

Arm up ..................................... Sec. 5,7 5,9 //////////////////// ////////////////////
Float position arm lowering ..................................... Sec. 4,4 4,6 //////////////////// ////////////////////
Bucket dump ..................................... Sec. 2,9 2,9 //////////////////// ////////////////////
Bucket roll back ..................................... Sec. 2,7 2,7 //////////////////// ////////////////////

TRAINING MANUAL
PRESSURE CHECKS ON 21C SERIES
For all pressure check operations, the hydraulic oil temperature must be at least 54°C (130°F).
❍ This operation is performed with engine running at full engine RPM.
❍ Hold the bucket control lever in the digging position for 30 secondes.
❍ Repeat this operation until the hydraulic temperature reaches 54°C.
❍ Run the engine at low iddle for 2 mn and them stop it
❍ Use the quick coupler fitting E47894 for the pressure point tests M1 - M2 - M3 - M4 - M5 - M6 - M7 already installed .
PILOT PRESSURE CHECK:

1. Stop the engine
2. Operate the brake pedal several times to empty the rear accumulator.
3. Install a pressure gauge (0 - 50 bar) in “M3”.
4. Run the engine at full RPM.
5. Read the pressure which should be between 36 and 40 bar
6. Adjust if necessary.
MAIN RELIEF VAL CHECK

1. Install a pressure gauge(0 - 250 bar) in “Ml1” at the outlet from stage (Ql).
2. Run the engine at full RPM.. 2200 RPM. on 621C - 721C - 821C and 2100 RPM on 921C
3. Operate the bucket roll back function against the stops and keep it here.
4. Read the pressure which should be between :
❍ 621C : 158 and 165 bar w/o unloading valve
❍ 621C : 165 and 186 bar with unloading valve M2
❍ 721C : 182 and 190 bar
❍ 821C : 177 and 186 bar
❍ 921C : 182 and 190bar
5. Adjust if necessary M1
SECONDARY RELIEF VALVE

1. This must be done using a pressure setting pump.
2. Connect the pressure setting pump between the control valve port and the cylinder
3. Operate the pump and read the pressure which should be between :
❍ 621C - 721C - 821C - 621CXT - 721CXT : 193 and 221 bar
❍ 921C : 214 bar
❍ On 621C XT - 721C XT : between103 and 117 bar on piston end port
UNLOADING VALVE CHECK item 27 (on 621C et 821C)

1. Install a pressure gauge(0 - 250 bar) in “Ml2” at the outlet from stage (Q2).
2. Run the engine at full RPM..
3. Operate the bucket roll back function against the stops.
4. Slowly operate the remote control lever and observe the pressure increase.
5. Read the pressure which should be between: 145 and 158 bar ; then the pressure should fall down to zero.
6. Perform several times the step 4. to check that the unloading valve operates properly .
STEERING PRESSURE CHECK

1. Install a pressure gauge(0 - 250 bar) in “Ml1” .
2. Run the engine at full RPM.
3. Turn the steering against the left and right stops
4. Read the pressure which should be between : 176 and 184 bar
5 If the pressure is incorrect, adjust the relief valve located in the steering priority valve (Item25)

TRAINING MANUAL
HYDRAULIC TANK
The tank (1) , which is of welded construction, contains hydraulic 4 5 621C

1 6
fkuid which is necessary for the attachment, steering circuit, pilot 721C
circuitand and brake circuit.
821C
It is pressurized at 0,4 bar.
This pressure is obtained by changes in the level of the hydraulic in
the tank. The pressure is controlled by a savety valve (set to 0,4 bar).
included in the vent. 3
2
In any operation is to performmed on the tank or on the hydraulic
circuit, stop the engine and de-pressurize the tank by gradually
unscrewing the filler cap (4).
Description
1 Tank
2 Service access plate
3 O-ring
4 Filler cap
5 Oil level gauge
6 Suction screen
7 Drain plug
8 Vent
Tank level check 7
Place the machine on a flat level ground.

The arm must be in the transport position, with the bucket flat on the
ground .
If the oil is cold, the level should be in the lower quarter of the sight
gauge. 4 921C
If the oil is warm, the level should be in the upper three quarters of
the sight gauge.
1
8 2 3
7

TRAINING MANUAL
HYDRAULIC PUMP 621C - 721C - 821C - 921C

This is a two stage , fixed flow balanced vane pump. It is mounted on the gear box and driven by the transmission PTO.
Description 1
3 2
1 Housing
2 Outlet Q1
3 Outlet Q2
4 Cartridge including ring, rotor
and vanes
5 Cartridge including ring, rotor
and vanes
annulaire, rotor et palettes
4 5
3
SUCTION
Vane in contact
with the small
Vane pusher receiving the discharge
diameter of the
pressure pump rig sealing
A the suction and
discharge orifice
SECTION A-A
DISCHARGE

