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1001

Section
1001

SAFETY, GENERAL INFORMATION


AND TORQUE SPECIFICATIONS

Copyright © 1999 Case France


Cre 7-56942GB Printed in France
Case Issued November 1999
1001-2

TABLE OF CONTENTS
SAFETY..................................................................................................................................................................... 3
TWIN WHEELS ......................................................................................................................................................... 5
Safety rules ........................................................................................................................................................... 5
Safety instructions................................................................................................................................................. 5
GENERAL INFORMATION .......................................................................................................................................6
CORRECT USE OF TORQUE WRENCHES ............................................................................................................ 7
HARDWARE TIGHTENING ORDER ........................................................................................................................ 8
STANDARD SCREW A TORQUE SPECIFICATIONS.............................................................................................. 9
Correct screw identification ................................................................................................................................... 9
METAL CAP REFERENCES...................................................................................................................................10
PLASTIC PLUG AND CAP REFERENCE CHART .................................................................................................11

Cre 7-56942GB Issued 11-99


1001-3

SAFETY

WARNING: This symbol means WARNING ! BE VIGILANT ! YOUR SAFETY IS AT RISK. The message
that follows the symbol contains important safety information. Read it carefully. Be sure you understand
! the possible risks of injury or even death.

To avoid all risks, always follow the safety notes con-


tained in this section and throughout this manual. WARNING : Prior to starting up the engine
read the safety messages contained in the
Put the warning tag shown below on the key for the operator’s manual carefully. Read all safety
keyswitch when servicing or repairing the machine. stickers on the machine. Have people move
One warning tag is supplied with each machine. back from the machine. Learn how to use the
Additional tags, Part Number 321-4614, are available controls before starting up the machine. It is
from your service parts supplier. ! your responsibility to follow the manufacturer’s
instructions on how to operate and maintain
the machine. It is your responsibility to follow
applicable rules and regulations. Service and
Operator’s Manuals are available from your
J.I. Case Dealer.

WARNING: If you wear loose clothing or if


you omit to use safety equipment for your
work, you risk injury. Always wear clothes
that do not risk getting caught in the
! machine. Other safety equipment may be
necessary, in particular : helmets, safety
shoes, ear plugs, safety glasses, protection
mask, thick gloves and reflecting clothes.

WARNING: When working close to the fan


with the engine running, avoid wearing loose
PDG0328
! clothing and operate with extreme caution.
WARNING: Read the Operator’s Manual
carefully and make sure you understand how WARNING: When checking the hydraulic cir-
! cuits, follow procedures to the letter. DO
to operate the controls correctly. ! NOT CHANGE procedures.
WARNING: Never operate the machine and
attachment controls unless you are seated in
the operator’s seat. If you are not in the
! operator’s seat, you run the risk of serious
injury.

WARNING: The machine is built to carry the


operator only. Do not allow passengers to
! ride on the machine.

Cre 7-56942GB Issued 11-99


1001-4

WARNING: Prior to operating the hydraulic WARNING: When performing maintenance


cylinders of this machine for setting or to or repair operations on the machine, make
! bleed the circuit, have all people standing sure that the work shop floor, the cab and
around the machine move away. the steps of the excavator are free from oil,
! water, grease, tools etc. Use oil absorbing
material or rags as necessary. Always think
WARNING: Wear gloves or insulated mittens
safety.
! when working on hot parts.

WARNING: Certain components of this


WARNING: Lower all attachments to the machine are very heavy. Use hoisting tools
ground or rest them on stands before carry-
! ing out maintenance jobs.
! or additionnal assistance as recommended
in this manual.

WARNING: Fine sprays of hydraulic oil WARNING: Exhaust fumes can cause death.
under pressure can penetrate the skin and If it is necessary to start up the engine in a
cause serious infection. If hydraulic oil under closed building, evacuate exhaust fumes
pressure penetrates the skin, see a doctor ! using an exhaust pipe extension. Open the
immediately. Maintain all hoses and pipes in doors and let fresh air into the building.
good condition. Make sure that all connec-
! tions are properly tightened. Change all
hoses or pipes that have been damaged or WARNING: When battery liquid is frozen,
that are suspect. DO NOT CHECK for leaks the battery can explode if : (1) you try to
with bare hands. Use a piece of cardboard charge the battery or (2) you try to start the
or wood. engine by connecting an auxiliary power
! source. To prevent battery electrolyte from
freezing keep the battery fully charged. If
WARNING: To remove a hardened pin such you do not follow these instructions, you or
as a pivot pin, or a hardened shaft, use a others nearby may be injured.
soft head hammer (brass or bronze) or a
! brass or bronze strip and a steel head ham-
mer. WARNING: Batteries contain acid and explo-
sive gases. A spark, a flame or an improper
cable connection may cause an explosion.
WARNING: When using a hammer to For proper connection of cables to the bat-
remove or reassemble pivot pins, or when ! tery of this machine see the Operator’s Man-
using compressed air, or when using a
! grinder make sure to wear safety glasses
ual. If you do not follow these instructions,
you risk severe injury.
that protect the eyes from all sides.

WARNING: Use proper lifting/hoisting equip-


ment to lift wheels or tracks and always work
! on safe ground. Prevent the machine from
moving using correct safety chocks.

Cre 7-56942GB Issued 11-99


1001-5

TWIN WHEELS
Safety rules Safety instructions
WARNING: In all cases, before removing twin • Use appropriate, good quality tools to disassemble
! wheels, always deflate both tyres completely. the various wheel components. Never use a ham-
mer. Use a rubber, plastic or copper-faced mallet.

WARNING: If a tyre bursts it can cause seri- IMPORTANT: Never remove the inner tyre valve
ous injury. Check tyres regularly to see that extension, as this will be necessary afterwards for
! they are in good condition and always be sure inflating and deflating the tyre.
to inflate them to the correct pressure. IMPORTANT: If the valve or the valve extension are
no longer accessible, take the necessary precautions
WARNING: Never face a tyre when checking and then, imperatively, puncture the tyre.
pressure or adding air. Always stand in front of • Use suitable grease to facilitate the installation and
the tread. Use an inflation cage if the wheel removal of the tyre.
! has been removed from the machine. Make
sure all people standing in the area move well • Never re-inflate a tyre on the machine which has
away. been used at a pressure lower than 5.6 bar.
• Check the various components: tyre, rim, shoulder,
WARNING: Never weld near a tyre.If this can retaining ring and replace any defective items.
! not be avoided, it is mandatory to remove the
tyre before performing any welding operations.
• Never reuse a retaining ring which is distorted or
rusty.

WARNING: Make sure that all decals on the


machine are perfectly legible, clean them regu-
! larly and replace any decals which are dam-
aged, missing or painted over, with new ones.

Cre 7-56942GB Issued 11-99


1001-6

GENERAL INFORMATION
CLEANING SEAL RINGS, O-RINGS, GASKETS
Clean all metal parts except bearings with white spirit Always use new seal rings. O-rings and gaskets.
or steam. Do not use caustic soda when steam Coat sealing rings and O-rings with vaseline.
cleaning. After cleaning, dry and lubricate all parts.
SHAFTS
Clean hydraulic lines with compressed air. Clean
bearings with kerosene, then dry them and lubricate Check all shafts showing signs of wear or damage.
them. Check that the surface of a shaft running in a bearing
is not damaged.
INSPECTION
SPARE PARTS
Check all parts when disassembled. Change all parts
showing wear or damage. Scratches that are not too Always use original CASE spare parts. To order
deep can be removed by honing or with a rag dipped spare parts, see the Spare Parts Catalogue to indi-
into buffing compound. A full visual inspection to cate the proper reference of original CASE spare
detect wear and pitting and subsequent changing of parts. Failures caused by the use of parts that are not
parts will prevent premature failure. original CASE spare parts are not covered by the
warranty.
BEARINGS
LUBRICATION
Check that bearings rotate freely. If their adjustment
is too loose or if they do not run regularly, change Use only oils and lubricants specified in the Opera-
them. Wash bearings with a good solvent or kero- tor’s and Service Manuals. Failures due to the use of
sene and let them dry. DO NOT DRY BEARINGS oils and lubricants not specified are not covered by
WITH COMPRESSED AIR. the warranty.
NEEDLE BEARINGS
Before inserting needle bearings into a bore, remove
all metal particles from the edge of the bore. Prior to
mounting bearings with a press, coat the inside and
the outside of the bearing with vaseline.
GEARS
Check all the gears for wear or damage. Change
worn or damaged gears.

Cre 7-56942GB Issued 11-99


1001-7

CORRECT USE OF TORQUE WRENCHES


TORQUE
Setting pointer Adjusting lever
WRENCHES Leverage point handle

Manipulator

1/2” square insert Extension SJ214, for doubling


capacity of S203 wrenches
Open-ended wrench
PDG0315

CORRECT USE

NO

a - Hold the wrench by the handle


provided.

b - When tightening, always keep the


wrench perpendicular to the screw.
NO
HAND

c - Keep one hand on the leverage


point handle on the wrench.

d - Tighten progressively in one


movement.

e - Position a correctly dimensioned


socket or open-ended wrench on the
flats of the screw head.
NO
PDG0316

Cre 7-56942GB Issued 11-99


1001-8

HARDWARE TIGHTENING ORDER


TORQUE
WRENCHES

PDG0317

INITIAL TORQUE

a - Torque wrench.

- Follow the correct order of proce-


dure when tightening.

- Cross or diagonal pattern tightening.

PDG0318

FINAL TORQUE

Always tighten in clockwise order.

PDG0319

Cre 7-56942GB Issued 11-99


1001-9

STANDARD SCREW A TORQUE SPECIFICATIONS


Correct screw identification

Steel grade Steel grade


PDG0320

Torque
Nm lb.ft
Diameter x Key
thread size
Grade 8.8

Two-part hydraulic connector


(to SAE J518 specifications) M5 x 0.8 4 8 5.5 5.5 4.1 4.1
M6 x 1 5 10 9 9 6.7 6.7
M8 x 1.5 6 13 22.5 22.5 16.6 16.6
M10 x 1.5 8 17 45 45 33.2 33.2
M12 x 1.75 10 19 70 80 51.6 59
M14 x 2 12 22 100 120 73.8 88.6
M16 x 2 14 24 170 200 125.5 147.6
M18 x 2.5 14 27 250 300 184.5 221.4
M20 x 2.5 17 30 350 400 258.3 295.2
M22 x 2.5 17 32 500 600 369 442.8
M24 x 3 - 36 600 700 442.8 516.6
M27 x 3 - 41 900 1000 664.2 738
M30 x 3.5 - 46 1200 1400 885.6 1033.2
PDG0321
Components assembled by
screws and bolts Grade 10.9
SCREW M5 x 0.8 4 8 75 75 5.6 5.6
M6 x 1 5 10 12.5 12.5 9.3 9.3
M8 x 1.5 6 13 35 35 25.8 25.8
M10 x 1.5 8 17 60 70 44.3 51.6
M12 x 1.75 10 19 100 120 73.8 88.6
M14 x 2 12 22 170 200 125.5 147.6
M16 x 2 14 24 250 300 184.5 221.4
M18 x 2.5 14 27 350 400 258.3 295.2
M20 x 2.5 17 30 500 600 369 442.8
M22 x 2.5 17 32 700 800 516.6 442.8
M24 x 3 - 36 900 1000 664.2 738
M27 x 3 - 41 1200 1400 885.6 1033.6
M30 x 3.5 - 46 1700 1900 1254.6 1402.2
BOLT
PDG0322

Zinc bichromate
Phosphate

Cre 7-56942GB Issued 11-99


1001-10

METAL CAP REFERENCES


To SAE J518 specifications

NP 250 bar NP 400 bar Part number


Ø ND Ø ND
A B

13 mm - D5327838 E5327839
19 mm - F5327840 G5327841
25 mm - H5327842 J5327843
32 mm - K5327844 L5327845
38 mm - M5327846 N5327847
- 13 mm U5327830 V5327831
- 19 mm W5327832 X5327833
- 25 mm Z5327834 A5327835
- 32 mm B5327836 C5327837

PDG0323

NP = Nominal pressure
NP = Nominal diameter

Cre 7-56942GB Issued 11-99


1001-11

PLASTIC PLUG AND CAP REFERENCE CHART


Dia. x pas Part number Dia. x pas Part number

Tapped orifices and connectors with tighten-


ing nuts = screw-type plugs
M10 x 1.5 F3237416 M20 x 1.5 L3237421
M12 x 1.5 G3237417 M22 x 1.5 M3237422
M14 x 1.5 H3237418 M24 x 1.5 N3237423
M16 x 1.5 J3237419 M27 x 2 Q3237448
M18 x 1.5 K3237420

PDG0324

Unions = Screw-type plugs


M12 x 1.5 X3237409 M20 x 1.5 C3237413
M14 x 1.5 Z3237410 M22 x 1.5 D3237414
M16 x 1.5 A3237411 M30 x 1.5 E3237415
M18 x 1.5 B3237412

PDG0325

S.A.E tube or hose collars = external plugs NP 250 bar NP 400 bar
30.2 J2537460 31.8 P2537465
38.1 K2537461 41.3 Q2537466
44.5 L2537462 47.6 R2537467
50.8 M2537463 54 S2537468
60.4 N2537464 63.6 T2537469
PDG0326

S.A.E orifices = caps for installation into NP 250 bar NP 400 bar
tapped fitting orifices L= L=
38.1 A2340480 40.5 K1640415
47.65 B2340481 50.8 R1640421
52.35 C2340482 57.15 S1640422
58.07 D2340483 66.7 T1640423
69.85 E2340484 79.4 Z1640479

PDG0327

NP = Nominal pressure
ND = Nominal diameter

Cre 7-56942GB Issued 11-99


1001-12

Cre 7-56942GB Issued 11-99


1002
Section
1002

SPECIFICATIONS
588 CRAWLER EXCAVATORS

Copyright  1999 Case France


Printed in France
Case Cre 7-80591GB November 1999
1002-2

TABLE OF CONTENTS
FLUIDS AND LUBRICANTS .................................................................................................................................... 3
Hydraulic fluid....................................................................................................................................................... 3
Transmission component oil ................................................................................................................................ 3
Grease ................................................................................................................................................................. 3
Engine oil ............................................................................................................................................................. 4
Oil viscosity/Oil range........................................................................................................................................... 4
Fuel ...................................................................................................................................................................... 5
Anti-freeze/Anti-corrosion..................................................................................................................................... 5
Environment ......................................................................................................................................................... 5
Plastic and resin parts .......................................................................................................................................... 5
MACHINE GENERAL SPECIFICATIONS ................................................................................................................ 6
Engine .................................................................................................................................................................. 6
Hydraulic system .................................................................................................................................................. 6
Electrical system .................................................................................................................................................. 7
Upperstructure ..................................................................................................................................................... 7
Cab....................................................................................................................................................................... 7
Operation ............................................................................................................................................................. 7
Undercarriage (depending on version)................................................................................................................. 8
Safety devices...................................................................................................................................................... 8
Indicators.............................................................................................................................................................. 8
Warning and indicator lamps................................................................................................................................ 8
Attachments ......................................................................................................................................................... 8
Noise level............................................................................................................................................................ 8
Ground pressure .................................................................................................................................................. 8
Travel ................................................................................................................................................................... 9
WEIGHTS ...............................................................................................................................................................10
Machine.............................................................................................................................................................. 10
Attachments ....................................................................................................................................................... 10
Counterweight .................................................................................................................................................... 10
Cab..................................................................................................................................................................... 10
BUCKETS ...............................................................................................................................................................11
CLAMSHELLS ........................................................................................................................................................12
MACHINE OVERALL DIMENSIONS ......................................................................................................................13
TRANSPORTATION OVERALL DIMENSIONS .....................................................................................................14

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message that follows, as there is a risk of serious injury.

Cre 7-80591GB Issued 11-99


1002-3

FLUIDS AND LUBRICANTS


Lubricants must have the correct properties for each application.

WARNING : The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid Grease
CASE hydraulic fluid is specially designed for high The type of grease to use depends on ambient tem-
pressure applications and for the CASE hydraulic perature.
system. The type of fluid to be used depends on the
ambient temperature.
Temperate and hot climates
-20°C to +60°C
Temperate climates
EP NLGI grade 2 extreme pressure grease, containing
-20°C to +40°C molybdenum disulphide.
Fluid type ISO VG 46
CASE Reference POHYDR
Cold climates
-40°C to +20°C
Hot climates
EP NLGI grade 0 extreme pressure grease.
0°C to +60°C
Fluid type ISO VG 100
CASE Reference POHYPC
Cold climates
-40°C to +20°C
Fluid type ISO VG 22
CASE Reference POHYPF
These different fluid grades must be in conformity
with CASE France specification P9903201Z.
Temperate country biodegradable fluid :
This yellow fluid is compatible with standard fluid. If
adopted, it is advisable to drain the circuit completely.
Fluid type ISO VG 46
CASE Reference CASYNTH46
This fluid grade must be in conformity with CASE
France specification P9903203B.

Transmission component oil


Extreme Pressure oil is used for all cased transmis-
sion components.
Extreme pressure oil TYPE API GL5 GRADE 80W90
and ISO VG 150

Cre 7-80591GB Issued 11-99


1002-4

Engine oil
CASE No 1 motor oil is the oil recommended for your
engine. This oil ensures correct lubrication of your
engine in all working conditions.
If CASE No 1 Multiperformance or Performance
engine oil cannot be obtained, use only oil of the API/
CE category.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in
this manual are based on tests carried out on CASE
lubricants.
RF97F136

RB97F100

Oil viscosity/Oil range

CS98M561
(A) FAHRENHEIT TEMPERATURE (2) WINTER
(B) CELSIUS TEMPERATURE (3) TROPICAL
(1) ALL SEASONS (4) ARTIC
(*) USE OF AN ENGINE OIL HEATER, OR AND ENGINE COOLANT HEATER IS REQUIRED.

Cre 7-80591GB Issued 11-99


1002-5

Fuel Environment
Use fuel which is to ASTM (American Society for Before carrying out any maintenance operation on
Testing and Materials) D975 standard. this machine and before disposing of used fluids or
lubricants, always think of the environment. Never
Use Grade No 2 fuel. The use of other types of fuel
pour oil or fluid onto the ground and never place it in
can result in a loss of power and may cause high fuel
leaking receptacles.
consumption.
Contact your local ecological recycling centre or to
When the temperature is very cold, the use of a mix-
obtain information on the correct method of disposing
ture of No 1 and No 2 fuel is permitted. See your fuel
of these materials.
vendor for winter fuel requirements in your area.
If the temperature falls below the fuel cloud point Plastic and resin parts
(point at which wax begins to form) the wax crystals
When cleaning polycarbonate windows, the console,
will cause power loss or will prevent the engine from
instrument panel, indicators, etc., do not use petrol,
starting.
paraffin, paint solvents, etc. Use only water, soap and
IMPORTANT : In cold weather, fill the fuel tank at the a soft cloth.
end of the day’s work, in order to prevent the forma-
The use of petrol, paraffin, paint solvents, etc. will
tion of condensation.
cause discoloration, cracks or warping of these parts.
Fuel storage
Long storage can lead to the accumulation of impuri-
ties and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the
temperature of the fuel should be kept as low as pos-
sible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling
system from corrosion and all risk of freezing.
For areas where ambient temperature is over -36°C,
use a blend of 50% ethylene-glycol based anti-freeze.
For areas where the temperature is below -36°C, it is
advisable to use a blend of 40% water and 60% anti-
freeze.

Cre 7-80591GB Issued 11-99


1002-6

MACHINE GENERAL SPECIFICATIONS


Engine
Make and model .................................................................................................................................... CASE 4T 390
Total SAE power rating at 2800 rpm................................................................................................ 79.8 kW (108 hp)
4 stroke, 4 cylinder diesel engine ...........................................................................................................turbocharged
Displacement............................................................................................................................................... 3920 cm3
Bore ................................................................................................................................................................102 mm
Stroke .............................................................................................................................................................120 mm
Cooling ................................................................................................................................................... water-cooled
Battery start ......................................................................................................... Two 12-volt batteries, 24 V, 100 Ah
Working specifications
Speed ...........................................................................................................................................................2000 rpm
Power rating :SAE.........................................................................................................................................68.5 kW (93 hp)
DIN 70020 - DIN 6271...............................................................................................................65 kW (88 hp)
EEC 80/1269 - ISO 9249 ..........................................................................................................65 kW (88 hp)
Performance maintained up to 3000 m altitude at a temperature of 25°C.
Capacities : Oil sump.....................................................................................................................................................10 L
Fuel tank ..................................................................................................................................................150 L
Electric fuel tank filler pump............................................................................................................................ optional
Average hourly consumption ............................................................................................................................. 12 L/h
Engine and pump assembly mounted on rubber blocks.
Heavy-duty dust filtration.

Hydraulic system
Variable flow circuit with all fuinctions independent and simultaneous.
Working pressure ............................................................................................................................................350 bar
Total capacity of hydraulic reservoir ................................................................................................................... 115 L
Total capacity of system ..................................................................................................................................... 184 L
2-body pump :
1 variable displacement body for the attachment and travel circuits ....................................................flow 210 L/min
1 fixed flow body for the upperstructure frame swing .............................................................................flow 44 L/min
Direct drive by flexible coupling.
Installed hydraulic power ................................................................................................................ 55.5 kW (75.4 hp)
Fixed displacement pumps for servo-duties.
Attachment and travel control valves, parallel, closed centre, acting on the “Load Sensing” pump regulation.
Flow rates per function independent of pressures.
Oil cooler with air cooling from engine.
High pressure, multi-spiral hoses
minimum safety factor .............................................................................................. 2 to 4 times working pressure
Self-lubricating hydraulic swivel.

Cre 7-80591GB Issued 11-99


1002-7

Electrical system
System voltage .......................................................................................................................24 volts, negative earth
Batteries .........................................................................................................two 12-volt, low maintenance batteries
All electrical system safety functions are grouped in an electrical cabinet with a printed circuit.
Instrument panel with printed circuit.
Automatic instrument panel lamp testing.
Two-stage alarm system.
Upperstructure electrical power connection (24 V, 15 Amp.).
Battery master switch.

Upperstructure
All welded frame
Modular structure.
Transverse access walkway to different components.
Sound-proofed, lockable cowling meeting all current regulations.
Tool box with tool set.
Swing
Hydraulic motor with reduction gear and automatic static brake.
Swing speed ................................................................................................................................................... 7.6 rpm
Turntable bearing............................................................................................. Alternate rollers, inner ring gear teeth
Bearing race and ring gear tooth lubrication.............................................................................................. centralized

Cab
Removable, sound-proofed, on flexible mounting blocks.
Up and over windshield.
Tinted windshield.
Pre-fitted for radio installation.
Sliding window on door.
Transparent roof hatch ................................................................................................................................... optional
Polycarbonate windows.................................................................................................................................. optional
Cab safety guard .........................................................................................................................available on request
Cab elevator ................................................................................................................................available on request
Anti-vandal cab............................................................................................................................................... optional

Operation
De-luxe seat with armrests and multi-position adjustment (vibration level III/ISO 7096).
Hydraulically assisted controls.
Attachment and swing .................................................................................................................................... 2 levers
Travel............................................................................................................................................................. 2 pedals
Speed programmer, also providing automatic speed range change on the two-speed version.
Single-speed windshield wiper, plus intermittent action, windshield washer, heating system, de-frosting, two-speed venti-
lation, cab light, cigarette lighter, sun shield.
Working/lights :
On upperstructure ................................................................................................................................2 x 70/75 W
On attachment................................................................................................................................................ 70 W
Rear (on cab) ................................................................................................................................................. 70 W
Front (on cab)............................................................................................................................................. optional
Air conditioning ............................................................................................................................................... optional
Cab visor ........................................................................................................................................................ optional
Cab fan ........................................................................................................................................................... optional

Cre 7-80591GB Issued 11-99


1002-8

Undercarriage (depending on version)


Monoblock chassis, with all-welded sections.
Permanently greased rollers.
Tractor type tracks; track tensioning by grease cylinders; shock absorber.
Removable drive sprocket ring gears.
Front chain guide (rear guide optional).

Safety devices
In the event of engine failure, the attachment can be lowered, under control, to the ground.
Cancellation of controls by lifting the left-hand control arm.
Tinted safety-glass windows, horn.
Cab safety guard .........................................................................................................................available on request
Safety valves .................................................................................................................................................. optional
Overload indicator .......................................................................................................................................... optional
Inertia type safety belt .................................................................................................................................... optional
Fire extinguisher ............................................................................................................................................. optional
Rotary light ...................................................................................................................... specific to certain countries

Indicators
Engine coolant solution temperature, hydraulic fluid temperature, fuel level and hourmeter.

Warning and indicator lamps


Engine oil pressure, battery charge, hydraulic oil filter and engine air filter restriction.
Warning/indicator lamp test.

Attachments
Sealed linkaged, all linkages greased from ground level or from the walkway.
Double acting cylinders fitted with end-of-stroke shock absorbers

Noise level
Certified by the manufacturer.
In accordance with European directive 86/662/EEC.
Internal noise level (LpA)...........................................................................................................................77 decibels
External noise level (LwA) ...................................................................................................................... 101 decibels

Vibration levels in operator’s cab


Lower limbs .................................................................................................................................... less than 2.5 m/s2
Body ............................................................................................................................................... less than 0.5 m/s2

Ground pressure
With attachment : 4.30 m boom, 2.10 m dipper and 480 L bucket
Machine fitted with 0.50 m pads ...................................................................................................................0.420 bar
Machine fitted with 0.60 m pads ...................................................................................................................0.350 bar
Machine fitted with 0.70 m pads ...................................................................................................................0.310 bar
Machine fitted with 0.85 m pads ...................................................................................................................0.260 bar

Cre 7-80591GB Issued 11-99


1002-9

Travel
Drive sprockets powered by hydraulic motors.
Each track driven independently.
Manually controlled travel control block for fine adjustment of travel speed regardless of force exerted on travel pedals.
Travel speed :
(Mono-speed machine). Max. speed............................................................................................from 0 to 3.6 kph
(Two-speed machine). Max. speed .......................................................................... first speed : from 0 to 3.6 kph
second speed : from 0 to 5.5 kph
Motor-mounted brakes (automatic static braking).
Gradeability ..........................................................................................................................................................77%
Tractive effort............................................................................................................................................ 10 380 daN
Automatic hydraulic motor speed limiter on downhill slopes.

Cre 7-80591GB Issued 11-99


1002-10

WEIGHTS
Machine

Pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.85 m

1.50 m 12 950 13 160 13 375 13 690

Monoblock 2.10 m 12 970 13 180 13 390 13 710

2.65 m 13 020 13 230 13 445 13 760

1.50 m 13 210 13 420 13 630 13 950

Articulated 2.10 m 13 225 13 435 13 650 13 965

2.65 m 13 275 13 485 13 700 14 015

1.50 m 13 270 13 480 13 695 14 010


Offset
2.10 m 13 290 13 500 13 710 14 030

NOTE: Loads shown are in kg with 480 L backhoe bucket.

Attachments
Booms (with dipper cylinder)
Monoblock.................................................................................................................................................. 1015 kg
Articulated .................................................................................................................................................. 1270 kg
Offset.......................................................................................................................................................... 1335 kg
Dipper (with yoke, connecting link and bucket cylinder)
1.50 m .......................................................................................................................................................... 505 kg
2.10 m .......................................................................................................................................................... 525 kg
2.65 m .......................................................................................................................................................... 575 kg
Quick Coupler (optional)................................................................................................................................... 210 kg

Counterweight
2100 kg

Cab
291 kg

Cre 7-80591GB Issued 11-99


1002-11

BUCKETS
NOTE: The selection of bucket capacity depends on the density of the material and the attachment configuration in
addition to the compactness and structure of the ground.

Earthmoving buckets
Width CECE Capacity Weight
0.60 m...........................................................................370 L .......................................................................... 330 kg
0.75 m...........................................................................480 L .......................................................................... 380 kg
0.85 m...........................................................................560 L .......................................................................... 400 kg
0.95 m...........................................................................630 L .......................................................................... 425 kg
1.05 m...........................................................................710 L .......................................................................... 460 kg
All earthmoving buckets are equipped with teeth with removable tooth tips.
Heavy duty supplement optional (add 5% to the capacity shown).
Side cutters optional (add 8 cm to the width shown).

Trench buckets with ejector


Width CECE Capacity Weight
0.35 m...........................................................................200 L .......................................................................... 375 kg
0.45 m...........................................................................265 L .......................................................................... 410 kg

Ditch cleaning buckets equipped with teeth


Width CECE Capacity Weight
1.25 m (2) .....................................................................420 L .......................................................................... 340 kg
1.80 m (2) .....................................................................620 L .......................................................................... 455 kg
2.40 m (1) .....................................................................280 L .......................................................................... 395 kg

Ditch cleaning buckets equipped with reversible blade (notched or smooth)


Width CECE Capacity Weight
1.25 m (2) .....................................................................420 L .......................................................................... 375 kg
1.80 m (2) .....................................................................620 L .......................................................................... 500 kg
2.20 m (1) .....................................................................260 L .......................................................................... 430 kg
2.40 m (1) .....................................................................280 L .......................................................................... 450 kg

V-shaped bucket
Width CECE Capacity Weight
0.35 - 2.10 m ................................................................340 L .......................................................................... 330 kg
0.50 - 2.60 m ................................................................400 L .......................................................................... 395 kg
(1) Small profile
(2) Large profile

Cre 7-80591GB Issued 11-99


1002-12

CLAMSHELLS
Trench clamshell with ejector
Width Opening Capacity Weight
0.32 m....................................... 1.45 m ............................................. 100 L..................................................... 430 kg
0.47 m....................................... 1.45 m ............................................. 145 L..................................................... 490 kg
0.65 m....................................... 1.45 m ............................................. 210 L..................................................... 660 kg

Earthmoving clamshells
Width Opening Capacity Weight
0.79 m....................................... 1.36 m ............................................. 250 L..................................................... 535 kg
0.96 m....................................... 1.48 m ............................................. 400 L..................................................... 635 kg

Rehandling clamshells
Width Opening Capacity Weight
0.97 m....................................... 1.40 m ............................................. 400 L..................................................... 525 kg
1.08 m....................................... 1.47 m ............................................. 550 L..................................................... 530 kg

Cylindrical boring clamshell


Opening diameter Capacity Weight
1.23 m...........................................................................175 L .......................................................................... 565 kg

Rectangular boring clamshells


Width Opening Capacity Weight
0.43 m....................................... 0.69 m .............................................. 70 L...................................................... 430 kg
0.60 m....................................... 1.11 m ............................................. 130 L..................................................... 465 kg

Sugar beet clamshell


Width Opening Capacity Weight
1.33 m....................................... 2.50 m ............................................ 1450 L.................................................. 1100 kg

5-tine stone grab with removable tine tips


Opening diameter Weight
1.55 m............................................................................................................................................................... 820 kg
1.56 m (1) ......................................................................................................................................................... 940 kg
(1) With heart-shaped tines

5-tine scrap grab (tines controlled by central cylinder)


Opening diameter Weight
1.35 m............................................................................................................................................................... 600 kg

Timber grab
Width Opening Capacity Weight
0.72 m....................................... 2.30 m ........................................ 0.1 - 0.9 m2 ................................................ 650 kg

Cre 7-80591GB Issued 11-99


1002-13

MACHINE OVERALL DIMENSIONS

CS96H024

A (pads 0.50 m) ................................................................................................................................................2.47 m


A (pads 0.60 m) ................................................................................................................................................2.57 m
A (pads 0.70 m) ................................................................................................................................................2.67 m
A (pads 0.85 m) ................................................................................................................................................2.92 m
B .......................................................................................................................................................................1.97 m
C .......................................................................................................................................................................0.43 m
D .......................................................................................................................................................................2.94 m
E .......................................................................................................................................................................2.44 m
F (radius) ..........................................................................................................................................................2.05 m
G.......................................................................................................................................................................0.86 m
H .......................................................................................................................................................................0.95 m
J........................................................................................................................................................................2.37 m
K .......................................................................................................................................................................2.78 m
L........................................................................................................................................................................3.55 m
M.......................................................................................................................................................................3.82 m

Cre 7-80591GB Issued 11-99


1002-14

TRANSPORTATION OVERALL DIMENSIONS

B
PDH0256

NOTE: For top of cab to ground, see “Overall dimensions“.

Boom Dipper A B

1.50 m 2.50 7.70

Monoblock 2.10 m 2.65 7.50

2.65 m 2.95 7.45

1.50 m 2.85 8.00

Articulated 2.10 m 2.85 7.81

2.65 m 2.95 7.75

1.50 m 2,45 7,70

Offset 2.10 m 2,60 7,50

NOTE: These values are given in metres.

Cre 7-80591GB Issued 11-99


1002
Section
1002

SPECIFICATIONS
588 WHEELED EXCAVATORS

Copyright  1999 Case France


Printed in France
Case Cre 7-80601GB November 1999
1002-2

TABLE OF CONTENTS
FLUIDS AND LUBRICANTS .................................................................................................................................... 3
Hydraulic fluid....................................................................................................................................................... 3
Transmission component oil ................................................................................................................................ 3
Grease ................................................................................................................................................................. 3
Engine oil ............................................................................................................................................................. 4
Oil viscosity/Oil range........................................................................................................................................... 4
Fuel ...................................................................................................................................................................... 5
Anti-freeze/Anti-corrosion..................................................................................................................................... 5
Environment ......................................................................................................................................................... 5
Plastic and resin components .............................................................................................................................. 5
MACHINE GENERAL SPECIFICATIONS ................................................................................................................ 6
Engine .................................................................................................................................................................. 6
Hydraulic system .................................................................................................................................................. 6
Electrical system .................................................................................................................................................. 7
Upperstructure ..................................................................................................................................................... 7
Cab....................................................................................................................................................................... 7
Operation ............................................................................................................................................................. 7
Undercarriage (depending on version)................................................................................................................. 8
Tyres .................................................................................................................................................................... 8
Brakes .................................................................................................................................................................. 8
Safety devices...................................................................................................................................................... 8
Indicators.............................................................................................................................................................. 8
Warning and indicator lamps................................................................................................................................ 8
Travel ................................................................................................................................................................... 9
Attachments ......................................................................................................................................................... 9
Noise level............................................................................................................................................................ 9
Vibration levels in Operator’s compartment ......................................................................................................... 9
WEIGHTS ...............................................................................................................................................................10
Machine.............................................................................................................................................................. 10
Attachments ....................................................................................................................................................... 10
Counterweight .................................................................................................................................................... 10
Cab..................................................................................................................................................................... 10
BUCKETS ...............................................................................................................................................................11
CLAMSHELLS ........................................................................................................................................................12
MACHINE OVERALL DIMENSIONS ......................................................................................................................13
P Version............................................................................................................................................................ 13
PL Version.......................................................................................................................................................... 14
P2A Version ....................................................................................................................................................... 15
P2AL Version ..................................................................................................................................................... 16
TRANSPORTATION OVERALL DIMENSIONS .....................................................................................................17
P - PL - P2A versions ......................................................................................................................................... 17
PL Version.......................................................................................................................................................... 17

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message that follows, as there is a risk of serious injury.

Cre 7-80601GB Issued 11-99


1002-3

FLUIDS AND LUBRICANTS


Lubricants must have the correct properties for each application.

WARNING : The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid Grease
CASE hydraulic fluid is specially designed for high The type of grease to use depends on ambient tem-
pressure applications and for the CASE hydraulic perature.
system. The type of fluid to be used depends on the
ambient temperature. Temperate and hot climates
Temperate climates -20°C to +60°C
EP NLGI grade 2 extreme pressure grease, containing
-20°C to +40°C
molybdenum disulphide.
Fluid type ISO VG 46
CASE Reference POHYDR Cold climates
Hot climates -40°C to +20°C
EP NLGI grade 0 extreme pressure grease.
0°C to +60°C
Fluid type ISO VG 100
CASE Reference POHYPC
Cold climates
-40°C to +20°C
Fluid type ISO VG 22
CASE Reference POHYPF
These different fluid grades must be in conformity
with CASE France specification P9903201Z.
Temperate country biodegradable fluid :
This yellow fluid is compatible with standard fluid. If
adopted, it is advisable to drain the circuit completely.
Fluid type ISO VG 46
CASE Reference CASYNTH46
This fluid grade must be in conformity with CASE
France specification P9903203B.

Transmission component oil


Extreme Pressure oil is used for all cased transmis-
sion components.
Extreme pressure oil TYPE API GL5 GRADE 80W90
and ISO VG 150

Cre 7-80601GB Issued 11-99


1002-4

Engine oil
CASE No 1 motor oil is the oil recommended for your
engine. This oil ensures correct lubrication of your
engine in all working conditions.
If CASE No 1 Multiperformance or Performance
engine oil cannot be obtained, use only oil of the API/
CE category.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in
this manual are based on tests carried out on CASE
lubricants.
RF97F136

RB97F100

Oil viscosity/Oil range

CS98M561
(A) FAHRENHEIT TEMPERATURE (2) WINTER
(B) CELSIUS TEMPERATURE (3) TROPICAL
(1) ALL SEASONS (4) ARTIC
(*) USE OF AN ENGINE OIL HEATER, OR AND ENGINE COOLANT HEATER IS REQUIRED.

Cre 7-80601GB Issued 11-99


1002-5

Fuel Environment
Use fuel which is to ASTM (American Society for Before servicing this machine and before disposing of
Testing and Materials) D975 standard. used fluids or lubricants, always think of the environ-
ment. Never pour oil or fluids on the ground or into
Use Grade No 2 fuel. The use of other types of fuel
leaking containers.
can result in a loss of power and may cause high fuel
consumption. Consult your local environmental recycling center for
the proper procedure for disposing of these materials.
When the temperature is very cold, the use of a mix-
ture of No 1 and No 2 fuel is permitted. See your fuel Plastic and resin components
vendor for winter fuel requirements in your area.
When cleaning polycarbonate windows, the console,
If the temperature falls below the fuel cloud point
the instrument panel, the gauges, etc., do not use
(point at which wax begins to form) the wax crystals
petrol, paraffin, paint solvents etc. Use only water,
will cause power loss or will prevent the engine from
soap and a soft cloth.
starting.
The use of petrol, paraffin, paint solvents or similar
IMPORTANT : In cold weather, fill the fuel tank at the
products, will cause discoloration, cracks or deforma-
end of the day’s work, in order to prevent the forma-
tion of these components.
tion of condensation.
Fuel storage
Long storage can lead to the accumulation of impuri-
ties and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the
temperature of the fuel should be kept as low as pos-
sible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling
system from corrosion and all risk of freezing.
For areas where ambient temperature is over -36°C,
use a blend of 50% ethylene-glycol based anti-freeze.
For areas where the temperature is below -36°C, it is
advisable to use a blend of 40% water and 60% anti-
freeze.

Cre 7-80601GB Issued 11-99


1002-6

MACHINE GENERAL SPECIFICATIONS


Engine
Make and model .................................................................................................................................... CASE 4T 390
Total SAE power rating at 2800 rpm................................................................................................ 79.8 kW (108 hp)
4 stroke, 4 cylinder diesel engine ...........................................................................................................turbocharged
Displacement............................................................................................................................................... 3920 cm3
Bore ................................................................................................................................................................102 mm
Stroke .............................................................................................................................................................120 mm
Cooling ................................................................................................................................................... water-cooled
Battery start ......................................................................................................... Two 12-volt batteries, 24 V, 100 Ah
Working specifications
Speed ...........................................................................................................................................................2000 rpm
Power rating :SAE.........................................................................................................................................68.6 kW (93 hp)
DIN 70020 - DIN 6271...............................................................................................................65 kW (88 hp)
EEC 80/1269 - ISO 9249 ..........................................................................................................65 kW (88 hp)
Performance maintained up to 3000 m altitude at a temperature of 25°C.
Capacities : Oil sump.....................................................................................................................................................10 L
Fuel tank ..................................................................................................................................................150 L
Electric fuel tank filler pump............................................................................................................................ optional
Average hourly consumption ............................................................................................................................. 12 L/h
Engine and pump assembly mounted on rubber blocks.
Heavy-duty dust filtration.

Hydraulic system
Variable output system with independent and simultaneous operation of all functions.
Working pressure ............................................................................................................................................350 bar
Total capacity of hydraulic reservoir ................................................................................................................... 115 L
Total capacity of system ..................................................................................................................................... 184 L
2-body pump :
1 variable displacement body for the attachment and travel ................................................................flow 210 L/min
1 fixed displacement body for upperstructure swing ..............................................................................flow 44 L/min
Direct drive by flexible coupling.
Installed hydraulic power ................................................................................................................ 55.5 kW (75.4 hp)
Multibody fixed displacement pump for the steering, braking and servo functions.
Attachment and travel control valves, closed centre, acting on the “Load Sensing” pump regulation.
Flow rates per function independent of pressures.
Oil cooler with air cooling from engine.
High pressure multispiral hoses
minimum safety factor .............................................................................................. 2 to 4 times working pressure
Self-lubricating hydraulic swivel.

Cre 7-80601GB Issued 11-99


1002-7

Electrical system
System voltage .......................................................................................................................24 volts, negative earth
Batteries .........................................................................................................two 12-volt, low maintenance batteries
All electrical system safety functions are grouped in an electrical cabinet with a printed circuit.
Instrument panel with printed circuit.
Automatic instrument panel lamp testing.
Two-stage alarm system.
Upperstructure electrical power connection (24 V, 15 Amp.).
Battery master switch.

Upperstructure
All welded frame
Modular structure.
Transverse access walkway to different components.
Sound-proofed, lockable cowling meeting all current regulations.
Tool box with tool set.
Swing
Hydraulic motor with reduction gear and automatic static brake.
Swing speed ................................................................................................................................................... 7.6 rpm
Turntable bearing............................................................................................. Alternate rollers, inner ring gear teeth
Bearing race and ring gear tooth lubrication.............................................................................................. centralized

Cab
Removable, sound-proofed, on flexible mounting blocks.
Tilting steering column.
Up and over windshield.
Tinted windshield.
Pre-fitted for radio installation.
Sliding window on door
Transparent roof hatch ................................................................................................................................... optional
Polycarbonate windows.................................................................................................................................. optional
Cab safety guard .........................................................................................................................available on request
Cab elevator ................................................................................................................................available on request
Anti-vandal cab............................................................................................................................................... optional

Operation
De-luxe seat with armrests and multi-position adjustment (vibration level III/ISO 7096).
Hydraulically assisted controls.
Attachment and swing .................................................................................................................................... 2 levers
Hydraulically assisted steering ............................................................................................................Orbitrol system
Single-speed windshield wiper, plus intermittent action, windshield washer, heating, de-frosting, two-speed ventilation,
cab light, cigarette lighter, sun shield.
Working/headlights :
On upperstructure ................................................................................................................................2 x 70/75 W
On attachment................................................................................................................................................ 70 W
Rear (on cab) ................................................................................................................................................. 70 W
Front (on cab)............................................................................................................................................. optional
Air conditioning ............................................................................................................................................... optional
Cab visor ........................................................................................................................................................ optional
Cab fan ........................................................................................................................................................... optional

Cre 7-80601GB Issued 11-99


1002-8

Undercarriage (depending on version)


Modular design able to accommodate a dozer blade or stabilizers at the rear.
Stabilizers with articulated pads which can be locked for uneven ground.
Front axle oscillation....................................................................................................................................... + or - 7°
Automatic hydraulic front axle locking can be disengaged when required.
Automatically locking dozer blade and stabilizers with check valves.
Two drive axles with planetary reduction gears.
Tool box.

Tyres
4 wheels 15 x 22.5XF
4 wheels 18-19,5XF
8 wheels 9.00 x 20PR14 (with dual wheel spacers)
IMPORTANT: It is mandatory for machines with a set of 4 wheels and fitted with articulated boom to be equipped
with 18 x 19.5 XF type wheels (excpet Germany).

Brakes
Multi-disc, oil-bath brakes.
Service brakes : double rear circuit, controlled hydraulically by foot pedal.
Parking and working brake : manual control by electro-hydraulic action on all 4 wheels.
Hydrostatic engine brake.

Safety devices
For travel or transport, the upperstructure can be locked from the driving position.
In the event of engine failure, the attachment can be lowered, under control, to the ground.
Cancellation of controls by lifting the left-hand control arm.
Tinted safety-glass windows, horn, flashing marker light.
Cab safety guard .........................................................................................................................available on request
Safety valves .................................................................................................................................................. optional
Overload indicator .......................................................................................................................................... optional
Inertia type safety belt .................................................................................................................................... optional
Fire extinguisher ............................................................................................................................................. optional
Rotary light ...................................................................................................................... specific to certain countries

Indicators
Engine coolant solution temperature, hydraulic fluid temperature, fuel level and hourmeter.

Warning and indicator lamps


Engine oil pressure, battery charge, hydraulic oil filter and engine air filter restriction, brake minimum pressure,
parking brake, steering assistance warning.
Warning/indicator lamp test.

Cre 7-80601GB Issued 11-99


1002-9

Travel
Hydromechanical transmission with variable displacement hydraulic motor and range selector providing
continuous speed variation ................................................................................from 0 to 7.5 kph (job site range)
from 0 to 25 kph (road range)
from 0 to 20 kph (special for Germany)
Control by pedal and manual inverter with gradual action, enabling any desired speed to be set.
Hydraulic speed limiter, automatic when descending slopes.
Gradeability - continuous......................................................................................................................................41%
Outer turning radius......................................................................................................................................... 6.49 m
Hydraulically assisted steering with safety system.

Attachments
Sealed linkages, greasing of all linkages possible from the ground, double acting cylinders fitted with end-of-stroke
shock absorbers.