TRAINING MANUAL
UNLOADING VALVE (27) 621C 821C
Description
1 Unloading valve body
2 Main valve (piloted check valve)
3 O-ring
4 O-ring
5 Backup ring
6 Backup ring
7 O-ring
8 Pilot valve
9 Ring
10 O-ring
11 O-ring
12 Backup ring
13 Backup ring
14 O-ring
15 Check valve
16 O-ring
17 O-ring
18 Backup ring
T8 P8
2 2a
S8
8a 15
8

TRAINING MANUAL
UNLOADING VALVE (27) 621C - 821C
Description
It varies the feed flow onthe loader attachment function
depending upon the hydraulique power which is being
used. 2a
8a
Operationnal principale
Pressure below158 bar
Flow Q2 enters block at (P8), opens and passes

through the check valve (15) and feeds the loader
attachment fuction.
The feed pressure acts on piston (8a) of the pilot valve T8

and on the front and rear section of spool (2a).
➧ ➧
Spool (2a) cannot open because the position of the
piston (8à) prevents the chambers on the spring side of
the spool (2à) from emptying to the tank.
➧ ➧
➧ ➧ ➧
In this case the attachment function treceives both flows
(Q1) and (Q2).
P8
➧
15
S8
Pressure over158 bar
2a
The pressure acts on piston (8à). 8a
The resultant movement of this piston connects the rear
of the spool chamber (2a), via internal ports, with the
return to the tank.
➧ ➧ ➧
Because the pressure is lower on the spring side, the
main spool (2a) opens and allows the flow (Q2) to pass ➧ ➧ ➧
➩
directly to the tank.

➧
➧ ➧ ➩
T8
➧
➧
➧
The check valve is closed by the pressure present at
➧
(S8).
➩
In this case the attachment function only receives flows
(Q1)
➧
P8
➧ ➧
➧
15
➧
S8
TRAINING MANUAL
ATTACHMENT CONTROL VALVES (5) - 621C- 721C - 821C - 921C
5c
5a
5h
5j
5h
5b
5h
5d
5e
5h
5f
5g
11
P1 T1
Z1
ZB1 B1 A1 ZA1
ZB2 B2 A2 ZA2
ZB3 B3 A3 ZA3
Specifications ................................................................................................... TIGHTENING TORQUES
Nuts (item 11)... ..............................................................................................................= 68 to 81 Nm

For disassembly and reassembly see SERVICE MANUAL: .......................................... 8005-3

TRAINING MANUAL
ATTACHMENT CONTROL VALVES (5) - 621C - 721C- 821C - 921C

5a - Inlet plate Z1
P1
P1. Flow inlet (Q1).
T1. Outlet to filters and tank
Z1. Inlet to counter-pressure valve pilot.
U2
T1
5b - Main relief valve
RA U1 RB
5c - Counter-pressure valve
5d - Section which feeds the bucket function

5a - Inlet plate
ZA1 - A1. Pilot and feed to bucket cylinder large chamber
5c - Counter-pressure valve
ZB1 - B1. Pilot and feed to bucket cylinder small chamber
5e - Section which feeds the raising and A1 B1
lowering of arms and the “floating arm”

function.
ZA1 ZB1
ZA2 - A2. Pilot and feed to small chambers of arm
cylinders and “floating arm” function.
ZB2 - B2. Pilot and feed to arm cylinder large chambers.
5f - Section which feeds the auxiliary function.

ZA3 - A3. Pilot and feed to options. 5f - Section which feeds the auxiliary function
ZB3 - B3. Pilot and feed to options. 5h - Secondary safety valve fitted with forced-feed valve
5g - End plate
5h - Secondary safety valve fitted with forced- A2 B2
feed valve.
5i - Plug ZA2 U2 ZB2
Note: Some machines may be fitted with a fourth section to

feed a second option. In this case the fourth section is
the same as the third.
5e - Section which feeds the raising and lowering of the

arms and the “floating arm” function.
5h - Secondary safety valve fitted with forced-feed valve.

TRAINING MANUAL
ATTACHMENTS CONTROL VALVE (5) - 621C XT- 721C XT
P1 T1
Z1
ZB1 B1 A1 ZA1
ZB2 B2 A2 ZA2
ZB3 B3 A3 ZA3
11
Specifications ................................................................................................. TIGHTENING TORQUES
Nuts (item: 11)... .............................................................................................................= 68 to 81 Nm

For disassembly and reassembly see SERVICE MANUAL:... ........................................ 8005-

TRAINING MANUAL
ATTACHMENT CONTROL VALVE (5) - 621C XT- 721C XT

5a - Inlet plate
P1
P1. Flow inlet (Q1).