Noise level
Certified by the manufacturer.
In accordance with European directive 86/662/EEC.
Internal noise level (LpA)...........................................................................................................................79 decibels
External noise level (LwA) .......................................................................................................................101 decibels

Vibration levels in Operator’s compartment


Upper limbs .................................................................................................................................... less than 2.5 m/s2
Body ............................................................................................................................................... less than 0.5 m/s2

Cre 7-80601GB Issued 11-99


1002-10

WEIGHTS
Machine
Version
Boom Dipper
P PL P2A P2AL

1.50 m 12,170 12,785 13,380 14,330

Monoblock 2.10 m 12,190 12,805 13,400 14,350

2.65 m 12,240 12,855 13,450 14,400

1.50 m 12,580 13,195 13,790 14,740


Offset backhoe
2.10 m 12,595 13,210 13,805 14,755

1.50 m 12,430 13,040 13,635 14,590

Articulated 2.10 m 12,445 13,060 13,655 14,605

2.65 m 12,495 13,110 13,705 14,655

NOTE: Weights are given in kilograms, with a 480 liter backhoe bucket and 8 wheel configuration, 9.00 X 20 (P, PL,
P2 versions) or 8 wheel configuration, 10.00 X 20 (P2AL version); with 4 wheels, 15 X 22.5: subtract 290 kg (P, PL,
P2A versions); with 4 wheels, 18 X 19.5: subtract 255 kg (P, PL, P2A versions) or 400 kg (P2AL version).
IMPORTANT: It is mandatory for machines with 4 wheel configuration and articulated boom to be equipped with
wheels type 18 x 19.5XF (except Germany).

Attachments
Booms (with dipper cylinder)
Monoblock.................................................................................................................................................. 1015 kg
Articulated .................................................................................................................................................. 1270 kg
Offset backhoe .......................................................................................................................................... 1,335 kg
Dipper (with yoke, connecting link and bucket cylinder)
1.50 m .......................................................................................................................................................... 505 kg
2.10 m .......................................................................................................................................................... 525 kg
2.65 m .......................................................................................................................................................... 575 kg
Quick Coupler (optional)................................................................................................................................... 210 kg

Counterweight
2100 kg

Cab
291 kg

Cre 7-80601GB Issued 11-99


1002-11

BUCKETS
NOTE: The selection of bucket capacity depends on the density of the material and the attachment configuration in
addition to the compactness and structure of the ground.

Earthmoving buckets
Width CECE Capacity Weight
0.60 m...........................................................................379 L .......................................................................... 330 kg
0.75 m...........................................................................480 L .......................................................................... 380 kg
0.85 m...........................................................................560 L .......................................................................... 400 kg
0.95 m...........................................................................630 L .......................................................................... 425 kg
1.05 m...........................................................................710 L .......................................................................... 460 kg
All earthmoving buckets are equipped with teeth with removable tooth tips.
Heavy duty supplement optional (add 5% to the capacity shown).
Side cutters optional (add 8 cm to the width shown).

Trench buckets with ejector


Width CECE Capacity Weight
0.35 m.......................................................................... 200 M .......................................................................... 375 kg
0.45 m...........................................................................265 L .......................................................................... 410 kg

Ditch cleaning buckets equipped with teeth


Width CECE Capacity Weight
1.25 m (2) .....................................................................420 L .......................................................................... 340 kg
1.80 m (2) .....................................................................620 L .......................................................................... 455 kg
2.40 m (1) .....................................................................280 L .......................................................................... 395 kg

Ditch cleaning buckets equipped with reversible blade (notched or smooth)


Width CECE Capacity Weight
1.25 m (2) .....................................................................420 L .......................................................................... 375 kg
1.80 m (2) .....................................................................620 L .......................................................................... 500 kg
2.20 m (1) .....................................................................260 L .......................................................................... 430 kg
2.40 m (1) .....................................................................280 L .......................................................................... 450 kg

V-shaped bucket
Width CECE Capacity Weight
0.35 - 2.10 m ................................................................340 L .......................................................................... 330 kg
0.50 - 2.60 m ................................................................400 L .......................................................................... 395 kg
(1) Small profile
(2) Large profile

Cre 7-80601GB Issued 11-99


1002-12

CLAMSHELLS
Trench clamshell with ejector
Width Opening Capacity Weight
0.32 m....................................... 1.45 m ............................................. 100 L..................................................... 430 kg
0.47 m....................................... 1.45 m ............................................. 145 L..................................................... 490 kg
0.65 m....................................... 1.45 m ............................................. 210 L..................................................... 660 kg

Earthmoving clamshells
Width Opening Capacity Weight
0.79 m....................................... 1.36 m ............................................. 250 L..................................................... 535 kg
0.96 m....................................... 1.48 m ............................................. 400 L..................................................... 635 kg

Rehandling clamshells
Width Opening Capacity Weight
0.97 m....................................... 1.40 m ............................................. 400 L..................................................... 525 kg
1.08 m....................................... 1.47 m ............................................. 550 L..................................................... 530 kg

Cylindrical boring clamshell


Opening diameter Capacity Weight
1.23 m...........................................................................175 L .......................................................................... 565 kg

Rectangular boring clamshells


Width Opening Capacity Weight
0.43 m....................................... 0.69 m .............................................. 70 L...................................................... 430 kg
0.60 m....................................... 1.11 m ............................................. 130 L..................................................... 465 kg

Sugar beet clamshell


Width Opening Capacity Weight
1.33 m....................................... 2.50 m ............................................ 1450 L.................................................. 1100 kg

5-tine stone grab with removable tine tips


Opening diameter Weight
1.55 m............................................................................................................................................................... 820 kg
1.56 m (1) ......................................................................................................................................................... 940 kg
(1) With heart-shaped tines

5-tine scrap grab (tines controlled by central cylinder)


Opening diameter Weight
1.35 m............................................................................................................................................................... 600 kg

Timber grab
Width Opening Capacity Weight
0.72 m....................................... 2.30 m ........................................ 0.1 - 0.9 m2 ................................................ 650 kg

Cre 7-80601GB Issued 11-99


1002-13

MACHINE OVERALL DIMENSIONS


P Version

CS96H019

A .......................................................................................................................................................................2.44 m
B .......................................................................................................................................................................3.25 m
C .......................................................................................................................................................................0.34 m
D .......................................................................................................................................................................2.47 m
E (radius) ..........................................................................................................................................................2.05 m
F .......................................................................................................................................................................2.64 m
G.......................................................................................................................................................................1.23 m
H .......................................................................................................................................................................0.95 m
J........................................................................................................................................................................2.30 m
K .......................................................................................................................................................................3.93 m
L........................................................................................................................................................................3.51 m

Cre 7-80601GB Issued 11-99


1002-14

PL Version

CS96H020

A .......................................................................................................................................................................2.44 m
B .......................................................................................................................................................................3.25 m
C .......................................................................................................................................................................0.34 m
D .......................................................................................................................................................................2.48 m
E (radius) ..........................................................................................................................................................2.05 m
F .......................................................................................................................................................................2.64 m
G.......................................................................................................................................................................1.23 m
H .......................................................................................................................................................................0.47 m
J........................................................................................................................................................................0.18 m
K .......................................................................................................................................................................0.95 m
L........................................................................................................................................................................2.30 m
M.......................................................................................................................................................................1.23 m
N .......................................................................................................................................................................4.10 m
P .......................................................................................................................................................................4.23 m

Cre 7-80601GB Issued 11-99


1002-15

P2A Version

CS96H021

A .......................................................................................................................................................................2.44 m
B .......................................................................................................................................................................3.25 m
C .......................................................................................................................................................................0.34 m
D .......................................................................................................................................................................2.49 m
E .......................................................................................................................................................................3.70 m
F (radius) ..........................................................................................................................................................2.05 m
G.......................................................................................................................................................................2.64 m
H .......................................................................................................................................................................1.23 m
J........................................................................................................................................................................0.95 m
K .......................................................................................................................................................................2.30 m
L........................................................................................................................................................................1.08 m
M.......................................................................................................................................................................3.90 m
N .......................................................................................................................................................................4.08 m

Cre 7-80601GB Issued 11-99


1002-16

P2AL Version

CS97K027

A .......................................................................................................................................................................2.44 m
B .......................................................................................................................................................................3.25 m
C .......................................................................................................................................................................0.34 m
D .......................................................................................................................................................................2.49 m
E .......................................................................................................................................................................3.70 m
F (radius) ..........................................................................................................................................................2.05 m
G.......................................................................................................................................................................2.54 m
H .......................................................................................................................................................................1.24 m
J........................................................................................................................................................................0.95 m
K .......................................................................................................................................................................2.30 m
L........................................................................................................................................................................1.08 m
M.......................................................................................................................................................................4.70 m
N .......................................................................................................................................................................4.73 m
P .......................................................................................................................................................................0.49 m
Q.......................................................................................................................................................................0.18 m

Cre 7-80601GB Issued 11-99


1002-17

TRANSPORTATION OVERALL DIMENSIONS

B
PDH0126

NOTE: For top of cab to ground, see “Overall dimensions“.

P - PL - P2A versions PL Version


Boom Dipper A B Boom Dipper A B

1.50 m 2.65 7.70 1.50 m 2.75 7.70

Monoblock 2.10 m 2.80 7.60 Monoblock 2.10 m 3.05 7.45

2.65 m 3.00 7.60 2.65 m 3.40 7.35

1.50 m 3.05 8.10 1.50 m 3.05 8.10

Articulated 2.10 m 3.00 7.85 Articulated 2.10 m 3.10 7.85

2.65 m 3.15 7.90 2.65 m 3.35 7.80

1.50 m 2.60 7.75 1.50 m 2.80 7.70


Offset backhoe Offset backhoe
2.10 m 2.70 7.60 2.10 m 3.00 7.45

NOTE: These values are given in metres.

Cre 7-80601GB Issued 11-99


1002-18

Cre 7-80601GB Issued 11-99


4001
Section
4001

ELECTRICAL SCHEMATICS
588 CRAWLER EXCAVATORS

Copyright  1997 Case France


Printed in U.K.
Case Cre 7-80630GB September 1997
4001-2

TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SCHEMATIC SYMBOLS .......................................................................................................................................... 3
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD EQUIPMENT) ............................. 4
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD) ..................................................................... 4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) ..................................................... 6
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL) ...................................................................... 6
PRINTED CIRCUIT SCHEMATIC GUIDE................................................................................................................ 8
P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)..................................................................... 10
INSTRUMENT PANEL WIRING............................................................................................................................. 11
INSTRUMENT PANEL (FRONT FACE)................................................................................................................. 11
RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM (STANDARD EQUIPMENT) .............................. 13
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)............................................................ 15
ELECTRICAL SCHEMATIC (PLATE 2) ................................................................................................................. 16
ELECTRICAL SCHEMATIC (PLATE 3) ................................................................................................................. 18
ELECTRICAL SCHEMATIC (PLATE 4) ................................................................................................................. 20
ELECTRICAL SCHEMATIC (PLATE 5) ................................................................................................................. 22
ELECTRICAL SCHEMATIC (PLATE 6) ................................................................................................................. 24
CAB FLOOR WIRING (STANDARD) ..................................................................................................................... 27
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)................................................................ 27
CAB FLOOR WIRING (OPTIONAL)....................................................................................................................... 29
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL) ................................................................. 29
CAB AND CAB OPTION WIRING .......................................................................................................................... 30
ALPHABETICAL INDEX......................................................................................................................................... 31

SPECIFICATIONS
System voltage ..........................................................................24 Volts negative earth and 12 Volts negative earth
Batteries ...................................................................................... 2 x 12 Volts 120 A/hrs, low maintenance batteries
Alternator ........................................................................................................................ BOSCH, 28 Volts, 45 Amps
Starter motor...................................................................................................................... BOSCH, 24 Volts, 4.0 kW

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-3

SCHEMATIC SYMBOLS Local earth

A (n) Radio/housing
B (n) Indicators/pressure switches/loudspeakers/pressostats/detectors/heat sender/gauge 1 Wire number
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators NC Closed circuit
H (n) Warning devices (visible and audible)
K (n) Relays
M (n) Motors NO Open circuit
P (n) Instruments
R (n) Resistors/heater plugs
S (n) Switches/battery master switch Intersection of two wires with connection point
Sh (n) Shunt resistors
V (n) Diodes
X (n) Supply line connections Intersection of two wires without connection point
Y (n) Solenoid valves, solenoids
NOTA : The (n) shows the component number. 1
Example : K2 is relay N°2. Link with following plate

1
Link with preceding plate
(n) Supply on printed circuit

A
Return to another plate with the same letter
(n) Battery terminal

Bulbs
(n) Printed circuit connection terminal

Test bulb
Printed circuit earth connector

Light emitting diode (LED)


A1 Instrument panel connector

Regulator
1 or 1 or 1 Harness identification

1(1) or 1(1) or 1 (1) Harness identification followed by path identification number

(1) or (1) Printed circuit earth connectors

3 2
The installation position for the harness connector (1) on connector (2) of the
printed circuit is identified by a red mark (3) followed by the figure 1 on the
printed circuit. This identification corresponds to the position of path 1 of the
1 1 2 3 4 5 6 7 8 9 10
harness connector (1). This position is completed when the path 1 line is
shown by a red ring (4) located on line 1 wire, or by a red paint mark on the
housing.

1
4

Cre7-80630GB Issued 09-97 Printed in U.K.


4001-4

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD EQUIPMENT) ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD)
2 4 terminal strip

7
1 Harness 10-way connector, floor harness
∆5 ∆ 37 V12

∆10 ∆ 33 ∆ 39 ∆ 40 2 Harness 10-way connector, floor harness


S8 V8 F19 3 Harness 10-way connector, floor harness

AAA
V10 5A

∆ 35 ∆ 36 2
V20 V7
V3 6 Harness 8-way connector, floor harness

AAA
V13
∆6 ∆ 16
k15
V23

AAA
F20 5A F21 5A
∆ 24 ∆ 21
K 20 F25 V9 5

AAA
7,5A
F9
8 Safety clips, upperstructure working light
∆9

AAA F1 30A
F13 5A
10A
F16
∆ 43 1 1
F23 5A F24
20 Harness, 6-way connector, cab power point
5A V6 5A
k2 k1 F17
V5 21 Harness, 6-way connector, cab power point
k5 5A
F12 26 Harness, 6-way connector, windshield wiper (K20 intermittent action)
∆ 38 3 F22 F18

AA
10A
S4
5A 5A S2
27 Harness, 2-way connector, windshield washer
k9
V11
3 F33
7,5A

AAA
Ø5 Ø2 ∆ 31 V2
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A

AAA
1 Harness, 8-way connector, common harness
K 53 F6

AAA
∆ 44 k4
F8
15A
F2
5A
15A V18 4 Harness, 8-way connector, engine
∆ 30

AAA
V1 V16
4 3
F5
10A ∆ 23

AA k7

AA
S7 V17 V19 k6
1 V21
F31 F4 F3 F10 F11 F27
15A 5A 7,5A 15A 7,5A 5A N° 1
S5 S6 S3 6

7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3

V22 k21
∆ 20
Ø4 N° 2 ∆ 27

A
A
1 2 3 4 5 20 30
2
F14 5A
N° 3
∆ 26
6 7 9 11 12 14 16 28 42 8 V4

CM96J005

1 24 Volts supply before contact K1 Starter motor relay


2 12 Volts supply before contact (radio) K2 General contact relay
3 Not used K3 Hourmeter relay
F2 5A Fuse, starter switch K5 Horn relay
F3 7.5A Fuse, instrument panel K6 Upperstructure and attachment working light
F4 5A Fuse, cab lighting, horn relay relay
F6 15A Fuse, upperstructure working lights and K20 Windshield wiper intermittent action
cab rear working light K21 LH control arm pilot safety relay
F7 10A Fuse, horn K53 Fuel heater relay
F8 15A Fuse, upperstructure power socket Sh2, Sh3, Sh4, Sh6 Shunt
F9 10A Fuse, windshield washer, windshield wiper Sh1, Sh5, Sh7, Sh8 Not used
F10 15A Fuse, blower, heater, fuel heater V1 General contact diode
F11 7.5A Fuse, cigarette lighter Ø 2 Starter motor connecting point
F12 10A Fuse, pilot safety Ø 4 Printed circuit earth
F15 F26 Not used Ø 5 Upperstructure power socket connecting point
F31 15A Fuse, windshield wiper intermittent action
F32 10A Fuse, not used
F33 7.5A Fuse, not used
H14 Not used

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-5

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 1 2 3 4 5 6

138 19 37 132 135


137 16 133 134 33

AAAA
AA
26 144 142 128 133 134
0 31 38 132 135

AAAA
AAA
AAA
AAA AAA ∆ 20
AAA ∆ 21 33

AAA
AAA
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
∆5 ∆ 37 V12 7 1
∆10 ∆ 33 ∆ 39 ∆ 40

S8 V8 F19 13 11 18 64 6 40 136 5 48 7
V10 5A 23 15 35 24 141 28 41 92 22
V20 V7
∆ 35 ∆ 36 2 V3
V13
∆6 ∆16

AA
1 2 3 4 5 6 k15
V23
F20 5A F21 5A
∆ 24 ∆ 21

AA
AAA
F25 V9 5
7,5A

AAA
144 0 141 F9

K 20 40 136 142 9 10A
∆ 43 1

AAA
F13 5A 1
F1 30A F16 F23 5A F24
5A V6 5A

AAA
AA AAA AAA AAAA
k2 k1 V5
F17
k5 5A

AAA AAA AAAA


F12 1 2 3 4 5 6 7 8
∆ 38 3 F22 F18
3 2
∆ 26
10A
5A 5A S2
S4

A
k9
V11
3 F33 29 31 167 147
7,5A
Ø5 Ø2 ∆ 31 168 38 105 148
V2
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A

F6
33 15A ∆ 44 k4
F8 F2 V18
15A 5A ∆ 30
V1 V16

2 F5
10A
4 3

23

A AAAA
k7
K 53 33 33

AAAA
S7 V17 V19 k6
1 V21
3 2 5 1 F31 F4 F3 F10 F11 F27
6
15A 5A 7,5A 15A 7,5A 5A N° 1
S5 S6 S3 6

7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3

V22 k21
0 14 ∆ 20
Ø4 N° 2 ∆ 27

A
2
1 2 3 4 5 20 30
2
F14 5A
N° 3
∆ 26
6 7 9 11 12 14 16 28 42 8 V4
0

N° 3 N° 1 N° 2
6 7 9 11 12 14 16 28 42 8 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 1 2 3 4 5 20 30 38

0 33 0 0 0 0

A 1 2 3 4 5 6 7 8

A 5
1 2

AA 1 2 3 4 5 6 7 8

A 2

70 16 137 36 0 40 18 14 11 4
55 33 19 138 14 15 23 13
0
0 33

AA
AA ∆8
AAA
AAA ∆ 27

AAAAAAA
AAAAAAA 1 AAAAAAAA
AAAAAAAA 4

CM96J004

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-6

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL)
1 Adjustable boom raising and lowering range limitation detector cable (specific to certain countries)
2 Harness, adjustable boom raising and lowering range limitation electro-control (specific to certain countries)
3 Strip (specific to certain countries)
4 Harness quick-attach control
5 Harness quick-attach control switch
∆5 ∆ 37 V12 7

∆10 ∆ 33
∆ 39 ∆ 40

S8
V8 F19
Cable adjustable boom raising height limiter (to terminal N°3)
V10 5A
V20 V7
K 20
k15 ∆6 ∆ 16
∆ 35 ∆ 36
V13
2 V3
K50 6 Harness, adjustable boom, (specific for Germany)
V23

F25
∆ 24 ∆ 21
F20 5A F21 5A

5
7 Harness, hood lighting (optional)
V9

∆9
7,5A
F9
10A
9 Harness, cold start assistance (optional)
∆ 43 1
F1 30A
F13 5A
F16
5A
1
F23 5A
V6
F24
5A
10 Harness, adjustable boom, (specific for Germany)
V5
k2 k1
k5
F17
5A 12 Harness, fuel heating device (optional)
F12
∆ 38 3 F22 F18
10A
S4 5A 5A S2
k9
15 Wire, adjustable boom raising and lowering range limitation (specific to certain countries)
a3 F33
7,5A
V11
16 Harness, overload indicator (optional)
∆ 31
Ø5 Ø2
F7
10A
F32
10A
F30
15A
F26
7,5A
F15
15A
4
V2
22 Harness, cold start assistance glow plug (optional)
K51
F8 F2
F6
15A ∆ 44
V18
k4 23 Harness, cold start assistance heating element (optional)
15A 5A ∆ 30
V1 V16
4 3
K53 24 Harness, front working lights on cab (optional)
F5
10A
23
33 Harness, overload indicator (optional)
k7

S7 V17 V19 k6
a1 V21
F31 F4 F3 F10 F11 F27
15A 5A 7,5A 15A 7,5A 5A N° 1
S5 S6 S3 6

7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3

V22 k21
∆ 20
R 10 Ø4 N° 2 ∆ 27

2
1 2 3 4 5 20 30 38
a2
F14 5A
N° 3
∆ 26
6 7 9 11 12 14 16 28 42 8 V4

PDH0245

F1 30A Fuse, cold start assistance (optional) V4 Radio diode (optional)


F5 10A Fuse, upperstructure working light and V21 Overload indicator diode (optional)
rotary light relay (specific to certain countries) V22 Rotary light indicator diode (specific to certain
F13 5A Fuse, overload indicator (optional) countries)
F14 5A Fuse, radio (optional)
F27 5A Fuse, adjustable or articulated boom
(optional)
F30 15 A Fuse, cab working lights (optional)
K15 Cold start assistance relay (optional)
K50 Adjustable boom raising range limitation relay
(optional)
K51 Adjustable boom lowering range limitation relay
K53 Fuel heater relay
R10 0.85 Ohm Resistor

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-7

∆ 23
∆5 ∆ 37 V12 7

1 2 ∆10 ∆ 33 K53
∆ 39 ∆ 40
V8 F19
S8
V20 V7 V10 5A 3 2 5 1
123 119 ∆ 35 ∆ 36 2 V3
V13
k15 ∆6 ∆ 16
V23
F20 5A F21 5A 41 41
∆ 24 ∆ 21
F25 V9 5
7,5A
F9
∆9
10A
1
∆ 23 F1 30A
F13 5A
F16
∆ 43 1
F23 5A F24
5A V6 5A
k2 k1 V5
F17
k5 5A K51 K50
F12
10A ∆ 38 3 F22 F18
5A 5A S2 85 86 30 87A 87
S4 85 86 30 87A 87
k9
V11
a3 F33
7,5A
Ø5 Ø2 ∆ 31 V2 0 126 59 124 0 126 56 125
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A
∆ 23 F6
15A ∆ 44 k4
F8 F2 V18
15A 5A ∆ 30 56 126126 124 0 0 0
V1 V16
4 3
F5
10A 23

3 123 119 k7

S7 V17 V19 k6
a1 V21
F31 F4 F3 F10 F11 F27
15A 5A 7,5A 15A 7,5A 5A N° 1
100 102 98 219 S5 S6 S3 6
56 56 56 126 59 0 0 0
R 10 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3 3
V22 k21
∆ 20
Ø4 N° 2 ∆ 27
100 102 98 219
2
1 2 3 4 5 20 30 38
a2
F14 5A
N° 3
∆ 26
6 7 9 11 12 14 16 28 42 8 V4
1

0 0 41 56 229

N° 3 N° 1
6 7 9 11 12 14 16 28 42 24 8 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8

0 0 0 0 0 0 26 56 229 229
56 229 119

∆ 10 ∆ 33 ∆9 ∆ 24 ∆ 6 ∆ 16

1 2 1 2 1 2 1 2 3 1 2 1 2

59 145 146 62 3 127 128 90 59 91 145


90 130

4 5 41
0
0
0 26
59

∆ 12 ∆ 10 ∆ 33 ∆ 24 ∆7 ∆ 6 ∆ 16 ∆ 22

∆9

CM96J006

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-8

PRINTED CIRCUIT SCHEMATIC GUIDE Sh2 Shunt


Sh3 Shunt
1 24 Volts supply before contact Sh4 Shunt
2 12 Volts supply before contact (radio) Sh6 Shunt
3 Not used Sh1,Sh5, Sh7, Sh8 Not used
F1 30A Fuse, cold start assistance (optional) V1 General contact diode
F2 5A Fuse, starter switch V2 Diode, Not used
F3 7.5A Fuse, instrument panel V3 Not used
F4 5A Fuse, cab lighting, horn relay V4 Radio diode (optional)
F5 10A Fuse, upperstructure working light and rotary light relay (specific to certain countries) V5 Diode, Not used
F6 15A Fuse, upperstructure headlights and rear cab working light V6 Diode, Not used
F7 10A Fuse, horn V7 Diode, Not used
F8 15A Fuse, upperstructure power socket V8 Diode, Not used
F9 10A Fuse, windshield washer, windshield wiper V9 Diode, Not used
F10 15A Fuse, ventilation, heater, fuel heater V10 Diode, Not used
F11 7.5A Fuse, cigarette lighter V11 Diode, Not used
F12 10A Fuse, pilot safety V12 Diode, Not used
F13 5A Fuse, overload indicator (optional) V13 Diode, Not used
F14 5A Fuse, radio (optional) V16, V17, V18, V19 Diode, Not used
F15 Not used V20 Diode, Not used
F16 Not used V21 Overload indicator diode (optional)
F17 Not used V22 Rotary light indicator diode (specific to certain countries)
F18 Not used V23 Diode, Not used
F19 Not used
F20 Not used Ø 2 Starter motor connecting point
F21 Not used Ø 4 Printed circuit earth
F22 Not used Ø 5 Upperstructure power socket connecting point
F23 Not used
F24 Not used
F25 Not used : see page 4
F26 Not used
F27 5A Fuse, adjustable or articulated boom (optional)
F30 15A Fuse, cab front working lights (optional)
F31 15A Fuse, windshield wiper intermittent action
F32 10A Fuse, not used
F33 7.5A Fuse, not used
H14 Not used
K1 Starter motor relay
K2 General contact relay 24V, 50A
K3 Hourmeter relay
K4 Not used
K5 Horn relay
K6 Working light relay
K7 Not used
K9 Not used
K10 Not used
K14 Not used
K15 Cold start assistance relay (optional)
K21 LH control arm pilot safety relay

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-9

CM95F016

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-10

AAA A AAA A AAAAAAA AA


P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)

B3 B5 C4 C6 F2 A4 C2 D3 A7 A2 B1

AA
+

AA
AA
(30s)

+

A AAAA AAAA 8 7 9 6 11

AA (2s)
AAAA AAA 13

AAA
12 14 15

AA A AA AAA
AAA A5

A AA AAA
AA
A
2 1

A AAAAAAAA
AA AAA
AA
A
AA AA AA AA
A
AAAA
AAA
AAAAAA AAA A
3

+ P2 + P1 + P3

AAA A A B4 B7 B6 A3

PDH0233

A2 Minimum pilot pressure red warning lamp connector 1 Stop alarm red warning lamp
A3 Hydraulic oil temperature indicator connector 2 Alarm orange indicator lamp
A4 Battery charge red warning lamp connector 3 Audible warning stop push button
A5 Audible warning red, orange indicator lamp connector 6 Engine oil pressure red warning lamp
A7 Engine oil pressure red warning lamp connector 7 Air filter restriction red warning lamp
8 Battery charge red warning lamp
B1 24 Volts supply
9 Hydraulic oil filter restriction red warning lamp
B3 Earth
11 Minimum pilot pressure red warning lamp
B4 Fuel level indicator connector
12 Overload indicator orange indicator lamp (optional)
B5 Indicator lighting connector
13 Instrument panel lamp
B6 Engine coolant temperature indicator connector
14 Not used
B7 Fuel minimum level connector
15 Rotary light orange indicator lamp (optional)
C2 Air filter restriction red warning lamp connector
C4 Overload indicator orange warning lamp connector (optional)
C6 Connector, not used
D3 Hydraulic oil filter restriction red warning lamp connector
F2 Rotary light orange indicator lamp connector (specific to certain countries)
P1 Engine coolant temperature indicator
P2 Fuel level indicator
P3 Hydraulic oil temperature indicator

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-11

INSTRUMENT PANEL WIRING INSTRUMENT PANEL (FRONT FACE)


A B

5 4 5 4
1 2 3
6 7 3 6 7 3
1 2
A B 1 2

P3

AAAAAA
AAA
C D
140 23 17 138 13 29 18 11 137 0 19 P1
C D
5 4
6 7 3
5 4
6 7 3 STOP
1 2 1 2

13
15 168 16
F
P2 C

5 4
6 7 3
1 2

F 8
E
167 1/2

AAAAA
6

9
AA A AA
AA AAA
AA

A 7 way connector : minimum pilot pressure red warning lamp, hydraulic oil temperature indicator, battery charge
PDH0235
11
AA 7
red warning lamp, audible warning cut-out push button, engine oil pressure red warning lamp, alarm orange
warning lamp, stop alarm red warning lamp.
B 7 way connector : 24 Volts supply, earth, fuel level indicator, indicator lighting, engine coolant temperature indi-
cator. 15
12
C 7 way connector : air filter restriction red warning lamp, overload indicator orange indicator lamp (optional).
D 7 way connector : hydraulic oil filter restriction red warning lamp. PDH0234

F 7 way connector : rotary light orange indicator lamp (optional). 1 Stop alarm red warning lamp P1 Engine coolant temperature indicator
2 Alarm orange indicator lamp P2 Fuel level indicator
3 Audible warning stop push button P3 Hydraulic oil temperature indicator
6 Engine oil pressure red warning lamp
7 Air filter restriction red warning lamp
8 Battery charge red warning lamp
9 Hydraulic oil filter restriction red warning lamp
11 Minimum pilot pressure red warning lamp
12 Overload indicator orange indicator lamp
(optional)
13 Instrument panel lamp
15 Rotary light orange indicator lamp (optional)

Cre7-80630GB Issued 09-97 Printed in U.K.


4001-12

38
29

10 9 0

AAA H11
141

AAA
8
136

AAA
6 5
37

AAA
4 3
H15 S6
AAA
1

AAA
38

AAA
V V
C C
141
0 140

AAA
29

0
AAA 10 9 0

AAA
0
H12
AAA
22 22 6
3

AAA
S3 5

AAAAA
AA AA
AAA
22
S26
AAAAA
AA AA
AAA
1 37

AAAAA
AAAAAAA 40
45
29

10 9 0

H13
5

3 1

S27 1

46
41
28
29

10 9 0

H10 2
S1 5

S4
S24 7 1

6
5 29

C C C C
105 105 64 147 6 7

6 2

CM96J007

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-13

RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM (STANDARD)


H10 Working light switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H15 Instrument panel audible warning
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S24 Pilot safety switch
S26 Windshield washer switch
S27 Heater blower switch
Floor harness

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-14

V52 V51 V50 H15

AA
101

AA
29
+ -
H53 10 9
AA
AA
101 0 10 9 0

H31
AA 8

AA
5 100 102 140
6 5 28

S53
1 AA
AA
S25 4 3
1 31

0
AA
H30 229
229
128
AA
AA
127
AAAAAAA AA AA
10 9 0
AAAAAAA AA AA
AA
AAAAAAAAAAA
AAAAA AA
AA
S20
5 3

3
62
1
S30

56

90 59

H58 S56 0

0
H32 229 10 9

229 10 9

7 100 S21 5

5 1
3 56

1 102 145 91

24 16 6 6
9

CM96J008

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-15

RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)


H30 Cold start assistance switch lighting (optional)
H31 Rotary light switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H53 Front working light switch lighting (optional)
H58 Quick-attach switch lighting (optional)
H15 Audible warning
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S25 Rotary light switch (optional)
S30 Adjustable or articulated boom switch
S53 Front working light a switch (optional))
S56 Rear foglight switch (optional)
V50 Quick-attach switch (optional)
V51 Quick-attach switch (optional)
V52 Quick-attach switch (optional)
1 Quick-attach harness (optional)
6 Rotary light harness (optional)
6 Adjustable boom control harness (specific to certain countries)
9 Cold start assistance harness (optional)
16 Overload indicator harness (optional)
24 Front cab working light, rear cab working light harness (optional)

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-16

ELECTRICAL SCHEMATIC (PLATE 2)


ELECTRICAL CABINET UPPERSTRUCTURE
F1 30A Fuse, cold start assistance G1 Batteries
F2 5A Fuse, starter switch S2 Battery master switch
K1 Starter motor relay
ENGINE
K2 General contact relay 24V, 50A
K3 Hourmeter relay G2 Alternator
G1 Y1 K15 Cold start assistance relay M1 Starter motor
G2
R11 R10 0.85 Ohm Resistor R11 Pre-heater plug
V1 General contact diode Y1 Injection pump solenoid
S1 M1
FLOOR
H30 Cold start assistance switch lighting (optional)
S1 Key switch
S20 Cold start assistance momentary switch
(optional)
: see page 4.

A
WIRING CONNECTIONS BETWEEN SCHEMATICS

A See schematic plate 6 page 24 H See schematic plate 3 page 18

B See schematic plate 4 page 20 I See schematic plate 3 page 18

E See schematic plate 4 page 20 J See schematic plate 3 page 18

F See schematic plate 3 page 18 K See schematic plate 5 page 22

S2 G See schematic plate 3 page 18 N1 See schematic plate 6 page 24

F1 - F2 - K1 - K2
K3 - K15 - R10 - V1
S20
H30

PDH0237

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-17

battery master battery starter battery relay thermostart cold


engine cut-out alternator
switch motor starter switch key start (optional)

+12 V +12 V 97
K
+24V +24V 2
97 J

2 +24V 9
1 I

F2 F1
5A 30A
G1
8 3
11
1 2 H
V1
5 2 9

S20 9 (2)
2 (5)
H30 13
S1
30 9 5 G

R012
58 50 15 10 1 3
1 K3
9 (1)
3 (9) 2 (9) 7 2 K3 5 4
62 24
4 6 13 14 F
2 3
K1 K15
5 1 4
1 1 K15 5 4 4 (8)
2 4 (6)
123 4 (4)
3 K1 2 2 K2 3 K2
30 B+ D+ W
23 (1)
M1 G2
50 R10
S2
23 (2)
119 2
229 Y1 24
22 1
0
9
R11

A B 4 4 E N1

CM96J009

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-18

ELECTRICAL SCHEMATIC (PLATE 3)


INSTRUMENT PANEL FLOOR
P10 Instrument panel (See schematic plate 1) B3 Pilot pressure pressostat
H15 Instrument panel audible warning
ELECTRICAL CABINET
P4 Hourmeter
F3 7.5A Fuse, instrument panel S3 Horn switch
F4 5A Fuse, cab lighting, horn relay
UPPERSTRUCTURE
F7 10A Fuse, horn
K5 Horn relay B1 Air filter restriction pressostat
B2 Hydraulic oil filter restriction pressostat
CAB
B21 Hydraulic oil temperature sender
B4
P10 E1 - S10 E1 Cab lighting H26 Horn
S10 Cab lighting switch P11 Fuel level indicator
B22 X1(K) Cab/Cab floor, cab lighting connector X10 (A),(B),(C) Fuel level indicator connectorsl
: see page 4. ENGINE
P11 - X10(A),(B),(C
B4 Engine oil pressure pressostat
B22 Engine coolant temperature sender

A
B1
WIRING CONNECTIONS BETWEEN SCHEMATICS

See schematic plate 2 page See schematic plate 5 page See schematic plate 4 page
F M T
16 22 20

See schematic plate 2 page See schematic plate 4 page See schematic plate 4 page
G N U
16 20 20

See schematic plate 2 page See schematic plate 4 page See schematic plate 5 page
H P V
16 20 22
B2
See schematic plate 2 page See schematic plate 4 page See schematic plate 5 page
I Q W
16 20 22

H15 B21 See schematic plate 2 page See schematic plate 6 page See schematic plate 3 page
J R X
16 24 20

X1 (K) See schematic plate 5 page See schematic plate 4 page See schematic plate 6 page
L S M1
22 20 24

H26
F3 - F4 - F7 - K5
S3 P4
B3

PDH0237

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-19

hourmeter Instrument panel cab lighting horn


battery air filter hydraulic pilot pres- engine oil fuel reserve level hydraulic instru- engine temperature
charge restriction oil filter sure pressure alarm oil temper- ment panel
warning restriction ature audible
lamp warning

2 +24V +24V 2
J U
9 +24V +24V 9
I T
F3 F4 F7
7.5A 5A 10A

W V
11
11 26 34
H 168
3 (3)
2 (10)
B1 E1 E3 F7 E5 F6 F5 D2 C4 E6 F1 E2 A6 29
B5 S
13 22
G A4 P10 B3
3 (1)
B6
C2 D3 A2 A7 B7 B4 A3 A5 D1 F2 S3
h P4

2 3
3 (10) 3 (4) 1 (4) 3 (2) 1 (2) 1 (3) 1 (1) 167 3 (5) 20 (1) K5
24 1 K5 5 4
F 15 16 17 23 137 19 138 140 18
35
X1 (K) R
4 (5) 1 (5) 4 (7) 1 (7) 1 (6) 1 (8) 4 (2) 3 (8)
E1
X10 (B) X10 (A)
148
P P P P S10
B21 B22
B1 B2 B3 B4 H15 H26
P11 X10 (C)

0
Q
0
P
4
M1 L M X N

CM96J010

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-20

ELECTRICAL SCHEMATIC (PLATE 4)


INSTRUMENT PANEL CAB
H10 Working light switch lighting E51 Cab rear working light
H11 Windshield wiper switch lighting H57 Rotary light (optional)
H12 Windshield washer switch lighting M2 Windshield wiper motor
H13 Heater blower switch lighting E : Blue
H31 Rotary light switch lighting (optional) J : White
S4 Working light switch L : Grey
E51 S6 Windshield wiper switch M : Black
S25 Rotary light switch (optional) X1 (F) Rotary light cab floor/cab connector (optional)
S26 Windshield washer switch X1 (E), (L), (M), (J) Windshield wiper motor cab floor/
E7 H57
S27 Heater blower switch cab connector
X1 (G) Floor connector : cab/rear cab working light
ELECTRICAL CABINET
M2 FLOOR
F5 10A Fuse, working light, rotary light relay
(optional) E7 Cigarette lighter
F6 15A Fuse, upperstructure headlights M3 Windshield washer motor
F9 10A Fuse, windshield washer, windshield wiper M4 Heater blower motor
F10 15A Fuse, blower, heater
UPPERSTRUCTURE
F11 7.5A Fuse, cigarette lighter

A F31
K6
K20
Sh3
15A Fuse, windshield wiper intermittent action
Working light relay
Windshield wiper intermittent action
Shunt
E2 Attachment working light (on boom)
E3 Upperstructure working light
X5 (A), (C) Attachment working light power connection

Sh6 Shunt
V22 Rotary light indicator diode (optional)
1 Strip
: See page 4.
WIRING CONNECTIONS BETWEEN SCHEMATICS

E3
B See schematic plate 2 page 16 Y See schematic plate 6 page 24

E See schematic plate 2 page 16 Z See schematic plate 5 page 22

N See schematic plate 2 page 16 A1 See schematic plate 6 page 24


X5(A),(C)
P See schematic plate 3 page 18 B1 See schematic plate 5 page 22
X1(E),(F),(L),(M),(J),(G
Q See schematic plate 3 page 18 C1 See schematic plate 5 page 22
E3
M4
M3 S See schematic plate 3 page 18 D1 See schematic plate 5 page 22
F5 - F6 - F9 - F10
F11 - F31 - K6 - K20 T See schematic plate 3 page 18 E1 See schematic plate 5 page 22
V22 - Sh3 - Sh6
H10 - H11 - H12 - H13 - H31
U See schematic plate 3 page 18 F1 See schematic plate 5 page 22
S4 - S6 - S25 - S26 - S27
X See schematic plate 3 page 18 K1 See schematic plate 2 page 16

PDH0237B

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-21

ROTARY LIGHT (OPTIONAL) WORKING LIGHTS WINDSHIELD WIPER WINDSHIELD WASHER BLOWER CIGARETTE LIGHTER
HEATER
UPPERSTRUCTURE REAR WORKING LIGHT
EQUIPMT AIR CONDITIONING

2 +24V +24V 2
U D1
9 +24V +24V 9
T C1

F5 F6 F31 F9 F10 F11


10A 15A 15A 10A 15A 7.5A
28 32 144 37 41 48
2 (4) 1 (5) 2 (6) 2 (7)
41
S25 S4 S6 S26 S27
H31 H10 H11 H12 H13
6 (1) 12
9 5 9 5 9 2 6 1 5 9 1 9 3
B1
Sh6 2 1 0 2 1 0

10 1 10 1 10 4 8 3 7 10 2 10 5 1 E7
136 38
29
S
31 29 2 (3) 6 (4) 2 (2)
142 26 (6) 40 ème ére
6 (3) 20 (3) 2 1
26 (4) 26 (5) A1
K1 2 (1) 45
20 (6)
Sh3 141 26 (1) 46
19 19 26 (2) 27 (2)
30
20 (2) V22 19
2 3 2B
4B
1A 20 (5)
X1 (F) 1 K6 5 4 K6 3B X1 (E) M3 M4
6 (5) 33 K20 5B X1 (L)
1B X1 (J)
X1 (M)
1(10) 8 1(4) 8
33
H57 X5 (G)
167 X5 (C) M2
E51
E3 E3 E2

0 X5 (A) 0
Q Z
0
P
1

8
26 (3) 20 27 (1)
X E1 E F1 P1 B Y N

CM96J011

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-22

ELECTRICAL SCHEMATIC (PLATE 5)


ELECTRICAL CABINET CAB
F8 15A Fuse, upperstructure power socket B5 RH loudspeaker (optional)
F13 5A Fuse, overload indicator (optional) B6 LH loudspeaker (optional)
F14 5A Fuse, radio E50 Front working lights (optional))
F30 15A Fuse, cab working light (optional) M6 Fan motor (optional)
V4 Radio diode (optional) S29 Fan switch (optional)
E50 V21 Overload indicator diode (optional) X1(A),(B),(C),(D) RH and LH loudspeaker connector
M6 - S29 - X14(1),(2) X1(H) Front working light connector (optional)
INSTRUMENT PANEL
Y51 - Y52 X14 (1),(2) Fan motor connector (optional)
B5 E12 - S28 H32 Overload indicator switch lighting (optional)
UPPERSTRUCTURE
X2 S21 Overload indicator switch (optional)
B23 Overload indicator pressostat, on boom foot
FLOOR
(optional)
A1 Radio (optional) X2 Upperstructure power socket
Y53 H53 Front working light switch lighting (optional) Y51 Quick-attach solenoid valve (optional)
H58 Quick-attach switch lighting (optional) Y52 Quick-attach solenoid valve (optional)
S53 Front working light switch (optional)) Y53 Fuel filler pump
S56 Rear foglight switch (optional)
ENGINE
V50 Quick-attach diode

A
V51 Quick-attach diode E12 Engine compartment light (optional)
V52 Quick-attach diode S28 Engine compartment lighting switch (optional)
1 4 terminal standard strip
: see page 4

WIRING CONNECTIONS BETWEEN SCHEMATICS

K See schematic plate 2 page 16 C1 See schematic plate 4 page 20

B6 L See schematic plate 3 page 18 D1 See schematic plate 4 page 20


B23
M See schematic plate 3 page 18 E1 See schematic plate 4 page 20
X1(A),(B),(C),(D),(H)
V See schematic plate 3 page 18 F1 See schematic plate 4 page 20

W See schematic plate 3 page 18 G1 See schematic plate 6 page 24


F8 - F13 - F14
F30 - V4 - V21
H32 - H53 Z See schematic plate 4 page 20 H1 See schematic plate 6 page 24
S21 - S53
V50 - V51 - V52
B1 See schematic plate 4 page 20
H58 - S56 A1

PDH0237

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-23

UPPERSTRUCTURE FUEL FILLER PUMP OVERLOAD INDICATOR (OPTIONAL) FRONT CAB WORKING LIGHTS ENGINE COM- CAB FAN RADIO QUICK ATTACH
POWER SOCKET PARTMENT (OPTIONAL) (OPTIONAL)
(OPTIONAL)
LIGHTING

97 12V
K

2 24V
D1

9 24V 24V 9
C1 H1

V B1 L M
97
48
101 140 V51
F8 F13 F30 F14 102
15A 5A 15A X14 (1) 5A V50
100
91 127
26 V52
16 (2) 24 (1) 93 7 1 9
S21 H53
S53 1 0 2
H32
9 5 9 5
7 V4
36 92
10 1 10 1 3 10
2 (8) S56 229
16 (1) H58 E1
+ 56
229 145
24 (3)
33 (1) A1
G1
128
5 -
1 (7) 1 (8) 1 (6) 1 (9) 102 100
21 (1)
132 134 133 135
P B23
Y53 X1 (H) 21 (4) 21 (5) 21 (3) 21 (6)
S29 2 2
S28
146 X1 (D) X1 (C) X1 (B) X1 (A)
4 1 Y51 1 Y52
M M6
33 (2) E12 + +
1 X2 E50 0 - -

V21 X14 (2) B5 HPD B6 HPG


6 (2)
168 0

16 7 14

F1 W Z

CM96J012

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-24

ELECTRICAL SCHEMATIC (PLATE 6)


ELECTRICAL CABINET UPPERSTRUCTURE
F12 10A Fuse, pilot safety B56 Adjustable boom raising range limitation detec-
F27 5A Fuse, adjustable boom and raising range tor (optional)
limitation (optional) Y7 Adjustable or articulated boom extending sole-
K21 Pilot safety relay noid valve
K50 Adjustable boom raising range limitation relay Y8 Adjustable or articulated boom retracting sole-
S30 (optional) noid valve
Y2 - Y7 - Y8 Y50 B56 K51 Adjustable boom lowering range limitation relay Y50 Adjustable boom raising range limitation sole-
K53 Fuel heater relay noid valve (optional)
R50 Sh2 Shunt, Pilot safety relay
ENGINE
Sh4 Shunt, Pilot safety relay
R50 Fuel heating device
: see la page 4
CAB
S30 Adjustable or articulated boom switch
FLOOR
S24 Pilot safety switch

A
Y2 Pilot safety solenoid valve

WIRING CONNECTIONS BETWEEN SCHEMATICS

A See schematic plate 2 page 16

R See schematic plate 3 page 18

Y See schematic plate 4 page 20

A1 See schematic plate 4 page 20

G1 See schematic plate 5 page 22

F12 - F27 - K21 - K50 H1 See schematic plate 5 page 22


K51 - K53 - Sh2 - Sh4
M1 See schematic plate 3 page 18

N1 See schematic plate 2 page 16


S24

PDH0237

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-25

ADJUSTABLE BOOM BOOM RAISING RANGE LIMIT PILOT SAFETY FUEL HEATING DEVICE
OR ARTICULATED (OPTIONAL) (OPTIONAL)
BOOM (OPTIONAL)

A1

9 +24V
H1

F27
5A F12
10A
14 41
49
56
15
Sh4
S30
2 6 (6)
1
90
4 S24
B56 3
126 NO NC
3 1 K53
59
3 (7) 6 (7)
56 4 5 2
6 (2) 64 147
6 (1) R50
10 (2)
Sh2 T°
K21 3
10 (1) 1
30 K51 30 K50
86 2 5 4
86 55

85 85
87A 87 87 87A
148
124 125
1 (2) 6 (8) 14
59
2 2 2

Y7 1 Y8 1 1 Y50 2
0 0
1 Y2
0
6
G1 Y A R 12 M1 N1

CM96J013

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-26

CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)

E2
E3

H26 B A
0 33 35 0 E3
33 0

33 0

P10
A B
H11 P11
S6 19 A
C D 137 B
H12
S26 0 C
X10
0 H15
S3 H13
Y2
S27
F

E
H10
22 22 S4
0 140
55 0
1 K53 8
4 1

B3 X2
M3 P4 M4
1 2 3 36 0 S2
16
17 148 S1 B2
40 0 24 11 45 46 0

7 5 B21
6

+
S24
0 138 Y1
105 144 31 G1 G1
132 11
X1 E7

+
142 B22 18
64 105 D
E

147 134 C L
M
F

G
33
133 B
K H 48 B1
A J
0 G2
B+
A1 15 0 B4
M1 D+
135 26 38 0 W
128
92
23 0 2 14 13
135 2 2 4
0 133
20
40 21
27 1 2 3 6 134
27 20 132
0

CM96J014

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-27

CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)
20, 20, 21, 27, 27 : See page 4 24 Volts supply before contact
1, 2, 3, 6 et 0 : See page 4 1, 4 et 8
FLOOR UPPERSTRUCTURE
A1 Radio (optional) B1 Air filter restriction pressostat
B3 Pilot pressure pressostat B2 Hydraulic oil filter pressostat
E3 Upperstructure working light B21 Hydraulic oil temperature sender
E7 Cigarette lighter E2 Attachment working light
H10 Working light switch lighting E3 Upperstructure working light
H11 Windshield wiper switch lighting G1 Batteries
H12 Windshield washer switch lighting P11 Fuel level indicator
H13 Heater blower switch lighting S2 Battery master switch
H15 Instrument panel audible warning X2 Upperstructure power socket
H26 Horn X5 Attachment working light power socket
M3 Windshield washer motor X10 Fuel level indicator connector
M4 Heater blower motor Y2 Pilot safety solenoid valve
P4 Hourmeter
ENGINE
P10 Instrument panel
S1 Key switch B4 Engine oil pressure pressostat
S3 Horn switch B22 Engine coolant temperature sender
S4 Working light switch G2 Alternator
S6 Windshield wiper switch K53 Fuel heater device (relay only fitted as standard)
S24 Pilot safety switch M1 Starter motor
S26 Windshield washer switch Y1 Engine cut-out solenoid valve
S27 Heater blower switch
X1 Cab floor/cab connector

Cre7-80630GB Issued 09-97 Printed in U.K.