T1. Outlet to filters and tank
U2
T1
RA U1 RB
5a - Inlet plate
5d - Section which feeds the bucket function A1 B1
ZA1 - A1. Pilot and feed to bucket cylinder large

chamber
ZA1 U2 ZB1
ZB1 - B1. Pilot and feed to bucket cylinder small
chamber
A2 B2
5e - Section which feeds the raising and
lowering of arms and the “floating arm”
function.
ZA2 U2 ZB2
ZA2 - A2. Pilot and feed to small chambers of
arm cylinders and “floating arm”
function.
ZB2 - B2. Pilot and feed to arm cylinder large
chambers.
5e - Section which feeds the arm function
5f - Section which feeds the auxiliary function. A 13 B 13
ZA3 - A3. Pilot and feed to options.

ZB3 - B3. Pilot and feed to options. Z A 13 3
ZB1
5g - End plate
5h - Secondary safety valve fitted with forced-

feed valve.
5f - Section which feeds the auxiliary function
5j - Forced-feed valve (fitted only on models
621B XT and 721B XT)
Note: Some machines may be fitted with a fourth

section to feed a second option. In this case the
fourth section is the same as the third.
5j - Forced-feed valve

TRAINING MANUAL
INLET PLATE(5a) - 621C - 721C - 821C - 921C

Description
5a Inlet plate assembly
2
1. Inlet plate body
2. Valve body
3. Pilot piston 5c 3
4. Valve
5. Locking ring
6. O-ring 4
5b Main relief valve 5a 5

5c Piloted counter-pressure valve
(not fitted on models 621B XT - 721B XT)
6
Ports:
P1. Flow inlet Q1 (for 621B and 721B) 1
Flow inlets Q1 and Q2 (for 821B) 5b
U1. Free passage
U2. Feed to section (5d)
RA-RB Return manifolds
T1. Outlet to tank
Z1 5c 5a 5b
P1
U2
T1
RA U1 RB
Specifications
For disassembly and reassembly of the counter-pressure valve (5c) see SERVICE MANUAL: ... ...............8005-24

TRAINING MANUAL
INLET PLATE (5a) 621C - 721C - 821C - 921C
Flow (Q1) arrives at (P1) from the pump which passes

through free passage (U1) and into (U2) which feeds the
first section.
Flows (Q1 and Q2) arrive at (P1) from the pumps and then
pass through free passage (U1) and into (U2) which feeds
the first section.
The feed pressure is controlled by the main relief valve (5b).
Manifolds (RA-RB) receive the return flows from the

attachment functions and also released flow from the
various safety valves.
After passing through valve (5c), when not piloted, these

return flows pass through the filters and into the tank via
orifice (T1).
VALVE PURPOSE (5C)

Control of the unloading speed
During the unloading phase, to avoid the load opening the
bucket too quickly, valve (5c) receives at (Z1) the pilot
pressure (ZB1) from the bucket section. This creates a
counter-pressure on the return circuit and slows the speed
at which the cylinder rod retracts.
Forced-feed to the small chamber is done by the safety

valve forced-feed (5h).
(see function page: 8.39.00)
General forced-feed
During the arm lowering phase, the feed flow may be
insufficient.
To avoid cavitation, forced-feed must be performed.
The general forced-feed function is done by the main relief
valve (5b).
(see function page: 8.35.00)
Inlet plate (5a) 621C XT and 721C XT
This inlet plate is fitted with a main relief valve (5b) and
forced-feed.
The counter-pressure valve (5c) is not fitted.
Spécifications
For disassembly and reassembly of the counter-pressure valve (5c) see SERVICE MANUAL: ... ...............8005-

TRAINING MANUAL
MAIN RELIEF VALVE (5b)
Description
1. Washer
2. Nut
3. Pressure setting screw
4. O-ring
5. Spring
6. Pilot valve
7. Body
8. O-ring
9. Valve seat
10. O-ring
11. O-ring
12. Seal support
13. Stop ring
14. Spring
15. Sleeve
16. O-ring
17. O-ring
18. Seal support
19. Stop ring
20. Filter
21. Tube
22. Primary valve
23. Body
24. O-ring
25. O-ring
26. Seal support
6 22
H
S
B A
T RB P

TRAINING MANUAL
MAIN RELIEF VALVE (5b)

Description
24 23 26 25
Operation
It limits the feed pressure on the Loader attachment

functions.
It is a pilot operated relief valve, this means that the

opening of valve (22) is controlled by the opening of the
pilot valve (6).
The oil, under pressure, acts on the front section of (A)

and passes through the orificet (H) to the section (B) of
valve (22) and also to section (S) of the pilot valve (6).
When the pressure reaches the needle valve opening
pressure setting, the oil escapes via the needle valve from
11
(B) to (T) but also from (A) to (B) via orifice (H).
This creates a loss of pressure between the two 12

chambers.
10
The pressure at (A) now being greater, valve (22) opens
and allows the flow to pass back to the tank. 7
General forced-feed function
During the arm lowering phase, the feed flow can be

insufficient.
To avoid cavitation on the small chambers side, forced- 15 22 20

feed function is performed.
When the pressure at (P) and therefore at (B) becomes

zero, the counter- pressure created in the return manifold
(RB) pushes on the annular section of the sleeve (15)
which moves backwards, pulling with it the primary valve
(22).
The forced-feed flow in (RB) is then connected with the

feed flow at (P).
12 16 17 18
Specifications
The main relief valve pressure setting is performed on the machine.
Run the engine at full speed.
Operate the feed to the bucket cylinder large chamber (digging)
Note the pressure on 621C:... .........................................................................................= 158 to 165 bar
Note the pressure on 621C after JEE0122501:... ...........................................................= 165 to 186 bar
Note the pressure on 721C:... ........................................................................................= 177 to 174 bar
Note the pressure on 821C:... ........................................................................................= 189 to 199 bar
Pressure setting is adjusted using the screw (item : 3).

For disassembly and reassembly of the main relief valve (5b) see SERVICE MANUAL:... 8005-28

TRAINING MANUAL
BUCKET SECTION (5d) - 621C - 721C- 821C - 921C
AUXILIARY ELEMENT (5f) - 621C - 721C - 821C - 921C et 621C XT - 721C XT
5h
5h
Description
1. Section body 11. Special screw

2. Three position spool 12. Stop washer
3. Cap screw 13. Spring
4. Washer 14. Spring
5. Cap 15. Stop cup
6. O-ring 16. O-ring
7. Special screw 17. Plug
8. Cap screw 18. O-ring
9. Washer 19. Load holding valve
10. Cap 20. Spring
5h. Secondary safety and forced-feed valve
Specifications ................................................................................................... TIGHTENING TORQUES

The spool screws (items: 7 and 11) are fitted using “LOCTITE 271”... ..........................= 24 to 27 Nm
Cap screws (items: 3 and 8)... ........................................................................................= 12 to 15 Nm
Disassembly and reassembly see SERVICE MANUAL:... .............................................. 8005-06

TRAINING MANUAL
BUCKET SECTION (5d) et BRAS (5e) - 621C XT- 721C XT
ARM SECTION (5e) - 621C - 721C - 821C - 921C
Description
1. Section body 17. Stop washer
2. Spool 18. Spring
3. Cap screw 19. Spring
4. Washer 20. Cup
5. Cap 21. O-ring
6. O-ring 22. Spacer
7. Spacer 24. Seal support
8. Stop washer 25. Centering ring
9. Spring 26. Plug
10. Stop spacer 27. O-ring
11. Cup 28. Load holding valve
12. Special screw 29. Spring
13. Cap screw 30. Plug (forced-feed valve on 621B XT - 721B XT)
14. Washer 31. O-ring
15. Cap 32. O-ring
16. Special screw 33. Seal support
Specifications .....................................................................................................TIGHTENING TORQUES
Spool screws (items: 12 and 16) are fitted using “LOCTITE 271”... ..............................................= 24 to 27 Nm
Cap screws (items: 3 and 13)... .....................................................................................................= 12 to 15 Nm
For disassembly and reassembly see SERVICE MANUAL:.. ........................................................ 8005-15
Démontage et Remontage voir MANUEL DE REPARATION : ....................................... 8005-15
TRAINING MANUAL
SECONDARY SAFETY VALVE AND ANTI CAVITATION VALVES 5h)
Description
1. Washer
2. Nut
3. Pressure setting screw
4. O-ring
5. Spring
6. Pilot valve
7. Body
8. O-ring
9. Sealed seat
10. O-ring
11. O-ring
12. Seal support
13. Locking ring
14. Spring
15. Sleeve
16. O-ring
17. O-ring
18. Seal support
19. Locking ring
20. Filter
21. Tube
22. Primary valve
23. Body
24. O-ring
25. O-ring
26. Seal support
27. Cap
3 6 S 22 H
➠ B
➠ A
Specifications Pressure setting for secondary safety valves is done

using the pressure setting pump.
Note the pressure on 621C - 721C - 821C (all secondary valves)..................................= 193 to 221 bar
Note the pressure on 621C XT - 721C XT (secondary bucket opening valve)... ...........= 103 to 117 bar
Note the pressure for 621C XT - 721C XT (other secondary valves)... ..........................= 193 to 221 bar
Pressure setting is adjusted using the screw (item: 3).
Disassembly and reassembly see SERVICE MANUAL:... .............................................. 8005-28

TRAINING MANUAL
SECONDARY SAFETY AND ANTICAVITATION VALVES (5h)