4001-28

CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)

V51

AA
101 B23

AA
AA
+ - H15

AA
V52 101 0
145 146
100 102 V50

AA 140
Y53

AA
AAAAAAA
AAAAAAA AA
AAAAA 82 90
0 Y7
7 K53
ø5
H58 H30 H53 H31 59
22 10 Y8
0 0
S56 S20 S53 S25 23 (1) K50
1 R10 125
124 33 102
23 (2) 12 Y52
56 0
K51
S30 41 100
56 0 Y51
56
B56
126
90 59 0 125
Y50
0

0
E12 26
41
R50
0
R11 S28
119

H32 + - + -
S21

9 24 6 16 15 6
102
100

14 19 14 1

CM96J015

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-29

CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)
ELECTRICAL CABINET ELECTRICAL CABINET
1 4 terminal strip 1 4 terminal strip
6, 9, 14, 16, 19, 24, 15, 14 et 6 7, 10, 12, 22, 23 (1) (2), 33
INSTRUMENT PANEL UPPERSTRUCTURE
H30 Cold start assistance switch lighting B23 Overload indicator
H31 Rotary switch lighting B56 Boom raising range limitation detector
H32 Overload indicator switch lighting K50 Adjustable boom raising range limitation relay
H53 Front working light switch lighting K51 Adjustable or articulated boom lowering limitation relay
H58 Quick-attach switch lighting K53 Fuel heater relay
S20 Cold start assistance switch R50 Fuel heating device
S21 Overload indicator switch Y7 Adjustable or articulated boom extending solenoid valve
S25 Rotary light switch (specific to certain countries) Y8 Adjustable or articulated boom retracting solenoid valve
S30 Adjustable or articulated boom switch Y50 Adjustable boom raising range limitation solenoid valve
S53 Front working light switch Y51 Quick-attach solenoid valve
S56 Quick-attach switch Y52 Quick-attach solenoid valve
V50 Quick-attach diode Y53 Fuel filler pump
V51 Quick-attach diode
ENGINE
V52 Quick-attach diode
H15 Audible warning E12 Engine compartment light
R10 Cold start assistance resistor
R11 Cold start assistance glow plug
S28 Engine compartment working light switch

Cre7-80630GB Issued 09-97 Printed in U.K.


4001-30

CAB AND CAB OPTION WIRING

E50 E50

127 0 128 0

A
B
M2 C
D

142
144

38
0
0
26
S10

A
E1 M6 S29
X14 (2) X14 (1)

0 E7 48

0 33 X1

31 F
G H 128
M J
144 E K
38 2 (7)
B6 132 D
L A 135 B5

133
- C B
-
132
135 134
+ 142 134 133 26 +

0 31 0 33

H57 E51
PDH0228

A White wire S29 Cab fan switch (optional)


B Grey wire X1 (A) (B) (C) (D) Cab floor/cab LH and RH loud-
C Blue wire speaker connector (optional)
D Black wire X1 (H) (G) Connector : cab floor/cab front (optional)
E1 Cab lighting and rear (standard) working lights
E7 Cigarette lighter (see page 26) X1 (E) (J) (M) (L) Cab floor/cab windshield wiper and
E50 Front working lights (optional) working light power connector
E51 Rear working light (standard) X1 (F) Cab floor/cab rotary light connector (specific to
H57 Rotary light (optional) certain countries)
B5 RH loudspeaker (optional) X1 (K) Cab floor/cab operator’s compartment lighting
B6 LH loudspeaker (optional) X14 (1) (2) Cab fan plug (optional)
M2 Windshield wiper motor 2 (7) 10 way connector (see printed circuit wiring
M6 Cab fan motor (optional) page 5)
S10 Cab lighting switch

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-31

INDEX
A C
Adjustable boom lowering range limitation Cold start assistance relay............................. 6, 8, 16
relay .........................................................6, 24, 29 Cold start assistance resistor................................. 29
Adjustable boom raising height limiter Cold start assistance switch............................. 15, 29
solenoid valve ....................................................24 Cold start assistance switch lighting ................ 15, 29
Adjustable boom raising range limitation relay ...6, 29 Cold start assistance switch lighting (optional) ...... 16
Adjustable boom raising range limitation relay Connector cab floor/cab front (optional) and rear
(optional) ............................................................24 (standard) working lights ................................... 30
Adjustable boom raising range limitation Connector (10 way)................................................ 30
solenoid valve ....................................................29
D
Adjustable boom range limiter detector ..................24
Adjustable or articulated boom extending Description of electrical cabinet printed circuit
electro valve .......................................................29 (optional equipment) ............................................ 6
Adjustable or articulated boom extending Description of electrical cabinet printed circuit
solenoid valve ....................................................24 (standard equipment) .......................................... 4
Adjustable or articulated boom retracting
E
solenoid valve ..............................................24, 29
Adjustable or articulated boom switch ........15, 24, 29 Electrical cabinet printed circuit wiring (optional
Air conditioning .......................................................21 equipment)........................................................... 6
Air filter restriction pressostat ...........................18, 27 Electrical cabinet printed circuit wiring (standard
Alternator ....................................................16, 17, 27 equipment)........................................................... 4
Attachment working light ........................................27 Electrical schematic (plate 2) ................................. 16
Attachment working light (on boom) .......................20 Electrical schematic (plate 3) ................................. 18
Attachment working light power connection ...........20 Electrical schematic (plate 4) ................................. 20
Attachment working light power socket ..................27 Electrical schematic (plate 5) ................................. 22
Audible warning ................................................15, 29 Electrical schematic (plate 6) ................................. 24
Engine compartment light ................................ 22, 29
B
Engine compartment light switch ........................... 29
Batteries ...........................................................16, 27 Engine compartment lighting switch ...................... 22
Battery charge warning lamp..................................19 Engine coolant solution temperature sender ......... 27
Battery master switch .................................16, 17, 27 Engine coolant temperature sender....................... 18
Boom raising range limitation detector ...................29 Engine cut-out control ............................................ 17
Engine cut-out solenoid valve ................................ 27
C
Engine module and upperstructure wiring
Cab and cab option wiring ......................................30 (optional)...................................................... 28, 29
Cab fan motor.........................................................30 Engine module and upperstructure wiring
Cab fan plug ...........................................................30 (standard) .................................................... 26, 27
Cab fan switch ........................................................30 Engine oil pressure pressostat......................... 18, 27
Cab floor wiring (Optional)......................................29
F
Cab floor wiring (optional).......................................28
Cab floor wiring (standard) ...............................26, 27 Fan......................................................................... 21
Cab floor/cab connector .........................................27 Fan motor............................................................... 22
Cab floor/cab LH and RH loudspeaker connector ..30 Fan motor connector.............................................. 22
Cab floor/cab operator’s compartment lighting .......30 Fan switch.............................................................. 22
Cab floor/cab rotary light connector........................30 Floor connector cab/rear cab working light ............ 20
Cab floor/cab windshield wiper and working light Front working light connector................................. 22
power connector.................................................30 Front working light switch........................... 15, 22, 29
Cab lighting.................................................18, 19, 30 Front working light switch lighting .............. 15, 22, 29
Cab lighting switch............................................18, 30 Front working lights.......................................... 22, 30
Cab rear working light.............................................20 Fuel filler pump ................................................ 22, 29
Cab/Cab floor, cab lighting connector ....................18 Fuel heater device (relay only fitted as standard) .. 27
Cigarette lighter ....................................20, 21, 27, 30 Fuel heater relay ...................................... 4, 6, 24, 29
Cold start assistance glow plug ..............................29 Fuel heating device.......................................... 24, 29
Cold start assistance momentary switch (optional) 16 Fuel level indicator ........................................... 18, 27

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-32
F H
Fuel level indicator connector.................................27 Hourmeter ........................................................ 18, 27
Fuel level indicator connectorsl ..............................18 Hourmeter relay ............................................. 4, 8, 16
Fuse (5A), not used ..................................................4 Hydraulic oil filter pressostat ............................ 18, 27
Fuse (7.5A), not used ...............................................8 Hydraulic oil temperature sender ..................... 18, 27
Fuse (10A) not used .................................................4
I
Fuse, adjustable and articulated boom (5A)...........24
Fuse, adjustable or articulated boom (5A)............6, 8 Injection pump solenoid ......................................... 16
Fuse, cab lighting, horn relay (5A)..................4, 8, 18 Instrument panel ........................................ 18, 19, 27
Fuse, cab working light (15A) .................................22 Instrument panel (front face).................................. 11
Fuse, cab working lights (15A) .................................6 Instrument panel audible warning .............. 13, 18, 27
Fuse, cigarette lighter (7.5A) ..........................4, 8, 20 Instrument panel wiring.......................................... 11
Fuse, cold start assistance (30A) .......................8, 16
K
Fuse, cold start assistance (optional) (30A) .............6
Fuse, front cab working lights (15A) .........................8 Key switch.................................................. 13, 16, 27
Fuse, horn (10A).............................................4, 8, 18
L
Fuse, instrument panel (7.5A) ........................4, 8, 18
Fuse, not used (7.5A) ...............................................8 Left-hand control arm pilot safety relay.................... 4
Fuse, overload indicator (5A) .............................8, 22 LH control arm pilot safety relay .............................. 8
Fuse, overload indicator (optional) (5A) ...................6 LH loudspeaker................................................ 22, 30
Fuse, pilot safety (10A)...................................4, 8, 24
O
Fuse, radio (5A)..............................................6, 8, 22
Fuse, starter switch (5A).................................4, 8, 16 Overload indicator............................................ 23, 29
Fuse, upperstructure headlights (15A) ...................20 Overload indicator diode ................................ 6, 8, 22
Fuse, upperstructure headlights and rear Overload indicator pressostat, on boom foot ......... 22
cab working light (15A).........................................8 Overload indicator switch........................... 15, 22, 29
Fuse, upperstructure power line connection Overload indicator switch lighting .............. 15, 22, 29
(15A) ....................................................................4
P
Fuse, upperstructure power socket (15A) ..........8, 22
Fuse, upperstructure working light and rotary light P10 instrument panel electrical schematic
relay (10A)............................................................8 (plate 1) ............................................................. 10
Fuse, upperstructure working light and rotary light Pilot pressure ......................................................... 19
relay (10A) (specific to certain countries) .............6 Pilot pressure pressostat ................................. 18, 27
Fuse, upperstructure working lights and cab rear Pilot safety relay..................................................... 24
working light (15A) ...............................................4 Pilot safety solenoid valve................................ 24, 27
Fuse, ventilation, heater (15A) ...............................20 Pilot safety switch ...................................... 13, 24, 27
Fuse, ventilation, heater, fuel heater (15A) ..........4, 8 Pre-heater plug ...................................................... 16
Fuse, windshield washer, windshield wiper Printed circuit schematic guide ................................ 8
(10A) ..........................................................4, 8, 20
Q
Fuse, windshield wiper intermittent action
(15A) ..........................................................4, 8, 20 Quick-attach........................................................... 23
Fuse, working light, rotary light relay (10A) ............20 Quick-attach solenoid valve ............................. 22, 29
Quick-attach switch.................................... 15, 22, 29
G
Quick-attach switch lighting ....................... 15, 22, 29
General contact diode ....................................4, 8, 16
R
General contact relay ...............................................4
General contact relay 24V, 50A..........................8, 16 Radio.......................................................... 22, 23, 27
Radio diode.................................................... 6, 8, 22
H
Rear attachment working light ............................... 21
Heater.....................................................................21 Rear foglight switch.......................................... 15, 22
Heater blower motor .........................................20, 27 Rear working light .................................................. 30
Heater blower switch ..................................13, 20, 27 RH and LH loudspeaker connector........................ 22
Heater blower switch lighting......................13, 20, 27 RH loudspeaker ............................................... 22, 30
Horn............................................................18, 19, 27 Resistor (0.85 Ohm)........................................... 6, 16
Horn relay .......................................................4, 8, 18 Right-hand and left-hand control arm wiring (optional)
Horn switch.................................................13, 18, 27 15

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001-33
R
Right-hand control arm, left-hand control arm
(standard equipment) .........................................13
Rotary light .................................................20, 21, 30
Rotary light cab floor/cab connector .......................20
Rotary light indicator diode .............................6, 8, 20
Rotary light switch ......................................15, 20, 29
Rotary light switch lighting ..........................15, 20, 29
S
Schematic symbols...................................................3
Shunt ..................................................................4, 20
Shunt, Pilot safety relay..........................................24
Specifications ...........................................................2
Starter motor.....................................................16, 27
Starter motor relay..........................................4, 8, 16
T
Terminal strip (4) ....................................................22
U
Upperstructure and attachment light relay................4
Upperstructure power socket......................22, 23, 27
Upperstructure working light.......................20, 21, 27
W
Windshield washer .................................................21
Windshield washer motor .................................20, 27
Windshield washer switch ..........................13, 20, 27
Windshield washer switch lighting ..............13, 20, 27
Windshield wiper ....................................................21
Windshield wiper intermittent action ...................4, 20
Windshield wiper motor ....................................20, 30
Windshield wiper motor cab floor/cab connector ....20
Windshield wiper switch .............................13, 20, 27
Windshield wiper switch lighting .................13, 20, 27
Working brake switch lighting ...........................13, 27
Working light relay ..............................................8, 20
Working light switch....................................13, 20, 27
Working light switch lighting ...................................20

Cre 7-80630GB Issued 09-97 Printed in U.K.


4001
Section
4001

ELECTRICAL SCHEMATICS
Crawler excavators

Copyright  1999 Case France


Printed in France
Case Cre 7-26570GB November 1999
4001-2

TABLE OF CONTENTS
SCHEMATIC SYMBOLS ......................................................................................................................................... 3
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD) ................................................... 4
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD) .................................................................... 4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) .................................................... 6
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL) ..................................................................... 6
PRINTED CIRCUIT SCHEMATIC GUIDE ............................................................................................................... 8
P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1) .................................................................... 10
INSTRUMENT PANEL WIRING ............................................................................................................................ 11
INSTRUMENT PANEL (FRONT FACE) ................................................................................................................ 11
RIGHT-HAND CONTROL ARM AND LEFT-HAND CONTROL ARM WIRING (STANDARD) ............................. 13
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL) ........................................................... 15
ELECTRICAL SCHEMATIC (PLATE 2) ................................................................................................................. 16
ELECTRICAL SCHEMATIC (PLATE 3) ................................................................................................................. 18
ELECTRICAL SCHEMATIC (PLATE 4) ................................................................................................................. 20
ELECTRICAL SCHEMATIC (PLATE 5) ................................................................................................................. 22
ELECTRICAL SCHEMATIC (PLATE 6) (788C/988C/1188C) ............................................................................... 24
ELECTRICAL SCHEMATIC (PLATE 7) ................................................................................................................. 26
ELECTRICAL SCHEMATIC (PLATE 8) ................................................................................................................. 28
CAB FLOOR WIRING (STANDARD) .................................................................................................................... 30
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD) ............................................................... 31
788C-988C-1188C ELECTRONIC WIRING CIRCUIT ......................................................................................... 32
DETAILS OF 35 PINS CONNECTOR X3 ON 788C-988C-1188C EXCAVATORS ............................................... 33
788C-988C-1188C ELECTRONIC WIRING CIRCUIT .......................................................................................... 33
CAB FLOOR WIRING (OPTIONAL) ...................................................................................................................... 34
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL) ................................................................ 35
CAB AND CAB OPTION WIRING ......................................................................................................................... 36
ALPHABETICAL INDEX ........................................................................................................................................ 37

SPECIFICATIONS
Circuit voltage ............................................................................... 24 volt negative earth and 12 volt negative earth
Batteries .......................................................................................................2 x 12 Volt 120 A/hrs, low maintenance
Alternator ..............................................................................................................................Bosch, 28 volt, 45 amps
Starter motor........................................................................................................................... Bosch, 24 volt, 4.0 kW

Cre 7-26570GB Issued 11-99


4001-3

SCHEMATIC SYMBOLS Local earth

A (n) Radio/housings
B (n) Indicators/pressure switches/loud-speakers/detectors/thermal detector/gauge Wire number
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators Closed circuit
H (n) Warning devices (lighted and audible)
K (n) Relays
M (n) Motors Open circuit
P (n) Instruments
R (n) Resistors/heating elements/heating plugs
S (n) Switches/rotating switches/main circuit breaker Intersection of two wires with connection point
Sh (n) Shunt resistors
V (n) Diodes
X (n) Supply line connections Intersection of two wires without connection point
Y (n) Solenoid valves, solenoid shut-off valves
NOTE: The (n) shows the component number.
Example: K2 is relay N°2. Link with following plate

Link with preceding plate


(n) Supply on printed circuit

A
Return to another plate with the same letter
(n) Battery terminal

Bulbs
(n) Printed circuit connection terminal

Test bulb
Printed circuit earth connector

Light emitting diode (LED)


A1 Instrument panel connector

Regulator
1 or 1 or 1 Identification of harness

1(1) or 1(1) or 1(1) Identification of harness, followed by path identification number

(1) or (1) Printed circuit earth connectors

3 2
The installation position for the harness connector (1) on connector (2) of the
printed circuit is identified by a red mark (3) followed by the figure 1 on the
printed circuit. This identification corresponds to the position of path 1 of the
1 harness connector (1). This position is completed when the path 1 line is
shown by a red ring (4) located on line 1 wire, or by red paint marking on the
housing.

1
4

Cre7-26570GB Issued 11-99


4001-4

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD) ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD)
1 Floor harness, 10 way connector
2 Floor harness, 10 way connector
3 Floor harness, 10 way connector
6 Floor harness, 10 way connector
8 Floor harness, 2 way connector

1 Common harness, 8-way connector


4 Engine harness, 8-way connector
8 Harness, RH front upperstructure working light, clip,
20 Cab socket harness, 5-way connector
21 Cab socket harness, 6-way connector
26 Harness time delay, 6-way connector
27 Harness windshield washer, 2-way connector
30 Electronic harness, 8-way connector (788/988/1188)
31 Diagnostic plug harness, 4-way connector (788/988/1188)
35 Step-down transformer harness 24V - 12V, 4-way connector
36 12V socket harness, 2-way connector
45 Upperstructure socket harness
50 Threshold detector harness, 5-way connector (788)
51 Harness, heavy lift solenoid valve (788)
8 Harness earth, front RH upperstructure working light, clip

A Standard earth
B Optional earth 1
C Option 1

CI99K501

1 24 volt printed circuit supply detector (788P heavy lift)


2 24 volt printed circuit supply F28 Fuse, 40 A, engine stop/start solenoid (injection)
4 (1) Printed circuit earth F30 Fuse, 10 A, windshield wiper (BAT +)
4 (2) Printed circuit earth F32 Fuse, 5 A, (BAT +) electronics
F1 Fuse, 30 A, starter motor solenoid, thermostart H14 Troubleshooting test LED
F2 Fuse, 5 A, starter key switch K1 Starter motor relay
F3 Fuse, 7.5 A, instrument panel, hourmeter K2 Battery relay
F4 Fuse, 5 A, cab lighting, horn (control), hood lighting K3 Hourmeter relay
F5 Fuse, 10 A, working lights (control), rotary light (std), K4 Electronic supply relay
night lighting for switch on instrument panel and elec- K5 Horn relay
tronics K6 Working light relay
F6 Fuse, 15 A, attachment working light, rear cab light, K13 Engine stop solenoid relay
upperstructure working lights K20 Windshield wiper intermittent action
F7 Fuse, 10 A, horn (power) K21 Safety relay piloting pressure switch piloting
F8 Fuse, 15 A, upperstructure socket, fuel pump K54 Frequency threshold detector relay (threshold: 1 =
F9 Fuse, 10 A, windshield washer, windshield wiper (BAT 1600 rpm) (788)
+ R) K55 Frequency threshold detector relay (threshold: 2 =
F10 Fuse, 10 A, heater 1400 rpm) (788)
F11 Fuse, 7.5 A, cigar lighter, cab blower K61 Battery relay (heater/air conditioner)
F12 Fuse, 10 A, pilot safety, overload indicator Sh3, Sh4, Sh6 Shunt
F14 Fuse, 10 A, step-down transformer / radio V1 Starter key switch diode
F15 Fuse, 15 A, general lighting V24 K54 relay diode
F27 Fuse, 5 A, remote controlled or articulated boom, tool V25 K55 relay diode
quick coupler, air suspension seat, speed threshold V30 Buzzer diode

Cre 7-26570GB Issued 11-99


4001-5

PDH0232

Cre 7-26570GB Issued 11-99


4001-6

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL)
6 Adjustable boom harness, 2-way connector
7 Hood lighting harness, clip
9 Cold start switch harness, 2-way connector
10 Adjustable boom harness, 2-way connector
12 Air conditioner harness, 5-way connector
16 Overload indicator switch harness, 2-way connector
22 Cold start plug harness, clip
23 Thermostart element harness, 2-way connector
24 Front cab light switch harness, 2-way connector
33 Overload indicator pressure switch harness
46 Fuel pump harness, clip
47 Fuel heater harness, clip
48 Quick coupler solenoid valve harness, clip

6 Adjustable boom harness earth, clip


7 Hood lighting harness earth, clip
12 Air conditioning harness earth, clip
33 Overload indicator pressure switch harness earth, clip
46 Harness earth, fuel pump, clip
47 Fuel heater harness earth, clip
1 48 Tool quick coupler harness earth, clip

1 Boom reach limitation detector cable


2 Boom reach limitation solenoid valve cable
3 Connection strip

B Optional earth
C Option 1
CI99J044

F1 Fuse, 30 A, starter motor solenoid, thermostart V21 Overload indicator lamp diode on instrument
F4 Fuse, 5 A, cab lighting, horn (control), hood panel
lighting V22 Rotary light diode on instrument panel
F5 Fuse, 10 A, working lights (control), rotary light V52 Quick coupler switch diode
(std), night lighting for switch on instrument
panel and electronics 1 Connection strip
F8 Fuse, 15 A, upperstructure socket, fuel pump
F11 Fuse, 7.5 A, cigar lighter, cab blower
F13 Fuse, 15 A, air conditioner
F27 Fuse, 5 A, remote controlled or articulated
boom, tool quick coupler, air suspension seat,
speed threshold detector (788P heavy lift)
F29 Fuse, 10 A, cab front working light
F31 Fuse, 10 A, fuel heater
K15 Thermostart relay
K50 Adjustable boom raising limiter relay
K51 Adjustable boom retracting limitation relay
K53 Fuel heater relay
K59 Air conditioning compressor relay
K60 Air conditioning condenser relay
K61 Battery relay (heater/air conditioner)
R10 Resistor, 0.85 Ohms

Cre 7-26570GB Issued 11-99


4001-7

1 3 2

CM99K019

Cre 7-26570GB Issued 11-99


4001-8

PRINTED CIRCUIT SCHEMATIC GUIDE K1 Starter motor relay


K2 Battery relay
1 (1) 24 V PCB supply K3 Hourmeter relay
1 (2) 24 V PCB supply K4 Electronic supply relay
4 (1) Printed circuit earth K5 Horn relay
4 (2) Printed circuit earth K6 Working light relay
F1 Fuse, 30 A, starter motor solenoid, thermostart K7 Not used
F2 Fuse, 5 A, starter key switch K9 Pilot safety relay/axle unlocking
F3 Fuse, 7.5 A, instrument panel, hourmeter K13 Engine stop solenoid relay
F4 Fuse, 5 A, cab lighting, horn (control), hood lighting K15 Thermostart relay
F5 Fuse, 10 A, working lights (control), rotary light (std), night lighting for switch on instrument panel and electro- K20 Windshield wiper intermittent action
nics K21 Safety relay piloting pressure switch piloting
F6 Fuse, 15 A, attachment working light, rear cab light, upperstructure working lights K52 Not used
F7 Fuse, 10 A, horn (power) K53 Fuel heater relay
F8 Fuse, 15 A, upperstructure socket, fuel pump K54 Frequency threshold detector relay (threshold: 1 = 1600 rpm) (788)
F9 Fuse, 10 A, windshield washer, windshield wiper (BAT + R) K55 Frequency threshold detector relay (threshold: 2 = 1400 rpm) (788)
F10 Fuse, 10 A, heater K56 Not used
F11 Fuse, 7.5 A, cigar lighter, cab blower K57 Not used
F12 Fuse, 10 A, pilot safety, overload indicator K58 Not used
F13 Fuse, 15 A, air conditioner K59 Air conditioning compressor relay
F14 Fuse, 10 A, step-down transformer / radio K60 Air conditioning condenser relay
F15 Fuse, 15 A, general lighting K61 Battery relay (heater/air conditioner)
F16 Not used S3 Shunt relay K7
F17 Not used S4 Not used
F18 Not used S5 Not used
F19 Not used S6 Night lighting (switch)
F20 Not used S8 Not used
F21 Not used S9 Not used
F22 Not used S10 Not used
F23 Not used S11 Not used
F24 Not used V1 Starter key switch diode
F25 Not used V2 Diode less engine running
F26 Not used V3 Not used
F27 Fuse, 5 A, remote controlled or articulated boom, tool quick coupler, air suspension seat, speed threshold V5, V6, V7, V8, V9, V10 Not used
detector (788P heavy lift) V12, V13, V14, V15, V16, V17, V18, V19, V20 Not used
F28 Fuse, 40 A, engine stop/start solenoid (injection) V21 Overload indicator lamp diode on instrument panel
F29 Fuse, 10 A, cab front working light V22 Rotary light diode on instrument panel
F30 Fuse, 10 A, windshield wiper (BAT +) V23 Not used
F31 Fuse, 10 A, fuel heater V24 K54 relay diode
F32 Fuse, 5 A, (BAT +) electronics V25 K55 relay diode
H14 Troubleshooting test LED V26 Not used
V27 Not used
V28 Not used
V30 Buzzer diode
V31 Not used
V52 Quick coupler switch diode

Cre 7-26570GB Issued 11-99


4001-9

CM99K032

Cre 7-26570GB Issued 11-99


4001-10

P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC P. 10 (PLATE 1)

PDH0233

A2 Minimum pilot pressure red warning lamp connector 1 Stop alarm red warning lamp
A3 Hydraulic oil temperature warning lamp connector 2 Alarm orange warning lamp
A4 Battery charge red warning lamp 3 Audible warning device stop push-button
A5 Red and orange warning lamp connector for audible warning device 6 Engine oil pressure red warning lamp
A7 Engine oil pressure red warning lamp connector 7 Air filter restriction red warning lamp
8 Battery charge red warning lamp
B1 24 volt power supply
9 Hydraulic oil filter restriction red warning lamp
B3 Earth
11 Minimum pilot pressure red warning lamp
B4 Fuel level warning lamp connector
12 Overload indicator orange warning lamp (option)
B5 Gauge lighting connector
13 Gauge lighting indicator lamp
B6 Engine coolant solution temperature gauge connector
14 Not used
B7 Fuel minimum connector
15 Rotary light orange indicator lamp (optional)
C2 Air filter restriction red warning lamp connector
C4 Overload indicator orange warning lamp connector (optional)
C6 Connector not used
D3 Hydraulic oil filter restriction red warning lamp connector
F2 Rotary light orange indicator lamp connector (special for certain countries)
P1 Engine coolant solution temperature indicator lamp
P2 Fuel level gauge
P3 Hydraulic oil temperature indicator

Cre 7-26570GB Issued 11-99


4001-11

INSTRUMENT PANEL WIRING INSTRUMENT PANEL (FRONT FACE)

1 2 3

P3
P1

13
P2

PDG0235
11
7
A 7 way connector: Minimum pilot pressure red warning lamp, hydraulic oil temperature indicator lamp, battery
charge red warning lamp, audible warning cancellation push-button, engine oil pressure red warning lamp,
orange alarm warning lamp, red stop alarm warning lamp
B 7 way connector: 24 Volts supply, earth, fuel level gauge, gauge lighting, engine coolant temperature indicator.
15
C 7 way connector: air filter restriction red warning lamp, overload indicator orange indicator lamp (optional). 12
D 7 way connector: hydraulic oil filter restriction red warning lamp. CS99K502
F 7 way connector: rotary light orange indicator lamp (optional). 1 Stop alarm red warning lamp P1 Engine coolant solution temperature indicator
2 Alarm orange warning lamp lamp
3 Audible warning device stop push-button P2 Fuel level gauge
6 Engine oil pressure red warning lamp P3 Oil temperature indicator
7 Air filter restriction red warning lamp
8 Battery charge red warning lamp
9 Hydraulic oil filter restriction red warning lamp
11 Minimum pilot pressure red warning lamp
12 Overload indicator orange warning lamp
(optional)
13 Gauge lighting indicator lamp
15 Rotary light orange indicator lamp (optional)

Cre 7-26570GB Issued 11-99


4001-12

H11

S6

H15

H12

S3 S26

H13

S27

H10

S4

S1 S22

S24

CM99K020

Cre 7-26570GB Issued 11-99


4001-13

RIGHT-HAND CONTROL ARM AND LEFT-HAND CONTROL ARM WIRING


(STANDARD)
H10 Working brake switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H15 Instrument panel audible warning
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S22 Control keyboard (788-988-1188)
S24 Pilot safety switch
S26 Windshield washer switch
S27 Heater blower switch
Floor harness
30 Electronic harness

Cre 7-26570GB Issued 11-99


4001-14

H31
H53
H30
S25
S53
S20

S30

H58

S56

H32

S21

CM99K021

Cre 7-26570GB Issued 11-99


4001-15

RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)


H30 Cold start assistance switch lighting (optional)
H31 Rotary light switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H53 Cab front working light switch lighting (optional)
H58 Quick coupler switch lighting (optional)
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S25 Rotary light switch (optional)
S30 Adjustable or articulated boom control switch (optional)
H53 Cab front working light switch lighting (optional)
S56 Quick coupler switch (optional)
6 Harness - adjustable boom control
9 Cold start assistance harness
16 Overload indicator harness
24 Harness – front working lights, rear working light
8 Floor harness

Cre 7-26570GB Issued 11-99


4001-16

ELECTRICAL SCHEMATIC (PLATE 2)


ELECTRICAL CABINET FLOOR
B25 Threshold detector (788) P4 Hourmeter
F1 Fuse, 30 A, starter motor solenoid, thermostart P10 Instrument panel
F2 Fuse, 5 A, starter key switch H30 Cold start assistance switch lighting (optional)
F3 Fuse, 7.5 A, instrument panel, hourmeter S1 Key switch
F27 Fuse, 5 A, remote controlled or articulated S4 Working light switch
S2 Y1 boom, tool quick coupler, air suspension seat, S20 Cold start assistance switch (optional)
G2
R11 speed threshold detector (788P heavy lift)
UPPERSTRUCTURE
F28 Fuse, 40 A, engine stop/start solenoid (injec-
S1 R50
tion) G1 Batteries
F31 Fuse, 10 A, fuel heater S2 Battery master switch
K1 Starter motor relay Y55 Heavy lift solenoid valve (788)
K2 Battery relay
ENGINE
K3 Hourmeter relay
M1 K13 Engine stop solenoid relay G2 Alternator
K15 Thermostart relay M1 Starter motor
K53 Fuel heater relay R11 Cold start assistance plug (optional)
K54 Frequency threshold detector relay (threshold: Y1 Engine shut-down solenoid valve
1 = 1600 rpm) (788) R50 Fuel heater (optional)
K55 Frequency threshold detector relay (threshold:
2 = 1400 rpm) (788)
K61 Battery relay (heater/air conditioner)
R10 Resistor, 0.85 Ohms
V1 Starter key switch diode
V24 K54 relay diode
V25 K55 relay diode
Sh6 Shunt

G1 Y55

P10
S4
B25 F1-F2-F3-F27-F28-F31
P4 K1-K2-K3-K13-K15-K53-K54-K55-K61
S20 R10-V1-V24-V25
H30 Sh6

CM99K022

Cre 7-26570GB Issued 11-99


4001-17

STARTER KEY SWITCH GENERAL


BATTERIES STARTER BATTERY RELAY RELAY
ENGINE STOP HOURMETER COLD START ASSISTANCE ALTERNATOR FUEL OIL HEATER SPEED THRESHOLD DETECTOR
BATTERY MASTER SWITCH MOTOR HEATER/AIR CONDI- ENGINE STOP
TIONER RELAY RELAY

CM99K009

Cre 7-26570GB Issued 11-99


4001-18

ELECTRICAL SCHEMATIC (PLATE 3)


INSTRUMENT PANEL UPPERSTRUCTURE
B1 Air filter restriction pressure switch
P10 Instrument panel
B2 Hydraulic oil filter restriction pressure switch
ELECTRICAL CABINET B21 Hydraulic oil temperature sender
B23 Overload indicator (optional)
F3 Fuse, 7.5 A, instrument panel, hourmeter
P11 Fuel level gauge
F12 Fuse, 10 A, pilot safety, overload indicator
Y2 Pilot safety solenoid valve
K21 Safety relay piloting pressure switch piloting
Sh4 Shunt
Sh6 Shunt ENGINE
V21, V26, V30 Diode
Y2 B4 B4 Engine oil pressure switch
S4-S21-H32
ON FLOOR B22 Engine coolant temperature sender
B3 Pilot pressure switch
H15 Instrument panel audible warning
B22 H32 Overload indicator switch lighting (optional)
P11 S4 Working light switch
S21 Overload indicator switch (optional)
S24 Pilot safety switch

B1

B23
B2

B21

P10 F3 - F12
S24 K21
V21 - V26 - V30
H15
B3 SH4 - SH6

CM99K022

Cre 7-26570GB Issued 11-99


4001-19

INSTRUMENT PANEL
INSTRUMENT
HYDRAULIC OIL ENGINE HYDR. OVERLOAD INDICATOR PILOT SAFETY SYSTEM
AIR FILTER FUEL LEVEL PANEL ENGINE
FILTER OIL FLUID
RESTRICTION RESERVE ALARM AUDIBLE TEMPERATURE
RESTRICTION PRESSURE TEMP.
WARNING

CM99K010

Cre 7-26570GB Issued 11-99


4001-20

ELECTRICAL SCHEMATIC (PLATE 4)


INSTRUMENT PANEL V22 Rotary light diode on instrument panel
H10 Working brake switch lighting CAB
H11 Windshield wiper switch lighting
E1 Cab lighting
H12 Windshield washer switch lighting
E50 Cab front working lights
H31 Rotary light switch lighting (optional)
E51 Cab rear working light
S4 Working light switch
H57 Standard or Italian rotary light
S6 Windshield wiper switch
M2 Windshield wiper motor
E50 E1-S10 E51 H57 S25 Rotary light switch (optional)
E Blue
S26 Windshield washer switch
J White
ELECTRICAL CABINET L Grey
M Black
F4 Fuse, 5 A, cab lighting, horn (control), hood
M2 P10 Instrument panel
lighting
S10 Cab lighting switch
F5 Fuse, 10 A, working lights (control), rotary light
(std), night lighting for switch on instrument
panel and electronics ON FLOOR
F6 Fuse, 15 A, attachment working light, rear cab
H26 Horn
light, upperstructure working lights
M3 Windshield washer motor
F9 Fuse, 10 A, windshield washer, windshield
S3 Horn switch
wiper (BAT + R)
F29 Fuse, 10 A, cab front working light UPPERSTRUCTURE
F30 Fuse, 10 A, windshield wiper (BAT +)
E2 Attachment working light on boom
K5 Horn relay
E3 Upperstructure working lights
K6 Working light relay
K20 Windshield wiper intermittent action
Sh3 Shunt
Sh6 Shunt

E3

P10

H26 E3
S3 M3 F4-F5-F6-F9-F29-F30
K5-K6-K20
Sh3-Sh6
S4-H10 V22
S6-H11
S25-H31
S26-H12

CM99K022

Cre 7-26570GB Issued 11-99


4001-21

WORKING LIGHTS: WORKING LIGHT


ROTARY LIGHT WINDSHIELD WIPER WINDSHIELD WASHER CAB LIGHTING HORN
ATTACHMENT REAR OF CAB UPPERSTRUCTURE AT FRONT OF CAB

CM99K011

Cre 7-26570GB Issued 11-99


4001-22

ELECTRICAL SCHEMATIC (PLATE 5)


ELECTRICAL CABINET CAB
B5 RH loudspeaker (optional)
F2 Fuse, 5 A, starter key switch
B6 LH loudspeaker (optional)
F4 Fuse, 5 A, cab lighting, horn (control), hood
M6 Cab blower motor (optional)
lighting
S29 Cab blower switch (optional)
F8 Fuse, 15 A, upperstructure socket, fuel pump
F10 Fuse, 10 A, heater UPPERSTRUCTURE
F11 Fuse, 7.5 A, cigar lighter, cab blower
X2 Upperstructure power line connection
X2 M6 - S29 B5 E12 - S28 F13 Fuse, 15 A, air conditioner
Y53 Fuel filler pump (optional)
F14 Fuse, 10 A, step-down transformer / radio
Sh6 Shunt ENGINE
ON FLOOR E12 Engine compartment light (optional)
S28 Engine compartment lighting switch (optional)
A1 Radio
E7 Cigarette lighter
Y53 G3 Step-down transformer 24V / 12V
H13 Heater blower switch lighting
M4 Heater blower motor
S4 Working light switch
S27 Heater blower switch
X5 12V accessories socket

B6
S4-S27
H13
F2-F4-F8-F10-F11-F13-F14
Sh6

G3
X5
M4

E7 A1

CM99K022

Cre 7-26570GB Issued 11-99


4001-23

UPPERSTRUCTURE
24V - 12V STEP-DOWN RADIO FUEL CIGARETTE CAB HOOD
POWER LINE CAB HEATER
TRANSFORMER LH AND RH LOUDSPEAKERS FILLER PUMP LIGHTER VENTILATION LIGHTING
CONNECTION

CM99K012

Cre 7-26570GB Issued 11-99


4001-24

ELECTRICAL SCHEMATIC (PLATE 6) (788C/988C/1188C)


ELECTRICAL CABINET UPPERSTRUCTURE
F2 Fuse, 5 A, starter key switch B7 Swing detection pressure switch (788-988-
F32 Fuse, 5 A, (BAT +) electronics 1188)
K4 Electronic supply relay B10 Swing motor speed detector (788-988-1188)
H14 Troubleshooting test LED B11 Hydraulic pressure sender (788-988-1188)
Sh6 Shunt Y5 Upperstructure brake release control solenoid
Y5-Y6 B8 B22 M5-P12-X9
S22 S1 V1 Diode valve
Y6 Travel motor displacement change electro-con-
trol valve
S4 CAB
ENGINE
A2 Electronic control box (788-988-1188)
S22 Control keyboard (788-988-1188) B9 Engine speed detector (788-988-1188)
X3 35-way connector (788-988-1188) B22 Engine coolant temperature sender
X4 Troubleshooting test socket (788-988-1188) M5 Injection pump servo-motor (788-988-1188)
P12 Servo-motor potentiometer (788-988-1188)
ON FLOOR
X6 Engine speed detector connector (788-988-
B8 Travel detector pressure switch (788-988-1188) 1188)
S1 Key switch X7 Upperstructure swing speed detector connector
S4 Working light switch X8 Hydraulic pressure sender connector (788-988-
1188)
X9 Injection pump servo-motor connector (788-
988-1188)
Y4 DRE4 proportional pressure reduction valve

B9-X6

F2-F32
K4
A2 - X3 H14
V1
B10-X7
Sh6
B7
B11-X8 X4

CM99K022

Cre 7-26570GB Issued 11-99


4001-25

TROU- PRESSURE
DRE4 SWING TRAV. BLE- SWITCH +28V
ENGINE TROUBLE- WA- U/STRUCTURE
SERVO-MOTOR PRESSURE +28V BK. REL. 0V SPEED SHOO INST. CONTROL PRESSURE
SPEED SHOOTING TER SWING SPEED
INJECTION PUMP REDUCTION BATTERIES SOL. BAT. CH. TING PANEL PANEL SENDER
DETECTOR SOCKET T° DETECTOR
VALVE VALVE SOL.V. TEST SWING TRAVEL LIGHTG.
LED

CM99K013

Cre 7-26570GB Issued 11-99


4001-26

ELECTRICAL SCHEMATIC (PLATE 7)

ELECTRICAL CABINET UPPERSTRUCTURE


B56 Boom raising range limitation detector (optional)
F27 Fuse, 5 A, remote controlled or articulated
Y7 Adjustable or articulated boom extending elec-
boom, tool quick coupler, air suspension seat,
tro-valve (optional)
speed threshold detector (788P heavy lift)
Y8 Adjustable or articulated boom retracting elec-
K50 Adjustable boom raising limiter relay
tro-valve (optional)
K51 Adjustable boom retracting limitation relay
Y7-Y8-Y52 Y50 B56 Y50 Adjustable boom raising height limiter solenoid
S4 S30 Sh6 Shunt
valve (optional)
V52 Diode
Y52 Quick coupler solenoid valve (optional)
H15-P10 INSTRUMENT PANEL
CAB
H15 Instrument panel audible warning
H58 Quick coupler switch lighting (optional)
P10 Instrument panel
S4 Working light switch
S30 Adjustable or articulated boom control switch
(optional)
S56 Quick coupler switch (optional)

F27
K50-K51
V52
Sh6

S56-H58

CM99K022

Cre 7-26570GB Issued 11-99


4001-27

ADJUSTABLE BOOM
ADJUSTABLE BOOM
OR QUICK TOOL COUPLER
RANGE LIMITATION
ARTICULATED BOOM

CM99K014

Cre 7-26570GB Issued 11-99


4001-28

ELECTRICAL SCHEMATIC (PLATE 8)