Operating summary
These valves protect the equipment circuit from excessive pressure,

due to excessive forces on the equipment cylinder during its operation
They also perform the forced-feed function for the bucket operation.
Safety function:
◆ These are pilot operated safety valves, this means that the
opening of valve (22) is controled by the opening of pilot valve (6).
◆ The oil, under pressure, acts on the front section at (A) and via
the orifice (H) on section (B) of valve (22) and, also, on section (S)
of the pilot valve (6).
◆ When the pressure reaches the pilot valve opening pressure
setting, oil escapes via the pilot valve from (B) to (T), and also from
(A) to (B) via orifice (H). B1
◆ This creates a pressure loss between the two chambers.
22 15
◆ Because the pressure at (A) is now higher, valve (22) opens
➡ ➡
and allows the flow to return to the tank.
5h
Forced-feed:
On the BUCKET and AUXILIARY function, forced-feed is performed by

a safety valve (5h).
U2 ➡ ➦
When the load pulls the cylinder rod more quickly than the feed flow
can follow it, the counter-pressure existing in the return manifolds (RB) B
makes up for this lack of flow. ➦
➡
➦
➡➦
When the pressure at (B1) and therefore at (B) becomes zero, the
counter- pressure existing in the return manifold (RB) acts on the
annular section of the sleeve (15) and causes it to move backwards,
➦ RB
pulling with it the primary valve (22).
The forced-feed flow at RB is then connected with the feed flow at (B1)
ANTI CAVITATION VALVE (5j) - 621C XT - 721C XT

On the ARM function on models (XT) the forced-feed function is
performed by two valves (5j).
They function in the same way as the forced-feed function of the safety
valve (5h).

TRAINING MANUAL
BUCKET DUMP
Pilotage
Pilot at ZB1en ZB1 - déversement
- bucket unloading godet
▼
▼ ▼
▼
▼ Z1
P1
U2
T1 ▼
▼ U1
▼
RA RB
▼
●
▼
▼
▼
A1 B1
➡
➡
▼
▼
➡
➡
➥
➦
➦ ➡
ZA1 U2 ZB1
➦
➡
➡
➦
➦
➥
●
RA RB
U1
Spool in neutral
Tiroir position
au neutre

TRAINING MANUAL
BUCKET FUNCTION (continued)
This function is manually controlled (Manu.) by the three position
hydraulic block:
7 Manu
1
Manu
Operate the detent switch (ST1 to B) ●
2
1 - RIGHT-HAND
- Bucket unloading (Manual) Auto
2 - LEFT-HAND
- Bucket digging (Manual)
14a
- Bucket return to level at ground (Auto.)
7 - CENTRAL
- Spool returns to neutral rest position
Position (2) can be controlled automatically (Auto.) by a magnetic

detent :
Move the switch (ST1 to A) this causes the bucket to be automatically

returned to the ground level (see page: 8.43.00)
Operation:
ZB1 piloting: bucket dump (Manual) ST1

Position (1) of the control lever is maintained manually which pilots the
spool at (ZB1). A
The position of spool (2) closes the free passage at (U1).

B
The pump flow arrives at (U2), opens the check (19), passes around
the spool and feeds the small chamber of the bucket at (B1).
The cylinder large chamber return enters at (A1), passes around the
spool and returns to the tank via manifold (RA).
Control of dump speed
During the unloading phase, to avoid the load pulling the bucket too ZB1
fast, the valve (5c) receives at (Z1) the pilot pressure (ZB1) from the
➠
bucket section, which creates a counter-pressure on the return circuit

5c 5a 5b
and slows the speed at which the cylinder rod retracts. Z1
Anticavitation feed P1
The small chamber forced-feed is performed by the forced-feed safety

valve (5h).
(see functioning page: 8.39.00)
U2
T1
RA U1 RB

TRAINING MANUAL
BUCKET ROLL BACK and BUCKET AUTOMATIC RETURN

Pilotage
Pilot at ZA1en ZA1 - position
- position “return"remise
to level”à of
niveau automatique" du godet (Auto)
bucket
m A)
➧
+
W (56) (+)
W (53B) C
SD1
➠
W (56)
W (53B)
14a
▼
C
▼
(+)
B3
▼
▼
▼
▼
▼
▼
▼ 19 ▼
A1 B1
➡
5h 5h
➡
➡
➡
▼
▼ ➦
➡
ZA1 ZB1
➡
U2
➡
➥
➦
➥
➥
● 2
RA RB
U1
Tiroir
Spool au neutre
at neutral position

TRAINING MANUAL
BUCKET FUNCTION (continued)
Function:
7
Pilot ZA1: Bucket forced-feed (Manual) 1
◆ Move the the detent switch (ST1 to B)
Manu ●
2
Position (2) of the control lever is maintained manually which pilots the
Auto
spool at (ZA1).
The position of spool (2) closes the free passage (U1).
The flow from the pump arrives at (U2), opens the check valve (19),
passes around the spool and feeds the large chamber of the bucket
cylinder at (A1). 14a
The return from the small chamber of the cylinder arrives at (B1), passes
around the spool and returns to the tank via manifold (RB).
Automatic bucket return to level (Auto.)
Position (2) can be controlled automatically by a magnetic detent, for this:
◆ Move the detent switch (ST1 to A)

to activate the magnetic detent solonoid (14b) and thus allow
the automatic functions to operate. ST1
Cancellation of this control is done by the proximity detector (SD1) fitted A

on the bucket cylinder.
B
Note
The automatic bucket return to level function can be done simultaneously

with the automatic arm lowering.
4,7 mm
SD1
Specifications
Gap setting for proximity detector (SD1)... .....................................................................= 4.7 mm
Bucket return to level adjustment see SERVICE MANUAL:... ........................................ 9005-09
For disassembly and reassembly of the control block (14a) see SERVICE MANUAL:... 8010-03

TRAINING MANUAL
RAISING AND HEIGHT CONTROL OF ARMS
Piloting aten
Pilotage ZB2:
ZB2position “Raising
: position "Levagearms to controlled
des bras height” (Auto.)
à hauteur contrôlée"(Auto)
ST1 (m A)
➧
SD2
(+)
(+) SD3
c
ST2 (-)
(+)
c
(-)
➠
H
▼
(+) c c (+)
▼
▼
▼
▼
▼
() A2 B2
)(
➡
➡
➡
➡
➦ ➡
ZA2 U2 ZB2
➡
➦
➦
➥
●
RA RB
U1
Spool at au
Tiroir neutral
neutreposition.

TRAINING MANUAL
ARM FUNCTION
This function is controlled by the hydraulic three position block (14b):
Manu
3 7
3 - FORWARD Auto
-
-
Arm lowering (Manual)
Pressure on ground (Manual)
●
- Floating arm (Manual/Auto.) Manu
4
- Return to dig (Auto.)
Auto
4 - REARWARDS
- Arm raising (Manual)
- Raising to controlled height (Auto.)
14b
7 - CENTRAL
- At rest position
Automatic controls:
Positions (3 and 4) can be controlled automatically (Auto.) by
magnetic detents, for this:
◆ Move f the detent switch (ST1 to A) to activate the hydraulic
block electrical coils (14b) and allow the automatic functions to
operate.
◆ Move the switch (ST2) in position:
(to A) This enables the “floating arm” position and the
“return to dig” position to be obtained.
(ST2 to B) This enables the “floating arm” position alone SD2
to be obtained. A
The proximity detectors (SD2 and SD3) limit the minimum and
maximum height of the arms, their positions are adjustable (see B
operators’ manual).
ST1 ST2
SD3
Operation:
Piloting ZB2: Raising the arms (Manual)

Position (4) of the control lever is maintained manually which pilots the spool at (ZB2).
The position of spool (2) closes the free passage at (U1).
The flow from the pump arrives at (U2), opens the check (28), passes around the spool and feeds the arm cylinders large chambers at (B2).
The return from the small chambers enters at (A2), passes around the spool and returns to the tank via manifold (RA).
Raising the arms to controlled height (Auto.)

◆ Operate the switch to the left (ST1 to A)
◆ The position of the switch (ST2) has no importance for this function.
This control enables the control lever (14b) to be electro- magnetically locked in position (4).
The control is cancelled by the proximity detector (SD2) fitted on the left-hand arm pivot.
Specifications
Adjustment of the proximity detector gap (SD2 and SD3)... ...........................................= 4.7 mm
Adjustment of the return to level see SERVICE MANUAL:... ......................................... 9005-15
For disassembly and reassembly of the control block (14b) see SERVICE MANUAL:... 8010-03

TRAINING MANUAL
“FLOATING ARMS” POSITION - “RETURN TO DIG” POSITION

Pilotage
Piloting en
in ZA2
ZA2position
position"bras flottant"
“floating (Auto)
arm” (Auto.)
➧
p A)
SD2
(+) W (56)
(+)
c
SD3
➧
(-)
ST2 (p A)
(+)
W (55B) c
(-)
W (56)
W (55A)
W (54B)
W (56)
(+) c c (+)
➠
➠
▼
B5 B4
▼
▼
▼
▼▼
▼
▼ ▼
▼ ▼
() A2 B2 )(
➡➡
➡➡
▼
▼
ZA2 U2 ZB2
➥
➥
➦
➦
➥
➥
Piloting at ZA2
Pilotage en ZA2 controlled ●
positioncontrôlée RA RB
▼
lowering
position descente U1
A2 B2 9 ▼
▼ ZA2 U2
▼ ZB2
➦
➦
➦
➦

TRAINING MANUAL
ARM FUNCTION (continued)
Operation: Manu
3 7
Piloting at ZA2: Auto
●
“Floating arms” position (Auto.)
◆ Operate the switch (ST1 to A) 4 Manu
◆ Operate the switcht (ST2 to B) Auto
These two controls enable the control lever (14b) to be electro-
magnetically locked in position (3), but cancels the action of the
proximity detector (SD3). 14b
Position (3) maximum position of lever (14b) pilots the spool (2)
completely, which enables a connection between the large chambers
(B2) with the small chambers (A2) via the return manifolds to the tank
(RA-RB).
To cancel the “floating arm” position, pull the lever to the rear or press
the left-hand side of the switch (ST2).
Return to dig position (Auto.)
◆ Operate the switch (ST1 to A)