ELECTRICAL CABINET CAB


F2 Fuse, 5 A, starter key switch B1 Air filter restriction pressure switch
F13 Fuse, 15 A, air conditioner B2 Hydraulic oil filter restriction pressure switch
B1 - B2 K59 Air conditioning compressor relay EC Compressor
EC - M
S1 R1 - R2 K60 Air conditioning condenser relay M Condenser blower and blower motors
T1 K61 Battery relay (heater/air conditioner) R1 Blower speed resistor
R2 Blower speed resistor
S1 Key switch
T1 Pressure switch

F2-F13
K59-K60-K61

CM99K022

Cre 7-26570GB Issued 11-99


4001-29

STARTER KEY SWITCH AIR CONDITIONER

CM99K015

Cre 7-26570GB Issued 11-99


4001-30

CAB FLOOR WIRING (STANDARD)

See page 4
FLOOR
A1 Radio
B3 Pilot pressure switch
B25 Threshold detector (788)
E3 Upperstructure working lights
E7 Cigarette lighter
G3 Step-down transformer 24V / 12V
H10 Working brake switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H15 Instrument panel audible warning
H26 Horn
K20 Windshield wiper intermittent action
M3 Windshield washer motor
M4 Heater blower motor
P4 Hourmeter
P10 Instrument panel
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S22 Control keyboard (788-988-1188)
S24 Pilot safety switch
S26 Windshield washer switch
S27 Heater blower switch
X1 Cab floor/cab connector
X4 Troubleshooting test socket (788-988-1188)
X5 12V accessories socket

CM99K023

Cre 7-26570GB Issued 11-99


4001-31

ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)

See page 4
UPPERSTRUCTURE
B1 Air filter restriction pressure switch
B2 Hydraulic oil filter restriction pressure switch
B21 Hydraulic oil temperature sender
E2 Attachment working light on boom
E3 Upperstructure working lights
G1 Batteries
P11 Fuel level gauge
S2 Battery master switch
X2 Upperstructure power line connection
X5 Attachment working light power connection
X10 Fuel level indicator connector
Y2 Pilot safety solenoid valve
Y55 Heavy lift solenoid valve (788)
ENGINE
B4 Engine oil pressure switch
B22 Engine coolant temperature sender
G2 Alternator
M1 Starter motor
Y1 Engine shut-down solenoid valve

CM99K027

Cre7-26570GB Issued 11-99


4001-32

788C-988C-1188C ELECTRONIC WIRING CIRCUIT


X9
4
1 Y4 6
2 B22
3
B10
X6
5

B9
M5 - P12

X7
Y5
7
8

28
X4

B7

9
Y6
9
25 27 10
26 B8
24 12
18
11 10
23 0
∆4 0
22
A2 ∆31
21
∆30
20
16 X8
19 B11

X3
17 S22
14
13

15
CM99K026 CS99K540

Cre 7-26570GB Issued 11-99


4001-33

DETAILS OF 35 PINS CONNECTOR X3 ON 788C-988C-1188C EXCAVATORS 788C-988C-1188C ELECTRONIC WIRING CIRCUIT

A2 Electronic control box (788-988-1188) 1 O-ring


B7 Swing detection pressure switch (788-988- 2 Ring
1188) 3 Washer
B8 Travel detector pressure switch (788-988-1188) 4 Lock
B9 Engine speed detector (788-988-1188) 5 Plug
B10 Swing motor speed detector (788-988-1188) 6 Clamp
B11 Hydraulic pressure sender (788-988-1188) 7 Pressure reduction valve
1 B22 Engine coolant temperature sender 8 Electronic harness
M5 Injection pump servo-motor (788-988-1188) 9 Screw
P12 Servo-motor potentiometer (788-988-1188) 10 O-ring
S22 Control keyboard (788-988-1188) 11 Travel block
X3 35-way connector (788-988-1188) 12 Swing block
X4 Troubleshooting test socket (788-988-1188) 13 Printed circuit card
X6 Engine speed detector connector (788-988- 14 Decal
1188) 15 Control panel retention
X7 Upperstructure swing speed detector connector 16 Nut
X8 Hydraulic pressure sender connector (788-988- 17 Washer
1188) 18 Rivet
X9 Injection pump servo-motor connector (788- 19 Screw
988-1188) 20 Bracket
Y4 DRE4 proportional pressure reduction valve 21 Nuts
X3 Y5 Upperstructure brake release control solenoid 22 Washer
valve 23 Screw
* Y6 Travel motor displacement change electro-con- 24 Handle
trol valve 25 Screw
26 Washer
27 Troubleshooting socket harness
28 Engine harness

CS99K546

* Wire 219, only on two-speed excavators


1 Electronic harness
X3 35-pin connector

Cre 7-26570GB Issued 11-99


4001-34

CAB FLOOR WIRING (OPTIONAL)


ELECTRICAL CABINET
1 Connecting strip
See page 6
INSTRUMENT PANEL
H30 Cold start assistance switch lighting (optional)
H31 Rotary light switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H53 Cab front working light switch lighting (optional)
H58 Quick coupler switch lighting (optional)
K50 Adjustable boom raising limiter relay
K51 Adjustable boom retracting limitation relay
R10 Resistor, 0.85 Ohms
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S25 Rotary light switch (optional)
S30 Adjustable or articulated boom control switch (optional)
S53 Front working lights switch (optional)
S56 Quick coupler switch (optional)
V52 Quick coupler switch diode

CM99K024

Cre 7-26570GB Issued 11-99


4001-35

ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)


ELECTRICAL CABINET
1 Connecting strip
2 Air conditioner
See page 6
UPPERSTRUCTURE
B23 Overload indicator (optional)
B56 Boom raising range limitation detector (optional)
R50 Fuel heater (optional)
Y7 Adjustable or articulated boom extending electro-valve (optional)
Y8 Adjustable or articulated boom retracting electro-valve (optional)
Y50 Adjustable boom raising height limiter solenoid valve (optional)
Y52 Quick coupler solenoid valve (optional)
Y53 Fuel filler pump (optional)
ENGINE
E12 Engine compartment light (optional)
R11 Cold start assistance plug (optional)
S28 Engine compartment lighting switch (optional)

CM99K028

Cre 7-26570GB Issued 11-99


4001-36

CAB AND CAB OPTION WIRING

A White wire X1 (A) (B) (C) (D) Cab floor/cab LH and RH loud-
B Grey wire speaker connector
C Blue wire X1 (H) (G) Cab floor/cab front and rear working lights
D Black wire connector (optional)
E1 Cab lighting X1 (E) (J) (M) (L) Cab floor/cab working light, wind-
E7 Cigarette lighter shield wiper motor connector
E50 Cab front working lights X1 (F) Cab floor/cab rotary light connector (specific to
E51 Cab rear working light certain countries)
H57 Standard or Italian rotary light X1 (K) Cab floor/cab interior lighting connector.
B5 RH loudspeaker (optional) X14 (1) (2) Cab blower plug (optional)
B6 LH loudspeaker (optional) 2 (7) 10 way connector (see printed circuit wiring on
M2 Windshield wiper motor page 5)
M6 Cab blower motor (optional)
S10 Cab lighting switch
S29 Cab blower switch (optional)

CM99J052

Cre 7-26570GB Issued 11-99


4001-37

ALPHABETICAL INDEX
Numerics (optional)......................................................................6
Description of electrical cabinet printed circuit
12V accessories socket.........................................22, 30
(standard) ....................................................................4
35-way connector (788-988-1188) ......................24, 33
Details of 35 pins connector x3 on 788c-988c-1188c
788c-988c-1188c Electronic wiring circuit ................ 32
excavators .................................................................33
788c-988c-1188c electronic wiring circuit ................ 33
Diode less engine running .............................................8
A DRE4 proportional pressure reduction valve..... 24, 33
Adjustable boom raising height limiter solenoid valve E
(optional) .............................................................26, 35
Electrical cabinet printed circuit wiring (optional).......6
Adjustable boom raising limiter relay ..............6, 26, 34
Electrical cabinet printed circuit wiring (standard) .....4
Adjustable boom retracting limitation relay ....6, 26, 34
Electrical schematic (Plate 2)......................................16
Adjustable or articulated boom control switch
Electrical schematic (Plate 3)......................................18
(optional) .......................................................15, 26, 34
Electrical schematic (Plate 4)......................................20
Adjustable or articulated boom extending electro-
Electrical schematic (Plate 5)......................................22
valve (optional)...................................................26, 35
Electrical schematic (Plate 6) (788C/988C/1188C).24
Adjustable or articulated boom retracting electro-valve
Electrical schematic (Plate 7)......................................26
(optional) .............................................................26, 35
Electrical schematic (Plate 8)......................................28
Air conditioning compressor relay......................6, 8, 28
Electronic control box (788-988-1188) ............... 24, 33
Air conditioning condenser relay........................6, 8, 28
Electronic supply relay ........................................ 4, 8, 24
Air filter restriction pressure switch................18, 28, 31
Engine compartment light (optional) ................... 22, 35
Alternator .................................................................16, 31
Engine compartment lighting switch (optional) . 22, 35
Attachment working light on boom ......................20, 31
Engine coolant temperature sender........18, 24, 31, 33
Attachment working light power connection............. 31
Engine module and upperstructure wiring (optional) .
B 35
Engine module and upperstructure wiring (standard)
Batteries ...................................................................16, 31
31
Battery master switch ............................................16, 31
Engine oil pressure switch.................................... 18, 31
Battery relay ..........................................................4, 8, 16
Engine shut-down solenoid valve........................ 16, 31
Battery relay (heater/air conditioner)...... 4, 6, 8, 16, 28
Engine speed detector (788-988-1188) ............. 24, 33
Boom raising range limitation detector (optional)...26,
Engine speed detector connector (788-988-1188) 24,
35
33
Buzzer diode ...............................................................4, 8
Engine stop solenoid relay ................................. 4, 8, 16
C
F
Cab and cab option wiring .......................................... 36
Frequency threshold detector relay .................. 4, 8, 16
Cab blower motor (optional) .................................22, 36
Front working lights switch (optional) ........................34
Cab blower switch (optional) ................................22, 36
Fuel filler pump (optional) ..................................... 22, 35
Cab floor wiring (optional) ........................................... 34
Fuel heater (optional) ............................................ 16, 35
Cab floor wiring (standard).......................................... 30
Fuel heater relay .................................................. 6, 8, 16
Cab floor/cab connector ........................................30, 36
Fuel level gauge..................................................... 18, 31
Cab front working light switch lighting (optional)15, 34
Fuel level indicator connector .....................................31
Cab front working lights .........................................20, 36
Fuse, 10 A, cab front working light.................... 6, 8, 20
Cab lighting..............................................................20, 36
Fuse, 10 A, fuel heater........................................ 6, 8, 16
Cab lighting switch .................................................20, 36
Fuse, 10 A, heater ............................................... 4, 8, 22
Cab rear working light............................................20, 36
Fuse, 10 A, horn (power) .......................................... 4, 8
Cigarette lighter ................................................22, 30, 36
Fuse, 10 A, pilot safety, overload indicator...... 4, 8, 18
Cold start assistance plug (optional) ...................16, 35
Fuse, 10 A, step-down transformer / radio ...... 4, 8, 22
Cold start assistance switch (optional)..........15, 16, 34
Fuse, 10 A, windshield washer, windshield wiper (BAT
Cold start assistance switch lighting (optional).15, 16,
+ R).................................................................... 4, 8, 20
34
Fuse, 10 A, windshield wiper (BAT +) .............. 4, 8, 20
Control keyboard (788-988-1188)........... 13, 24, 30, 33
Fuse, 10 A, working lights (control), rotary light (std),
D night lighting for switch on instrument panel and
electronics ....................................................4, 6, 8, 20
Description of electrical cabinet printed circuit

Cre 7-26570GB Edition 11-99


4001-38
Fuse, 15 A, air conditioner ...........................6, 8, 22, 28 O
Fuse, 15 A, attachment working light, rear cab light,
Overload indicator (optional) ................................18, 35
upperstructure working lights ........................ 4, 8, 20
Overload indicator lamp diode on instrument panel 6,
Fuse, 15 A, general lighting ..................................... 4, 8
8
Fuse, 15 A, upperstructure socket, fuel pump . 4, 6, 8,
Overload indicator switch (optional) ..............15, 18, 34
22
Overload indicator switch lighting (optional) 15, 18, 34
Fuse, 30 A, starter motor solenoid, thermostart4, 6, 8,
16 P
Fuse, 40 A, engine stop/start solenoid (injection) 4, 8,
P10 instrument panel electrical schematic p. 10 (plate
16
1) ................................................................................ 10
Fuse, 5 A, (BAT +) electronics........................... 4, 8, 24
Pilot pressure switch ..............................................18, 30
Fuse, 5 A, cab lighting, horn (control), hood lighting4,
Pilot safety relay/axle unlocking................................... 8
6, 8, 20, 22
Pilot safety solenoid valve.....................................18, 31
Fuse, 5 A, remote controlled or articulated boom, tool
Pilot safety switch.............................................13, 18, 30
quick coupler, air suspension seat, speed threshold
Printed circuit schematic guide .................................... 8
detector (788P heavy lift).....................4, 6, 8, 16, 26
Fuse, 5 A, starter key switch........... 4, 8, 16, 22, 24, 28 Q
Fuse, 7.5 A, cigar lighter, cab blower ........................22
Quick coupler solenoid valve (optional) ..............26, 35
Fuse, 7.5 A, instrument panel, hourmeter .4, 8, 16, 18
Quick coupler switch (optional) ......................15, 26, 34
H Quick coupler switch diode .................................6, 8, 34
Quick coupler switch lighting (optional) ........15, 26, 34
Heater blower motor .............................................. 22, 30
Heater blower switch ....................................... 13, 22, 30 R
Heater blower switch lighting ......................... 13, 22, 30
Radio ........................................................................22, 30
Heavy lift solenoid valve (788)............................. 16, 31
Resistor, 0.85 Ohms ..........................................6, 16, 34
Horn ......................................................................... 20, 30
RH loudspeaker (optional) ....................................22, 36
Horn relay.............................................................. 4, 8, 20
Right-hand and left-hand control arm wiring (optional)
Horn switch ....................................................... 13, 20, 30
15
Hourmeter ............................................................... 16, 30
Right-hand control arm and left-hand control arm
Hourmeter relay ................................................... 4, 8, 16
wiring (standard) ...................................................... 13
Hydraulic oil filter restriction pressure switch18, 28, 31
Rotary light diode on instrument panel .............6, 8, 20
Hydraulic oil temperature sender ........................ 18, 31
Rotary light switch (optional) ..........................15, 20, 34
Hydraulic pressure sender (788-988-1188)....... 24, 33
Rotary light switch lighting (optional).............15, 20, 34
Hydraulic pressure sender connector (788-988-1188)
24, 33 S
I Safety relay piloting pressure switch piloting ...4, 8, 18
Schematic symbols ........................................................ 3
Injection pump servo-motor (788-988-1188) ..... 24, 33
Servo-motor potentiometer (788-988-1188) ......24, 33
Injection pump servo-motor connector (788-988-
Shunt relay K7 ................................................................ 8
1188) ................................................................... 24, 33
Standard or Italian rotary light ..............................20, 36
Instrument panel ..................................16, 18, 20, 26, 30
Starter key switch diode ......................................4, 8, 16
Instrument panel (front face).......................................11
Starter motor ...........................................................16, 31
Instrument panel audible warning ...........13, 18, 26, 30
Starter motor relay ...............................................4, 8, 16
Instrument panel wiring................................................11
Step-down transformer 24V / 12V .......................22, 30
K Swing detection pressure switch (788-988-1188).. 24,
33
K54 relay diode .................................................... 4, 8, 16
Swing motor speed detector (788-988-1188) ....24, 33
K55 relay diode .................................................... 4, 8, 16
Key switch .............................................13, 16, 24, 28, 30 T
L Thermostart relay .................................................6, 8, 16
Threshold detector (788).......................................16, 30
LH loudspeaker (optional) .................................... 22, 36
Travel detector pressure switch (788-988-1188) ... 24,
N 33
Travel motor displacement change electro-control
Night lighting (switch) .....................................................8
valve ....................................................................24, 33
Troubleshooting test LED ...................................4, 8, 24

Cre 7-26570GB Edition 11-99


4001-39
Troubleshooting test socket (788-988-1188)24, 30, 33
U
Upperstructure brake release control solenoid valve .
24, 33
Upperstructure power line connection ................22, 31
Upperstructure swing speed detector connector24, 33
Upperstructure working lights .........................20, 30, 31
W
Windshield washer motor......................................20, 30
Windshield washer switch ...............................13, 20, 30
Windshield washer switch lighting .................13, 20, 30
Windshield wiper intermittent action........... 4, 8, 20, 30
Windshield wiper motor .........................................20, 36
Windshield wiper switch ..................................13, 20, 30
Windshield wiper switch lighting ....................13, 20, 30
Working brake switch lighting .........................13, 20, 30
Working light relay................................................4, 8, 20
Working light switch ......... 13, 16, 18, 20, 22, 24, 26, 30

Cre 7-26570GB Edition 11-99


4001
Section
4001

ELECTRICAL SCHEMATICS
588 WHEELED EXCAVATORS

Copyright  1997 Case France


Printed in U.K.
Case Cre 7-80640GB September 1997
4001-2

TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 2
SCHEMATIC SYMBOLS ........................................................................................................................................... 3
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD)..................................................... 4
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD) ...................................................................... 4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) ...................................................... 6
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL) .......................................................................6
PRINTED CIRCUIT SCHEMATIC GUIDE................................................................................................................. 8
P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)......................................................................10
INSTRUMENT PANEL WIRING..............................................................................................................................11
INSTRUMENT PANEL (FRONT FACE)..................................................................................................................11
RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM AND COMMODO WIRING (STANDARD) ..........13
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL).............................................................15
ELECTRICAL SCHEMATIC (PLATE 2) ..................................................................................................................16
ELECTRICAL SCHEMATIC (PLATE 3) ..................................................................................................................18
ELECTRICAL SCHEMATIC (PLATE 4) ..................................................................................................................20
ELECTRICAL SCHEMATIC (PLATE 5) ..................................................................................................................22
ELECTRICAL SCHEMATIC (PLATE 6) ..................................................................................................................24
ELECTRICAL SCHEMATIC (PLATE 7) ..................................................................................................................26
ELECTRICAL SCHEMATIC (PLATE 8) ..................................................................................................................28
ELECTRICAL SCHEMATIC (PLATE 9) ..................................................................................................................30
CAB FLOOR WIRING (STANDARD) ......................................................................................................................33
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD).................................................................33
CAB FLOOR WIRING (OPTIONAL)........................................................................................................................35
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL) ..................................................................35
CAB AND CAB OPTION WIRING ...........................................................................................................................36
INDEX......................................................................................................................................................................37

SPECIFICATIONS
System voltage ...........................................................................24 Volts negative earth and 12 Volts negative earth
Batteries ....................................................................................... 2 x 12 Volts 120 A/hrs, low maintenance batteries
Alternator ......................................................................................................................... BOSCH, 28 Volts, 45 Amps
Starter motor....................................................................................................................... BOSCH, 24 Volts, 4.0 kW

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-3

SCHEMATIC SYMBOLS Local earth

A (n) Auto-radio/boîtiers
B (n) Indicators/pressure switches/loudspeakers/pressostats/detectors/heat sender/gauge 1 Wire number
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators NC Closed circuit
H (n) Warning devices (visible and audible)
K (n) Relays
M (n) Motors NO Open circuit
P (n) Instruments
R (n) Resistors/heater plugs
S (n) Shunt resistors/switches/battery master switch Intersection of two wires with connection point
Sh (n) Shunt
V (n) Diodes
X (n) Supply line connections Intersection of two wires without connection point
Y (n) Solenoid valves, solenoids
NOTE : The (n) shows the component number. 1
Example : K2 is relay N°2. Link with following plate

1
Link with preceding plate
(n) Supply on printed circuit

A
Return to another plate with the same letter
(n) Battery terminal

Bulbs
(n) Printed circuit connection terminal

Test bulb
Printed circuit earth connector

Light emitting diode (LED)


A1 Instrument panel connector

Regulator
1 or 1 or 1 Harness identification

1(1) or 1(1) or 1 (1) Harness identification followed by path identification number

(1) or (1) Printed circuit earth connectors

3 2
The installation position for the harness connector (1) on connector (2) of the
printed circuit is identified by a red mark (3) followed by the figure 1 on the
1 1 2 3 4 5 6 7 8 9 10
printed circuit. This identification corresponds to the position of path 1 of the
harness connector (1). This position is completed when the path 1 line is
shown by a red ring (4) located on line 1 wire, or by a red paint mark on the
housing.

4 1

Cre7-80640GB Issued 09-97 Printed in U.K.


4001-4

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD) V1 General contact diode V12 2nd speed indicator lamp diode
V2 K3 relay diode V13 1st speed indicator lamp diode
V3 Dipped headlight diode V20 RH direction indicator diode
V6 Main beam headlight diode V23 Hazard warning diode
∆ 37
V7 RH direction indicator green indicator lamp Ø2 Starter motor connecting point
∆5 V12 7

∆ 10 ∆ 33
∆ 39 ∆ 40
V8 LH direction indicator green indicator lamp Ø4 Printed circuit earth
S8
V8 F19
5A
V9 Hazard warning diode Ø5 Upperstructure power socket connecting point
V20 V7 V10
K 20 ∆ 35 ∆ 36
V13
2 V3
K 53
V10 LH direction indicator diode
k15 ∆6 ∆ 16
V23
F20 5A F21 5A
∆ 24 ∆ 21

∆9
F25
7,5A
F9
V9 5
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD)
10A
F13 5A ∆ 43 1 1
F1 30A F16
5A
F23 5A
V5
V6
F24
5A 1 Harness 10-way connector, floor harness
k2 k1 F17
k5 5A 2 Harness 10-way connector, floor harness
F12
∆ 38
10A
S4
3 F22
5A
F18
5A S2 3 Harness 10-way connector, floor harness
K 14
a3 F33
V11
k9
4 Harness 10-way connector, floor harness
Ø5 Ø2
7,5A
∆ 31
V2
5 Harness 10-way connector, floor harness
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A
6 Harness 8-way connector, floor harness
F6
F8 F2
15A ∆ 44
V18
k4
7 Harness 10-way connector, floor harness
15A 5A ∆ 30
V1
K 10 V16
4 3
F5
10A ∆ 23

k7
5 Harness, 3 way connector, direction indicator, hazard warning
S7 V17 V19 k6
20 Harness, 6-way connector, cab power socket
a1 V21
F31
15A
F4
5A
F3 F10 F11 F27
7,5A 15A 7,5A 5A N° 1
21 Harness, 6-way connector, cab power socket
S5 S6 S3 6
26 Harness, 6-way connector, windshield wiper (K20 intermittent action)
7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3
27 Harness, 2-way connector, windshield washer
V22 k21

Ø4 N° 2 ∆ 27
∆ 20
28 Safety clip, working brake, parking brake
2
37 Harness, 5 way connector, two-speed
1 2 3 4 5 20 30 38
a2
39 Harness, 2-way connector, parking brake pressure switch
F14 5A

6 7 9 11 12 14 16 28 42 8
N° 3 ∆ 26
40 Harness, 5 way connector, two-speed control
V4
44 Harness, 3 way connector, flasher unit

CM96J016

1 24 Volts supply before contact F24 5A Fuse, LH main beam headlight 1 Harness, 8-way connector, common harness
2 12 Volts supply before contact (radio) F25 7.5A Fuse, parking brake 2 Harness, 10 way connector, lighting and electro
3 Not used F26 7.5A Fuse, direction indicators, hazard warning 3 Harness, 6 way connector, brake unit
F2 5A Fuse, starter switch F31 15A Fuse, windshield wiper intermittent action 4 Harness, 8-way connector, engine
F3 7.5A Fuse, instrument panel F32 10A Fuse, not used 1 Clip, common harness
F4 5A Fuse, cab lighting, horn relay F33 7.5A Fuse, not used 2 Clip, lighting and electro
F6 15A Fuse, upperstructure headlights and cab H14 Not used 3 Clip, brake unit
rear working light 4 Clip, engine
K1 Starter motor relay
F7 10A Fuse, horn
K2 General contact relay 24V, 50A 28Clip, working brake, parking brake
F8 15A Fuse, upperstructure power socket
K3 Hourmeter relay 5 Clip, direction indicator, hazard warning
F9 10A Fuse, windshield washer, windshield wiper
K4 Not used 20 Clip, cab power socket
F10 15A Fuse, fan, heater, fuel heater
K5 Horn relay
F11 7.5A Fuse, cigarette lighter
K6 Working light relay
F12 10A Fuse, pilot safety
K7 Upperstructure and attachment working light
F15 15A Fuse, main beam headlight
relay
F16 5A Fuse, RH stop light
K9 Axle unlocking relay
F17 5A Fuse, LH stop light
K10 Flasher unit relay
F18 5A Fuse, RH front position light
K14 Speed change relay
F19 5A Fuse, LH front position light
K53 Fuel heater relay
F20 5A Fuse, RH front dipped headlight
K20 Windshield wiper intermittent action
F21 5A Fuse, LH front dipped headlight
K21 LH control arm pilot safety relay
F23 5A Fuse, RH main beam headlight
Sh2, Sh4, Sh5 Shunt
Sh1, Sh3, Sh6, Sh7, Sh8 Not used

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-5

1 2 1 2 3 4 5 1 2 3

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 1 2 3 4 5 6
121 121 0 158 68 165
49 122 157 71
99 87 88 160 165
71 89 162 163 165
0 26 144 142 128 133 134
31 38 132 135
∆ 39 ∆ 40
∆5
33
∆ 20 ∆ 21

∆5 ∆ 37 V12 7

∆ 10 ∆ 33 ∆ 39 ∆ 40
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V8
7
S8 F19
V10 5A
V20 V7
∆ 35 ∆ 36 2 V3
V13 65 84 63 159 156 54 51 161 77 69
k15 ∆6 ∆ 16 82 83 86 94 79 50 72 74 166 164
V23
F20 5A F21 5A
∆ 24 ∆ 21
1 2 3 4 5 6 F25 V9 5
7,5A

∆9 F9
10A
F13 5A ∆ 43 1 1
144 0 141 F1 30A F16 F23 5A F24
5A V6 5A
K 20 40 136 142 V5
k2 k1 F17
k5 5A
F12
∆ 38 3 F22 F18
10A
5A 5A S2
S4

∆ 26 V11
k9
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
a3 F33 4 5
1 2 3 4 5 7,5A
Ø5 Ø2 ∆ 31
F7 F32 F30 F26 F15 V2
4
10A 10A 15A 7,5A 15A 13 11 18 35 24 138 19 37 132 135
F6 23 15 64 6 137 16 133 134
98 52 15A ∆ 44 k4
F8 F2 V18
0 49 106 15A 5A ∆ 30
V1 V16
3
K 14 4
F5
10A ∆ 23

∆ 37
k7

S7 V17 V19 k6
a1 V21
1 2 3
F31 F4 F3 F10 F11 F27
15A 5A 7,5A 15A 7,5A 5A N° 1
S5 S6 S3 6
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
3 1
85 86 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3

0 K 10
V22 k21
∆ 20 29 31 167 147 40 135 5 48 7
Ø4 N° 2 ∆ 27 168 38 105 148 141 28 41 92 22

2
1 2 3 4 5 20 30 38
a2
∆ 44 N° 3
F14 5A
∆ 26
6 7 9 11 12 14 16 28 42 0 8 V4

K 53 1 2 3 4 5

14 0 6 2

N° 3 N° 1 N° 2
6 7 9 11 12 14 16 28 42 24 8 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 1 2 3 4 5 20 30 38

0 94 33 0 0 0 0 0 0

1 2 3 4 5 6 7 8 1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
5 2

70 16 137 36 0 40 14 11 0 4 66 83 82 67 106 70 73 50
55 33 19 138
18
15 23 13 63 84 65 58 52 169 51 78

14
∆ 28 ∆ 27

1 4 3 2

CM96J017

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-6

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL)
1 Adjustable boom raising and lowering range limitation detector cable (specific to certain countries)
2 Harness, adjustable boom raising and lowering range limitation electro-control (specific to certain countries)
3 Strips (specific to certain countries)
∆5 ∆ 37 V12 7
4 Quick-attach control harness
∆ 10 ∆ 33
∆ 39 ∆ 40 5 Quick-attach control switch harness
V8 F19
S8
5A
K 20 ∆ 35 ∆ 36 2
V20 V7 V10
V3
Cable, adjustable boom raising range limitation (to terminal N°3)
V13 K50
k15 ∆6 ∆ 16

∆ 24 ∆ 21
V23
F20 5A F21 5A 6 Harness, adjustable boom (special to certain countries)
F25
7,5A
V9 5
7 Harness, hood lighting (optional)
F9
∆9
F13 5A
10A
F16
∆ 43 1 1
F24
9 Harness, cold start assistance (optional)
F1 30A F23 5A

k2 k1
5A
F17
V5
V6 5A
K53 10 Harness, adjustable boom (special to certain countries)
k5 5A
F12
∆ 38 3 F22 F18
11 Rear foglight harness (special to certain countries)
10A

K 14
S4 5A 5A S2
k9
12 Harness, fuel heating device (optional)
V11
a3 F33
7,5A
15 Wire to terminal N°1, adjustable boom raising and lowering range limitation (special to certain countries)
Ø5 Ø2 ∆ 31
F7
10A
F32
10A
F30
15A
F26
7,5A
F15
15A
4
V2
16 Harness, overload indicator (optional)
F8 F2
F6
15A ∆ 44 ∆ 30
V18
k4 17 Harness, upperstructure rotary light (special to certain countries)
V1
15A 5A
22 Harness, cold start assistance glow plug (optional)
K 10
F5
V16
4 3
3 23 Harness, cold start assistance heating element (optional)
10A ∆ 23

K51 24 Harness, front working lights on cab (optional)


k7

S7 V17 V19 k6
33 Harness, overload indicator (optional)
a1 V21
F31
15A
F4
5A
F3 F10 F11 F27
7,5A 15A 7,5A 5A N° 1
38 Harness, pilot system cancellation (special to certain countries)
S5 S6 S3 6
42 Cable, pilot system cancellation (special to certain countries)
7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3 6
k21
43 Rear foglight harness (special to certain countries)
V22
∆ 20
R 10 Ø4 N° 2 ∆ 27

2
1 2 3 4 5 20 30 38
a2
F14 5A
N° 3 ∆ 26

6 7 9 11 12 14 16 28 42 8 V4

CM96J018

F1 30A Fuse, cold start assistance (optional) V4 Radio diode (optional)


F5 10A Fuse, headlight and rotary light relay (spe- V5 Rear foglight indicator lamp diode (specific to
cific to certain countries) certain countries)
F13 5A Fuse, overload indicator (optional) V11 Pilot system cancellation diode (specific to cer-
F14 5A Fuse, radio (optional) tain countries)
F22 5A Fuse, Rear foglight (specific to certain coun- V16, V17, V18, V19 Pilot system cancellation diode
tries) (specific to certain countries)
F27 5A Fuse, adjustable or articulated boom V21 Overload indicator diode (optional)
(optional) V22 Rotary light indicator diode (specific to certain
F30 15A Fuse, cab front working lights (optional) countries)
K15 Cold start assistance relay (optional) Sh8 Shunt (pilot system cancellation) remove shunt
K50 Adjustable boom raising range limitation relay Sh4 and install it at Sh8
K51 Adjustable boom lowering range limitation relay
6 Second travel speed indicator lamp shunt (Italy
R10 0.85 Ohm Resistor
only)

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-7

∆ 23
∆5 ∆ 37 V12 7

1 2 ∆ 10 ∆ 33 ∆ 39 ∆ 40
V8 F19
S8
V10 5A
V20 V7
123 119 ∆ 35 ∆ 36 2 V3
V13
k15 ∆6 ∆ 16
V23
F20 5A F21 5A
∆ 24 ∆ 21
F25 V9 5
7,5A

∆9 F9
10A
1 K51 K50 K53
∆ 23 F1 30A
F13 5A
F16
∆ 43 1
F23 5A F24
5A V6 5A
V5
k2 k1 F17 85 86 30 87A 87 85 86 30 87A 87 3 2 5 1
k5 5A
F12
10A ∆ 38 3 F22 F18
S4 5A 5A S2
k9 0 126 59 124 0 126 56 125 41 41
V11
a3 F33
7,5A
Ø5 Ø2 ∆ 31 V2
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A 56 126126 124 0 0 0
∆ 23
F6
15A ∆ 44 k4
F8 F2 V18
15A 5A ∆ 30
V1 V16
4 3
F5
10A ∆ 23

3 123 119
k7

56 56 56 126 0 0
F31 F4 F3 F10 F11 F27
a1
S7 V17 V19
V21
k6
3 59 0

100 102
15A 5A 7,5A 15A 7,5A 5A N° 1
S5 S6 S3 6 2
R 10 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3

V22 k21

100 102
Ø4 N° 2 ∆ 27
∆ 20
1
2
1 2 3 4 5 20 30 38
a2
F14 5A
N° 3
∆ 26
6 7 9 11 12 14 16 28 42 8 V4

229
0 0 0 0 76 41 56 229 229 229

N° 3 N° 1 N° 2
6 7 9 11 12 14 16 28 42 24 8 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 1 2 3 4 5 20 30 38

0 0 0 0 0 0 0 26 56 229 229 110 0


56 31 229 119

∆ 43 ∆ 10 ∆ 33 ∆9 ∆ 24 ∆6 ∆ 16 ∆ 38
1 2 1 2 1 2 1 2 3 1 2 1 2
1 2
1 2 3

76 75 0 90 59 59 145 146 62 3 127 128 90 59 91 145


4 5 106 105
109

31 0 26

∆ 11 ∆ 12 ∆ 43 ∆ 10 ∆ 33 ∆ 24 ∆ 17 ∆7 ∆6 ∆ 16 ∆ 42 ∆ 22

∆9 ∆ 38

CM96J019

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-8

PRINTED CIRCUIT SCHEMATIC GUIDE Sh2 Shunt


Sh4 Shunt
1 24 Volts supply before contact Sh5 Shunt
2 12 Volts supply before contact (radio) Sh1, Sh3, Sh6, Sh7 Not used
3 Not used Sh8 Shunt (pilot system cancellation) remove shunt Sh4 and install it at Sh8
F1 30A Fuse, cold start assistance (optional) V1 General contact diode
F2 5A Fuse, starter motor switch V2 K3 relay diode
F3 7.5A Fuse, instrument panel V3 Dipped headlight diode
F4 5A Fuse, cab lighting, horn relay V4 Radio diode (optional)
F5 10A Fuse, headlight and rotary light relay (specific to certain countries) V5 Rear foglight indicator lamp diode (specific to certain countries)
F6 15A Fuse, upperstructure headlights and cab rear working light V6 Main beam headlight diode
F7 10A Fuse, horn V7 RH direction indicator green indicator lamp
F8 15A Fuse, upperstructure power socket V8 LH direction indicator green indicator lamp
F9 10A Fuse, windshield washer, windshield wiper V9 Hazard warning diode
F10 15A Fuse, fan, heater, fuel heater V10 LH direction indicator diode
F11 7.5A Fuse, cigarette lighter V11 Pilot system cancellation diode (specific to certain countries)
F12 10A Fuse, pilot safety V12 2nd speed indicator lamp diode
F13 5A Fuse, overload indicator (optional) V13 1st speed indicator lamp diode
F14 5A Fuse, radio (optional) V16, V17, V18, V19 Pilot system cancellation diode (specific to certain countries)
F15 15A Fuse, main beam headlight V20 RH direction indicator diode
F16 5A Fuse, RH stop light V21 Overload indicator diode (optional)
F17 5A Fuse, LH stop light V22 Rotary light indicator diode (specific to certain countries)
F18 5A Fuse, RH front position light V23 Hazard warning diode
F19 5A Fuse, LH front position light
F20 5A Fuse, RH front dipped headlight Ø 2 Starter motor connecting point
F21 5A Fuse, LH front dipped headlight Ø 4 Printed circuit earth
F22 5 A Fuse, Rear foglight (specific to certain countries) Ø 5 Upperstructure power socket connecting point
F23 5A Fuse, RH main beam headlight
F24 5A Fuse, LH main beam headlight
F25 7.5A Fuse, parking brake : see page 4
F26 7.5A Fuse, direction indicators, hazard warning
F27 5A Fuse, adjustable or articulated boom (optional)
F30 15 A Fuse, cab front working lights (optional)
F31 15A Fuse, windshield wiper intermittent action
F32 10A Fuse, not used
F33 7.5A Fuse, not used
H14 Not used
K1 Starter motor relay
K2 General contact relay 24V, 50A
K3 Hourmeter relay
K4 Not used
K5 Horn relay
K6 Working light relay
K7 Upperstructure and attachment working light relay
K9 Axle unlocking relay
K10 Flasher unit relay
K14 Speed change relay
K15 Cold start assistance relay (optional)
K21 LH control arm pilot safety relay

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-9

CM95F016

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-10

AAA AAAAAA AAAAAA AA


P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)

B5 B3 A4 C2 D3 A7 A2 F7 E3 E1 B1

AA
+

AA –
+

AA AAAAAA AAAAAAA
(30s)
8 7 9 6 11 25 26 27

AA AA AAA
39
(2s)

AA A AA AAA
AAA
AAA A5

A AA
A
AA
2 1

A AAAAAAAAAAAAA
A
AAA
AAAA AA
AA AA
AAAAA
A
AAA
AA
AAAA AA
AA AA
AAAAA
AA
3
16 30 29 31 24 32 33
+ P2 + P1 + P3

AA
AA A
A A
A AA
AA
AAA AAA AAA AAAAAAA A A A A
12 13 14 28

AAA AAA AAA AAAAAAA A A A A


C4 C6 D2 E5 A6 F6 F1 F5 F2 E2 E6 B4 B7 B6 A3

PDH0217

A2 Minimum pilot pressure red warning lamp connector E1 Minimum braking pressure red warning lamp connector 9 Hydraulic oil filter restriction red warning lamp
A3 Hydraulic oil temperature indicator connector E2 Hazard warning red warning lamp connector 11 Minimum pilot pressure red warning lamp
A4 Battery charge red warning lamp connector E3 Parking brake red warning lamp connector 12 Overload indicator orange indicator lamp (optional)
A5 Audible warning red, orange indicator lamp connector E5 Rear fog light indicator orange indicator lamp connector (specific to 14 Pilot system cancellation green indicator lamp (specific to certain countries)
A6 Front axle unlocking orange indicator lamp connector certains countries) 16 Front axle unlocking orange indicator lamp
A7 Engine oil pressure red warning lamp connector E6 RH direction indicator green indicator lamp connector 24 Rotary light orange indicator lamp (specific to certain countries)
25 Minimum steering pressure red warning lamp
B1 24 Volts supply F1 LH direction indicator green indicator lamp connector
26 Parking brake and working brake red warning lamp
B3 Earth F2 Rotary light orange indicator lamp connector (specific to certain coun-
27 Minimum braking pressure red warning lamp
B4 Fuel level indicator connector tries)
28 Rear foglight orange indicator lamp (specific to certain countries)
B5 Indicator lighting connector F5 Dipped headlight green indicator lamp connector
29 LH direction indicator green indicator lamp
B6 Engine coolant temperature indicator connector F6 Main beam blue indicator lamp connector
30 Main beam blue indicator lamp
thermique F7 Minimum steering pressure red warning lamp connector
31 Dipped headlight green indicator lamp
B7 Fuel minimum level connector
P1 Engine coolant temperature indicator 32 Hazard warning red warning lamp
C2 Air filter restriction red warning lamp connector P2 Fuel level indicator 33 RH direction indicator green indicator lamp
C4 Overload indicator orange warning lamp connector (optional) P3 Hydraulic oil temperature indicator 39 Instrument panel lamp
D2 Pilot system cancellation green indicator lamp connector (specific to cer- 1 Stop alarm red warning lamp
tain countries) 2 Alarm orange indicator lamp
D3 Hydraulic oil filter restriction red warning lamp connector 3 Audible warning stop push button
6 Engine oil pressure red warning lamp
7 Air filter restriction red warning lamp
Cre 7-80640GB
8 Battery charge red warning lamp Issued 09-97 Printed in U.K.
4001-11

INSTRUMENT PANEL WIRING INSTRUMENT PANEL (FRONT FACE)

A B 1 2 3
P1
6
5
7
4
3 6
5
7
4
3
P3
1 2
A B 1 2

39
C D
140 159 23 17 138 13 71 18 11 137 0 19 P2 6
5 4 C D 5 4
6 7 3 6 7 3
1 2 1 2
11 7
15 168
156 16
E F
8
5 4 5 4
6 7 3 6 7 3 9
1 2 1 2

F
E 14
161 162 84 164 83 160 166 163 82 167

12

16

26
25

24 28

29 33

PDH0218
30 31 32 27
A 7 way connector : minimum pilot pressure red warning lamp, hydraulic oil temperature gauge, battery charge PDH0219
red warning lamp, audible warning stop push button, front axle unlocking orange indicator lamp, engine oil
pressure red warning lamp, alarm orange warning lamp, stop alarm red warning lamp. 1 Stop alarm red warning lamp 25 Minimum steering pressure red warning lamp
2 Alarm orange indicator lamp 26 Parking brake and working brake red warning
B 7 way connector : 24 Volts supply, earth, fuel level indicator, indicator lighting, engine coolant temperature 3 Audible warning stop push button lamp
indicator. 6 Engine oil pressure red warning lamp 27 Minimum braking pressure red warning lamp
C 7 way connector : air filter restriction red warning lamp, overload indicator orange indicator lamp (optional). 7 Air filter restriction red warning lamp 28 Rear foglight orange indicator lamp (specific to
8 Battery charge red warning lamp certain countries)
D 7 way connector : pilot system cancellation green indicator lamp (specific to certain countries), hydraulic oil fil- 9 Hydraulic oil filter restriction red warning lamp 29 LH direction indicator green indicator lamp
ter restriction red warning lamp. 11 Minimum pilot pressure red warning lamp 30 Main beam blue indicator lamp
E 7 way connector : minimum braking pressure red warning lamp, hazard warning red warning lamp, parking 12 Overload indicator orange indicator lamp 31 Dipped headlight green indicator lamp
brake red warning lamp, rear foglight orange indicator lamp (specific to certain countries), RH direction indi- (optional) 32 Hazard warning red warning lamp
cator green indicator lamp. 14 Pilot system cancellation green indicator lamp 33 RH direction indicator green indicator lamp
(specific to certain countries) 39 Instrument panel lamp
F 7 way connector : LH direction indicator green indicator lamp, rotary light orange indicator lamp (specific to 16 Front axle unlocking orange indicator lamp
certain countries), dipped headlight green indicator lamp, main beam blue indicator lamp, minimum steering P1 Engine coolant temperature indicator
24 Rotary light orange indicator lamp (specific to
pressure red warning lamp. P2 Fuel level indicator
certain countries)
P3 Hydraulic oil temperature indicator

Cre7-80640GB Issued 09-97 Printed in U.K.