◆ Operate the switc (ST2 to A)
These two controls enable the control lever (14b) to be electrically
locked in position (3). A
The control is cancelled by the proximity detector (SD3) fitted on the

left-hand arm pivot. B
Controlled arm lowering and pressure on ground ST1 ST2

(Manual)
The intermediate position (3) of the control lever is maintained

manually, which pilots spool at ZA2 (between 0 and 25 bar) until
contact is made with the spring (9).
The free passage closes at (U1).
The pump flow arrives at (U2) opens the retaining valve (28), passes
around the spool and feeds the arm cylinder small chambers at (A2).
The return from the large chambers arrives at (B2), passes around the
spool and returns to the tank via manifold (RB).
SD3

TRAINING MANUAL
ARM CYLINDERS (7) 621C - 721C
Description
1 Extruded tub cylinder

2 Ring
3 Seal
4 Bearing screw
5 Scraper seal
6 Seal
7 Seal
8 Carrier ring
9 Back up ring
10 O-ring
11 O-ring
13 Rod
14 Back up ring
15 O-ring
16 Piston
17 O-ring
18 Back up ring
19 Carrier ring
20 Stop dowel
21 Lock ring
Specifications
Démontage et Remontage : Manuel de réparation.................................................................................................... 8006

TRAINING MANUAL
ARM CYLINDERS 821C - 921C (7)
Description
1. Cylinder barrel
2. Ring
3. Seal
4. Bearing screw
5. Washer
6. Cylinder bearing
7. Scraper seal
8. Seal
9. Seal support
10. Carrier ring
11. Seal support
12. O-ring
13. Cylinder rod
14. Seal support
15. O-ring
16. Piston
17. Seal
18. Seal support
19. Carrier ring
20. Stop dowel
21. Locking ring
Specifications
Démontage et Remontage : Manuel de réparation.................................................................................................... 8006

TRAINING MANUAL
BUCKET CYLINDER 621C - 721C - 821C - 921C (6)
Description
1. Cylinder body
2. Ring
3. Seal
4. Bearing screw
5. Washer
6. Cylinder bearing
7. Scraper seal
8. Seal
9. Seal support
10. Carrier ring
11. Seal support
12. O-ring
13. Cylinder rod
14. Ring
15. Seal
16. Seal support
17. 0-ring
18. Piston
19. Seal
20. Carrier ring
21. Stop dowel
22. Locking ring
"XT"BUCKET CYLINDER (6)
Description
1. Cylinder barrel
2. Ring
3. Seal
4. Screwed bearing
5. Scraper seal
6. Carrier ring
8. Seal
9. O-ring
10. Seal support
11. Cylinder rod
12. Piston
13. Seal
14. Seal
15. Carrier ring
16. Piston screw
17. Washer
18. Grease fitting
19. Stop screw

TRAINING MANUAL
HYDRAULIC FILTERS (11)
Description SS1
1. Filter heads
2. Flat washer
3. Nuts
4. Washer
5. O-ring
6. O-ring
7. Clogging pressure switch
8. “By-pass” valve plug
9. O-ring
10. “By-pass” valve assembly
11. Filter cartridges
12. O-ring
Specifications
For disassembly and reassembly: Repair Manual... ..................................................................................................

TRAINING MANUAL
HYDRAULIC FILTERS (11) and OIL COOLING - 621C - 721C - 821C
FILTERS
To obtain the best operation and the best conditions for
all components, it is very important to ensure that the
hydraulic fluid is filtered via the two filter cartridges (11).
SS1
In addition, the clogging pressure switch (7) indicates, by
the warning light (H5) and the audible warning which 7
sounds for three seconds, that the filters are beginning to
be clogged.
In case the cartridges become completely clogged, a “by-

11
pass” valve (10) prevents the filters bursting.
Non-return valves (13) protect the circuit from pollution

contained in the filters when the “by-pass” valve opens.
H5
It also means that the reservoir does not have to be
drained when changing the oil filter cartridges.
HYDRAULIC OIL TEMPERATURE
The temperature of the hydraulic circuit is sensed by the H8

sensor (SS1) located at the inlet to the filters.
If the temperature is too high (about 85°C) the sensor

transmits the information electrically to the instrument
panel:
On 621C - 721C - 821C models, the hydraulic oil cooler is

located above the engine.
SS2
The cooling flow is from the general return.:

TRAINING MANUAL
HYDRAULIC COOLER BY-PASS (8) 621C - 721C
An internal restrictor limits the cooling flow.