4001-12

SC1 V14 V15 SC4 S6


H11
38

AA
0

AA AA 10 9

AA AA
71
SC2
AA
141
8

AA
AA
6
4
5

3
136
37

AA SC3 B52 H15 AA 1

AA AA
V V
C C

140 0

AA
38
S3 141

AA
0 40
0

AA
65 66

AA
10 9 71
22 22 0 3

H51 22 0 22
B51
84
AA
AAAAAAAAAAA
AAAA
AAAAA
H12 6

AA
AAAAAAAAAAA
AAAA
AAA
82 0 5

10 9 AA 1 S26
S51 37
B53 45
0
6 5
10 9 71
2 1
3
H13
5

3 1

H50 10 9
1 S27
A 46
8 63 0
0 83 41
6 B 28
STOP
0
S50 4 3

AA
2 1 10 9 71
S1
AA
AA
2

AA
5 7 5

6 3 6 3 6 3
Y15 B50

6
1 29
5 2 5 2 5 2
C C C C
105 105 64 147 63 71 0 63 99 94 94 48 86 71 0 86 89 165 4 1 4 1 5 6 7
4 1

H10 S4
J14 87
J13 J15
2
0 6 3 72 6 3 54 6 3 50

22 5 2 69 5 2 53 5 2 105 H18 S12 H17


77 4 1 4 1 4 1 0

6 7 4 2 122
65 86 51 121
88
S24 2
0 121 0
158 122 157

40
40

CM96J020

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-13

RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM AND COM-


MODO WIRING (STANDARD)
B50 Working brake pressure switch
B51 Stop light pressure switch
B52 Minimum braking pressure pressure switch
B53 Steering pressure switch
H10 Working light switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H15 Instrument panel audible warning
H17 1st speed green indicator lamp
H18 2nd speed blue indicator lamp
H50 Working brake and parking brake switch lighting
H51 Hazard warning switch lighting
J13 Steering column connector
J14 Steering column connector
J15 Steering column connector
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S12 Two-speed switch
S50 Working brake and parking brake switch
S51 Hazard warning switch
S24 Pilot safety switch
S26 Windshield washer switch
S27 Heater blower switch
SC1 Combined switch for direction indicator (commodo), dipped headlights, main beam headlights, sidelights,
headlight flasher and horn
SC2 Front axle automatic and manual unlocking switch
SC3 Front axle locking switch
SC4 Stabilizer lowering and raising momentary inverter switch
V14-V15 Stabilizer solenoid valve diodes
Y15 Parking brake and working brake control solenoid valve
3 Braking unit harness
Floor harness
40Two-speed control harness

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-14

V52 V51 H15

H31 S25
AA
101

AA
0
H53 + -
82 0 10 9
AA 71

AA
101 0 10 9

S53
AA V50
8

AA
5 100 102 140 28
6 5
82 0

1 AA
AA
4 3
1 31

0
AA
229
229

128 AA
AA
229

127
AAAAAAA AA AA
AAAAAAA AA AA
10 9 0
H30 10 9 0 3

AA
AAAAAAAAAAA
AAAAA AA
AA
8
6 5 75
S20 5 3
4 3
3
1 76
1 62

H55 S55
56

H52 S52 S30


90 59
229

STOP
0 10 9

H58 S56 0
7 105
0 5 106
229 10 9
H32
1 109
229 10 9

5
7 100 S21
1
3 56

1 102 145 91

38 24 16 6 43 6
9

2 1

CM96J021

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-15

RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)


H30 Cold start assistance switch lighting (optional)
H31 Rotary light switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H52 Pilot system cancellation switch lighting (specific to certain countries)
H53 Front working light switch lighting (optional)
H55 Rear foglight switch lighting (specific to certain countries)
H58 Quick-attach switch lighting (optional)
H15 Audible warning
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S25 Rotary light switch (optional)
S30 Adjustable or articulated boom switch
S52 Pilot system cancellation switch (specific to certain countries)
S53 Front working light switch (optional))
S55 Rear working light switch (optional)
S56 Rear foglight switch (optional)
V50 Quick-attach switch (optional)
V51 Quick-attach switch (optional)
V52 Quick-attach switch (optional)
1 Steering brake harness (specific to certain countries)
2 Quick-attach harness (optional)
3 Braking unit harness (standard)
6 Rotary light harness (optional)
6 Adjustable boom control harness (specific to certain countries)
9 Cold start assistance harness (optional)
16 Overload indicator harness (optional)
24 Front working lights (optional)
38 Pilot system cancellation harness (specific to certain countries)
43 Rear foglight harness (specific to certain countries)

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-16

ELECTRICAL SCHEMATIC (PLATE 2)


ELECTRICAL CABINET ENGINE
F1 30A Fuse, cold start assistance G2 Alternator
F2 5A Fuse, starter switch M1 Starter motor
K1 Starter motor relay R11 Pre-heater plug
K2 General contact relay 24 Volts, 50A Y1 Injection pump solenoid
K3 Hourmeter relay
G1 Y1 G2 R11 M1 K15 Cold start assistance relay
R10 0.85 Ohm Resistor
V1 General contact diode
Ø1, Ø2, Ø3, Ø4 : see page 4
FLOOR
S1 Key switch
H30 Cold start assistance switch lighting (optional)
S20 Cold start assistance momentary switch
(optional)
S1 UPPERSTRUCTURE

A
G1 Batteries
S2 Battery master switch

WIRING CONNECTIONS BETWEEN SCHEMATICS

A See schematic plate 5 page 22 H See schematic plate 7 page 26

B See schematic plate 3 page 18 K See schematic plate 4 page 20

C See schematic plate 3 page 18 L See schematic plate 6 page 24

D See schematic plate 3 page 18 A4 See schematic plate 8 page 28

E See schematic plate 3 page 18

F See schematic plate 3 page 18

G See schematic plate 6 page 24


S20 H30 F1 - F2 - K1 - K2 S2
K3 - K15 - R10 - V1

PDH0221

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-17

BATTERY MASTER STARTER MOTOR BATTERY RELAY BATTERY RELAY THERMOSTART ASSISTANCE ENGINE CUT-OUT ALTERNATOR
SWITCH BATTERIES STARTER SWITCH KEY (OPTIONAL)

+12 V +12 V 97
A
+24V +24V 2
97 B

2 +24V 9
1 C

F2 F1
5A 30A
G1
8 3
11
1 2 D
V1
5 2 9

S20 9 (2)
2 (5)
H30 13
S1
30 9 5
E

R012
58 50 15 10 1 3
1 K3
9 (1)
3 (9) 2 (9) 7 2 K3 5 4
62 24
4 6 13 14 F
2 3
K1 K15
5 1 4
1 1 K15 5 4 4 (8)
2 4 (6)
123 4 (4)
3 K1 2 2 K2 3 K2
30 B+ D+ W
0 23 (1)
M1 G2
50 R10
S2
23 (2)
119 2
229 Y1
22 1
0
9
R11

L K 4 4 H A4

CM96J022

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-18

ELECTRICAL SCHEMATIC (PLATE 3)


INSTRUMENT PANEL FLOOR
P10 Instrument panel (see schematic plate 1 page 8) B3 Pilot pressure pressostat
H15 Instrument panel audible warning
ELECTRICAL CABINET
H26 Horn
F3 7.5A Fuse, instrument panel P4 Hourmeter
F4 5A Fuse, cab lighting, horn relay S3 Horn switch
F7 10A Fuse, horn
P10 E1 - S10 B4 UPPERSTRUCTURE
K5 Horn relay
B1 Air filter restriction pressostat
: see page 4
B2 Hydraulic oil filter restriction pressostat
CAB B21 Hydraulic oil temperature sender
P11 Fuel level indicator
E1 Cab lighting
X10 (A) (B) (C) Fuel level indicator connectors
B22 S10 Cab lighting switch
P11 - X10(A),(B),(C) X1(K) Cab/cab floor connector ENGINE
B4 Engine oil pressure pressostat
B1
B22 Engine coolant temperature sender

A WIRING CONNECTIONS BETWEEN SCHEMATICS

B See schematic plate 2 page


16
T See schematic plate 5 page
22
E1 See schematic plate 7 page
26

See schematic plate 2 page See schematic plate 7 page See schematic plate 7 page
C U F1
16 26 26

See schematic plate 2 page See schematic plate 4 page See schematic plate 6 page
D V G1
16 20 24

See schematic plate 2 page See schematic plate 4 page See schematic plate 5 page
E X H1
16 20 22
B2
See schematic plate 2 page See schematic plate 5 page See schematic plate 8 page
F Y I1
16 22 28
B21
H15 See schematic plate 4 page See schematic plate 5 page See schematic plate 8 page
M Z J1
20 22 28

X1 (K) See schematic plate 4 page See schematic plate 7 page See schematic plate 8 page
N 20
A1 26
K1 28
F3 - F4 - F7 - K5

H26 See schematic plate 4 page See schematic plate 7 page See schematic plate 6 page
P 20
B1 26
L1 24
S3
P4
B3
See schematic plate 6 page See schematic plate 7 page See schematic plate 8 page
Q 24
C1 26
B4 28

See schematic plate 4 page See schematic plate 8 page


R 20
D1 28

See schematic plate 4 page


PDH0221A S 20

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-19

HOURMETER INSTRUMENT PANEL CAB LIGHTING HORN


BATTERY AIR HYDRAU- PILOT ENGINE FUEL RESERVE HYDR. OIL INSTR. ENGINE TEMPERATURE
CHARGE FILTER LIC OIL PRES- OIL LEVEL ALARM TEMP. PANEL
WARNING RESTRIC- FILTER SURE PRES- AUDIBLE
LAMP TION RESTRIC- SURE WARNING
TION

2 +24V +24V 2
B M
9 +24V +24V 9
C N
F3 F4 F7
7.5A 5A 10A

A1 B1 C1 D1 E1 F1 G1 H1 I1 J1 K1 L1 T
11
11 26 34
D 160 164
84 83 82 161 168 162
3 (3) 166 156 163 159
2 (10)
B1 E1 E3 F7 E5 F6 F5 D2 C4 E6 F1 E2 A6 71
B5 P
13 22
E A4 P10 B3
3 (1)
B6
C2 D3 A2 A7 B7 B4 A3 A5 D1 F2 S3
h P4

2 3
3 (10) 3 (4) 1 (4) 3 (2) 1 (2) 1 (3) 1 (1) 167 3 (5) 20 (1) K5
24 1 K5 5 4
F 15 16 17 23 137 19 138 140 18
35
X1 (K) Q
4 (5) 1 (5) 4 (7) 1 (7) 1 (6) 1 (8) 4 (2) 3 (8)
E1
X10 (C) X10 (A)
148
P P P P S10
B21 B22
B1 B2 B3 B4 H15 H26
P11 X10 (B)

0
R
0
S
4
B4 Z Y X V U

CM96J023

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-20

ELECTRICAL SCHEMATIC (PLATE 4)


INSTRUMENT PANEL CAB
H10 Working light switch lighting E51 Cab rear working light
H11 Windshield wiper switch lighting M2 Windshield wiper motor
H12 Windshield washer switch lighting X1 (E) Cab floor/Cab windshield wiper motor blue
H13 Heater blower switch lighting connector
H31 Rotary light switch lighting (specific to certain X1 (J) Cab floor/Cab windshield wiper motor white
E7 E51 H56 - H57 countries) connector
M2 S4 Working light switch X1 (L) Cab floor/Cab windshield wiper motor grey
S6 Windshield wiper switch connector
S25 Rotary light switch (specific to certain countries) X1 (M) Cab floor/Cab windshield wiper motor black
S26 Windshield washer switch connector
S27 Heater blower switch X1 (F) Cab floor/Cab rotary light connector (specific to
certain countries)
ELECTRICAL CABINET
X1 (G) Cab floor/Cab rear working light connector
F5 10A Fuse, headlight and rotary light relay (spe-
FLOOR
cific to certain countries)
F6 15A Fuse, upperstructure working lights E7 Cigarette lighter
F9 10A Fuse, windshield washer, windshield wiper M3 Windshield washer motor
F10 15A Fuse, blower, heater M4 Heater blower motor

A
F11 7.5A Fuse, cigarette lighter
UPPERSTRUCTURE
F31 15A Fuse, windshield wiper intermittent action
K6 Working light relay E2 Attachment working light (on boom)
K7 Upperstructure and attachment working light H57 Standard rotary light (optional)
relay H56 Rotary light (specific to certain countries)
K20 Windshield wiper intermittent action X5 (A), (C) Attachment working light power connection
V22 Rotary light diode (specific to certain countries)
Ø1, Ø2, Ø3, Ø4 : see page 4

WIRING CONNECTIONS BETWEEN SCHEMATICS

K See schematic plate 2 page V See schematic plate 3 page See schematic plate 9 page
16 18 S1 30

X5(A),(C) See schematic plate 3 page See schematic plate 3 page See schematic plate 5 page
M X V1
18 18 22

See schematic plate 3 page See schematic plate 6 page See schematic plate 9 page
N N1 W1
18 24 30
H10 - H11 - H12 - H13 - H31 X1(E), (F), (J), (L), (M), (G)
S4 - S6 - S26 - S27 - S25 See schematic plate 3 page See schematic plate 8 page See schematic plate 5 page
P P1 T1
18 28 22
F5 - F6 - F9 - F10 - F11
M4 M3 F31 - K6 - K20 - K7 - V22
See schematic plate 3 page See schematic plate 5 page See schematic plate 5 page
R Q1 U1
18 22 22

See schematic plate 3 page See schematic plate 8 page


S 18
R1 28

PDH0221B

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-21

ROTARY LIGHT (OPTIONAL) ATTACHMENT WORKING LIGHTS WINDSHIELD WIPER WINDSHIELD WASHER BLOWER CIGARETTE LIGHTER
REAR WORKING LIGHT HEATER
ITALY STANDARD
AIR CONDITIONING

2 +24V +24V 2
M U1
9 +24V +24V 9
N T1

F5 F6 F31 F9 F10 F11


10A 15A 15A 10A 15A 7.5A
28 32 144 37 41 48
2 (4) 1 (5) 2 (6) 2 (7)
41 13
S25 S4 S6 S26 S27
H31 H10 H11 H12 H13 12
9 5 9 5 9 2 6 1 5 9 1 9 3
V1 W1
2 1 0 2 1 0

10 1 10 1 10 4 8 3 7 10 10 5 1 E7
5
136 38
71 71
P S1
31 29 2 (3) 6 (4) 2 (2)
26 (6) 40 ére
6 (3) 6 (1) 142
20 (3) 2 ème 1
26 (4) 26 (5) R1
2 (1) 45
3 20 (6)
167 K7 141 26 (1) 46
4 5 26 (2) 27 (2)
17 20 (2) V22 30
2 3 2B
4B
5 4 K6 1A 20 (5)
X1 (F) 1 K6 3B X1 (E) M3 M4
6 (5) 33 K20 5B X1 (L)
1B X1 (J)
1(4) X1 (M)
8
33 X5 (C)
H56 H57
X1 (G) M2

E51 E2

0 X5 (A) 0
R Q1
0
S

26 (3) 20 27 (1)
X K N1 P1 V

CM96J024

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-22

ELECTRICAL SCHEMATIC (PLATE 5)


ELECTRICAL CABINET CAB
F8 15A Fuse, upperstructure power socket B5 RH loudspeaker (optional)
F13 5A Fuse, overload indicator (optional) B6 LH loudspeaker (optional)
M6 - S29 - X14(1),(2) F14 5A Fuse, radio E50 Front working lights
F30 15A Fuse, front cab working light (optional) M6 Fan motor (optional)
E50 V4 Radio diode (optional) X1(A),(B),(C),(D) Cab floor/cab LH and RH loud-
X2 V21 Overload indicator diode (optional) speaker connector (optional)
B5 X1 (H) Cab floor/Cab front working light connector
E12 - S28 : see page 4
(optional)
Y51 -Y52 INSTRUMENT PANEL X14 (1),(2) Fan motor connector (optional)
H32 Overload indicator switch lighting (optional) UPPERSTRUCTURE
H53 Front working light switch lighting (optional)
B23 Overload indicator pressostat, on boom foot
S21 Overload indicator switch (optional)
(optional)
S53 Front working light switch (optional)
X2 Upperstructure power socket
S29 Fan switch (optional)
Y53 Y51 Quick-attach solenoid valve (optional)
FLOOR Y52 Quick-attach solenoid valve (optional)
Y53 Fuel filler pump (optional)
A1 Radio (optional)
H58 Quick-attach switch lighting (optional) ENGINE

A
S56 Rear foglight switch (optional)
E12 Engine compartment light (optional)
V50 Quick-attach diode
S28 Engine compartment lighting switch (optional)
V51 Quick-attach diode
V52 Quick-attach diode
1 Standard 4 terminal strip

WIRING CONNECTIONS BETWEEN SCHEMATICS

See schematic plate 2 page See schematic plate 4 page See schematic plate 8 page
A T1 A2
16 20 28

See schematic plate 3 page See schematic plate 4 page See schematic plate 8 page
Y U1 B2
B23 18 20 28

See schematic plate 3 page See schematic plate 4 page See schematic plate 7 page
B6 Z V1 C2
18 20 26
X1(A),(B),(C),(D),(H)
See schematic plate 3 page See schematic plate 7 page See schematic plate 6 page
H32 - S21 T X1 E2
18 26 24
V50 - V51 - V52

F8 - F13 - F14 See schematic plate 3 page See schematic plate 7 page See schematic plate 6 page
H1 18
Y1 26 24
A1 F30 - V4 - V21
H58 - S56 See schematic plate 8 page
See schematic plate 4 page See schematic plate 9 page D2 28
Q1 Z1
S53 - H53 20 30 See schematic plate 9 page
30

PDH0221C

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-23

UPPERSTRUCTURE FUEL PUMP OVERLOAD INDICATOR (OPTIONAL) FRONT CAB WORKING LIGHTS ENGINE COM- CAB FAN RADIO QUICK ATTACH
POWER SOCKET PARTMENT (OPTIONAL) (OPTIONAL)
(OPTIONAL)
LIGHTING

97 12V
A

2 24V 24V 2
U1 E2
9 24V 24V 9
T1 D2

T V1 Z Y
97
48
101 140 V51
F8 F13 F30 F14 102
15A 5A 15A 5A V50
X14 (1)
100
91 127
26 V52
16 (2) 24 (1) 93 7 1 9
S21 H53
S53 1 0 2
H32
9 5 9 5
7 V4
36 92
10 1 10 1 3 10
2 (8) S56 229
16 (1) H58 C2
+ 56
229 145
24 (3)
33 (1) A1
B2
128
5 -
1 (7) 1 (8) 1 (6) 1 (9) 102 100
21 (1)
132 134 133 135
P B23
Y53 X1 (H) 21 (4) 21 (5) 21 (3) 21 (6)
S29 2 2
S28
X1 (D) X1 (C) X1 (B) X1 (A)
4 146 1 Y51 1 Y52
M M6
E12 + +
1 X2 33 (2) E50 0 - -

V21 X14 (2) B5 HPD B6 HPG


6 (2)
168 0

16 7 14

X1 H1 Q1 Y1 Z1 A2

CM96J025

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-24

ELECTRICAL SCHEMATIC (PLATE 6)


ELECTRICAL CABINET S12 Two-speed switch
S52 Pilot system cancellation switch (specific to cer-
F12 10A Fuse, pilot safety
tain countries)
K9 Front axle unlocking relay
S24 Pilot safety switch (hand control lever shown in
K14 Speed change relay
raised position)
K21 Pilot safety relay
V14-V15 Stabilizer solenoid valve diodes (in com-
Sh4 Shunt (standard equipment)
modo)
Y2 - Y11 - Y12 - Y13 Sh8 Shunt (pilot cancellation option special for Italy,
Y14 - Y26 - Y27 remove shunt Sh4 and substitute shunt Sh8) UPPERSTRUCTURE
V2 K3 relay diode
B12 Two-speed brake pressure switch
V11 Pilot system cancellation indicator lamp (spe-
SC2 - SC3 - SC4 Y2 Pilot safety solenoid valve
cific to certain countries)
Y11 Gear box solenoid valve (first speed)
V12 2nd speed indicator lamp diode
Y12 Gear box solenoid valve (second speed)
H17 - H18- S12 V13 1st speed indicator lamp diode
Y13 Front axle unlocking solenoid valve
V16, V17, V18 et V19 Pilot system cancellation
Y14 Pilot system cancellation solenoid valve (spe-
diodes (specific to certain countries)
cific to certain countries)
1 4 terminal strip
V14 - V15 Y26, Y27 Stabilizer solenoid valves
: see page 4
FLOOR

A SC2 Front axle automatic and manual unlocking


switch
SC3 Front axle locking and unlocking switch
SC4 Stabilizer raising and lowering momentary
inverter switch
B54 Front axle unlocking pressure switch
H17 1st speed green indicator lamp
H18 2nd speed blue indicator lamp
H52 Pilot system cancellation switch lighting (spe-
cific to certain countries)
J15 Steering column connectors

WIRING CONNECTIONS BETWEEN SCHEMATICS

L See schematic plate 2 page 16 G See schematic plate 2 page 16

B12 Q See schematic plate 3 page 18 J2 See schematic plate 7 page 26


F12 - K9 - K14 - K21
Sh4 - Sh8 - V2 - V11 G1 See schematic plate 3 page 18 L2 See schematic plate 7 page 26
V12 - V13 - V16 - V17
V18 - V19 L1 See schematic plate 3 page 18 M2 See schematic plate 7 page 26

J15(2),(3),(4),(5),(6) S24 N1 See schematic plate 4 page 20 N2 See schematic plate 7 page 26
S52
H52 See schematic plate 5 page 22 P2 See schematic plate 7 page 26
D2 See schematic plate 8 page 29
B54 See schematic plate 9 page 30

E2 See schematic plate 5 page 22

PDH0221D

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-25

TWO-SPEED PILOT CANCELLATION AXLE UNLOCKING PILOT SAFETY STABILIZERS


(OPTIONAL)

2 24V 24V 2
E2 P2
9 24V 24V 9
D2 N2
F12
10A

49
Sh4 105

37 (2) 39 (1) 6 (6)


40 (5) 40 (5) 49
K14 3 J15 (2)
158 S24
H18 H17 B12
ème 4 5 1 ère
2 NO NC
P 57
V13 V12 SC4 SC2
37 (5) 37 (4) 39 (2) 3 (7) 6 (7)
SC3
64 147 V15
121 105
V14
40 (3)
40 (1) J15 (3) J15 (4) J15 (5) J15 (6)
38 (1)
10 5 6 K21 3 5 (2) 5 (3) 53 105
3 1
H52 5 (1)
Sh8 S52 40 (2) S12 54
1 0 1 0
5 4 2 5 4 P B54
9 1 7 2 8 122 K9
1
37 (1) 2
38 (2) 38 (3) K9
109 31B
4 (7) K14
15 51
V18 V19 V16 V17 V11 98 58 55 148 50
0 229 159 106 52

42 4 (9)
2 (3) 2 (4) 110 2 (2) 1 (2) 6 (8) 2 (9) 2 (8)
37 (3)
2 2 2 2 2 2 2

1 Y11 1 Y12 1Y14 156 1 Y13 1 Y2 1 Y26 1 Y27


V2

M2
24

42
J2 L1 L G1 G N1 Q 2 L2

CM96J026

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-26

ELECTRICAL SCHEMATIC (PLATE 7)


ELECTRICAL CABINET FLOOR
F15 15A Fuse, main beam headlights B50 Parking brake pressure switch
F16 5A Fuse, RH brake lights B51 Stop light pressure switch
F17 5A Fuse, LH brake light B52 Pressure switch for minimum braking pressure
F18 5A Fuse, RH front side light B53 Steering pressure switch
E10 - E13 F19 5A Fuse, LH front side light B55 Steering brake pressure switch (optional)
F20 5A Fuse, RH front dipped headlight J14 Steering column connectors
F21 5A Fuse, LH front dipped headlight X5 (B) Steering brake pressure switch
F23 5A Fuse, RH main beam headlight
UPPERSTRUCTURE
F24 5A Fuse, LH main beam headlight
SC1 K7 Upperstructure and attachment working light E10 RH rear stop light
relay E11 LH rear stop light
Sh5 Shunt E12 Front RH side light
V3 Dipped headlight diode E13 Rear RH side light
V6 Main beam headlight diode E14 Front LH side light
E15 Rear LH side light
: see page 4
E16 Front RH dipped headlight
CAB E17 Front LH dipped headlight
E18 RH main beam headlight
SC1 Direction indicator (combination switch), main

A
E19 LH main beam headlight
beam and dip switch, side lights and headlight
flasher switch

WIRING CONNECTIONS BETWEEN SCHEMATICS

See schematic plate 2 page See schematic plate 5 page See schematic plate 8 page
H C2 R3
16 22 28

See schematic plate 3 page See schematic plate 9 page See schematic plate 8 page
U G2 S3
18 30 28
E12
See schematic plate 3 page See schematic plate 9 page See schematic plate 8 page
E16 - E18 E1 H2 T3
18 30 28

See schematic plate 3 page See schematic plate 6 page See schematic plate 8 page
X5(B) E11 - E15
F1 J2 U3
18 24 28

B51 - B52 - B53 See schematic plate 3 page See schematic plate 6 page See schematic plate 8 page
A1 L2 V3
18 24 28

J14(1),(2),(3),(4),(5),(6) See schematic plate 3 page See schematic plate 6 page See schematic plate 8 page
F15 - F16 - F17 - F18 - F19 B1 18 M2 24 W3 28
F20 - F21 - F23 - F24
K7 - Sh5 - V3 - V6
See schematic plate 3 page See schematic plate 6 page See schematic plate 8 page
C1 18 N2 24 X3 28
E17 - E19 B50
B55 See schematic plate 5 page See schematic plate 6 page See schematic plate 8 page
E14
X1 22 P2 24 Y3 28

See schematic plate 5 page See schematic plate 8 page


Y1 22 Q3 28

PDH0221E

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-27

POSITION LIGHTS COMMODO DIPPED HEADLIGHTS MAIN BEAM HEADLIGHTS PRESSURE

2 +24V 2 +24V
P2 Y3

9 +24V 9 +24V
N2 X3
F15
15A
65 U

22 C1 B1 A1
4 (1)
3 (6) SC1 J14 (1) J14 (5)

P 0123
B51 77
66
J14 (2)
3 (1) J14 (3) J14 (6) J14 (4) 4 (2) 4 (4) 4 (3)
5 (9) P B55
69 5 (4) 72 5 (7)

F16 F17 F18 F19 F20 F21 F23 F24


5A 5A 5A 5A 5A 5A 5A 5A
82 83 84
67 1
71
68 2 K7
5 (1) 1 (3) 2 (5) 7 (2) 2 (10) 4 (10) V6 3 (5) 3 (3) 3 (4)
2 (1) 5 (2)
X5 (B) 70 V3 166
Sh5
0 78 79
229 P P P
160
B53 B50 B52
19 2 (7) 5 (8)
19 19 19 7 (7) 5 (6)
73 74
E10 E14

E11 E12 E13 E15 E16 E17 E18 E19

0
W3

V3

U3

T3

5 3
M2 L2 Q3 G2 Y1 H X1 R3 J2 C2 F1 S3 E1 H2

CM96J027

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-28

ELECTRICAL SCHEMATIC (PLATE 8)


ELECTRICAL CABINET UPPERSTRUCTURE
F22 5A Fuse, rear foglight (specific to certain coun- B56 Adjustable boom range limitation detector
tries) (optional)
F26 7.5A Fuse, direction indicator, hazard warning E20 RH front direction indicator
F27 5A Fuse, adjustable boom and range limitation E21 RH rear direction indicator
K10 Flasher unit relay E22 LH rear direction indicator
H55 V7 RH direction indicator green indicator diode E23 LH front direction indicator
S55 Y8 - Y7 Y50 B56 E21 R50 E29
lamp E24 Dipper lighting (specific to certain countries)
V8 LH direction indicator green indicator diode E25 Rear foglight (specific to certain countries)
lamp E29 Licence plate lighting (specific to certain coun-
S30 V9 Hazard warning diode tries)
V10 LH direction indicator diode E31 RH front side-mounted direction indicator
V20 RH direction indicator diode E32 LH front side-mounted direction indicator
V23 Hazard warning diode J13 Steering column connectors
K50 Adjustable boom raising range limitation relay X5 (A) Dipper lighting connector
(optional) Y7 Adjustable or articulated boom extending sole-
E31 K51 Adjustable boom lowering range limitation relay noid valve
(optional) Y8 Adjustable or articulated boom retracting sole-
K53 Fuel heating device relay noid valve

A
V5 Foglight indicator lamp diode Y50 Adjustable boom range limitation solenoid valve
(optional)
: see page 4
ENGINE
CAB
R50 Fuel heating device
H51 Hazard warning switch lighting
H55 Rear foglight switch lighting (specific to certain
countries)
SC1 Direction indicator (dipped headlights, main
beam headlights, parking lights and headlight
flasher selection combination switch)
E20
S30 Adjustable or articulated boom switch
S51 Hazard warning switch
S55 Rear foglight switch (specific to certain coun-
tries)
E22 - E25
WIRING CONNECTIONS BETWEEN SCHEMATICS
X5(A) D1 See schematic plate 3 page 18 B2 See schematic plate 5 page 22 U3 See schematic plate 7 page 26

J1 See schematic plate 3 page 18 See schematic plate 5 page 22 V3 See schematic plate 7 page 26
J13(1),(2),(3) F22 - F26 - F27 - K10
V5 - V7 - V8 - V9 - V10 - V20 D2 See schematic plate 6 page 24
V23 - K50 - K51 - K53 I1 See schematic plate 3 page 18 See schematic plate 9 page 30 W3 See schematic plate 7 page 26
SC1
E23
H51 K1 See schematic plate 3 page 18 F2 See schematic plate 9 page 30 X3 See schematic plate 7 page 26
S51
E32 P1 See schematic plate 4 page 20 Q3 See schematic plate 7 page 26 Y3 See schematic plate 7 page 26

R1 See schematic plate 4 page 20 R3 See schematic plate 7 page 26 A4 See schematic plate 2 page 16

A2 See schematic plate 5 page 22 S3 See schematic plate 7 page 26 B4 See schematic plate 3 page 18

T3 See schematic plate 7 page 26


PDG0221G

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-29

FLASHING LIGHT WARNING ADJUSTABLE BOOM ADJUSTABLE BOOM RANGE LIMITATION FUEL HEATING FOGLIGHT DIPPER LIGHTING
OR (OPTIONAL) DEVICE LICENCE PLATE LIGHTING
ARTICULATED BOOM

2 +24V
Y3 J1 K1 R1 S3 R3 R3 Q3

9 +24V
X3 D2 72

85 F27 41 F22
F26 5A
7.5A 5A
49 31
K10
49A 14 75 229 229 70
44 (1) 56
44 (3)
163 15
4 (6)
J13 (1) 86 S30
164 2 43 (2)
3
6 5 10 1 1
SC1 90 K53
0 4 2
5
0
1 1 9 5
J13 (2) J13 (3) 3 4
I1 B56 S55
1 9 126 14
8 2 7
59 H55
162 88 S51 10 1
7 (6) 7 (3) 7 (5) 7 (8) 7 (4) 7 (9) H51 5(10) 56
6 (2) 76
6 (1) R50
V7 87 V8 V9
89 10 (2)
V10 T°
165 43 (1)
10 (1)
V20
K51 30 K50
30 86
86 V5
V23
2 (6) 5 (3) 7 (10) 5 (5) 11
44 (2)
71 85 85
0 87A 87 87 87A
124 125

59
2 2 2 E25 E29 E24
E20 E31 E21 E22 E23 E32
Y7 1 Y8 1 1 Y50 0 0 161 0 0
W3 X5 (A)

V3 0
0
6 11
U3 F2 A2 B2 12 B4 A4 D1 P1

T3

CM96J028

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-30

ELECTRICAL SCHEMATIC (PLATE 9)


ELECTRICAL CABINET UPPERSTRUCTURE
F25 7.5A Fuse, parking brake Y15 Parking brake and working brake control sole-
noid valve
: see page 4
Y16 Working brake solenoid valve (standard) except
FLOOR excavators for Germany
Y17, Y18 Working brake solenoid valves (specific for
H50 Working light and parking light switch lighting
Y16 - Y17 - Y18 Germany)
(standard or specific for Germany and Italy)
S50 Working brake, parking light switch (standard or
specific for Germany and Italy)

WIRING CONNECTIONS BETWEEN SCHEMATICS

S1 See schematic plate 4 page 20 F2 See schematic plate 8 page 28

W1 See schematic plate 4 page 20 G2 See schematic plate 7 page 26

Z1 See schematic plate 5 page 22 H2 See schematic plate 7 page 26

A D2
See schematic plate 5 page 22
See schematic plate 6 page 24
See schematic plate 8 page 28

Y15 F25
S50
H50

PDH0221D

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-31

WORKING BRAKE-GERMANY STANDARD WORKING BRAKE WORKING BRAKE-ITALY


PARKING BRAKE PARKING BRAKE PARKING BRAKE

9 24V 9 24V 9 24V


D2 D2 D2
F25 F25 F25
7.5A 7.5A 7.5A

99 99 99
7 (1) 7 (1)
7 (1)
0
Z1 0
0
Z1 Z1

H50 H50
H50 10 3 4 8
S50 S50
7
S50 0 1 0 10 1 7 2 8 10 1 7 2 8
1
2 2
1 0 1 0 1 0 1 0
9 1 5 2 6
9 5 6 9 5 6
48
W1
71 71 71
S1 S1 S1

4 (8) 4 (5) 4 (5) 4 (8) 4 (5) 4 (8)


F2 94 63 F2 63 94 F2 63 94
G2 28 3 (2) G2 3 (2) 28 G2 3 (2) 28

2 2 2 2 2 2 2
1 1 1 1 1 1 1
Y18 Y17 Y15 Y15 Y16 Y15 Y16

28
H2 28 28
H2 H2

CM96J029

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-32

CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)

E23 - E14 E19 - E17

H26 E2
0 165 71 0 79 74 35 0
E32 E16 - E18
E12 - E20
B51 B52 B53
C A X5
1 2 3
4 5 6 33 0 7078 73 169 169 E31
65 66 84 0 82 0 0
169
49 0
J14 J13 J15 P10
B50 3 21 3 2 1 3 2 1
0 6 5 4 6 5 4 6 5 4
A B
H11 121
72 22 65 88 50 53 0 S6 P11
83 69 0 77 87 86 105 54 51
19 A
Y15 C D

0
H12 137 B
S26 52 0 C
63 Y12
H15 0 X10
H13
S3 S27
F Y11 Y27 Y26 Y13 Y2
E
H10
22 22 0 S4
H51 0 140
S51
K53 106 0 51 0 50 0 58 0 55 0
5 1 2
4 1 28 39
B3 H18 S12 H1 94
M3 P4 Y17
7 0 X2
M4
94
0 Y18
17 0 S1 36 0 S2
40 0
H50 24
16 94
Y16
11 46 45 0 0
S50 B2
0 158 157 0

122 122 7 5
B54 B21
6
S24

+
105 144 31
132 0 138 Y1
53 105 G1 G1
X1 E7 11
142
64 105 E

+
D

147 134 C
F
B22 18
L M
G
33
133 B
K H 48
A J
0 B1
A1 G2
12 12
15 0 B+
135 26 38 128 0 34 B4 34
M1 D+
W
92
0
71 68 165 70 67 0 169
135 23 0 2 14 13
0 133 2 2 4
20 3 4
0 21
40 4 0
1 2 3 4 3 134 E11 -E15 - E22 E10 - E13 - E21
27 27 20 0
132
5 6 7

CM96J030

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-33

CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)
3, 3, 20, 20, 21, 27, 40, 40, 24 Volts supply before contact
1, 2, 3, 4, 5, 6, 7 et 0 1, 2, 3, 4, 5 28 et 39
FLOOR UPPERSTRUCTURE
A1 Radio (optional) B1 Air filter restriction pressostat
B3 Pilot pressure pressostat B2 Hydraulic oil filter restriction pressostat
B50 Parking brake pressure switch B12 Two-speed brake pressure switch
B51 Stop light pressure switch B21 Hydraulic oil temperature sender
B52 Braking minimum pressure switch E2 Attachment working light on boom
B53 Steering pressure switch E10 RH rear stop light
B54 Front axle unlocking pressure switch E11 LH rear stop light
E7 Cigarette lighter E12 Front RH side light
E14 Front LH side light E13 Rear RH side light
E17 Front LH dipped headlight E15 Rear LH side light
E19 LH main beam headlight E16 Front RH dipped headlight
E23 LH front direction indicator E18 RH main beam headlight
E32 LH side-mounted direction indicator E20 RH front direction indicator
H10 Working light switch lighting E21 RH rear direction indicator
H11 Windshield wiper switch lighting E22 LH rear direction indicator
H12 Windshield washer switch lighting E31 RH side-mounted direction indicator
H13 Heater blower switch lighting G1 Batteries
H15 Instrument panel audible warning P11 Fuel level indicator
H17 1st speed green indicator lamp S2 Battery master switch
H18 2nd speed blue indicator lamp X2 Upperstructure power socket
H26 Horn X5 Attachment working light power connection
H50 Parking brake and working brake switch lighting X10 Fuel level indicator connector
H51 Hazard warning switch lighting Y2 Pilot safety solenoid valve
J13 Steering column connector (commodo) Y11 Gear box solenoid valve (first speed)
J14 Steering column connector (commodo) Y12 Gear box solenoid valve (second speed)
J15 Steering column connector (commodo) Y13 Front axle unlocking solenoid valve
M3 Windshield washer motor Y15 Parking brake and working brake solenoid valve
M4 Heater blower motor Y16 Working brake solenoid valve (Standard)
P4 Hourmeter Y17-Y18 Working brake solenoid valves (specific to certain countries)
P10 Instrument panel Y26-Y27 Stabilizer raising and lowering solenoid valves
S1 Key switch
ENGINE
S3 Horn switch
S4 Working light switch B4 Engine oil pressure pressostat
S6 Windshield wiper switch B22 Engine coolant temperature sender
S12 Two-speed switch G2 Alternator
S24 Pilot safety switch K53 Fuel heating device
S26 Windshield washer switch M1 Starter motor
S27 Heater blower switch Y1 Engine cut-out solenoid valve
S50 Parking brake and working brake switch
S51 Hazard warning switch
X1 Cab floor/cab power connector

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-34

CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)

E24

AA
101 B23

AA X5

AA
+ - H15 0 70

AA
V52 101 0
145 146
100 102 V50

82 82 AA
AA
140
Y53

A A AA
A AA
0 0
V51

A A AA
A AA
AAA AAAA ø5 1 90
Y7
7 4 42 0
H58 H52 H30 H53 H55 H31 11 59
22 K53 10 Y8
0 0
S56 S52 S20 S53 S55 S25 23 (1) K50 110
1 R10 19 125 0 Y14
12 33 102
23 (2) 124 Y51
0
S30 K51
100
56 56 0 Y52
56
B56
126
90 59 0 125
Y50
0
B55
0
0
82
E12 26
41
R50
0
R11 S28
119
+ - + -
H32
S21

0
76 229

38 9 3 24 15 6 16 43 6 E25
102
100
229 0
14 19 14 1

E29
CM96J031

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-35

CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)
ELECTRICAL CABINET ELECTRICAL CABINET
1 4 terminal strip 1 4 terminal strip
3, 6, 9, 14, 14, 15, 16, 19, 24, 38, 43 et 6 1, 4, 10, 11, 12, 19, 22, 23 (1) (2), 33, 42 et ∅ 5
INSTRUMENT PANEL UPPERSTRUCTURE
B55 Steering brake pressure switch B23 Overload indicator
H30 Cold start assistance switch lighting B56 Boom raising range limitation detector
H31 Rotary switch lighting E24 Dipper lighting
H32 Overload indicator switch lighting E25 Rear foglight
H52 Pilot system cancellation switch lighting E29 Licence plate lighting
H53 Front working light switch lighting K50 Adjustable boom raising range limitation relay
H55 Foglight switch lighting K51 Adjustable boom lowering range limitation relay
H58 Quick-attach switch lighting K53 Fuel heating device relay (fitted standard)
S20 Cold start assistance switch R50 Fuel heating device
S21 Overload indicator switch Y3 Fuel filler pump
S25 Rotary light switch (specific to certain countries) Y7 Adjustable or articulated boom extending solenoid valve
S30 Adjustable or articulated boom switch Y8 Adjustable or articulated boom retracting solenoid valve
S52 Pilot system cancellation switch Y14 Pilot system cancellation solenoid valve
S53 Front working lights switch Y50 Adjustable boom raising range limitation solenoid valve
S55 Foglight switch Y51 Quick-attach solenoid valve
S56 Quick-attach switch Y52 Quick-attach solenoid valve
V50 Quick-attach diode Y53 Fuel filler pump
V51 Quick-attach diode X5 Steering column connector
V52 Quick-attach diode
ENGINE
H15 Audible warning
E12 Engine compartment light
R10 Cold start assistance resistor
R11 Cold start assistance glow plug
S28 Engine compartment working light switch

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-36

CAB AND CAB OPTION WIRING


E50 E50

127 0 128 0

A
B
M2 C
D

142
144

38
0
0
26
S10

A
E1 M6 S29
X14 (2) X14 (1)

0 E7 48

0 33 X1

31 F
G H 128
M J
144 E K
38 2 (7)
B6 132 D
L A 135 B5

133
- C B
-
132
135 134
+ 142 134 133 26 +

0 31 0 33

H56-H57 E51
CM95F014

A White wire S29 Cab fan switch (optional)


B Grey wire X1 (A) (B) (C) (D) Cab floor/cab lh and RH loud-
C Blue wire speaker connector (optional)
S Black wire X1 (H) (G) Cab floor/Cab front (optional) and rear
E1 Cab lighting (standard) working light
E7 Cigarette lighter (see wiring page 32) X1 (E) (J) (M) (L) Cab floor/cab windshield wiper
E50 Front working lights (optional) motor connector
E51 Rear working light (standard) X1 (F) Cab floor/cab rotary light connector (specific to
H56 Standard rotary light (optional) certain countries)
H57 Rotary light (optional) X1 (K) Cab floor/cab operator’s compartment lighting.
B5 RH loudspeaker (optional) X14 (1) (2) Cab fan plug (optional)
B6 LH loudspeaker (optional) 2 (7) 10 way connector (see printed circuit wiring
M2 Windshield wiper motor page 5)
M6 Cab fan motor (optional)
S10 Cab lighting switch

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-37

INDEX
A C
Adjustable...............................................................15 Cab floor/cab operator’s compartment lighting ...... 36
Adjustable boom.....................................................29 Cab floor/cab power connector .............................. 33
Adjustable boom lowering range Cab floor/cab rear working light connector ............ 20
limitation relay ..........................................6, 28, 35 Cab floor/cab rotary light connector ....................... 20
Adjustable boom raising range limitation Cab floor/cab rotary light connector ....................... 36
detector ..............................................................28 Cab floor/cab windshield wiper motor black connector
Adjustable boom raising range limitation 20
relay .........................................................6, 28, 35 Cab floor/cab windshield wiper motor blue
Adjustable boom raising range limitation connector ........................................................... 20
solenoid valve ..............................................28, 35 Cab floor/cab windshield wiper motor
Adjustable or articulated boom extending connector ........................................................... 36
solenoid valve ..............................................28, 35 Cab floor/cab windshield wiper motor grey
Adjustable or articulated boom retracting connector ........................................................... 20
solenoid valve ....................................................35 Cab floor/cab windshield wiper motor white connector
Adjustable or articulated boom switch ........15, 28, 35 20
Air conditioning .......................................................21 Cab front working lights ......................................... 23
Air filter restriction pressostat ...........................18, 33 Cab lighting ...................................................... 18, 36
Alternator ....................................................16, 17, 33 Cab lighting switch ........................................... 18, 36
Articulated boom.....................................................29 Cab rear working light ............................................ 20
Attachment working light ........................................21 Cab/cab floor connector......................................... 18
Attachment working light (on boom) .......................20 Cigarette lighter.................................... 20, 21, 33, 36
Attachment working light on boom .........................33 Cold........................................................................ 15
Attachment working light power connection .....20, 33 Cold start assistance glow plug ............................. 35
Audible warning ................................................15, 35 Cold start assistance momentary switch
Axle unlocking ........................................................25 (optional)............................................................ 16
Axle unlocking relay..............................................4, 8 Cold start assistance relay............................. 6, 8, 16
Cold start assistance resistor................................. 35
B
Cold start assistance switch............................. 15, 35
Batteries ...........................................................16, 33 Cold start assistance switch lighting ................ 15, 35
Battery charge warning lamp..................................19 Cold start assistance switch lighting (optional) ...... 16
Battery master switch .................................16, 17, 33 Combination switch................................................ 27
Battery relay ...........................................................17 Combined switch for direction indicator
Blower.....................................................................21 (commodo),dipped headlights, main beam
Boom raising range limitation detector ...................35 headlights, sidelights, headlight flasher
Braking minimum pressure switch..........................33 and horn .........................................................13
Braking unit harness (standard) .............................15 Connector (10 way)................................................ 36
C D
Cab and cab option wiring ......................................36 Description of electrical cabinet printed circuit
Cab fan motor.........................................................36 (optional equipment) ............................................ 6
Cab fan plug ...........................................................36 Description of electrical cabinet printed circuit
Cab fan switch ........................................................36 (standard equipment) .......................................... 4
Cab floor wiring (optional).......................................35 Dipped headlight diode .................................. 4, 8, 26
Cab floor wiring (optional).......................................34 Dipped headlights .................................................. 27
Cab floor wiring (standard) ...............................32, 33 Dipper lighting ............................................ 28, 29, 35
Cab floor/Cab front (optional) and rear Dipper lighting connector ....................................... 28
(standard) working light ......................................36 Direction indicator .................................................. 29
Cab floor/Cab front working light connector Direction indicator (dipped headlights, main beam
(optional) ............................................................22 headlights, parking lights and headlight flasher
Cab floor/cab LH and RH loadspeaker connector selection combination switch).........................28
(optional) ............................................................22
Cab floor/cab lh and RH loudspeaker connector
(optional) ............................................................36

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-38
E F
Electrical cabinet printed circuit wiring (optional Fuse, adjustable or articulated boom (5A)
equipment) ...........................................................6 (optional).............................................................. 6
Electrical cabinet printed circuit wiring (standard Fuse, blower, heater (15A) .................................... 20
equipment) ...........................................................4 Fuse, cab lighting, horn relay (5A) ................. 4, 8, 18
Electrical schematic (plate 2)..................................16 Fuse, cigarette lighter (7.5A).......................... 4, 8, 20
Electrical schematic (plate 3)..................................18 Fuse, cold start assistance (30A)....................... 8, 16
Electrical schematic (plate 4)..................................20 Fuse, cold start assistance (30A) (optional)............. 6
Electrical schematic (plate 5)..................................22 Fuse, direction indicator, hazard
Electrical schematic (plate 6)..................................24 warning (7.5A) ................................................... 28
Electrical schematic (plate 7)..................................26 Fuse, direction indicators, hazard
Electrical schematic (plate 8)..................................28 warning (7.5A) ................................................. 4, 8
Electrical schematic (plate 9)..................................30 Fuse, fan, heater, fuel heater (15A) ..................... 4, 8
Engine compartment light.................................22, 35 Fuse, front cab working light (optional) (15A) ........ 22
Engine compartment lighting switch .......................22 Fuse, front cab working lights (15A) .................... 6, 8
Engine compartment working light switch ..............35 Fuse, headlight and rotary light relay (10A) ... 6, 8, 20
Engine coolant temperature sender .................18, 33 Fuse, horn (10A) ............................................ 4, 8, 18
Engine cut-out control.............................................17 Fuse, instrument panel (7.5A)........................ 4, 8, 18
Engine cut-out solenoid valve.................................33 Fuse, LH brake light (5A) ....................................... 26
Engine module and upperstructure wiring Fuse, LH front dipped headlight (5A) ............. 4, 8, 26
(optional) ......................................................34, 35 Fuse, LH front position light (5A) ......................... 4, 8
Engine module and upperstructure wiring Fuse, LH front side light (5A) ................................. 26
(standard).....................................................32, 33 Fuse, LH main beam headlight (5A) .............. 4, 8, 26
Engine oil pressure pressostat .........................18, 33 Fuse, LH stop light (5A) ....................................... 4, 8
Fuse, main beam headlight (15A)........................ 4, 8
F
Fuse, main beam headlights (15A) ........................ 26
Fan motor ...............................................................22 Fuse, overload indicator (5A)......................... 6, 8, 22
Fan motor connector (optional) ..............................22 Fuse, parking brake (7.5A) ............................ 4, 8, 30
Fan switch ..............................................................22 Fuse, pilot safety (10A) .................................. 4, 8, 24
Flasher unit relay ............................................4, 8, 28 Fuse, radio (5A) ............................................. 6, 8, 22
Foglight indicator lamp diode..................................28 Fuse, rear foglight (5A) ........................................ 6, 8
Foglight switch........................................................35 Fuse, rear foglight (5A) .......................................... 28
Foglight switch lighting ...........................................35 Fuse, RH brake lights (5A)..................................... 26
Front axle automatic and manual unlocking Fuse, RH front dipped headlight (5A) ............ 4, 8, 26
switch ...........................................................13, 24 Fuse, RH front position light (5A)......................... 4, 8
Front axle locking and unlocking switch .................24 Fuse, RH front side light (5A)................................. 26
Front axle locking switch ........................................13 Fuse, RH main beam headlight (5A).............. 4, 8, 26
Front axle unlocking pressure switch ...............24, 33 Fuse, RH stop light (5A)....................................... 4, 8
Front axle unlocking relay.......................................24 Fuse, starter switch (5A) ................................ 4, 8, 16
Front axle unlocking solenoid valve..................24, 33 Fuse, upperstructure headlights and cab rear
Front LH dipped headlight ................................26, 33 working light......................................................... 4
Front LH side light ............................................26, 33 Fuse, upperstructure headlights and cab rear
Front RH dipped headlight................................26, 33 working light (15A)........................................... 4, 8
Front RH side light............................................26, 33 Fuse, upperstructure power socket (15A)...... 4, 8, 22
Front working light switch lighting.....................15, 35 Fuse, upperstructure working lights (15A) ............. 20
Front working light switch lighting (optional)...........22 Fuse, windshield washer, windshield
Front working lights ..........................................22, 36 wiper (10A) ................................................ 4, 8, 20
Front working lights switch .........................15, 22, 35 Fuse, windshield wiper intermittent
Fuel filler pump ...........................................22, 23, 35 action (15A) ............................................... 4, 8, 20
Fuel heater relay...........................................4, 28, 35
G
Fuel heating device ....................................28, 33, 35
Fuel level indicator............................................18, 33 Gear box solenoid valve ........................................ 24
Fuel level indicator connector.................................33 Gear box solenoid valve (first speed) .................... 33
Fuel level indicator connectors ...............................18 Gear box solenoid valve (second speed)............... 33
Fuse, adjustable and range limitation boom (5A) ...28 General contact diode.................................... 4, 8, 16
Fuse, adjustable or articulated boom (5A)................8 General contact relay 24 Volts, 50A ...................... 16

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001-39
G P
General contact relay 24V, 50A............................4, 8 P10 instrument panel electrical schematic
(plate 1) ............................................................. 10
H
Parking brake and working brake control
Hazard warning ......................................................29 solenoid valve .................................................... 13
Hazard warning diode.....................................4, 8, 28 Parking brake and working brake solenoid
Hazard warning switch ...............................13, 28, 33 control valve ...................................................... 30
Hazard warning switch lighting ...................13, 28, 33 Parking brake and working brake solenoid valve... 33
Heater.....................................................................21 Parking brake and working brake switch ............... 33
Heater blower motor .........................................20, 33 Parking brake and working brake switch lighting ... 33
Heater blower switch ..................................13, 20, 33 Parking brake pressure switch......................... 26, 33
Heater blower switch lighting......................13, 20, 33 Pilot pressure ......................................................... 19
Horn..................................................................18, 33 Pilot pressure pressostat ................................. 18, 33
Horn relay .......................................................4, 8, 18 Pilot safety ............................................................. 25
Horn switch.................................................13, 18, 33 Pilot safety relay..................................................... 24
Hourmeter.........................................................18, 33 Pilot safety solenoid valve................................ 24, 33
Hourmeter relay..............................................4, 8, 16 Pilot safety switch ...................................... 13, 24, 33
Hydraulic oil filter restriction pressostat ............18, 33 Pilot system cancellation........................................ 25
Hydraulic oil temperature sender......................18, 33 Pilot system cancellation diode............................ 6, 8
Pilot system cancellation diode
I
(specific to certain countries) ......................... 6, 39
Injection pump solenoid..........................................16 Pilot system cancellation diodes
Instrument panel.........................................18, 19, 33 (specific to certain countries) ............................. 24
Instrument panel (front face) ..................................11 Pilot system cancellation indicator lamp ................ 24
Instrument panel audible warning...............13, 18, 33 Pilot system cancellation solenoid valve.......... 24, 35
Instrument panel wiring ..........................................11 Pilot system cancellation switch................. 15, 24, 35
Pilot system cancellation switch lighting .... 15, 24, 35
K
Position .................................................................. 27
K3 relay diode.................................................4, 8, 24 Pre-heater plug ...................................................... 16
Key switch ..................................................13, 16, 33 Pressure switch for minimum braking pressure ..... 26
Printed circuit earth .................................................. 8
L
Printed circuit schematic guide ................................ 8
LH control arm pilot safety relay ...........................4, 8
Q
LH direction indicator diode ............................4, 8, 28
LH direction indicator green indicator lamp ....4, 8, 28 Quick...................................................................... 15
LH front direction indicator................................28, 33 Quick-attach........................................................... 23
LH front side mounted direction indicator ...............28 Quick-attach diode ..................................... 15, 22, 35
LH loudspeaker ................................................22, 36 Quick-attach solenoid valve ............................. 22, 35
LH main beam headlight...................................26, 33 Quick-attach switch.......................................... 15, 35
LH rear direction indicator ................................28, 33 Quick-attach switch lighting ....................... 15, 22, 35
LH rear stop light ..............................................26, 33
R
LH side-mounted direction indicator .......................33
Licence plate lighting ........................................28, 35 Radio.......................................................... 22, 23, 33
Radio diode.................................................... 6, 8, 22
M
Rear foglight..................................................... 28, 35
Main beam headlight diode ............................4, 8, 26 Rear foglight indicator lamp diode ....................... 6, 8
Main beam headlights ............................................27 Rear foglight switch................................................ 22
Minimum braking pressure switch ..........................13 Rear foglight switch lighting ............................. 15, 28
Rear LH side light ............................................ 26, 33
O
Rear RH side light............................................ 26, 33
Overload indicator ............................................23, 35 Rear working light ............................................ 21, 36
Overload indicator diode.................................6, 8, 22 Rear working light switch ................................. 15, 28
Overload indicator pressostat, on boom foot..........22 Resistor (0.85 Ohm)........................................... 6, 16
Overload indicator switch ...........................15, 22, 35 RH direction indicator diode........................... 4, 8, 28
Overload indicator switch lighting ...............15, 22, 35 RH direction indicator green indicator lamp ... 4, 8, 28
RH front direction indicator .............................. 28, 33
RH front side mounted direction indicator.............. 28
Cre 7-80640GB Issued 09-97 Printed in U.K.
4001-40
R S
RH loudspeaker................................................22, 36 Stop light pressure switch .......................... 13, 26, 33
RH main beam headlight ..................................26, 33
T
RH rear direction indicator................................28, 33
RH rear stop light..............................................26, 33 Terminal strip (4).................................................... 24
RH side-mounted direction indicator ......................33 Thermostart (optional)............................................ 17
Right-hand and left-hand control arm wiring (optional) Two-speed ............................................................. 25
15 Two-speed brake pressure switch ................... 24, 33
Right-hand control arm, left-hand control arm and Two-speed switch ...................................... 13, 24, 33
combination switch wiring (standard) .................13
U
Rotary .....................................................................15
Rotary light .................................................20, 21, 36 Upperstructure and attachment working
Rotary light indicator diode ...................................6, 8 light relay ............................................. 4, 8, 20, 26
Rotary light indicator lamp diode ............................20 Upperstructure power socket ..................... 22, 23, 33
Rotary light switch ......................................15, 20, 35 Upperstructure power socket connecting point........ 8
Rotary switch lighting..................................15, 20, 35
W
S
Windshield washer................................................. 21
Schematic symbols...................................................3 Windshield washer motor................................. 20, 33
Second travel speed indicator lamp shunt Windshield washer switch.......................... 13, 20, 33
(Italy only).............................................................6 Windshield washer switch lighting ............. 13, 20, 33
Shunt ........................................................4, 8, 24, 26 Windshield wiper.................................................... 21
Shunt (pilot cancellation option special for Italy, Windshield wiper intermittent action .................. 4, 20
remove shunt Sh4 and substitute Windshield wiper motor.................................... 20, 36
shunt Sh8)...................................................... 24 Windshield wiper switch............................. 13, 20, 33
Shunt (pilot system cancellation)..............................6 Windshield wiper switch lighting ................ 13, 20, 33
Shunt (pilot system cancellation) remove Working brake - Italy .............................................. 31
shunt Sh4 and install it at Sh8..............................8 Working brake and parking brake switch ............... 13
Specifications ...........................................................2 Working brake and parking brake switch
Speed blue indicator lamp (2nd).................13, 24, 33 lighting ......................................................... 13, 30
Speed change relay........................................4, 8, 24 Working brake pressure switch.............................. 13
Speed green indicator lamp (1st) ...............13, 24, 33 Working brake solenoid valve ................................ 30
Speed indicator lamp diode (1st)....................4, 8, 24 Working brake solenoid valve (standard)............... 33
Speed indicator lamp diode (2nd)...................4, 8, 24 Working brake solenoid valves ........................ 30, 33
Stabilizer lowering and raising momentary Working brake, parking light switch ....................... 30
inverter switch ....................................................13 Working light Germany .......................................... 31
Stabilizer raising and lowering momentary Working light relay ......................................... 4, 8, 20
inverter switch ....................................................24 Working light switch ................................... 13, 20, 33
Stabilizer raising and lowering solenoid valves ......33 Working light switch lighting....................... 13, 20, 33
Stabilizer solenoid valve diodes .............................13
Stabilizer solenoid valve diodes (in commodo) ......24
Stabilizer solenoid valves .......................................24
Stabilizers ...............................................................25
Standard 4 terminal strip ........................................22
Standard rotary light ...............................................36
Standard rotary light (optional) ...............................20
Standard working light ............................................31
Starter motor.....................................................16, 33
Starter motor connecting point .................................8
Starter motor relay..........................................4, 8, 16
Steering ..................................................................15
Steering brake pressure switch ........................26, 35
Steering column connector...............................13, 35
Steering column connector (commodo)..................33
Steering column connectors .......................24, 26, 28
Steering pressure switch ............................13, 26, 33

Cre 7-80640GB Issued 09-97 Printed in U.K.


4001
Section
4001

ELECTRICAL SCHEMATICS
Wheeled excavators

Copyright  1999 Case France


Printed in France
Case Cre 7-26540GB November 1999
4001-2

TABLE OF CONTENTS
SCHEMATIC SYMBOLS .......................................................................................................................................... 3
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD).................................................... 4
PRINTED CIRCUIT WIRING (STANDARD)............................................................................................................. 4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) .................................................... 6
PRINTED CIRCUIT WIRING (OPTIONAL) .............................................................................................................. 6
PRINTED CIRCUIT SCHEMATIC GUIDE ................................................................................................................ 8
P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)..................................................................... 10
INSTRUMENT PANEL WIRING............................................................................................................................ 11
INSTRUMENT PANEL (FRONT SIDE) ................................................................................................................. 11
RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM AND COMMODO WIRING (STANDARD) ........ 13
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL............................................................. 15
ELECTRICAL SCHEMATIC (PLATE 2) ................................................................................................................ 16
ELECTRICAL SCHEMATIC (PLATE 3) ................................................................................................................ 18
ELECTRICAL SCHEMATIC (PLATE 4) ................................................................................................................ 20
ELECTRICAL SCHEMATIC (PLATE 5) ................................................................................................................ 22
ELECTRICAL SCHEMATIC (PLATE 6) ................................................................................................................ 24
ELECTRICAL SCHEMATIC (PLATE 7) ................................................................................................................ 26
ELECTRICAL SCHEMATIC (PLATE 8) ................................................................................................................ 28
ELECTRICAL SCHEMATIC (PLATE 9) ................................................................................................................ 30
ELECTRICAL SCHEMATIC (PLATE 10) .............................................................................................................. 32
ELECTRICAL SCHEMATIC (PLATE 11) ............................................................................................................... 34
ELECTRICAL SCHEMATIC (PLATE 12) .............................................................................................................. 36
ELECTRICAL SCHEMATIC (PLATE 13) .............................................................................................................. 38
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD) ............................................................... 41
ELECTRONIC CIRCUIT WIRING (788P/988P/1188P) ......................................................................................... 42
ELECTRONIC CIRCUIT WIRING (788P/988P/1188P) ......................................................................................... 43
DETAILS OF 35 PIN CONNECTOR X3 EXCAVATORS 788P/988P/1188P.......................................................... 43
CAB FLOOR WIRING (OPTIONAL)...................................................................................................................... 44
ENGINE AND UPPERSTRUCTURE MODULE WIRING (OPTIONAL) ................................................................ 45
CAB AND CAB OPTIONS WIRING ....................................................................................................................... 46
ALPHABETICAL INDEX ........................................................................................................................................ 47

SPECIFICATIONS
Circuit voltage ............................................................................... 24 volt negative earth and 12 volt negative earth
Batteries .......................................................................................................2 x 12 Volt 120 A/hrs, low maintenance
Alternator ..............................................................................................................................Bosch, 28 volt, 45 amps
Starter motor........................................................................................................................... Bosch, 24 volt, 4.0 kW

Cre 7-26540GB Issued 11-99


4001-3

SCHEMATIC SYMBOLS Local earth

A (n) Radio/housings
B (n) Indicators/pressure switches/loud-speakers/detectors/thermal detector/gauge Wire number
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators Closed circuit
H (n) Warning devices (lighted and audible)
K (n) Relays
M (n) Motors Open circuit
P (n) Instruments
R (n) Resistors/heating elements/heating plugs
S (n) Shunt resistors/switches/rotating switches/main switch Intersection of two wires with connection point
Sh (n) Shunt
V (n) Diodes
X (n) Supply line connections Intersection of two wires without connection point
Y (n) Solenoid valves, solenoids
NOTE: The (n) shows the component number.
Example: K2 is relay N°2. Link with following plate

Link with preceding plate


(n) Supply on printed circuit

Return to another plate with the same letter


(n) Battery terminal

Bulbs
(n) Printed circuit connection terminal

Test bulb
Printed circuit earth connector

Light emitting diode (LED)


A1 Instrument panel connector

Regulator
1 or 1 or 1 Identification of harness

1(1) or 1(1) or 1(1) Identification of harness, followed by path identification number

(1) or (1) Printed circuit earth connectors

3 2
The installation position for the harness connector (1) on connector (2) of the
printed circuit is identified by a red mark (3) followed by the figure 1 on the
printed circuit. This identification corresponds to the position of path 1 of the
harness connector (1). This position is completed when the path 1 line is
shown by a red ring (4) located on line 1 wire, or by red paint marking.

4 1

Cre 7-26540GB Issued 11-99


4001-4

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD) K52 Speed change relay (except 588) K56 Reverse travel relay
K54 Frequency threshold detector relay (threshold: 1 = K57 Forward travel relay
1600 rpm) K58 Two-speed supply relay
K55 Frequency threshold detector relay (threshold: 2 = K61 Battery relay (heater/air conditioner)
1400 rpm) Sh4, Sh5, Sh9 Shunt

Sh6, Sh8, Sh10, Sh11 Not used V13 1st speed indicator lamp diode on 588P
V1 Starter key switch diode V14 Stab lowering diode
V2 Diode less engine running V15 Stab raising diode
V3 Dipped headlight indicator lamp diode on instru- V18 Axle unlocking indicator lamp diode on instru-
ment panel ment panel
V6 Main beam headlight indicator lamp diode on V20 RH flasher diode
instrument panel V22 Rotary light diode on instrument panel
V7 RH flashing indicator lamp diode on instrument V23 Warning diode
panel V24 K54 relay diode
V8 LH flashing indicator lamp diode on instrument V25 K55 relay diode
panel V26 Axle unlocking diode
V9 Warning indicator lamp diode on instrument panel V30 Buzzer diode
V10 LH flasher diode V31 K58 relay diode
V12 2nd speed indicator lamp diode on 588P

PRINTED CIRCUIT WIRING (STANDARD)

1 (1) 24 volt printed circuit supply 36 12V socket harness, 2-way connector
1 (2) 24 volt printed circuit supply 37 Bi-stable relay harness on 588, 5-way connector
39 Brake pressure switch harness on 588, 2-way
4 (1) Printed circuit earth connector
4 (2) Printed circuit earth 40 Two-speed control box harness, 5-way connec-
tor (588)
CI99J043 1 Floor harness, 10 way connector
44 Flasher unit harness, 3-way connector
2 Floor harness, 10 way connector 45 Upperstructure socket harness
F1 Fuse, 30 A, starter motor solenoid, thermostart F23 Fuse, 5 A, RH main beam headlight 3 Floor harness, 10 way connector
50 Threshold detector harness, 5-way connector
F2 Fuse, 5 A, starter switch 4 Floor harness, 10 way connector
F24 Fuse, 5 A, LH main beam headlight (788)
F3 Fuse, 7.5 A, instrument panel, hourmeter 5 Floor harness, 10 way connector 51 Heavy lift solenoid valve harness (788), clip
F25 Fuse, 7.5 A, parking brake electro, working brake 6 Floor harness, 10 way connector
F4 Fuse, 5 A, cab lighting, horn (control), hood lighting electro (std/D/I)
F5 Fuse, 10 A, working lights (control), rotary light (std), 7 Floor harness, 10 way connector
F26 Fuse, 7.5 A, flasher, warning 8 Floor harness, 2 way connector
rotary light (Italy) 1 Floor harness earth, clip
F27 Fuse, 5 A, remote controlled or articulated boom, 9 Floor harness, 2 way connector
F6 Fuse, 15 A, attachment working light, rear cab light 2 Floor harness earth, clip
tool quick coupler, air suspension seat, speed
F7 Fuse, 10 A, horn (power)
threshold detector (788P heavy lift)
F8 Fuse, 15 A, upperstructure socket, fuel pump 1 Common harness, 8-way connector
F28 Fuse, 40 A, engine stop/start solenoid (injection) 2-1 Lighting / solenoid valve harness, 5-way connec- 1 Common harness earth, clip
F9 Fuse, 10 A, windshield washer, windshield wiper 2 Lighting / solenoid valve harness earth, clip
F30 Fuse, 10 A, windshield wiper (BAT +) tor
(BAT + R) 3 Brake unit earth harness, clip
F32 Fuse, 5 A, (BAT +) electronics 2-2 Lighting / solenoid valve harness, 6-way connec-
F10 Fuse, 10 A, heater 4 Engine harness earth, clip
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ H14 Troubleshooting test LED tor
5 LH rear harness earth, clip
K1 Starter motor relay 3 Central brake harness, 6-way connector
working brake for Germany 20 Cab socket harness, clip
4 Engine harness, 8-way connector
F12 Fuse, 10 A, two-speed electro, axle unlocking, pilo- K2 Battery relay 28 Working brake solenoid valve harness, clip
5 LH rear lighting harness, 4-way connector
ting neutralisation (std - Italy), stabilizers, direc- K3 Hourmeter + transmission brake pressure switch 30 Electronic harness earth, clip
20 Cab socket harness, 5-way connector
tion of travel control, overload indicator + two-speed supply relay 51 Heavy lift solenoid valve harness, clip
21 Cab socket harness, 6-way connector
F14 Fuse, 10 A, step-down transformer / radio K4 Electronic supply relay 26 Windshield wiper time delay harness, 6-way con-
F15 Fuse, 15 A, general lighting K5 Horn relay A Standard earth
nector
K6 Working light relay B Optional earth
F16 Fuse, 5 A, RH rear brake light 27 Windshield washer, 2-way connector
28 Working brake solenoid valve harness, clip C option
F17 Fuse, 5 A, LH rear brake light K7 Relay authorizing working lights if sidelights on
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting + K9 Pilot safety relay/axle unlocking 30 Electronic harness, 8-way connector (788/988/
cassette K10 Flasher unit relay 1188)
F19 Fuse, 5 A, LH front/rear sidelight + night lighting K13 Engine stop solenoid relay 31 Diagnostic plug harness, 3-way connector (788/
K14 Speed change relay (588) 988/1188)
F20 Fuse, 5 A, RH front dipped headlight
35 Step-down transformer harness 24V - 12V, 4-way
F21 Fuse, 5 A, LH front dipped headlight K20 Windshield wiper intermittent action
connector
F22 Fuse, 5 A, rear fog light K21 Safety relay piloting pressure switch piloting

Cre 7-26540GB Issued 11-99


4001-5

CM99J047

Cre 7-26540GB Issued 11-99


4001-6

DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) 1 Connection strip

PRINTED CIRCUIT WIRING (OPTIONAL)

6 Adjustable boom harness, 2-way connector


7 Hood lighting harness, clip
9 Cold start switch harness, 2-way connector
10 Adjustable boom harness, 2-way connector
12 Air conditioner harness, 5-way connector
13 Working brake
14 Adjustable boom maximum reach limitation harness, clip
16 Overload indicator switch harness, 2-way connector
17 Upperstructure rotary light harness, clip
19 Registration plate harness, clip
19 Option switches lighting harness, clip
22 Cold start plug harness, clip
23 Thermostart element harness, 2-way connector
24 Front cab light switch harness, 2-way connector
28 Working brake solenoid valve harness
33 Overload indicator pressure switch, 2-way connector
1 38 Pilot system cancellation switch, Italy, 3-way connector
43 Rear fog light switch harness, 2-way connector
46 Fuel pump harness
47 Fuel heater harness, clip
48 Quick coupler solenoid valve harness, clip
52 Direction of travel reverser switch harness, 4-way connector
53 Direction of travel reverser relay harness, 2-way connector
54 Direction of travel reverser indicator lamp, 3-way connector
CI99J044
6 Adjustable boom harness earth, clip
7 Hood lighting harness earth, clip
12 Air conditioning harness earth, clip
F1 Fuse, 30 A, starter motor solenoid, thermostart F29 Fuse, 10 A, cab front working light 33 Overload indicator pressure switch harness earth, clip
F4 Fuse, 5 A, cab lighting, horn (control), hood F31 Fuse, 10 A, fuel heater 47 Fuel heater harness earth, clip
lighting K15 Thermostart relay 48 Tool quick coupler harness earth, clip
F5 Fuse, 10 A, working lights (control), rotary light K50 Adjustable boom raising limiter relay (optional)
(std), rotary light (Italy) K51 Adjustable boom retracting limitation relay (optio- 1 Boom reach limitation solenoid valve cable
F6 Fuse, 15 A, attachment working light, rear cab nal) 2 Connection strip
light K53 Fuel heater relay 3 Boom reach limitation detector cable
F8 Fuse, 15 A, upperstructure socket, fuel pump K59 Air conditioning compressor relay
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ K60 Air conditioning condenser relay
working brake for Germany R10 Resistor, 0.85 Ohms
F12 Fuse, 10 A, two-speed electro, axle unlocking, V5 Fog light indicator lamp diode on instrument panel
piloting neutralisation (std - Italy), stabilizers, V16, V17, V19 Diode for Italy
direction of travel control, overload indicator V21 Overload indicator lamp diode on instrument
F13 Fuse, 15 A, air conditioner panel
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting + V27 Axle electro unlocking diode for Italy
cassette V28 Pilot system cancellation indicator lamp diode on
F22 Fuse, 5 A, rear fog light instrument panel
F27 Fuse, 5 A, remote controlled or articulated boom, V52 Quick coupler switch diode
tool quick coupler, air suspension seat, speed Sh8, Sh9, Sh10, Sh11 Shunt
threshold detector (788P heavy lift) Sh3, Sh4, Sh5, Sh6 Not used

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4001-7

1 2 3

CM99J048

Cre 7-26540GB Issued 11-99


4001-8

PRINTED CIRCUIT SCHEMATIC GUIDE K56 Reverse travel relay


K57 Forward travel relay
1 (1) 24 V PCB supply K58 Two-speed supply relay
1 (2) 24 V PCB supply K59 Air conditioning compressor relay
K60 Air conditioning condenser relay
F1 Fuse, 30 A, starter motor solenoid, thermostart K61 Battery relay (heater/air conditioner)
F2 Fuse, 5 A, starter switch
F3 Fuse, 7.5 A, instrument panel, hourmeter Sh4 Shunt OK Standard - not Italy
F4 Fuse, 5 A, cab lighting, horn (control), hood lighting Sh5 Shunt Night lighting (switch) + P excavator registration plate
F5 Fuse, 10 A, working lights (control), rotary light (std), rotary light (Italy) Sh8 Shunt OK Italy - not standard
F6 Fuse, 15 A, attachment working light, rear cab light Sh9 Shunt contact K58 two-speed supply
F7 Fuse, 10 A, horn (power) Sh10Shunt if dozer - stab independent
F8 Fuse, 15 A, upperstructure socket, fuel pump Sh11 Shunt - Italy axle unlocking
F9 Fuse, 10 A, windshield washer, windshield wiper (BAT + R)
F10 Fuse, 10 A, heater V1 Starter key switch diode
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ working brake for Germany V2 Diode less engine running
F12 Fuse, 10 A, two-speed electro, axle unlocking, piloting neutralisation (std - Italy), stabilizers, direction of travel con- V3 Dipped headlight indicator lamp diode on instrument panel
trol, overload indicator V5 Fog light indicator lamp diode on instrument panel
F13 Fuse, 15 A, air conditioner V6 Main beam headlight indicator lamp diode on instrument panel
F14 Fuse, 10 A, step-down transformer / radio V7 RH flashing indicator lamp diode on instrument panel
F15 Fuse, 15 A, general lighting V8 LH flashing indicator lamp diode on instrument panel
F16 Fuse, 5 A, RH rear brake light V9 Warning indicator lamp diode on instrument panel
F17 Fuse, 5 A, LH rear brake light V10 LH flasher diode
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting + cassette V12 2nd speed indicator lamp diode on 588P
F19 Fuse, 5 A, LH front/rear sidelight + night lighting V13 1st speed indicator lamp diode on 588P
F20 Fuse, 5 A, RH front dipped headlight V14 Stab lowering diode
F21 Fuse, 5 A, LH front dipped headlight V15 Stab raising diode
F22 Fuse, 5 A, rear fog light V16 Diode for Italy
F23 Fuse, 5 A, RH main beam headlight V17 Diode for Italy
F24 Fuse, 5 A, LH main beam headlight V18 Axle unlocking indicator lamp diode on instrument panel
F25 Fuse, 7.5 A, parking brake electro, working brake electro (std/D/I) V19 Diode for Italy
F26 Fuse, 7.5 A, flasher, warning V20 RH flasher diode
F27 Fuse, 5 A, remote controlled or articulated boom, tool quick coupler, air suspension seat, speed threshold detector V21 Overload indicator lamp diode on instrument panel
(788P heavy lift) V22 Rotary light diode on instrument panel
F28 Fuse, 40 A, engine stop/start solenoid (injection) V23 Warning diode
F29 Fuse, 10 A, cab front working light V24 K54 relay diode
F30 Fuse, 10 A, windshield wiper (BAT +) V25 K55 relay diode
F31 Fuse, 10 A, fuel heater V26 Axle unlocking diode
F32 Fuse, 5 A, (BAT +) electronics V27 Axle electro unlocking diode for Italy
V28 Pilot system cancellation indicator lamp diode on instrument panel
H14 Troubleshooting test LED V30 Buzzer diode
V31 K58 relay diode
K1 Starter motor relay V52 Quick coupler switch diode
K2 Battery relay
K3 Hourmeter + transmission brake pressure switch + two-speed supply relay Ø 4 (1) printed circuit earth
K4 Electronic supply relay Ø 4 (2) printed circuit earth
K5 Horn relay
K6 Working light relay
K7 Relay authorizing working lights if sidelights on
K9 Pilot safety relay/axle unlocking
K13 Engine stop solenoid relay
K15 Thermostart relay
K21 Safety relay piloting pressure switch piloting
K52 Speed change relay (except 588)
K53 Fuel heater relay
K54 Frequency threshold detector relay (threshold: 1 = 1600 rpm)
K55 Frequency threshold detector relay (threshold: 2 = 1400 rpm)

Cre 7-26540GB Issued 11-99


4001-9

CM99K032

Cre 7-26540GB Issued 11-99


4001-10

P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC P. 10 (PLATE 1)

CM97G029

E1 Brake minimum pressure red warning lamp connector 9 Hydraulic oil filter restriction red warning lamp
A2 Minimum pilot pressure red warning lamp connector E2 Hazard warning red indicator lamp connector 11 Minimum pilot pressure red warning lamp
A3 Hydraulic oil temperature warning lamp connector E3 Parking brake red warning lamp connector 12 Overload indicator orange warning lamp (option)
A4 Battery charge red warning lamp E5 Rear fog light orange indicator lamp connector (special for 14 Pilot system cancellation green indicator lamp (special for certain coun-
A5 Red and orange warning lamp connector for audible warning device certain countries) tries)
A6 Orange warning lamp connector for front axle unlocking E6 Right-hand direction indicator green indicator lamp connector 16 Front axle unlocking orange warning lamp
A7 Engine oil pressure red warning lamp connector 24 Rotary light orange indicator lamp (special for certain countries)
F1 Left-hand direction indicator green indicator lamp connector
25 Minimum steering pressure red warning lap
B1 24 volt power supply F2 Rotary light orange indicator lamp connector (special for certain countries)
26 Parking brake and working brake red warning lamp
B3 Earth F5 Dipped headlight green indicator lamp connector
27 Minimum braking pressure red warning lamp
B4 Fuel level warning lamp connector F6 Main beam headlight blue connector
28 Rear fog light orange indicator lamp (special for certain countries)
B5 Gauge lighting connector F7 Steering minimum pressure red warning lamp connector
29 Left-hand direction indicator green indicator lamp
B6 Engine coolant solution temperature gauge connector
P1 Engine coolant solution temperature indicator 30 Main beam headlight blue indicator lamp
B7 Fuel minimum connector
P2 Fuel level gauge 31 Dipped headlight green indicator lamp
C2 Air filter restriction red warning lamp connector P3 Hydraulic oil temperature indicator 32 Hazard warning light red warning lamp
C4 Overload indicator orange warning lamp connector (optional) 33 Right-hand direction indicator green indicator lamp
1 Stop alarm red warning lamp
39 Gauge lighting indicator lamp
D2 Pilot system cancellation green indicator lamp (special for certain coun- 2 Orange alarm warning lamp
tries) 3 Audible warning device stop push-button
D3 Hydraulic oil filter restriction red warning lamp connector 6 Engine oil pressure red warning lamp
7 Air filter restriction red warning lamp
8 Battery charge red warning lamp
Cre 7-26540GB Issued 11-99
4001-11

INSTRUMENT PANEL WIRING INSTRUMENT PANEL (FRONT FACE)

1 2 3

P3
P1

39

6
P2

11 8

9 12

14 16

27
25

24 28

29 33

CM97G031

A 7 way connector: minimum pilot pressure red warning lamp, hydraulic oil temperature indicator, battery charge
red warning lamp, audible warning stop push button, front axle unlocking orange indicator lamp, engine oil
pressure red warning lamp, alarm orange warning lamp, stop alarm red warning lamp.
B 7 way connector: 24 Volts supply, earth, fuel level gauge, gauge lighting, engine coolant temperature indicator.
30 31 26 32
C 7 way connector: air filter restriction red warning lamp, overload indicator orange indicator lamp (optional).
CS9K501
D 7 way connector: pilot system cancellation green indicator lamp (specific to certain countries), hydraulic oil fil-
ter restriction red warning lamp. 1 Stop alarm red warning lamp 27 Minimum braking pressure red warning lamp
E 7 way connector: minimum braking pressure red warning lamp, hazard warning red warning lamp, parking 2 Alarm orange warning lamp 28 Rear fog light orange indicator lamp (special for
brake red warning lamp, rear fog light orange indicator lamp (specific to certain countries), RH direction indica- 3 Audible warning device stop push-button certain countries)
tors green indicator lamp. 6 Engine oil pressure red warning lamp 29 Left-hand direction indicator green indicator
7 Air filter restriction red warning lamp lamp
F 7 way connector: LH direction indicator green indicator lamps, rotary light orange indicator lamp (specific to 8 Battery charge red warning lamp 30 Headlight main beam blue indicator lamp
certain countries), side light green indicator lamp, main beam blue indicator lamp, minimum steering pressure 9 Hydraulic oil filter restriction red warning lamp 31 Dipped headlight green indicator lamp
red warning lamp. 11 Minimum pilot pressure red warning lamp 32 Hazard warning light red warning lamp
12 Overload indicator orange warning lamp 33 Right-hand direction indicator green indicator
(optional) lamp
14 Pilot cancellation green indicator lamp (special 39 Gauge lighting indicator lamp
for certain countries)
P1 Engine coolant solution temperature indicator
16 Front axle unlocking orange indicator lamp
lamp
24 Rotary light orange indicator lamp (special for
P2 Fuel level gauge
certain countries)
P3 Oil temperature indicator
25 Minimum steering pressure red warning lamp
26 Parking brake red warning lamp

Cre7-26540GB Issued 11-99


4001-12

SC1 V14 V15


SC4
H11

SC2 S6
H15
SC3

H12
S3

H51 S26

S51
H13
S22
H50 S27

S50
H10

S4

J13 J14 J15


S1
H31

S25

S24

H18 S12 H17 H55 S55

CM99J045

Cre 7-26540GB Issued 11-99


4001-13

RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM AND


COMMODO WIRING (STANDARD)
H10 Working brake switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H14 Troubleshooting test LED
H15 Instrument panel audible warning
H17 First speed green indicator light (588)
H18 Second speed blue indicator light (588)
H31 Rotary light switch lighting
H50 Working brake and parking brake switch lighting (optional)
H51 Hazard warning switch lighting
H55 Rear fog light switch lighting
J13 Steering column connector
J14 Steering column connector
J15 Steering column connector
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S12 Two-speed switch (588)
S22 Control keyboard (788-988-1188)
S24 Pilot safety switch
S25 Rotary light switch (optional)
S26 Windshield washer switch
S27 Heater blower switch
S51 Hazard warning switch
S52 Pilot system cancellation switch (optional)
S55 Rear fog light switch
SC1 Direction indicator combination switch (commodo), main beam and dip switch, side lights and headlight flasher
switch
SC2 Front axle automatic and manual unlocking switch
SC3 Front axle locking and unlocking switch (in the axle unlocked position)
SC4 Stabilizer raising and lowering momentary inverter switch
V14-V15Stabilizer solenoid valve diodes (in combination switch (commodo)
Floor harness

30 Electronic harness
40 Two-speed control box harness (588)

Cre 7-26540GB Issued 11-99


4001-14

H53

S53

H30

S20

H52 S30

H58

S52

S56

H32

1 S21

CM99J046

Cre 7-26540GB Issued 11-99


4001-15

RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)


H30Cold start assistance switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H52 Pilot system cancellation switch lighting (optional)
H53 Cab front working light switch lighting (optional)
H58 Quick coupler switch lighting (optional)
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S30 Adjustable or articulated boom control switch (optional)
S52 Pilot system cancellation switch (optional)
S53 Cab front working light switch (optional)
S56 Quick coupler switch (optional)
1 Steering brake harness
3 Central braking harness (standard)
6 Adjustable boom control harness
9 Cold start assistance harness
16 Overload indicator harness
24 Front working lights harness
38 Pilot system cancellation harness

8 Floor harness

Cre 7-26540GB Issued 11-99


4001-16

ELECTRICAL SCHEMATIC (PLATE 2)


ELECTRICAL CABINET UPPERSTRUCTURE
F1 Fuse, 30 A, starter motor solenoid, thermostart G1 Batteries
F2 Fuse, 5 A, starter switch S2 Battery master switch
F3 Fuse, 7.5 A, instrument panel, hourmeter B25 Threshold detector (788)
F19 Fuse, 5 A, LH front/rear sidelight + night lighting Y55 Heavy lift solenoid valve (788)
Y1 G2 F27 Fuse, 5 A, remote controlled or articulated boom,
R11 ENGINE
S1 S2 tool quick coupler, air suspension seat, speed
R50 threshold detector (788P heavy lift) G2 Alternator
P10 F28 Fuse, 40 A, engine stop/start solenoid (injection) M1 Starter motor
F31 Fuse, 10 A, fuel heater R11 Cold start assistance plug (optional)
M1 K1 Starter motor relay R50 Fuel heater (optional)
K2 Battery relay Y1 Engine shut-down solenoid valve
K3 Hourmeter + transmission brake pressure switch
CAB
+ two-speed supply relay
K13 Engine stop solenoid relay P4 Hourmeter
K15 Thermostart relay P10 Instrument panel
K53 Fuel heater relay SC1 Direction indicator combination switch (com-
K54 Frequency threshold detector relay (threshold: 1 = modo), main beam and dip switch, side lights
1600 rpm) and headlight flasher switch
K55 Frequency threshold detector relay (threshold: 2 =
1400 rpm)
K61 Battery relay (heater/air conditioner)
R10 Resistor, 0.85 Ohms
Sh5 Shunt Night lighting (switch) + P excavator regi-
stration plate
V1 Starter key switch diode
V24 K54 relay diode
V25 K55 relay diode
FLOOR
S1 Key switch
H30 Cold start assistance switch lighting (optional)
S20 Cold start assistance switch (optional)

Y55

G1

B25 F1 - F2 - F3 - F19
SC1 F27 - F28 - F31 -
K1 - K2 - K3 -K13
S20 - H30 K15 - K53 - K54 - K55
P4
R10 - V1 - V24 - V25
Sh5

CM99K025

Cre 7-26540GB Issued 11-99


4001-17

BATTERY STARTER KEY SWITCH


GENERAL RELAY SPEED THRESHOLD DETECTOR
MASTER STARTER STARTER MOTOR RELAY HOUR-
ENGINE STOP RELAY COLD START ASSISTANCE (OPTIONAL) ALTERNATOR FUEL HEATER HEAVY LIFT SOLENOID VALVE
SWITCH MOTOR HEATER RELAY METER
ENGINE STOP (788)
BATTERIES AIR CONDITIONER RELAY

CM99H001

Cre 7-26540GB Issued 11-99


4001-18

ELECTRICAL SCHEMATIC (PLATE 3)


INSTRUMENT PANEL FLOOR
P10 Instrument panel B50 Parking brake pressure switch
H32 Overload indicator switch lighting (optional) B52 Pressure switch for minimum braking pressure
S21 Overload indicator switch (optional) B53 Steering pressure switch
P10 B22 ELECTRICAL CABINET
E15 Rear LH side light
B4
P11 - X10 B1 F3 Fuse, 7.5 A, instrument panel, hourmeter UPPERSTRUCTURE
F19 Fuse, 5 A, LH front/rear sidelight + night lighting
B1 Air filter restriction pressure switch
Sh5 Shunt Night lighting (switch) + P excavator regi-
B2 Hydraulic oil filter restriction pressure switch
stration plate
B21 Hydraulic oil temperature sender
V21 Overload indicator lamp diode on instrument panel
B23 Overload indicator (optional)
V30 Buzzer diode
P11 Fuel level gauge
CAB X10 Fuel level indicator connector
ENGINE
SC1 Direction indicator combination switch (commodo),
main beam and dip switch, side lights and B4 Engine oil pressure switch
headlight flasher switch B22 Engine coolant temperature sender

B23

H15 -V30

B52 - B53 B21


B2
S21 - H32 SC1 B50 F3 - F19
V21 - Sh5

CM99K025

Cre 7-26540GB Issued 11-99


4001-19

INSTRUMENT PANEL
PARKING BRAKE
HYDRAULIC FUEL LEVEL HYDR. INST. PANEL ORBITROL COMBINATION SWITCH
AIR FILTER ENGINE OIL BRAKE MINIMUM OVERLOAD INDICATOR
OIL FILTER RESERVE FLUID AUDIBLE ENGINE TEMPERATURE PRESSURE (COMMODO)
RESTRICTION PRESSURE PRESSURE PRESSURE
RESTRICTION ALARM TEMP. WARNING

CM99H002

Cre 7-26540GB Issued 11-99


4001-20

ELECTRICAL SCHEMATIC (PLATE 4)


ELECTRICAL CABINET UPPERSTRUCTURE
F12 Fuse, 10 A, two-speed electro, axle unlocking,
Y2 Pilot safety solenoid valve
piloting neutralisation (std - Italy), stabilizers,
Y11 Gear box solenoid valve (first speed)
direction of travel control, overload indicator
Y2 - Y11 - Y12 F19 Fuse, 5 A, LH front/rear sidelight + night lighting
Y12 Gear box solenoid valve (second speed)
SC2 - SC3 - SC4 Y13 - Y26 - Y27 F25 Fuse, 7.5 A, parking brake electro, working brake
Y13 Front axle unlocking solenoid valve
Y16 Y15 Parking brake solenoid valve
electro (std/D/I)
Y16 Working brake solenoid valve
K3 Hourmeter + transmission brake pressure switch
V14 - V15 H17 - H18 - S12 + two-speed supply relay
Y26 Stabilizer raising solenoid valve
Y27 Stabilizer lowering solenoid valve
K9 Pilot safety relay/axle unlocking
K14 Speed change relay (588) CAB
K21 Safety relay piloting pressure switch piloting
H17 First speed green indicator light (588)
K52 Speed change relay (except 588)
H18 Second speed blue indicator light (588)
K58 Two-speed supply relay
P10 Instrument panel
Sh4 Shunt OK Standard - not Italy
SC1 Direction indicator combination switch (com-
Sh9 Shunt contact K58 two-speed supply
modo), main beam and dip switch, side lights
V2 Diode less engine running
and headlight flasher switch
V12 2nd speed indicator lamp diode on 588P
V13 1st speed indicator lamp diode on 588P
V18 Axle unlocking indicator lamp diode on instrument
panel
V31 K58 relay diode
FLOOR
A2 Electronic control box (788-988-1188)
B3 Pilot pressure switch
B12 Brake pressure switch (588)
B54 Front axle unlocking pressure switch
B57 Speed change pressure switch
H50 Working brake and parking brake switch lighting
(optional)
J14 Steering column connector
J15 Steering column connector
SC2 Front axle automatic and manual unlocking switch
SC3 Front axle locking and unlocking switch (in the
F12 - F19 - F25 axle unlocked position)
K3 - K9 - K14 - K21 SC4 Stabilizer raising and lowering momentary inverter
K52 - K58 switch
P10 S12 Two-speed switch (588)
Sh4 - Sh9
S24 Pilot safety switch
V2 - V12 - V13 - V18 S50 Parking brake and working brake switch (optional)
B57 - B12 V31 V14-V15Stabilizer solenoid valve diodes (in combina-
tion switch (commodo)
S24 X3 35-way connector (788-988-1188)
J14 - J15
B54
SC1
B3 Y15
A2 - X3 S50 - H50

CM99K025

Cre 7-26540GB Issued 11-99


4001-21

588 TWO-SPEED TRAVEL 788/988/1188 TWO-SPEED TRAVEL PILOT PRESSURE


TWO-SPEED PILOT SYSTEM AXLE LOCKING COMBINATION SWITCH WORKING
TWO-SPEED TWO-SPEED TWO-SPEED STABILIZERS AXLE LOCKING PARKING BRAKE
INDICATOR LAMPS SAFETY INDICATOR (COMMODO) BRAKE
RELAY RELAY SOLENOID VALVE LAMPS
TWO-SPEED SOLENOID VALVE

CM99H003

Cre 7-26540GB Issued 11-99


4001-22

ELECTRICAL SCHEMATIC (PLATE 5)


ELECTRICAL CABINET FLOOR
F4 Fuse, 5 A, cab lighting, horn (control), hood B51 Brake light pressure switch
lighting H26 Horn
F7 Fuse, 10 A, horn (power) J14 Steering column connector
F15 Fuse, 15 A, general lighting
UPPERSTRUCTURE
F16 Fuse, 5 A, RH rear brake light
F17 Fuse, 5 A, LH rear brake light E10 RH rear brake light
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting + E11 LH rear brake light
E10 - E13 - E21 cassette E12 Engine compartment light (optional)
SC1 S3 F19 Fuse, 5 A, LH front/rear sidelight + night lighting E12 Front RH side light
P10 F20 Fuse, 5 A, RH front dipped headlight E13 Rear RH side light
F21 Fuse, 5 A, LH front dipped headlight E14 Front LH side light
F23 Fuse, 5 A, RH main beam headlight E15 Rear LH side light
E31 F24 Fuse, 5 A, LH main beam headlight E16 Front RH dipped headlight
F26 Fuse, 7.5 A, flasher, warning E17 Front LH dipped headlight
K5 Horn relay E18 RH main beam headlight
K7 Relay authorizing working lights if sidelights on E19 LH main beam headlight
K10 Flasher unit relay E20 RH front direction indicator
Sh5 Shunt Night lighting (switch) + P excavator regi- E21 RH rear direction indicator
stration plate E22 LH rear direction indicator
V3 Dipped headlight indicator lamp diode on instru- E23 LH front direction indicator
ment panel E31 RH side-mounted direction indicator
V6 Main beam headlight indicator lamp diode on E32 LH side-mounted direction indicator
instrument panel
V7 RH flashing indicator lamp diode on instrument
panel
V8 LH flashing indicator lamp diode on instrument
panel
V9 Warning indicator lamp diode on instrument panel
V10 LH flasher diode
V20 RH flasher diode
V23 Warning diode
CAB
E20
H51 Hazard warning switch lighting
P10 Instrument panel
E12 - E16 S3 Horn switch
E18 S51 Hazard warning switch
E11 - E15 - E22 SC1 Direction indicator combination switch (com-
modo), main beam and dip switch, side lights
F4 - F7 - F15 - F16 and headlight flasher switch
F17 - F18 - F19 - F20
B51 F21 - F23 - F24 - F26
S51 - H51 K5 - K7 - K10 - Sh5
H1 - H26 E32 V3 - V6 - V7 - V8 - V9 - V10
J14 V20 - V23
E23
E14 - E17
E19