The temperature sender SS2 is located as shown.
8
SS2
HYDRAULIC COOLER BY-PASS (8) - 821C - 921C
his prevents the oil being cooled before it has reached the normal operating temperature. In this case the return circuit is directed to the filters
and the tank.
Description
1. Screw
2. Flange
3. O-ring
4. Spring
5. Piston
6. By-pass body

RAINING MANUAL
COMBINATION VALVE WITH PILOT PRESSURE REDUCTION VALVE
Description
The pressure reducing valve is fitted into the combination valve
with the parking brake solenoids and the pilot pressure
solenoid.
1 Parking brake solenoid valve ACF
2 Lock out pilot pressure solenoid valve
3 Pressure reducing valve set at 40 / 43 bars. PS1F
ACR
The purpose of this pressure reducing valve is to maintain a
constant pressure in the hydraulic control lever’s pilot circuit (14 - PS1R
15) regardless of it’s supply pressure.
In case of engine failure, it receives the reserve oil under

1 3 2
pressure from one of the brake circuit accumulators.
T
3 PP
AUX
PB
FB RB
RB
PP
Spécifications
Pressure reducing valve setting ................................................................................................................................= 40 to 43 bar
Resistor value of the lock out pilot pressure solenoid valve (2) ................................................................................= 28 Ohm
Resistor value of the coils of the park brake solenoid valve checked at the connector ...........................................= 19 Ohm
For disassembly and reassembly: see Repair Manual.........................................................................................

TRAINING MANUAL
HYDRAULIC CONTROL VALVE (14)
PP
B A C
Description
1 Coils for attachment automatisms

T Tank
PP Piloting pressure (40 to 43bar)
D Arm lowering
B Arm raising
A Bucket dump
C Bucket roll back
Specifications
Coil item 1 : Resistor value at 20°C.......................................................................................................................= 84,5 Ohm
For disassembly and reassembly: see Repair Manual.........................................................................................8010

Centre de formation
RN 330 Penchard
77122 MONTHYON
FRANCE
Tel : (33)1-64-36-54-70
Fax : (33)1-64-36-54-89

Wheel Loader Training Manuel

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Wheel Loader Training Manuel

Caricato da

Copyright:

Formati disponibili

WHEEL LOADER

“21C SERIES” WHEEL LOADERS PRESENTATION ............................................1.02.00

DRIVING POSITION ..............................................................................................1.06.00

CONTROLS AND SAFETY FEATURES ..............................................................1.08.00

CHECKING THE GENERAL CONDITION OF THE MACHINE ............................1.10.00

SERVICING PRODUCT GUIDE ............................................................................1.12.00

Training Center 1.1.00

“21C SERIES” WHEEL LOADERS PRESENTATION

1.2.00 Training center

“21C SERIES” WHEEL LOADERS PRESENTATION

Two types of attachment geometry are offered :

✸ on 621C - 721C - 821C -921C "Z" bar geometry

STABILITY AND MANOEUVRABILITY

COMFORT AND SIMPLICITY

Training center 1.3.00

MACHINE TYPE 621C 721C 821C 921C

Bucket width ....................................................m 2,50 2,50 2,75 3,20

Break-out force ................................................daN 10780 14970 15225 20300

1.4.00 Training center

The undercarriage is made from two welded box sections.

❍ 621C : 391 mm ❍ 721C : 412 mm

1SRT 2ND 3RD 4TH

621C 7,0 / 7,4 13,5 / 14,2 23,6 / 24,9 37,4

The “parallel arm” version is used for special attachments.

Training center 1.5.00

1. Speed change and direction change lever (SP3)

3. Parking brake control switch

4. Engine accelerator pedal.

ATTACHMENTS CONTROL LEVERS

6 Cross-pattern control lever 2

1.6.00 Training center

19. Detent switch (ST1)

21. Bucket quick hitch locking switch (ST3).

23 Air conditioning system control.

Training center 1.7.00

DRIVING POSITION - INSPECTIONS AND SAFETY ITEMS

Lights and bar graph lights

1.8.00 Training center

Training center 1.9.00

CHECKING THE GENERAL CONDITION OF THE MACHINE

■ CHECK THE ENGINE SPEED

621C & 621CXT 721C & 721CXT 821C 921C

■ PERFORM “STALL” TEST

1.10.00 Training center

MAINTENANCE OPERATIONS ON 21C SERIES WORKING HOURS MAINTENANCE INTERVALS

Check the engine oil level.................................................... ●

Check hydraulic oil level ...................................................... ●

Lubricate loader pivots......................................................... ●

Change engine oil................................................................ ●

Change the fuel filter............................................................ ●

Adjust valve rockers............................................................. ●

Change axle oil .................................................................... ●

Clean engine air filter........................................................... ●

Training center 1.11.00

Fuel tank 193 l. 204 l. 272 l. 394 l No 2 diesel fuel

Axles (old type) ZF AP ZF AP ZF AP GKN

Axles (new type)

A/C circuit 1,6 kg 1,6 kg 1,6 kg 1,6 kg Fluide HFC134a

1.12.00 Training center

FUSES, RELAYS, AND OTHER ELECTRONIC COMPONENTS (DESCRIPTION / SPECIFICATION).................................. 4.03.00

ELECTRICAL SCHEMATIC ....................................................................................................................................................... 4.04.00 to 4.17.00

Training center 4.1.00