CM99K025

Cre 7-26540GB Issued 11-99


4001-23

COMBINATION SWITCH DIPPED MAIN BEAM


HORN BRAKE LIGHTS SIDE LIGHTS INDICATOR LIGHTS HAZARD WARNING LIGHTS
(COMMODO) HEADLIGHTS HEADLIGHTS

CM99H004

Cre 7-26540GB Issued 11-99


4001-24

ELECTRICAL SCHEMATIC (PLATE 6)


INSTRUMENT PANEL CAB
H10 Working brake switch lighting E1 Cab lighting
H11 Windshield wiper switch lighting H50 Working brake and parking brake switch lighting
H12 Windshield washer switch lightinH31Rotary light (optional)
switch lighting (optional) H51 Hazard warning switch lighting
H53 Cab front working light switch lighting (optional) M2 Windshield wiper motor
S4 Working light switch cable item 144 = blue cable
E1 - S10 S6 Windshield wiper switch cable item 142 = grey cable
E51 H57 S25 Rotary light switch (optional) cable item 0 = black cable
H50
M2 S26 Windshield washer switch cable item 38 = white cable
S53 Cab front working light switch (optional) P10 Instrument panel
S10 Cab lighting switch
ELECTRICAL CABINET
SC1 Direction indicator combination switch (com-
F4 Fuse, 5 A, cab lighting, horn (control), hood
modo), main beam and dip switch, side lights
lighting
and headlight flasher switch
F5 Fuse, 10 A, working lights (control), rotary light
X1 (E) Cab floor/Cab windshield wiper motor blue
(std), rotary light (Italy)
connector
F6 Fuse, 15 A, attachment working light, rear cab
X1 (G) Cab floor/cab connector
light
X1 (J) Cab floor/Cab windshield wiper motor white
F9 Fuse, 10 A, windshield washer, windshield wiper
connector
(BAT + R)
X1 (K) Cab floor/cab connector
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting +
X1 (L) Cab floor/Cab windshield wiper motor grey
cassette
connector
F19 Fuse, 5 A, LH front/rear sidelight + night lighting
X1 (M) Cab floor/Cab windshield wiper motor black
F29 Fuse, 10 A, cab front working light
connector
F30 Fuse, 10 A, windshield wiper (BAT +)
X1 (F) Cab floor/Cab rotary light connector (optional)
H57 Standard or Italian rotary light
K6 Working light relay FLOOR
K7 Relay authorizing working lights if sidelights on
M3 Windshield washer motor
K20 Windshield wiper intermittent action
Sh5 Shunt Night lighting (switch) + P excavator regi- UPPERSTRUCTURE
stration plate
E2 Attachment working light on boom
V22 Rotary light diode on instrument panel
H57 Standard or Italian rotary light
X5 (A), (C) Attachment working light power connection

X1
X5
E2
F4 - F5 - F6 - F9
F18 - F19 - F29 - F30
K6 - K7 - K20
P10 V22
S4 - S6 - S25 - S26 - S53 SC1 Sh5
M3
H10 - H11 - H12 - H31 - H53

CM99K025

Cre 7-26540GB Issued 11-99


4001-25

CAB FRONT
CAB ROTARY ROTARY LIGHT ATTACHMENT WORKING COMBINATION SWITCH
CAB REAR WORKING LIGHT WINDSHIELD WIPER WINDSHIELD WASHER WORKING LIGHTS
LIGHTING LIGHT INDICATOR LAMP LIGHT (COMMODO)
(OPTIONAL)

CM99H005

Cre 7-26540GB Issued 11-99


4001-26

ELECTRICAL SCHEMATIC (PLATE 7)


ELECTRICAL CABINET CAB
F8 Fuse, 15 A, upperstructure socket, fuel pump B5 RH loudspeaker (optional)
F10 Fuse, 10 A, heater B6 LH loudspeaker (optional)
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ M6 Cab blower motor (optional)
working brake for Germany X1(A),(B),(C),(D) Cab floor/cab LH and RH loud-
F14 Fuse, 10 A, step-down transformer / radio speaker connector (optional)
F19 Fuse, 5 A, LH front/rear sidelight + night lighting X5 12V accessories socket
G3 Step-down transformer 24V / 12V X14 (1),(2) Blower motor connector (optional)
B5 B6
Y53 M6 - S29 - X14 UPPERSTRUCTURE
INSTRUMENT PANEL
X2 Upperstructure power line connection
SC1 H13 Heater blower switch lighting Y53 Fuel filler pump (optional)
X2 S27 Heater blower switch
S29 Cab blower switch (optional)
FLOOR
A1 Radio (optional)
E7 Cigarette lighter
M4 Heater blower motor
SC1 Direction indicator combination switch (com-
modo), main beam and dip switch, side lights
and headlight flasher switch

X1

F8 - F10 - F11 - F14


F19
G3
S27 - H13 A1 X5
M4 E7

CM99K025

Cre 7-26540GB Issued 11-99


4001-27

UPPER-
STEP-DOWN
RADIO (OPTIONAL) STRUCTURE FUEL FILLER COMBINATION SWITCH CIGARETTE CAB BLOWER
TRANSFORMER VENTILATION/HEATING
ACCESSORY SOCKET POWER LINE PUMP (OPTIONAL) (COMMODO) LIGHTER (OPTIONAL)
24V - 12V
CONNECTION

CM99H006

Cre 7-26540GB Issued 11-99


4001-28

ELECTRICAL SCHEMATIC (PLATE 8)


ELECTRICAL CABINET UPPERSTRUCTURE
F2 Fuse, 5 A, starter switch B7 Swing detection pressure switch
F12 Fuse, 10 A, two-speed electro, axle unlocking, B10 Swing motor speed detector
piloting neutralisation (std - Italy), stabilizers, B11 Hydraulic pressure sender (788-988-1188)
direction of travel control, overload indicator B57 Speed change pressure switch
F19 Fuse, 5 A, LH front/rear sidelight + night lighting G1 Batteries
F32 Fuse, 5 A, (BAT +) electronics S2 Battery master switch
M5 - X9 - P12 H14 Troubleshooting test LED Y5 Upperstructure brake release control solenoid
Y5 B10 - X7 S2
S22 K3 Hourmeter + transmission brake pressure switch valve
SC1 G2 + two-speed supply relay
B22 ENGINE
K4 Electronic supply relay
B9 Engine speed detector (788-988-1188)
K52 Speed change relay (except 588)
Y4 B22 Engine coolant temperature sender
K58 Two-speed supply relay
G2 Alternator
Sh5 Shunt Night lighting (switch) + P excavator regi-
M5 Injection pump servo-motor (788-988-1188)
stration plate
P12 Servo-motor potentiometer (788-988-1188)
V1 Starter key switch diode
X6 Engine speed detector connector (788-988-1188)
V2 Diode less engine running
X7 Upperstructure swing speed detector connector
V31 K58 relay diode
X8 Hydraulic pressure sender connector (788-988-
CAB 1188)
X9 Injection pump servo-motor connector (788-988-
S1 Key switch
1188)
S22 Control keyboard (788-988-1188)
Y4 DRE4 proportional pressure reduction valve
SC1 Direction indicator combination switch (com-
modo), main beam and dip switch, side lights
and headlight flasher switch
X3 35-way connector (788-988-1188)
X4 Troubleshooting test socket (788-988-1188)
FLOOR
B8 Travel detector pressure switch
S1 Key switch

B9 - X6

B57 X4 G1

F2 - F12 - F19 - F32


K3 - K4 - K52 - K58
B7 V1 - V2 - V31
B8 H14
Sh5
S1 A2 - X3 B11 - X8

CM99K025

Cre 7-26540GB Issued 11-99


4001-29

SWING UPPER- TROU PRESSURE +28V


DRE4 TROUBLE- BRAKE 0V TRAV- STRUC- BLE- SWITCH INSTRU-
INJECTION PUMP ENGINE WA- SPEED CHANGE
PRESSURE SHOOTING + 28V RELEASE BAT- EL TURE SHOO MENT CONTROL PRESSURE
SERVO-MOTOR SPEED TER PRESSURE
REDUCTION TEST BATTERIES SOLE- TERY SPEED SWING TING PANEL PANEL KEYBOARD SENDER
DETECTOR T° SWING TRAVEL LIGHT- SWITCH
VALVE SOCKET NOID RELAY SPEED TEST
VALVES DETECTOR LED ING

CM99H007

Cre 7-26540GB Issued 11-99


4001-30

ELECTRICAL SCHEMATIC (PLATE 9)


ELECTRICAL CABINET UPPERSTRUCTURE
F19 Fuse, 5 A, LH front/rear sidelight + night lighting B56 Boom raising range limitation detector (optional)
F27 Fuse, 5 A, remote controlled or articulated boom, Y7 Adjustable or articulated boom extending electro-
tool quick coupler, air suspension seat, speed valve (optional)
threshold detector (788P heavy lift) Y8 Adjustable or articulated boom retracting electro-
K50 Adjustable boom raising limiter relay (optional) valve (optional)
K51 Adjustable boom retracting limitation relay (optio- Y50 Adjustable boom raising height limiter solenoid
nal) valve (optional)
Y52 Y50 B56 Sh5 Shunt Night lighting (switch) + P excavator regi- Y52 Quick coupler solenoid valve (optional)
stration plate
Y7 - Y8 INSTRUMENT PANEL
CAB
H15 Instrument panel audible warning
S30 H58 Quick coupler switch lighting (optional)
P10 Instrument panel
SC1 Direction indicator combination switch (com-
V30 Buzzer diode
P10 modo), main beam and dip switch, side lights
V52 Quick coupler switch diode
and headlight flasher switch
S30 Adjustable or articulated boom control switch
(optional)
S56 Quick coupler switch (optional)

H15

F19 - F27
K50 - K51
Sh5
SC1 V30 - V52

S56 - H58

CM99K025

Cre 7-26540GB Issued 11-99


4001-31

ADJUSTABLE BOOM
ADJUSTABLE BOOM RANGE
OR QUICK COUPLER (OPTIONAL)
LIMITATION (OPTIONAL)
ARTICULATED BOOM (OPTIONAL)

CM99H008

Cre 7-26540GB Issued 11-99


4001-32

ELECTRICAL SCHEMATIC (PLATE 10)


ELECTRICAL CABINET UPPERSTRUCTURE
F2 Fuse, 5 A, starter switch Y53 Forward travel solenoid valve (optional)
F12 Fuse, 10 A, two-speed electro, axle unlocking, Y54 Reverse travel solenoid valve (optional)
piloting neutralisation (std - Italy), stabilizers,
direction of travel control, overload indicator
F13 Fuse, 15 A, air conditioner
T1 - B1 - B2 F19 Fuse, 5 A, LH front/rear sidelight + night lighting
H59 - H60 EC - M K56 Reverse travel relay
S59 - S60 S1 Y53 - Y54 R1 - R2 K57 Forward travel relay
K59 Air conditioning compressor relay
K60 Air conditioning condenser relay
K61 Battery relay (heater/air conditioner)
Sh5 Shunt Night lighting (switch) + P excavator regi-
stration plate
CAB
B1 Condenser blower relay pressure switch
B2 Condenser blower relay pressure switch
EC Compressor
H59 Forward travel green indicator lamp (optional)
H60 Reverse travel red indicator lamp (optional)
M Condenser blower and blower motors
R1 Blower speed resistor
R2 Blower speed resistor
SC1 Direction indicator combination switch (com-
modo), main beam and dip switch, side lights
and headlight flasher switch
S1 Key switch
S59 Forward travel switch (optional)
S60 Reverse travel switch (optional)
S61 Direction of travel reverser switch (optional)
T1 Pressure switch

F2 - F12 - F13 - F19


K56 - K57 - K59 - K60 - K61
SC1 S61 Sh5

CM99K025

Cre 7-26540GB Issued 11-99


4001-33

CM99H009

Cre 7-26540GB Issued 11-99


4001-34

ELECTRICAL SCHEMATIC (PLATE 11)

Supplement for Italy UPPERSTRUCTURE

ELECTRICAL CABINET E29 Registration plate lighting (optional)


H56 Upperstructure rotary light (Italy) (optional)
F5 Fuse, 10 A, working lights (control), rotary light Y2 Pilot safety solenoid valve
(std), rotary light (Italy) Y11 Gear box solenoid valve (first speed)
F12 Fuse, 10 A, two-speed electro, axle unlocking, Y12 Gear box solenoid valve (second speed)
piloting neutralisation (std - Italy), stabilizers, Y13 Front axle unlocking solenoid valve
H56 direction of travel control, overload indicator Y15 Parking brake solenoid valve
SC2 - SC3 - SC4 H57
Y2 - Y11 - Y12 F19 Fuse, 5 A, LH front/rear sidelight + night lighting Y16 Working brake solenoid valve
V14 - V15
Y13 - Y26 - Y27 F25 Fuse, 7.5 A, parking brake electro, working brake Y26 Stabilizer raising solenoid valve
P10 electro (std/D/I) Y27 Stabilizer lowering solenoid valve
K3 Hourmeter + transmission brake pressure switch
+ two-speed supply relay CAB
K9 Pilot safety relay/axle unlocking H31 Rotary light switch lighting
K52 Speed change relay (except 588) H57 Standard or Italian rotary light
K58 Two-speed supply relay P10 Instrument panel
Sh5 Shunt Night lighting (switch) + P excavator regi- SC1 Direction indicator combination switch (com-
stration plate modo), main beam and dip switch, side lights
Sh8 Shunt OK Italy - not standard and headlight flasher switch
Sh9 Shunt contact K58 two-speed supply S25 Rotary light switch (optional)
Sh11 Shunt - Italy axle unlocking X1 Cab floor/cab connector
V2 Diode less engine running
V16 Diode for Italy
V17 Diode for Italy
V18 Axle unlocking indicator lamp diode on instrument
panel
V19 Diode for Italy
V26 Axle unlocking diode
V27 Axle electro unlocking diode for Italy
V31 K58 relay diode
FLOOR
A2 Electronic control box (788-988-1188)
B54 Front axle unlocking pressure switch
B55 Steering brake pressure switch (optional)
H50 Working brake and parking brake switch lighting
E29 (optional)
X1 H52 Pilot system cancellation switch lighting (optional)
SC2 Front axle automatic and manual unlocking switch
F5 - F12 - F19 - F25 SC3 Front axle locking and unlocking switch (in the
S25 - H31 S24 K3 - K9 - K52 - K58 axle unlocked position)
B55 Sh5 - Sh8 - Sh9 - Sh11 SC4 Stabilizer raising and lowering momentary inverter
B54 V2 - V16 - V17 - V18 switch
Y16 S24 Pilot safety switch
V19 - V26 - V27 - V31
S50 - S52 Y15 S50 Parking brake and working brake switch (optional)
A2 - X3 S52 Pilot system cancellation switch (optional)
H50 - H52
V14-V15Stabilizer solenoid valve diodes (in combina-
SC1 tion switch (commodo)
X3(20) 35-way connector for A2 control box

CM99K025

Cre 7-26540GB Issued 11-99


4001-35

UPPER-
AXLE
FIRST SPEED PILOT WORKING STRUCTURE REGISTRA- STEERING
SECOND SPEED UNLOCKING AXLE UNLOCKING CAB ROTARY
SOLENOID MAIN BEAM POSITION FOR ITALY SAFETY STABILIZER PARKING BRAKE BRAKE FOR ROTARY TION PLATE BRAKE
SOLENOID VALVE SOLENOID CONTROL LIGHT
VALVE SYSTEM ITALY LIGHT FOR FOR ITALY PRESSURE
VALVE
ITALY

CM99H010

Cre 7-26540GB Issued 11-99


4001-36

ELECTRICAL SCHEMATIC (PLATE 12)


Supplement for Switzerland Supplement for Belgium
ELECTRICAL CABINET ELECTRICAL CABINET
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ F15 Fuse, 15 A, general lighting
working brake for Germany F19 Fuse, 5 A, LH front/rear sidelight + night lighting
F25 Fuse, 7.5 A, parking brake electro, working brake F22 Fuse, 5 A, rear fog light
electro (std/D/I) Sh5 Shunt Night lighting (switch) + P excavator regi-
CAB stration plate
V5 Rear fog light diode
E12 - S28 E29 H50 Working brake and parking brake switch lighting
(optional) CAB
P10 Instrument panel
S50 Parking brake and working brake switch (optional) H55 Rear fog light switch lighting
P10 Instrument panel
FLOOR SC1 Direction indicator combination switch (com-
B55 Steering brake pressure switch (optional) modo), main beam and dip switch, side lights
and headlight flasher switch
UPPERSTRUCTURE S55 Rear fog light switch
E20 RH front direction indicator UPPERSTRUCTURE
E23 LH front direction indicator
Y15 Parking brake solenoid valve E25 Rear fog light
Y17 Working brake solenoid valve (Germany) (optio- E29 Registration plate lighting (optional)
nal)
Y18 Working brake solenoid valve (Germany) (optio-
nal)

Supplement for Northern Europe


ELECTRICAL CABINET
F4 Fuse, 5 A, cab lighting, horn (control), hood
lighting
ENGINE
E20
E12 Engine compartment light (optional)
E25 S28 Engine compartment lighting switch (optional)

B55 F4 - F11 - F15 - F19


P10 F22 - F25
Sh5
Y15 V5
S55 - H55 Y17 - Y18
S50 - H50

E23 SC1

CM99K025

Cre 7-26540GB Issued 11-99


4001-37

ENGINE COMPART-
FRONT RIGHT-HAND FRONT LEFT-HAND DIRECTION REAR FOG LIGHT
STEERING BRAKE MENT LIGHTING REGISTRATION PLATE LIGHTING FOR FOG LIGHT FOR
WORKING BRAKE FOR SWITZERLAND PARKING BRAKE DIRECTION INDICATOR FOR INDICATOR INDICATOR LAMP
PRESSURE FOR NORTHERN BELGIUM BELGIUM
SWITZERLAND FOR SWITZERLAND FOR BELGIUM
EUROPE

CM99H011

Cre 7-26540GB Issued 11-99


4001-38

ELECTRICAL SCHEMATIC (PLATE 13)

Supplement for Germany Supplement for Austria


ELECTRICAL CABINET CAB
F11 Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+ P10 Instrument panel
working brake for Germany
ON FLOOR
F15 Fuse, 15 A, general lighting
F18 Fuse, 5 A, RH front/rear sidelight, dipper lighting + B55 Upperstructure steering brake pressure
cassette
F25 Fuse, 7.5 A, parking brake electro, working brake
electro (std/D/I)
CAB
H50 Working brake and parking brake switch lighting
(optional)
P10 Instrument panel
SC1 Direction indicator combination switch (com-
modo), main beam and dip switch, side lights
and headlight flasher switch
S50 Parking brake and working brake switch (optional)

ON FLOOR
B55 Upperstructure steering brake pressure
SWITCH
E24 Dipper lighting (optional)
X5(A), X5(B) Dipper lighting connector (optional)
Y15 Parking brake solenoid valve
Y17 Working brake solenoid valve (Germany) (optio-
nal)
P10 Y18 Working brake solenoid valve (Germany) (optio-
P10 nal)

E24 - X5

B55 F11 - F15 - F18 - F25

P10 Y15
Y17 - Y18
S50 - H50

SC1

CM99K025

Cre 7-26540GB Issued 11-99


4001-39

STEERING BRAKE STEERING BRAKE


WORKING BRAKE FOR GERMANY PARKING BRAKE DIPPER LIGHTING FOR GERMANY
PRESSURE PRESSURE FOR AUSTRIA

CM99H012

Cre 7-26540GB Issued 11-99


4001-40

CAB FLOOR WIRING (STANDARD)


See page 4
FLOOR
A1 Radio (optional)
B3 Pilot pressure switch
B12 Brake pressure switch (588)
B25 Threshold detector (788)
B50 Parking brake pressure switch
B51 Brake light pressure switch
B52 Pressure switch for minimum braking pressure
B53 Steering pressure switch
B54 Front axle unlocking pressure switch
E7 Cigarette lighter
E14 Front LH side light
E17 Front LH dipped headlight
E19 LH main beam headlight
E23 LH front direction indicator
E32 LH side-mounted direction indicator
G3 Step-down transformer 24V / 12V
H10 Working brake switch lighting
H11 Windshield wiper switch lighting
H12 Windshield washer switch lighting
H13 Heater blower switch lighting
H15 Instrument panel audible warning
H17 First speed green indicator light (588)
H18 Second speed blue indicator light (588)
H26 Horn
H31 Rotary light switch lighting
H50 Working brake and parking brake switch lighting (optional)
H51 Hazard warning switch lighting
H55 Rear fog light switch lighting
K10 Flasher unit relay
K20 Windshield wiper intermittent action
K52 Speed change relay (except 588)
M3 Windshield washer motor
M4 Heater blower motor
P4 Hourmeter
P10 Instrument panel
S1 Key switch
S3 Horn switch
S4 Working light switch
S6 Windshield wiper switch
S12 Two-speed switch (588)
S22 Control keyboard (788-988-1188)
S24 Pilot safety switch
S25 Rotary light switch (optional)
S26 Windshield washer switch
S27 Heater blower switch
S50 Parking brake and working brake switch (optional)
S51 Hazard warning switch
S55 Rear fog light switch
X4 Troubleshooting test socket (788-988-1188)
X5 12V accessories socket
CM99J049
Y15 Parking brake solenoid valve

Cre 7-26540GB Issued 11-99


4001-41

ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)

See page 4

UPPERSTRUCTURE
B1 Air filter restriction pressure switch
B2 Hydraulic oil filter restriction pressure switch
B21 Hydraulic oil temperature sender
E2 Attachment working light on boom
E10 RH rear brake light
E11 LH rear brake light
E12 Front RH side light
E13 Rear RH side light
E15 Rear LH side light
E16 Front RH dipped headlight
E18 RH main beam headlight
E20 RH front direction indicator
E21 RH rear direction indicator
E22 LH rear direction indicator
E25 Rear fog light
E31 RH side-mounted direction indicator
G1 Batteries
P11 Fuel level gauge
S2 Battery master switch
X2 Upperstructure power line connection
X5 Attachment working light power connection
X10 Fuel level indicator connector
Y2 Pilot safety solenoid valve
Y11 Gear box solenoid valve (first speed)
Y12 Gear box solenoid valve (second speed)
Y13 Front axle unlocking solenoid valve
Y16 Working brake solenoid valve
Y17 Working brake solenoid valve (Germany) (optional)
Y18 Working brake solenoid valve (Germany) (optional)
Y26 Stabilizer raising solenoid valve
Y27 Stabilizer lowering solenoid valve
Y55 Heavy lift solenoid valve (788)
ENGINE
B4 Engine oil pressure switch
B22 Engine coolant temperature sender
G2 Alternator
M1 Starter motor
Y1 Engine shut-down solenoid valve

CM99K029

Cre7-26540GB Issued 11-99


4001-42

ELECTRONIC CIRCUIT WIRING (788P-988P-1188P)


X9
6
1 2
3 4 B22
Y4
B10 5

X6

X7 7
M5 - P12
B9
9 8
Y5
X4

28 9
B8 B7
9
B57
27 10
25
26 10
24 12
11 10
23
4
22
31
21 A2 18
30
16
20 B11
14
19

X3 17 X8
S22

13

15

CM99J050 CS99J591

Cre 7-26540GB Issued 11-99


4001-43

ELECTRONIC CIRCUIT WIRING (788P-988P-1188P) DETAILS OF 35 PIN CONNECTOR X3 EXCAVATORS 788P/988P/1188P


See page 4 1 O-ring
2 Ring
1 Electrical harness
3 Washer
A2 Electronic control box (788-988-1188) 4 Lock
B7 Swing detection pressure switch 5 Plug
B8 Travel detector pressure switch 6 Clamp
B9 Engine speed detector (788-988-1188) 7 Pressure reduction valve
B10 Swing motor speed detector 8 Electronic harness
B11 Hydraulic pressure sender (788-988-1188) 9 Screw
B22 Engine coolant temperature sender 10 O-ring
B57 Speed change pressure switch 11 Travel block
M5 Injection pump servo-motor (788-988-1188) 12 Swing block
P12 Servo-motor potentiometer (788-988-1188) 13 Printed circuit card
S22 Control keyboard (788-988-1188) 14 Decal
X3 35-way connector (788-988-1188) 15 Control panel fixing hardware
X4 Troubleshooting test socket (788-988-1188) 16 Nut
1
X6 Engine speed detector connector (788-988-1188) 17 Washer
X7 Upperstructure swing speed detector connector 18 Rivet
X8 Hydraulic pressure sender connector (788-988- 19 Screw
1188) 20 Bracket
X9 Injection pump servo-motor connector (788-988- 21 Nuts
1188) 22 Washer
Y4 DRE4 proportional pressure reduction valve 23 Screw
Y5 Upperstructure brake release control solenoid 24 Handle
valve 25 Screw
26 Washer
27 Troubleshooting socket harness
28 Engine harness
X3

CS99K546

Cre 7-26540GB Issued 11-99


4001-44

CAB FLOOR WIRING (OPTIONAL)


ELECTRICAL CABINET
1 Connecting strip
See page 6
INSTRUMENT PANEL
B55 Steering brake pressure switch (optional)
H30 Cold start assistance switch lighting (optional)
H32 Overload indicator switch lighting (optional)
H52 Pilot system cancellation switch lighting (optional)
H53 Cab front working light switch lighting (optional)
H58 Quick coupler switch lighting (optional)
K50 Adjustable boom raising limiter relay (optional)
K51 Adjustable boom retracting limitation relay (optional)
R10 Resistor, 0.85 Ohms
S20 Cold start assistance switch (optional)
S21 Overload indicator switch (optional)
S30 Adjustable or articulated boom control switch (optional)
S52 Pilot system cancellation switch (optional)
S53 Cab front working light switch (optional)
S56 Quick coupler switch (optional)

CM99J051

Cre 7-26540GB Issued 11-99


4001-45

ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)


ELECTRICAL CABINET
1 Connecting strip
2 Air conditioner
See page 6
UPPERSTRUCTURE
B23 Overload indicator (optional)
B56 Boom raising range limitation detector (optional)
E24 Dipper lighting (optional)
E29 Registration plate lighting (optional)
H56 Upperstructure rotary light (Italy) (optional)
R50 Fuel heater (optional)
X5 Dipper lighting connector (optional)
Y7 Adjustable or articulated boom extending electro-valve (optional)
Y8 Adjustable or articulated boom retracting electro-valve (optional)
Y50 Adjustable boom raising height limiter solenoid valve (optional)
Y52 Quick coupler solenoid valve (optional)
Y53 Fuel filler pump (optional)
ENGINE
E12 Engine compartment light
R11 Cold start assistance plug (optional)
S28 Engine compartment lighting switch (optional)

CM99K030

Cre7-26540GB Issued 11-99


4001-46

CAB AND CAB OPTION WIRING

A White wire X1 (A) (B) (C) (D) Cab floor/cab LH and RH loud-
B Grey wire speaker connector
C Blue wire X1 (H) (G) Cab floor/cab front and rear working lights
D Black wire connector (optional)
B5 RH loudspeaker (optional) X1 (E) (J) (M) (L) Cab floor/cab windshield wiper
B6 LH loudspeaker (optional) motor connector
E1 Cab lighting X1 (F) Cab floor/cab rotary light connector (specific to
E7 Cigarette lighter certain countries)
E50 Cab front working lights X1 (K)Cab floor/cab interior lighting connector
E51 Cab rear working light X14 (1) (2) Cab blower plug (optional)
H57 Standard or Italian rotary light 2 (7) 10 way connector (see printed circuit wiring on
M2 Windshield wiper motor page 5)
M6 Cab blower motor (optional)
S10 Cab lighting switch
S29 Cab blower switch (optional)

CM99J052

Cre 7-26540GB Issued 11-99


4001-47
ALPHABETICAL INDEX

Numerics Cab lighting ...................................................... 24, 46


Cab lighting switch ........................................... 24, 46
12V accessories socket....................................26, 40
Cab rear working light ............................................ 46
1st speed indicator lamp diode on 588P ........4, 8, 20
Cigarette lighter.......................................... 26, 40, 46
2nd speed indicator lamp diode on 588P .......4, 8, 20
Cold start assistance plug (optional)................ 16, 45
35-way connector (788-988-1188) .............20, 28, 43
Cold start assistance switch (optional)....... 15, 16, 44
A Cold start assistance switch lighting (optional) 15, 16,
44
Adjustable boom raising height limiter solenoid valve
Combination switch (commodo)............................. 19
(optional) ......................................................30, 45
Compressor ........................................................... 32
Adjustable boom raising limiter relay (optional).6, 30,
Condenser blower and blower motors ................... 32
44
Condenser blower relay pressure switch ............... 32
Adjustable boom retracting limitation relay (optional) .
Control keyboard (788-988-1188)........ 13, 28, 40, 43
6, 30, 44
Adjustable or articulated boom control switch D
(optional) ................................................15, 30, 44
Description of electrical cabinet printed circuit
Adjustable or articulated boom extending electro-
(optional).............................................................. 6
valve (optional) .............................................30, 45
Description of electrical cabinet printed circuit
Adjustable or articulated boom retracting electro-valve
(standard) ............................................................ 4
(optional) ......................................................30, 45
Diode for Italy................................................. 6, 8, 34
Air conditioning compressor relay ..................6, 8, 32
Diode less engine running ................. 4, 8, 20, 28, 34
Air conditioning condenser relay ....................6, 8, 32
Dipped headlight indicator lamp diode on instrument
Air filter restriction pressure switch...................18, 41
panel .......................................................... 4, 8, 22
Alternator ....................................................16, 28, 41
Dipper lighting (optional) .................................. 38, 45
Attachment working light on boom ...................24, 41
Dipper lighting connector (optional) ................. 38, 45
Attachment working light power connection .....24, 41
Direction indicator combination switch (commodo),
Axle electro unlocking diode for Italy ..............6, 8, 34
main beam and dip switch, side lights and headlight
Axle unlocking diode.......................................4, 8, 34
flasher switch13, 16, 18, 20, 22, 24, 26, 28, 30, 32,
Axle unlocking indicator lamp diode on instrument
34, 36, 38
panel ....................................................4, 8, 20, 34
Direction of travel reverser switch (optional).......... 32
B DRE4 proportional pressure reduction valve ... 28, 43
Batteries .....................................................16, 28, 41 E
Battery master switch .................................16, 28, 41
Electrical schematic (plate 10) ............................... 32
Battery relay ...................................................4, 8, 16
Electrical schematic (plate 11) ............................... 34
Battery relay (heater/air conditioner) ........4, 8, 16, 32
Electrical schematic (plate 12) ............................... 36
Blower motor connector (optional)..........................26
Electrical schematic (plate 13) ............................... 38
Blower speed resistor .............................................32
Electrical schematic (plate 2) ................................. 16
Boom raising range limitation detector (optional) ..30,
Electrical schematic (plate 3) ................................. 18
45
Electrical schematic (plate 4) ................................. 20
Brake light pressure switch...............................22, 40
Electrical schematic (plate 5) ................................. 22
Brake pressure switch (588).............................20, 40
Electrical schematic (plate 6) ................................. 24
Buzzer diode.............................................4, 8, 18, 30
Electrical schematic (plate 7) ................................. 26
C Electrical schematic (plate 8) ................................. 28
Electrical schematic (plate 9) ................................. 30
Cab and cab option wiring ......................................46
Electronic circuit wiring (788P-988P-1188P) ... 42, 43
Cab blower motor (optional) .............................26, 46
Electronic control box (788-988-1188)....... 20, 34, 43
Cab blower switch (optional) ............................26, 46
Electronic supply relay ................................... 4, 8, 28
Cab floor wiring (optional).......................................44
Engine compartment light (optional) ................ 22, 36
Cab floor wiring (standard) .....................................40
Engine compartment lighting switch (optional) 36, 45
Cab floor/cab connector .......................24, 26, 34, 46
Engine coolant temperature sender..... 18, 28, 41, 43
Cab front working light switch (optional) .....15, 24, 44
Engine module and upperstructure wiring (optional) .
Cab front working light switch lighting (optional) ...15,
45
24, 44
Engine module and upperstructure wiring (standard)
Cab front working lights ..........................................46

Cre 7-26540GB Edition 11-99


4001-48
41 Fuse, 40 A, engine stop/start solenoid (injection)4, 8,
Engine oil pressure switch................................18, 41 16
Engine shut-down solenoid valve .....................16, 41 Fuse, 5 A, (BAT +) electronics ....................... 4, 8, 28
Engine speed detector (788-988-1188)............28, 43 Fuse, 5 A, cab lighting, horn (control), hood lighting4,
Engine speed detector connector (788-988-1188) 28, 6, 8, 22, 24, 36
43 Fuse, 5 A, LH front dipped headlight ............. 4, 8, 22
Engine stop solenoid relay .............................4, 8, 16 Fuse, 5 A, LH front/rear sidelight + night lighting 4, 8,
16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36
F
Fuse, 5 A, LH main beam headlight............... 4, 8, 22
First speed green indicator light (588) ........13, 20, 40 Fuse, 5 A, LH rear brake light ........................ 4, 8, 22
Flasher unit relay ..........................................4, 22, 40 Fuse, 5 A, rear fog light.............................. 4, 6, 8, 36
Fog light indicator lamp diode on instrument panel .6, Fuse, 5 A, remote controlled or articulated boom, tool
8 quick coupler, air suspension seat, speed threshold
Forward travel green indicator lamp (optional) .......32 detector (788P heavy lift)................. 4, 6, 8, 16, 30
Forward travel relay........................................4, 8, 32 Fuse, 5 A, RH front dipped headlight............. 4, 8, 22
Forward travel solenoid valve (optional).................32 Fuse, 5 A, RH front/rear sidelight, dipper lighting +
Forward travel switch (optional)..............................32 cassette ..................................... 4, 6, 8, 22, 24, 38
Frequency threshold detector relay (threshold Fuse, 5 A, RH main beam headlight .............. 4, 8, 22
1 = 1600 rpm) .................................................4, 8, 16 Fuse, 5 A, RH rear brake light ....................... 4, 8, 22
2 = 1400 rpm) .................................................4, 8, 16 Fuse, 5 A, starter switch .................... 4, 8, 16, 28, 32
Front axle automatic and manual unlocking switch13, Fuse, 7,5 A, cigarette-lighter, cab blower, batt.+
20, 34 working brake for Germany ....... 4, 6, 8, 26, 36, 38
Front axle locking and unlocking switch (in the axle Fuse, 7.5 A, flasher, warning ......................... 4, 8, 22
unlocked position) ..................................13, 20, 34 Fuse, 7.5 A, instrument panel, hourmeter 4, 8, 16, 18
Front axle unlocking pressure switch .........20, 34, 40 Fuse, 7.5 A, parking brake electro, working brake
Front axle unlocking solenoid valve............20, 34, 41 electro (std/D/I) ........................ 4, 8, 20, 34, 36, 38
Front LH dipped headlight ................................22, 40
G
Front LH side light ............................................22, 40
Front RH dipped headlight................................22, 41 Gear box solenoid valve (first speed) ........ 20, 34, 41
Front RH side light............................................22, 41 Gear box solenoid valve (second speed)... 20, 34, 41
Fuel filler pump (optional) .................................26, 45
H
Fuel heater (optional) .......................................16, 45
Fuel heater relay.............................................6, 8, 16 Hazard warning switch............................... 13, 22, 40
Fuel level gauge ...............................................18, 41 Hazard warning switch lighting ............ 13, 22, 24, 40
Fuel level indicator connector...........................18, 41 Heater blower motor ........................................ 26, 40
Fuse, 10 A, cab front working light .................6, 8, 24 Heater blower switch.................................. 13, 26, 40
Fuse, 10 A, fuel heater ...................................6, 8, 16 Heater blower switch lighting ..................... 13, 26, 40
Fuse, 10 A, heater ..........................................4, 8, 26 Heavy lift solenoid valve (788) ......................... 16, 41
Fuse, 10 A, horn (power)................................4, 8, 22 Horn ................................................................. 22, 40
Fuse, 10 A, step-down transformer / radio .....4, 8, 26 Horn relay ...................................................... 4, 8, 22
Fuse, 10 A, two-speed electro, axle unlocking, piloting Horn switch ................................................ 13, 22, 40
neutralisation (std - Italy), stabilizers, direction of Hourmeter ........................................................ 16, 40
travel control, overload indicator4, 6, 8, 20, 28, 32, Hourmeter + transmission brake pressure switch +
34 two-speed supply relay............ 4, 8, 16, 20, 28, 34
Fuse, 10 A, windshield washer, windshield wiper (BAT Hydraulic oil filter restriction pressure switch ... 18, 41
+ R) ............................................................4, 8, 24 Hydraulic oil temperature sender ..................... 18, 41
Fuse, 10 A, windshield wiper (BAT +) ............4, 8, 24 Hydraulic pressure sender (788-988-1188) ..... 28, 43
Fuse, 10 A, working lights (control), rotary light (std), Hydraulic pressure sender connector (788-988-1188)
rotary light (Italy) ..............................4, 6, 8, 24, 34 28, 43
Fuse, 15 A, air conditioner..............................6, 8, 32
I
Fuse, 15 A, attachment working light, rear cab light4,
6, 8, 24 Injection pump servo-motor (788-988-1188).... 28, 43
Fuse, 15 A, general lighting................4, 8, 22, 36, 38 Injection pump servo-motor connector (788-988-
Fuse, 15 A, upperstructure socket, fuel pump.4, 6, 8, 1188) ........................................................... 28, 43
26 Instrument panel16, 18, 20, 22, 24, 30, 34, 36, 38, 40
Fuse, 30 A, starter motor solenoid, thermostart ..4, 6, Instrument panel (front face).................................. 11
8, 16 Instrument panel audible warning .............. 13, 30, 40

Cre 7-26540GB Edition 11-99


4001-49
Instrument panel wiring ..........................................11 Quick coupler switch diode ............................ 6, 8, 30
Quick coupler switch lighting (optional)...... 15, 30, 44
K
R
K54 relay diode...............................................4, 8, 16
K55 relay diode...............................................4, 8, 16 Radio (optional)................................................ 26, 40
K58 relay diode...................................4, 8, 20, 28, 34 Rear fog light.................................................... 36, 41
Key switch ......................................13, 16, 28, 32, 40 Rear fog light switch................................... 13, 36, 40
Rear fog light switch lighting ...................... 13, 36, 40
L
Rear LH side light ...................................... 18, 22, 41
LH flasher diode .............................................4, 8, 22 Rear RH side light............................................ 22, 41
LH flashing indicator lamp diode on instrument panel Registration plate lighting (optional)........... 34, 36, 45
4, 8, 22 Relay authorizing working lights if sidelights on.. 4, 8,
LH front direction indicator..........................22, 36, 40 22, 24
LH loudspeaker (optional) ................................26, 46 Resistor, 0.85 Ohms .................................... 6, 16, 44
LH main beam headlight...................................22, 40 Reverse travel red indicator lamp (optional) .......... 32
LH rear brake light ............................................22, 41 Reverse travel relay ....................................... 4, 8, 32
LH rear direction indicator ................................22, 41 Reverse travel solenoid valve (optional) ................ 32
LH side-mounted direction indicator .................22, 40 Reverse travel switch (optional)............................. 32
RH flasher diode ............................................ 4, 8, 22
M
RH flashing indicator lamp diode on instrument panel
Main beam headlight indicator lamp diode on 4, 8, 22
instrument panel.........................................4, 8, 22 RH front direction indicator ........................ 22, 36, 41
RH loudspeaker (optional) ............................... 26, 46
O
RH main beam headlight ................................. 22, 41
Overload indicator (optional) ............................18, 45 RH rear brake light........................................... 22, 41
Overload indicator lamp diode on instrument panel 6, RH rear direction indicator ............................... 22, 41
8, 18 RH side-mounted direction indicator................ 22, 41
Overload indicator switch (optional) ...........15, 18, 44 Right-hand and left-hand control arm
Overload indicator switch lighting (optional)15, 18, 44 wiring (optional) ................................................. 15
Right-hand control arm, left-hand control arm and
P
commodo wiring (standard) ............................... 13
P10 instrument panel electrical schematic p. 10 (plate Rotary light diode on instrument panel .......... 4, 8, 24
1) ........................................................................10 Rotary light switch (optional)................ 13, 24, 34, 40
Parking brake and working brake switch (optional)20, Rotary light switch lighting ......................... 13, 34, 40
34, 36, 38, 40
S
Parking brake pressure switch .........................18, 40
Parking brake solenoid valve..........20, 34, 36, 38, 40 Safety relay piloting pressure switch piloting . 4, 8, 20
Pilot pressure switch.........................................20, 40 Schematic symbols .................................................. 3
Pilot safety relay/axle unlocking ...............4, 8, 20, 34 Second speed blue indicator light (588)..... 13, 20, 40
Pilot safety solenoid valve ..........................20, 34, 41 Servo-motor potentiometer (788-988-1188) .... 28, 43
Pilot safety switch .................................13, 20, 34, 40 Shunt.................................................................... 4, 6
Pilot system cancellation indicator lamp diode on Shunt - Italy axle unlocking ................................ 8, 34
instrument panel...............................................6, 8 Shunt contact K58 two-speed supply........... 8, 20, 34
Pilot system cancellation switch (optional) 13, 15, 34, Shunt if dozer - stab independent ............................ 8
44 Shunt Night lighting (switch) + P excavator
Pilot system cancellation switch lighting (optional) 15, registration plate . 8, 16, 18, 22, 24, 28, 30, 32, 34,
34, 44 36
Pressure switch ......................................................32 Shunt OK Italy - not standard............................. 8, 34
Pressure switch for minimum braking pressure18, 40 Shunt OK Standard - not Italy ............................ 8, 20
printed.......................................................................4 Speed change pressure switch.................. 20, 28, 43
Printed circuit schematic guide.................................8 Speed change relay (588).................................. 4, 20
printed circuit wiring (optional)..................................6 Speed change relay (except 588) 4, 8, 20, 28, 34, 40
printed circuit wiring (standard) ................................4 Stab lowering diode ............................................. 4, 8
Stab raising diode ................................................ 4, 8
Q
Stabilizer lowering solenoid valve .............. 20, 34, 41
Quick coupler solenoid valve (optional) ............30, 45 Stabilizer raising and lowering momentary inverter
Quick coupler switch (optional)...................15, 30, 44 switch..................................................... 13, 20, 34

Cre 7-26540GB Edition 11-99


4001-50
Stabilizer raising solenoid valve .................20, 34, 41
Stabilizer solenoid valve diodes (in combination
switch (commodo) ..................................13, 20, 34
Standard or Italian rotary light ....................24, 34, 46
Starter key switch diode ...........................4, 8, 16, 28
Starter motor.....................................................16, 41
Starter motor relay..........................................4, 8, 16
Steering brake pressure switch (optional) ..34, 36, 44
Steering column connector.........................13, 20, 22
Steering pressure switch ..................................18, 40
Step-down transformer 24V / 12V ....................26, 40
Swing detection pressure switch ......................28, 43
Swing motor speed detector.............................28, 43
T
Thermostart relay ...........................................6, 8, 16
Threshold detector (788) ..................................16, 40
Travel detector pressure switch........................28, 43
Troubleshooting test LED .........................4, 8, 13, 28
Troubleshooting test socket (788-988-118828, 40, 43
Two-speed supply relay......................4, 8, 20, 28, 34
Two-speed switch (588) .............................13, 20, 40
U
Upperstructure brake release control solenoid valve .
28, 43
Upperstructure power line connection ..............26, 41
Upperstructure rotary light (Italy) (optional) ......34, 45
Upperstructure swing speed
detector connector .......................................28, 43
W
Warning diode ................................................4, 8, 22
Warning indicator lamp diode on instrument panel .4,
8, 22
Windshield washer motor .................................24, 40
Windshield washer switch ..........................13, 24, 40
Windshield washer switch lighting ..............13, 24, 40
Windshield wiper intermittent action .............4, 24, 40
Windshield wiper motor ....................................24, 46
Windshield wiper switch .............................13, 24, 40
Windshield wiper switch lighting .................13, 24, 40
Working brake and parking brake switch lighting
(optional) ........................13, 20, 24, 34, 36, 38, 40
Working brake solenoid valve.....................20, 34, 41
Working brake solenoid valve (Germany) (optional) ..
36, 38, 41
Working brake switch lighting .....................13, 24, 40
Working light relay ..........................................4, 8, 24
Working light switch....................................13, 24, 40

Cre 7-26540GB Edition 11-99


8001
Section
8001

TESTS, ADJUSTMENTS
AND HYDRAULIC SCHEMATICS
588 Crawler Excavators

Copyright  1999 Case France


Printed in France
Case Cre 7-80771GB December 1999
8001-2

TABLE OF CONTENTS
TOOLS REQUIRED ................................................................................................................................................. 3

TOOLS TO BE MANUFACTURED .......................................................................................................................... 5

LOCATION OF HYDRAULIC COMPONENTS......................................................................................................... 7

588C GENERAL HYDRAULIC SYSTEM (SINGLE-SPEED EXCAVATORS).......................................................... 9

588C GENERAL HYDRAULIC CIRCUIT (TWO-SPEED EXCAVATORS)............................................................. 11

588C PRESSURE SETTINGS ............................................................................................................................... 12

Cre 7-80771GB Issued 12-99


8001-3

TOOLS REQUIRED
1 Test equipment sure differential (Delta P), temperature, temperature
There are three possible choices: differential, rotational speed and volumetric flow,
a) Multi-Handi test kit 2051.........................E5444449 amperage, voltage, connection to PC and printer,
memory capacity 60000.
The test kit includes:
1 Multi-Test 4020 unit................................. Q5344455
2 pressure detectors 0-600 bar.................. V5344460
2 straight adaptors for detector ................. W5344461
1 elbow adaptor for detector ...................... X5344462
1 rotational speed detector ........................ Z5344463
1 temperature sender................................. B3144469
2 double PT cables .................................... B5344465
4 cables length 5 m.................................... E3144472
1 x 220V 50Hz power supply ..................... D5344467
1 cigarette lighter cable.............................. E5344468
1 instruction manual.................................... -------------
1 carry-case ............................................... P5344477
CP96E001
The Multi-Handi test kit is recommended as the basic c) Multi-System 5000 test kit ..................... U5344459
tool of the mechanic.
The Multi-Handi can be used to carry out the follow-
ing tests:
Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, rotational
speed and volumetric flow.
The test kit includes:
1 Multi-Handi 2051 unit ............................. D5444448
2 pressure detectors 0-600 bar ..................V5344460
2 straight adaptors for detector..................W5344461
1 elbow adaptor for detector.......................X5344462
1 rotational speed detector .........................Z5344463
2 cables length 5 m ....................................E3144472
1 x 220 V 50 Hz power supply .................. D5344467
1 cigarette lighter cable ..............................E5344468 CP96E002

1 instruction manual ................................... ------------- The Multi-System is recommended for specialist


1 carry-case............................................... N5344476 departments (Engineering Design Office and tests at
customer’s premises).
b) Multi-Test 4020 test kit .......................... T5344458 The Multi-System can carry out the following tests:
Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, temperature
differential, rotational speed and volumetric flow,
amperage, voltage, torque, force, movement, speed,
connection to PC and printer, memory capacity
120000.
The test kit includes:
1 Multi-System 5000 unit ........................... R5344456
2 pressure detectors 0-600 bar.................. V5344460
2 straight adaptors for detector ................. W5344461
1 elbow adaptor for detector ...................... X5344462
1 rotational speed detector ........................ Z5344463
1 temperature sender................................. A5344464
CP96E003
2 double PT cables .................................... B5344465
The Multi-Test is recommended to carry out in-depth 4 cables length 5 m.................................... E3144472
diagnostics. Values read can be recorded in its mem- 1 x 220V 50Hz power supply ..................... D5344467
ory and transferred to a PC and a printer. 1 cigarette lighter cable.............................. E5344468
The Multi-Test can be used to carry out the following 1 instruction manual.................................... -------------
tests: 1 carry-case ............................................... P5344477
Two pressure measurements, pressure peaks, pres-
Cre 7-80771GB Issued 12-99
8001-4

CP96E004 PG04005
TEMPERATURE SENDER A5344464 ONE PRESSURE TEST POINT M14 X 1,5
A3237549
Use with Multi-Handi 2051 test kit
MAGNETIC BASE G5344470
Use with Multi-Handi 2051, Multi-Test 4020 and Multi-
System 5000 test kits

PE18402
TWO MINIMESS HOSES LENGTH 2500 mm P2144487
TWO HOSE UNIONS C5144412

PF01410
600 LITRES FLOWMETER, ORDER THE FOLLOW-
ING:
ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45 X 2) D4323359
TWO FLANGES (DIA. 24) B8230183
ONE HIGH PRESSURE HOSE DN25 W5431976
TWO SEALS D330421
FOUR HALF-FLANGES D4024267
EIGHT SCREWS (12 X 75) Z1232983
ONE HIGH PRESSURE HOSE DN19 Q5931990
ONE LOW PRESSURE HOSE DN12 B8031969 PG04006
TWO PLUGS 27X200 Q3337452
ONE FEMALE UNION 27X200 P4234556
ONE MALE/FEMALE UNION D12 L3237536

Cre 7-80771GB Issued 12-99


8001-5

PDH0505 PG04012

TWO REDUCTION GEARS DN25 - DN19 G1037352 ONE PLUG Q3337498 + T3843639
(SEALS: N1245232 + J30460)

PDH0506

ONE SPECIAL UNION W5137530

TOOLS TO BE MANUFACTURED

PDG0239

One spacer to limit the stroke of the control lever


spools

Cre 7-80771GB Issued 12-99


8001-6

This page is intentionally left blank

Cre 7-80771GB Issued 12-99


8001-7

LOCATION OF HYDRAULIC COMPONENTS


4 - Low flow option control valve (clamshell rotation, articulated boom)
6 - High pressure pump with:
1 fixed flow body for the swing
1 variable flow bodies for the attachment, travel and options
7 - Low pressure pump for the steering/braking system
Low pressure pump for the pilot systems
8 - Hose/accumulator on the variable flow pump LS information
10 - Anti-surge valve on the pump LS1 circuit
11 - Filter on pilot circuit
22a - Foot control block for the RH travel function
22b - foot control block for the LH travel function
23 - Manual travel control block (INCHING)
31 - Low flow option control valve (clamshell rotation, articulated boom)
41 - Swing control valve block
42 - Swing function safety flange
43 - Hydraulic swing motor
61 - Hydraulic piloting block including:
61a - Automatic swing braking and brake release block
61b - Safety control arm electro-control valve
61d - 35 bar pressure limiter (P35)
81 - Attachment control valve (boom, dipper, bucket)
82 - P10 counter-pressure valve
90 - Hydraulic swivel
101 - Travel control valve block
102 - Fixed displacement hydraulic travel motors (single-speed excavators)
104 - Variable displacement hydraulic travel motors (two-speed excavators)

CM99K001

Cre 7-80771GB Issued 12-99


8001-8

CM99K002

Cre 7-80771GB Issued 12-99


8001-9

588C GENERAL HYDRAULIC SYSTEM (SINGLE-SPEED EXCAVATORS)


1 - Reservoir 81 - Attachment control valve (boom, dipper, bucket)
2 - Reservoir filler cap with self-pressurizing valve and screen filter 82 - P10 counter-pressure valve
3 - Return manifold with element type filters and restriction indicator 83 - Braking check valve on dipper cylinder small chamber
4 - Element type filter on functional leak return lines 84 - Dipper cylinder with dashpot on large and small chamber
5 - Block with filter on the travel L information (LS2) 85 - Backhoe / clamshell selector block
6 - High pressure hydraulic pump with: 86 - Bucket cylinder with dashpot on small chamber
1 fixed flow body for the swing 87 - Boom cylinder supply distribution block with flow limiter on cylinder large chambers
1 variable flow body for the attachment, travel and options 88 - Boom cylinders with dashpot on large chambers
7 - Low pressure fixed flow pump for the pilot circuit 89 - Pressure selector between attachment / options and travel LS information circuits
8 - Hose/accumulator 90 - Hydraulic swivel
9 - Pressure test points 92 - Filter on return circuit
10 - Anti-surge valve and filter on LS information (attachment/options)
101 - Travel control valve block
11 - Pilot circuit filter
101a- Anti-excess flow valve
21 - Boom and bucket (or clamshell) function manual control block 101b- Automatic hydraulic travel motor brake release valve
22a - RH travel control block 101c- Speed limiter
22b - LH travel control block 102 - Fixed displacement hydraulic travel motors (with static brake)
23 - Manual travel control block 103 - Travel anti-drift block
25 - Pressure release pump (foot control) 110 - Hydraulic oil cooler
26 - Pilot circuits manifold
M1 - Pressure test point for attachment, travel and options (if any)
27 - Pilot circuit minimum pressure switch
M2 - Pressure test point for swing
29 - Dipper and swing function manual control block
M3 - Pressure test point for LS circuit
41 - Swing control valve block M4 - Pressure test point for pilot circuits
42 - Hydraulic swing motor with static brake M6 - Pressure test point for travel manual control block outlet
43 - Safety / force-feed flange on swing function M7 - Pressure test point for swing braking and brake release
44 - 3 bar counter-pressure valve M17 - Pressure test point travel brake release on speed limiter
45 - Braking valves on swing control valve spool pilots
46 - 0.5 bar check valve on force-feed circuit (mounted on swing control valve)
48 - Swing circuit restriction
61 - Electro-control valve block including:
61a - Spring type accumulator
61b - Automatic swing braking and brake release block
61b - Safety control arm electro-control valve
61d - 35 bar pressure limiter (P35)

Cre 7-80771GB Issued 12-99


8001-10

CM99K003

Cre 7-80771GB Issued 12-99


8001-11

588C GENERAL HYDRAULIC CIRCUIT (TWO-SPEED EXCAVATORS)


1 - Reservoir 81 - Attachment control valve (boom, dipper, bucket)
2 - Reservoir filler cap with self-pressurizing valve and screen filter 82 - P10 counter-pressure valve
3 - Return manifold with element type filters and restriction indicator 83 - Braking check valve on dipper cylinder small chamber
4 - Element type filter on functional leak return lines 84 - Dipper cylinder with dashpot on large and small chamber
5 - Block with filter on the L.S travel circuit (LS2) 85 - Backhoe / clamshell selector block
6 - High pressure hydraulic pump with: 86 - Bucket cylinder with dashpot on small chamber
1 fixed flow body for the swing 87 - Boom cylinder supply distribution block with flow limiter on cylinder large chambers
1 variable flow body for the attachment, travel and options 88 - Boom cylinders with dashpot on large chambers
7 - Low pressure fixed flow pump for the pilot circuit 89 - Pressure selector between attachment / options and travel LS information circuits
8 - Hose/accumulator 90 - Hydraulic swivel
9 - Pressure test points 92 - Filter on return circuit
10 - Anti-surge valve on the LS circuit (attachment/options)
101 - Travel control valve block including additionally a 101d automatic variable displacement motor displace-
11 - Hydraulic filter on pilot circuit
ment change selector
21 - Boom and bucket (or clamshell) function manual control block 101a - Anti-excess flow valve
22a - RH travel control block 101b - Automatic hydraulic travel motor brake release valve
22b - LH travel control block 101c - Speed limiter
23 - Manual travel control block 103 - Travel anti-drift block
25 - Decompression pump (foot control) 104 - Variable displacement hydraulic travel motors
26 - Pilot circuits manifold 110 - Hydraulic oil cooler
27 - Pilot circuit minimum pressure switch
M1 - Pressure test point for attachment, travel and options (if any)
29 - Dipper and swing function manual control block
M2 - Pressure test point for swing
41 - Swing control valve block M3 - Pressure test point for LS circuit
42 - Hydraulic swing motor with static brake M4 - Pressure test point for pilot circuits
43 - Safety / force-feed flange on swing function M6 - Pressure test point for travel manual control block outlet
44 - 3 bar counter-pressure valve M7 - Pressure test point for swing braking and brake release
45 - Braking valves on swing control valve spool pilots M17 - Travel brake release pressure test point on speed limiter
46 - 0.5 bar check valve on force-feed circuit (mounted on swing control valve)
48 - restriction in swing circuit
61 - Electro-control valve block including:
61a - Spring type accumulator
61b - Automatic swing braking and brake release electro-control valve
61b - Safety control arm electro-control valve
61c - Pressure limiter P35

Cre 7-80771GB Issued 12-99


8001-12

588C PRESSURE SETTINGS


Location of the various pressure test points installed on the machine
M1 on the attachment control valve
M2 on the swing control valve
M3 on the anti-surge valve
M4 on the manifold
M7 on the swing brake selector block.

Location of pressure test points to be installed


M6 on the manifold
M17 on the speed limiter

Installing the flowmeter on the A1 pump body (for the attachment and travel)
Install the flowmeter with the hose specified in the tools list

Raising the circuit temperature to between 50 and 55°C


Use the attachment to raise one track.
Travel with the bucket or clamshell against the stops.

Checking engine speeds


Install the tachometer
Idle ............800 to 900 (rpm)
Max .........2140 to 2220 (rpm)

CM99K004

Cre 7-80771GB Issued 12-99


8001-13
CAUTION! ALL CHECKS AND ADJUSTMENTS ARE Checking the flow adjustment valve
CARRIED OUT AT VARIOUS ENGINE SPEEDS flows
AND AT A TEMPERATURE OF 50°C.
Attachment control valves
Checking the pilot pressure with the
Supply the large chambers of the boom, bucket and
control arm lowered dipper cylinders, one after another.
Connect the multitester to the manifold at M4. The flows should be between:
Run the engine at full speed.
- 140 and 160 (l/min) on the boom.
The pressure should be greater than 34 (bar).
- 90 and 110 (l/min) on the bucket.
If it is not, check the P35 or the electrical circuit.
- 115 and 135 (l/min) on the dipper.
AFTER EACH CHECK, IF THE PARAMETERS ARE
Travel control valve
INCORRECT, ADJUST AT THE COMPONENT
CONCERNED OR CHANGE THE COMPONENT. WARNING! The difference in the flows between the
two tracks should not exceed 4 (l/min).
Setting the LS valve pressure
Travel control valve
Static test using the same 0/40 bar pressure
gauge: WARNING! The difference in the flows between the
two tracks should not exceed 4 (l/min).
WARNING! Start the engine running, before connect-
ing the pressure gauge at M1. Forward travel:
Raise the left-hand control arm as a safety measure. Select the speed 1 (two-speed excavators).
Run the engine at full speed Use the attachment to raise each track. Set the inch-
Connect the pressure gauge at M3. The pressure ing valve control lever to maximum.
should be between 8 and 12 (bar). If it is not, check Operate each track in the forward direction.
the P10. The flows noted should be between 100 and
Connect the pressure gauge at M1. The difference 120 (l/min).
between M1 and M3 should be 21 to 25 (bar). If the values found are between 95 and 125 (l/min),
adjust the flow adjustment valves.
Dynamic test using multitester: If not, check the adjustment of the automatic flow dis-
Assemble the spacer on the boom raising control tribution.
lever push-rod. Using a chronometer:
Connect the two outlets from the multitester at M1
and M3. The number of revolutions of the sprockets should be
Operate the boom raising control. between 30 and 36 (rpm).
The pressure difference (∆P) should be between 21 If the values found are between 29 and 37 (rpm),
and 23 (bar). adjust the flow adjustment valves.
If not, check the adjustment of the automatic flow dis-
Checking the variable displacement tribution. (A.F.D.)
pump maximum flow
Reverse travel:
Run the engine at full speed.
Connect the multitester for flow measurement. The process is the same as for forward travel.
Retract the dipper and close the bucket simultane- If the value of the flows is between 100 and 120 (l/min)
ously. or the revolutions of the sprockets between 30 and
The flow should be greater than 205 (l/min) and the 36 (rpm), adjust the mechanical stops in the control
pressure at M1 lower than 125 (bar). valve spool caps.
LH travel (section at inlet plate end): small cap.
RH travel large cap.
If the values noted are lower or higher than those
shown above, adjust the automatic flow distribution
(A.F.D.)
WHEN THESE ADJUSTMENTS HAVE BEEN COM-
PLETED, REMOVE THE FLOWMETER.

Cre 7-80771GB Issued 12-99


8001-14

Checking or adjusting all valves Checking or adjusting the swing


Connect the multitester at M1. Circuit pressure without load
Run the engine at full speed.
Connect the multitester at M2.
Overtighten the relief valve by one turn.
Run the engine at full speed.
Overtighten the attachment and travel flow cancella-
The pressure read should be between 15 and
tion valve by two turns.
17 (bar).
Safety valves on the attachment control valve If it is not, check the P3.
Install the plugs Q3337498 and T3843639 at the out- Relief valve
let while supplying the boom cylinder small cham-
bers. Lock the upperstructure mechanically.
Run the engine at full speed. Overtighten one safety valve by one turn.
The pressures read with the dipper and bucket cylin- Supply the direction of swing concerned.
ders against the stops in both directions and boom The pressure read should be between 370 and
raising, should be between 380 and 410 (bar). 400 (bar).
The pressure read when lowering the boom should Swing secondary relief valves
be between 390 and 420 (bar).
If the dipper cylinder small chamber is equipped with Supply the swing in both directions.
a safety check valve or a load holding valve and the The pressure read should be between 305 and
pressure cannot be reached, check that valve. 330 (bar).

Safety valves on travel control valve Checking the swing brake release

Lock the tracks mechanically in both travel directions. Connect the two outlets of the multitester at M2 and
Run the engine at full speed and set the inching valve M7.
lever on maximum. With the upperstructure immobilised, feather the
Supply each track, one after another, in both direc- swing control lever.
tions The pressure at M7 should be 35 (bar) before the
The pressures read should be between 385 and pressure rises at M2.
415 (bar). If it is not, check the brake release circuit.

Adjusting the relief valve


Supply the bucket opening function.
Untighten the relief valve until the same pressure is
obtained as on the bucket secondary relief valve.
Adjusting the attachment and travel flow
cancellation valve
Untighten this valve two turns.
Operate the bucket against the stop.
Adjust to a value between 355 and 365 (bar).

Cre 7-80771GB Issued 12-99


8001-15

Checking the travel brake release Procedure for complete adjustment of


Install a pressure test point at M17. 588C single and two-speed excavator
Connect the two outlets of the multitester at M1 and travel control valves
M17. The troubleshooting method.
Lock one track mechanically.
Press down fully on the foot pedal concerned. A complete adjustment of the flow adjustment valves
Feather at the inching valve. and the anti-excess flow valve can be performed by
The pressure at M17 should be 11 (bar) before the this method.
pressure rises at M1. This procedure should be applied when the control
If it is not, check the brake release circuit. valve has been completely misadjusted or when an
in-depth inspection is taking place.
Checking the flow limiters on the boom
and dipper It can be applied by means of either of the following
two measurement methods:
If the boom lowering speed is not correct, adjust the
- measuring the flow by means of a flowmeter.
spring to L = 26.5 mm.
- measuring the number of sprocket revolutions per
minute.
BASIC ASSUMPTIONS
L
- The following values are correct:
a) Max engine speed.
b) Pilot pressures.
c) ∆p L.S.
d) Max main pump flow.
e) Spool pilot pressures ≥ 24 bar.
- The hydraulic oil is at 50°C.
METHODS
Use the attachment to raise each track in turn.
PDH509
Push the control lever to maximum on the single
speed and to the indexing point on the two-speed.
Operate each track in both directions of travel.
Read the flows at the flowmeter or count the number
of sprocket revolutions.
The flow should be between:
- 110 and 120 (l/min).
The number of sprocket revolutions should be
between:
- 34 to 36 (rpm)
IF THE FLOWS OR THE NUMBER OF SPROCKET
REVOLUTIONS ARE INCORRECT:
Overtighten the anti-excess flow valve.
Remove the valve.
Eliminate the adjustment protection ring.
Overtighten the adjusting screw by screwing it fully
home.

Cre 7-80771GB Issued 12-99


8001-16

Checking excess flow on each track Adjusting the track speeds in forward
Operate each track in both directions of travel. travel
Read the flows at the flowmeter or count the number Assemble the springs and push-rods on each section
of sprocket revolutions. Operate each forward travel.
The flows should be between Adjust the flows between:
- 115 and 125 (l/min). - 115 and 125 (l/min).
The number of sprocket revolutions should be The number of sprocket revolutions between:
between - 34 to 38 (rpm)
- 34 and 38 (rpm). WARNING! Unscrew to increase flow and vice versa.
IF THE FLOWS OR THE NUMBER OF REVOLU- Adjusting the anti-excess flow valve
TIONS OF THE SPROCKETS ARE INCORRECT.
Remove the valve.
Cancel the effect of the spool stops Untighten the pressure adjustment screw a quarter
Disconnect the pilot pipes. turn.
Unscrew the spool mechanical stops in the caps and Install the valve.
put them in contact with the installations. Operate one forward travel.
Reconnect the pilot lines.
The flow should be between:
Cancel the action of the flow adjustment valve - 110 and 120 (l/min)
springs The number of sprocket revolutions should be
between:
Remove the springs and push-rods.
- 33 to 36 (rpm)
Measure the flow on each track.
If they are not so, carry out the adjustment of the anti-
Use the attachment to raise each track in turn. excess flow valve again.
Operate each track in both directions of travel.
WARNING! Screw in to increase flow and vice versa.
Read the flows at the flowmeter or count the number
of sprocket revolutions. Then carry out a complete check again.
Note these values.
Adjusting so as to provide symmetrical
flows
TAKE THE LOWEST FLOW VALUE OR NUMBER
OF SPROCKET REVOLUTIONS INTO CONSIDER-
ATION
For the 3 other flows:
Disconnect the pilot line opposite to the spool move-
ment.
Operate the direction of travel concerned.
Read the flow or count the number of sprocket revo-
lutions.
Tighten the stop until the flow or the number of
sprocket revolutions is equal to the value found on
the slowest track
NOTE: It is normal to find leaks at the caps during
these adjustments. They are due to the pilot heating
system.

Cre 7-80771GB Issued 12-99


8001-17

Procedure for complete adjustment of Adjusting so as to provide symmetrical


single and two-speed excavator travel flows
control valves
TAKE THE LOWEST FLOW VALUE OR NUMBER
(if a control valve section has been changed and the OF SPROCKET REVOLUTIONS INTO CONSIDER-
sprocket revolutions do not correspond to the indi- ATION
cated values or if a complete overhaul is taking
place) For the 3 other flows:

A complete adjustment of the flow adjustment valves Disconnect the pilot line opposite to the spool move-
and the anti-excess flow valve can be performed by ment.
this method. Operate the direction of travel concerned.
This procedure should be applied when the control Read the flow or count the number of sprocket revo-
valve has been completely misadjusted or when an lutions.
in-depth inspection is taking place. Screw in the stop until the flow or the number of
sprocket revolutions is equal to the value shown for
It can be applied by means of either of the two follow- the slower of the two tracks.
ing methods:
NOTE: It is normal to find leaks at the caps during
- measuring the flow by means of a flowmeter.
- measuring the number of sprocket revolutions per
these adjustments
They are due to the pilot heating system.
minute.
BASIC ASSUMPTIONS Adjusting flows or track speeds in
forward travel
- The following values are correct:
a) Max engine speed. Assemble the springs and push-rods on each section
b) Pilot pressures. Operate each forward travel.
c) ∆p L.S. Adjust the flows between:
d) Max main pump output. - 115 and 125 (l/min).
e) Spool pilot pressures ≥ 24 bar. The number of sprocket revolutions between:
- The hydraulic oil is at 50°C. - 34 to 38 (rpm)
METHODS WARNING! Unscrew to increase flow and vice versa.
Preparation for the various adjustments.
Adjusting the anti-excess flow valve
Overtighten the anti-excess flow valve fully home.
Remove the valve.
Disassemble the springs and push-rods from the flow
Untighten the pressure adjustment screw a quarter
adjustment valves.
turn.
Disconnect the pilot pipes.
Install the valve.
Untighten the spool mechanical stops in the caps and
Operate one forward travel.
place them in contact with the Installations.
Reconnect the pilot lines. The flow should be between:
- 110 and 120 (l/min)
Measure the flows on each track.
The number of sprocket revolutions should be
Use the attachment to raise each track in turn. between
Operate each track in both directions of travel. - 33 to 36 (rpm)
Read the flows at the flowmeter or count the number
If they are not, carry out the adjustment of the anti-
of sprocket revolutions.
excess flow valve again.
Note these values.
WARNING! Screw in to increase flow and vice versa.
Then carry out a complete check again.

Cre 7-80771GB Issued 12-99


8001
Section
8001

TESTS, ADJUSTMENTS
AND HYDRAULIC SCHEMATICS
588 wheeled excavators

Copyright  1999 Case France


Printed in France
Case Cre 7-80781GB December 1999
8001-2

TABLE OF CONTENTS
TOOLS REQUIRED .................................................................................................................................................. 3

TOOLS TO BE MANUFACTURED .......................................................................................................................... 5

LOCATION OF HYDRAULIC COMPONENTS......................................................................................................... 7

588P GENERAL HYDRAULIC SYSTEM: LIST OF HYDRAULIC COMPONENTS .................................................. 9

588P PRESSURE SETTING.................................................................................................................................. 10

Cre 7-80781GB Issued 12-99


8001-3

TOOLS REQUIRED
1 Test equipment The Multi-Test can be used to carry out the following
There are three possible choices: tests:
a) Multi-Handi test kit 2051.........................E5444449 Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, temperature
differential, rotational speed and volumetric flow,
amperage, voltage, connection to PC and printer,
memory capacity 60000.
The test kit includes:
1 Multi-Test 4020 unit................................. Q5344455
2 pressure detectors 0-600 bar.................. V5344460
2 straight adaptors for detector ................. W5344461
1 elbow adaptor for detector ...................... X5344462
1 rotational speed detector ........................ Z5344463
1 temperature sender................................. B3144469
2 double PT cables .................................... B5344465
4 cables length 5 m.................................... E3144472
1 x 220V 50Hz power supply ..................... D5344467
1 cigarette lighter cable.............................. E5344468
CP96E001 1 instruction manual.................................... -------------
The Multi-Handi test kit is recommended as the basic 1 carry-case ............................................... P5344477
tool of the mechanic. c) Multi-System 5000 test kit ..................... U5344459
The Multi-Handi can be used to carry out the follow-
ing tests:
Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, rotational
speed and volumetric flow.
The test kit includes:
1 Multi-Handi 2051 unit ............................. D5444448
2 pressure detectors 0-600 bar ..................V5344460
2 straight adaptors for detector..................W5344461
1 elbow adaptor for detector.......................X5344462
1 rotational speed detector .........................Z5344463
2 cables length 5 m ....................................E3144472
1 x 220 V 50 Hz power supply .................. D5344467
1 cigarette lighter cable ..............................E5344468
CP96E002
1 instruction manual ................................... -------------
The Multi-System is recommended for specialist
1 carry-case............................................... N5344476
departments (Engineering Design Office and tests at
b) Multi-Test 4020 test kit .......................... T5344458 customer’s premises).
The Multi-System can carry out the following tests:
Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, temperature dif-
ferential, rotational speed and volumetric flow,
amperage, voltage, torque, force, movement, speed,
connection to PC and printer, memory capacity 120000.
The test kit includes:
1 Multi-System 5000 unit ........................... R5344456
2 pressure detectors 0-600 bar.................. V5344460
2 straight adaptors for detector ................. W5344461
1 elbow adaptor for detector ...................... X5344462
1 rotational speed detector ........................ Z5344463
1 temperature sender................................. A5344464
2 double PT cables .................................... B5344465
4 cables length 5 m.................................... E3144472
CP96E003 1 x 220V 50Hz power supply ..................... D5344467
The Multi-Test is recommended to carry out in-depth 1 cigarette lighter cable.............................. E5344468
diagnostics. Values read can be recorded in its mem- 1 instruction manual.................................... -------------
ory and transferred to a PC and a printer. 1 carry-case ............................................... P5344477
Cre 7-80781GB Issued 12-99
8001-4

CP96E004 PG04005

TEMPERATURE SENDER A5344464 ONE PRESSURE TEST POINT M14 X 1,5


A3237549
Use with Multi-Handi 2051 test kit
MAGNETIC BASE G5344470
Use with Multi-Handi 2050, Multi-Test 4020 and
Multi-System 5000 test kits

PE18402

TWO MINIMESS HOSES LENGTH 2500 mm


P2144487
TWO HOSE UNIONS C5144412
PF01410

600 LITRES FLOWMETER, ORDER THE FOLLOW-


ING:
ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45 X 2) D4323359
TWO FLANGES (DIA. 24) B8230183
ONE HIGH PRESSURE HOSE DN25 W5431976
TWO SEALS D330421
FOUR HALF-FLANGES D4024267
EIGHT SCREWS (12 X 75) Z1232983
ONE HIGH PRESSURE HOSE DN19 Q5931990
ONE LOW PRESSURE HOSE DN12 B8031969
PG04006

TWO PLUGS 27 X 200 Q3337452


ONE FEMALE UNION 27 X 200 P4237556
ONE MALE/FEMALE UNION D12 L3237536

Cre 7-80781GB Issued 12-99


8001-5

PDH0505

TWO REDUCTION PIECES DN25 - DN19


G1037352

PDH0506

ONE SPECIAL UNION W5137530

TOOLS TO BE MANUFACTURED

PDG0239

One spacer to limit the stroke of the control lever


spools

Cre 7-80781GB Issued 12-99


8001-6

This page is intentionally left blank

Cre 7-80781GB Issued 12-99


8001-7

LOCATION OF HYDRAULIC COMPONENTS


4 - Low flow option control valve (clamshell rotation, backhoe offset articulated boom, telescopic boom)
5 - Block with filter on the circuit LS2 (stabilizer travel)
6 - High pressure pump with:
1 fixed flow body for the swing
1 variable flow body for the attachment and travel
7 - Low pressure pump for the steering/braking system
Low pressure pump for the pilot systems
8 - Hose/accumulator on the pump LS information circuit
10 - Anti-surge valve on the attachment LS1 circuit
11 - Brake system hydraulic filter
12 - Pilot circuit filter
22 - Travel control pedal
23 - Travel direction reverser (INCHING)
26 - Pilot circuits manifold
28 - Steering box (ORBITROL)
29 - Braking unit
35 - Parking brake control electro-control valve block
41 - Swing control valve block
42 - Hydraulic swing motor safety flange
43 - Fixed flow hydraulic swing motor
61 - Hydraulic piloting block including:
61a - Automatic swing braking and brake release selector
61b - Electro-control valve (Y2 and Y13): control arm raising safety, front axle locking and unlocking)
61d - 35 bar pressure limiter (P35)
61e - Travel speed change electro-control valve (Y11: job-site speed - Y12: road speed)
61f - Stabilizer and blade electro-control valve (Y26: raising - Y27: lowering)
81 - Attachment control valve (boom, dipper, bucket)
82 - P10 counter-pressure valve
91 - 16 passage hydraulic swivel
101 - Travel and stabilizer/blade control valve block
102 - Variable displacement hydraulic travel motors
103 - Travel motor force-feed flange
104 - Speed limiter and safety block
105 - Two-speed box with parking brake
109 - Rear axle
110 - Front axle

CM99K005

Cre 7-80781GB Issued 12-99


8001-8

T
2 F5
F3
0,4 bar 3 3,1 bar 16 F1
B2 43 F2
P 120 F L G2 M1 82
F4

+
F6
B A
T2

4 40 42 T4
T3
T1 T5
X M2
M
M1 P3
1 G B 9
P2 P4 92
P1
B21 Θ T
3bar
LS
10
44 87
7 B1 T3 A1
A1
T T Zb1 B B1
10
R2
6 M A1 A S1 41
Za1 A1
R1 T2 B2
36
S B B1 A A2
16 T
107 X6 P
P 89 88
12 4
M3
1 2 A2
9 Zb2
B B1
B2
3 Za2
8 85
M 10 A2 86
X3 C 21 B2 A
9 A1
X4
Zb1 Za1
M2 P
A
B 45 T A3
Za'4 Zb'4 1 4 Zb3 A B

Za3
83
2

Zb4
B3
3 84
Za4
A
81
A1
48
90 C1

5
61 C
11
MF MP
B5

61f
Y13
26 T7
F12 P2 P3 P5 T0 T5 T3 T9 T4
P0
1(6) B4 Zb6
P1 P7 P4 P8 P6 T11 T2 T8 T1 T10 T6
+ 49 55 A4 Za6
9 1
58 61e 108
Y27 M4
K9 2,35 22
Y26 10
54 64 17 P
F 23
B3
27 25 T
12
54 105 A3 B5 A P
7
S24 Y12 Y11 61d P B
B P A
M6 8 B
61c 9 32a
SC 3 T B2 106 C
57 105 4 A
53
16
A2 A
manu 15 107
B1 T 9 MB G G P Z
F G T
SC 2 6 P M
auto W + B
54 ALTER (12V) M 18
5 B'
A1 B1 B
53
53 61b Y2 29 Za1
R Zb1 A
105 SC 4 98 K3
50 A1 A
51 A 86 35 34 105
52 106 2 3
M7
101 A'
K14
P3 Y G G'
P B53
49 LS
49 MA
B 82
122 B2 X
63 61a 63 P Za6 2 Za6
49 Zb'
4 104 103
Sh Zb Za' Za F P DS Zb6 M 22 110
49 Zb6 3
4 4 4
S12 33a P PP A2' A2 F2 F1 A4 A1 P1 P S
94 83 P P
84 91 A2 B
121 M8 9 65 102 9
49 B50 66
63 B12 33b
B52
P

49 49 B51 30b
11 T1 A
F
112
P II
31 30a 111 B A

94 9 203
60

Y15
62
B
MF MP

202
P
90b 90c 32b L 14 201
Ø : 2,5
28

205
T
R 109
13 204
204 205
CM99K006

Cre 7-80781GB Issued 12-99


8001-9

588P GENERAL HYDRAULIC SYSTEM: 81 - Attachment control valve (boom, dipper, bucket)
82 - P10 counter-pressure valve
LIST OF HYDRAULIC COMPONENTS
83 - Braking valve on dipper cylinder small chamber
1 - Reservoir 31 - Braking pressure switch for travel speed 84 - Dipper cylinder with dashpot on large and small chamber
2 - Reservoir filler cap with self-pressurizing valve change 85 - Backhoe/clamshell selector lever valve (optional)
and screen filter 32a - Travel pilot pressure switch (automatic front 86 - Bucket cylinder with dashpot on small chamber
3 - Return manifold with element type filters and axle unlocking) 87 - Boom cylinder supply block with flow limiter on the large chambers
restriction indicator 32b - Pressure switch (brake lights) 88 - Boom cylinders with dashpot on large chambers
4 - Element type filter on functional leak return 33a - Parking brake pressure switch 89 - Lever valve on boom cylinder large chambers (for transportation position)
lines 33b - Minimum braking pressure switch 90 - Pressure selector on attachment and travel/stabilizer LS circuits
5 - Block with filter on LS2 circuit (travel / 34 - Minimum steering pressure switch 90b and 90C - Pressure selector on braking circuits (Working brake and service brake)
stabilizers) 35 - Parking brake control electro-control valve 91 - 16 passage hydraulic swivel
6 - High pressure pump with: block 92 - Return circuit restriction
1 fixed flow body for the swing 36 - Boom - bucket function manual control block
1 variable flow body for the attachment, travel 101 - Travel and stabilizer/blade control valve block
41 - Swing control valve block
and option 102 - Variable displacement hydraulic travel motors
42 - Hydraulic swing motor safety/force-feed flange
7 - Low pressure pump 103 - Travel motor force-feed flange
43 - Fixed displacement hydraulic swing motor (with
1 body for the steering/braking system 104 - Speed limiter and safety block
static brake)
1 body for the pilot systems 105 - Two-speed box with parking brake and speed range change cylinder
44 - 3 bar check valve for swing force-feed
8 - Hose/accumulator on the pump LS information 106 - Speed range change indexing and safety block
45 - Braking valves on swing control valve pilot cir-
circuit 107 - Hydraulic travel motor pressure release block (for speed range change)
cuits
9 - Pressure test points 108 - Calibrated orifice on the parking brake circuit
48 - Restriction in swing circuit
M1 - Pressure test point for travel and 109 - Brakes on front axle
options, if any 61 - Hydraulic piloting block including: - Steering cylinder
M2 - Pressure test point for swing 61a - Swing braking and brake release valve 110 - Brakes on rear axle
M3 - Pressure test point for LS circuit 61b - Y2 electro-control valve for control arm 111 - Front axle locking cylinder
M4 - Pressure test point for pilot circuits raising safety system 112 - Stabilizer/blade selector lever valve
M6 - Pressure test point for travel manual 61c - P35 pressure limiter 120 - Oil-cooler
control block outlet 61d - Displacement change electro-control
M7 - Pressure test point for swing braking valve (Y11 work-site speed Y12 road 201 - Blade cylinder
and brake release speed) 202 - Calibrated orifice on blade cylinder large chamber
M8 - Pressure test point for braking unit 61e - Stabilizer and blade electro-control 203 - Flow limiter on stabilizer cylinder small chambers
M18 - Pressure test point for travel and stabi- valve (Y26: raising - Y27: lowering) 204 - Stabilizer cylinder
lizer control valve 61f - Front axle locking and unlocking elec- 205 - Stabilizer cylinder piloted check valve (on the small chambers)
M22 - Pressure test point for hydraulic travel tro-control valve (Y13)
motor displacement change circuit 62 - Working brake electro-control valve (Y15)
10 - Anti-surge valve and filter on the attachment
LS1 circuit
11 - Steering/braking system filter
12 - Filter on pilot circuit
21 - Dipper and swing function manual control block
22 - Travel control pedal
23 - Travel direction reverser (INCHING)
25 - Pressure release pump (foot control)
26 - Pilot circuits manifold
27 - Pilot circuit minimum pressure switch
28 - Steering box (ORBITROL)
29 - Braking unit
30a - Accumulator on the front axle braking circuit

30b - Accumulator on the rear axle braking circuit

Cre 7-80781GB Issued 12-99


8001-10

588P PRESSURE SETTING


Location of the various pressure test points installed on the machine
M1 on the attachment control valve
M2 on the swing control valve
M3 on the anti-surge valve
M4 on the manifold
M6 on the direction of travel reverser
M7 on the swing brake selector block
M8 on the parking brake electro-control valve
M22 on the travel motor

Location of pressure test points to be installed


M5 on the steering circuit
M10 on the front axle
M11 on the rear axle

Installing the flowmeter on the variable flow pump body


(for the attachment and travel)
Install the flowmeter using the hose specified in the tools list.

Raising the circuit temperature to between 50 and 55°C


Use the stabilizers and the blade to raise the excavator
Operate the bucket or clamshell against the stops

Checking the engine speeds


Install the tachometer
Idle.....................800 to 900 (rpm)
Maximum ........2140 to 2220 (rpm)

CM99K007

Cre 7-80781GB Issued 12-99


8001-11
ALL CHECKS AND ADJUSTMENTS ARE CARRIED Checking the balance valve flows
OUT AT VARIOUS ENGINE SPEEDS AND AT A
TEMPERATURE OF 50°C. Attachment control valves
Supply the large chambers of the boom, bucket and
Checking the pilot pressure with dipper cylinders, one after another.
the control arm lowered The flows should be between:
Connect the multitester to the manifold at M4. - 140 and 160 (l/min) on the boom.
Run the engine at full speed. - 90 and 110 (l/min) on the bucket.
The pressure should be greater than 34 (bar). - 115 and 135 (l/min) on the dipper.
If it is not, check the P35 or the electrical circuit.
Travel control valve
AFTER EACH CHECK, IF THE PARAMETERS ARE
Connect the multitester at M6 to check the travel con-
INCORRECT, ADJUST AT THE COMPONENT
trol valve spool pilot pressure in forward and reverse
CONCERNED OR CHANGE THE COMPONENT.
travel.
Setting the LS valve pressure Raise the excavator using the stabilizers and the
blade.
Static test using the same 0/40 bar pressure Select job-site speed, travel forward and reverse.
gauge: The pressure readings should be 24 (bar) minimum.
If they are not, adjust the pressure regulator or add
WARNING! Start the engine running, before connect-
shims under the travel reverser spool spring(s).
ing the pressure gauge at M1.
Forward travel The flow reading should be between
Raise the left-hand control arm as a safety measure. 163 and 173 (l/min).
Run the engine at full speed. If it is not, adjust the balance valve.
Connect the pressure gauge at M3. The pressure Reverse travel The flow reading should be between
should be between 8 and 12 (bar). If not, check the 160 and 173 (l/min). The universal joint speeds in
P10. work-site speed range should be between 649 and
Connect the pressure gauge at M1. The difference 659 rpm or (547 and 556 rpm for German excavators
between M1 and M3 should be 21 to 25 (bar). in forward travel and between 627 and 659 rpm or
(523 and 556 rpm for German excavators) in reverse
Dynamic test using multitester:
travel.
Assemble the spacer on the boom raising control The universal joint speeds in road speed range
lever push-rod. should be between 2166 and 2196 rpm or (1825 and
Connect the two outlets from the multitester at M1 1855 rpm for German excavators) in forward travel
and M3. and between 2091 and 2196 rpm or (1745 and
Operate the boom raising control. 1855 rpm for German excavators) in reverse travel.
The pressure differential should be between 21 and
Stabilizer and blade control valve.
23 (bar).
When descending a slope, the flow should be for:
Checking the maximum flow from - 2 stabilizer pads: between 150 and 180 (l/min)
the variable displacement pump - 1 dozer blade: between 60 and 80 (l/min)
If not, adjust the balance valve, or check the jet at the
Run the engine at full speed.
large chamber inlet for the blade.
Connect the multitester for flow measurement.
Retract the dipper and close the bucket simultane- When raising, the flow should be for:
ously. - 2 stabilizer pads: between 40 and 50 (l/min)
The flow should be greater than 205 (l/min) and the - 1 blade: between 15 and 30 (l/min)
pressure at M1 lower than 125 (bar). If it is not, check the flow limiter(s) at the front or rear
of the chassis when equipped with stabilizer pads.

Cre 7-80781GB Issued 12-99


8001-12

Checking the engine hydraulic Travel safety valve


power under load (on speed limiter)
Connect the multitester at M1 and M2. Disconnect the wire 94 (brown colour) at ∆28, behind
Run the engine at full speed. the cabinet printed circuit board.
Block one attachment function and the swing function
to check their maximum pressures which should be
between 355 and 365 (bar) on the attachment
Adjust the dipper cylinder large chamber safety valve
to 300 bar.
Supply the dipper retracting function..
The flow from the pump should be greater than
88 (l/min).
The engine speed should be a minimum of between
1980 and 2020 (rpm).
WHEN THESE ADJUSTMENTS HAVE BEEN COM-
PLETED, REMOVE THE FLOWMETER.

Checking or adjusting valves PDH0507

Connect the multitester at M1. Run the engine at full speed.


Run the engine at full speed. Apply the parking brake.
Overtighten the relief valve by one turn. Select road speed.
Overtighten the attachment and travel flow cancella- Operate the direction of travel reverser in one direc-
tion valve by two turns. tion.
Press the travel pedal.
Safety valves on the attachment Repeat the operation in the opposite direction of
travel.
control valve The pressures read should be between 380 and
Close the lever valve on the boom component. 410 (bar).
Run the engine at full speed
The pressure readings, with the dipper and bucket Secondary relief valves on travel
against the stops in both directions and with the control valve
boom raising, should be between 380 and 410 (bar).
The pressure reading, with the boom lowering, Operate against the stop, raising and lowering.
should be between 390 and 420 (bar). The pressures read should be between 380 and
If the small chamber of the dipper is equipped with a 410 (bar).
safety valve or load holding valve, and the pressure
cannot be reached, check these valves.
Adjusting the relief valve
Supply the bucket opening function.
Untighten the relief valve until the same pressure is
obtained as the bucket secondary relief valve.

Adjusting the attachment and


travel flow cancellation valve
Untighten this valve two turns.
Operate the bucket against the stop.
Adjust to a value between 355 and 365 (bar).

Cre 7-80781GB Issued 12-99


8001-13

Hydraulic travel motor Service brake pressures


displacement change On the front axle
Connect the two outlets from the multitester at M1 Install a Minimess pressure test union (A3237549) at
and M22. M10 in place of the bleed screw adaptor.
Unscrew the travel reverser brake. Bleed the circuit. Connect the multitester.
Set the FINE mode. Press the brake pedal.
With the wire 94 still disconnected. The pressure read should be between 45 and
Apply the parking brake. 60 (bar).
Select the road speed. Release the brake pedal, the pressure should drop to
Press the travel pedal. a value below 0.5 (bar).
Feather the travel reverser. If not, check the circuit or the braking unit.
At a pressure between 240 and 260 (bar) at M1, the
pressure at M22 should start to rise. On the rear axle
If it does not, adjust at the motor. Same as the front axle at M11.
WARNING! Unscrew to increase pressure.
Checking or adjusting the swing
Retighten the travel reverser brake.
Reconnect the wire 94. Checking the circuit pressure without load
Connect the multitester at M2.
Orbitrol steering box relief valve Run the engine at full speed.
Install a pressure test union (W1237213) at M5 at the The pressure read should be between 15 and
inlet P to the steering box. 17 (bar).
Connect the multitester. If it is not, check the P3.
Turn against the stops in both directions. Checking the relief valve
The pressures read should be between 155 and
160 (bar). Lock the upperstructure mechanically.
If they are not, disassemble the steering box and Overtighten one safety valve by one turn.
check all the valves. Supply the direction of swing concerned.
The pressure read should be between 370 and
Braking unit disengagement and 400 (bar).
engagement pressures Checking the safety valves

Connect the multitester at M8. Supply the swing in both directions.


Operate the parking brake several times. The pressure reading should be between 305 and
The minimum engagement pressure should be 330 (bar).
between 120 and 140 (bar). Checking the swing brake release
The maximum disengagement pressure should be
165 (bar). Connect the two outlets of the multitester at M2 and
If not, check the braking unit. M7.
With the upperstructure immobilised, feather the
Parking brake pressure swing control lever.
The pressure at M7 should be 35 (bar) before the
Install a pressure test union (U1237211) at M8. pressure rises at M2.
Bleed the parking brake circuit. If it is not, check the brake release circuit.
Connect the multitester.
With the parking brake control in the disengaged
position, the pressure read should be between 120
and 160 (bar).
With the control in the brake engaged position, the
pressure should not exceed 0.5 (bar).
If not, check the circuit.

Cre 7-80781GB Issued 12-99


8001-14

Checking the flow limiters, boom


If the boom lowering speed is not correct, adjust the
spring to L = 26.5 mm.

PDH0509

Cre 7-80781GB Issued 12-99

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