Case Hydraulics Excavators 788 988 Update 06 2000 Shop Manual PDF

HYDRAULICS EXCAVATORS
788 & 988

Update 06-2000
Copyright 1999 Case France

Imprim en France
Case Cre 7-80403GB Juin 2000
CRAWLER AND WHEELED EXCAVATORS
788, 788 PLUS, 988, 988 PLUS
SCHEMATIC SET
TABLE OF CONTENTS
SECTION SECTION No. REFERENCE No.
Safety, general information and torque specifications.................................................. 1001 7-56942GB
Specifications
Crawler excavators ....................................................................................... 1002 7-80071GB
Wheeled excavators ..................................................................................... 1002 7-80062GB
Electrical schematics
Crawler excavators - before November 99 ................................................... 4001 7-80040GB
Crawler excavators - after November 99 ...................................................... 4001 7-26570GB
Wheeled excavators - before November 99 ................................................. 4001 7-80021GB
Wheeled excavators - after November 99 .................................................... 4001 7-26540GB
Electronic and troubleshooting system
Tests, adjustments and hydraulic schematics
Large size hydraulic and electrical schematics
Crawler excavators 788 ............................................................................ Pocket 7-80190GB
Crawler excavators 788 Plus ..................................................................... Pocket 7-26730GB
Wheeled excavators 788 .......................................................................... Pocket 7-80200GB
Wheeled excavators 788 Plus ................................................................... Pocket 7-26760GB
Crawler excavators 988, 988 Plus - before November 99 ......................... Pocket 7-58960GB
Crawler excavators 988 Plus - after November 99 .................................... Pocket 7-26770GB
Wheeled excavators 988, 988 Plus - before November 99 ....................... Pocket 7-58970GB
Wheeled excavators 988 Plus - after November 99 .................................. Pocket 7-26780GB
NOTE: CASE Company reserves the right to make changes in the specification and
design of the machine without prior notice and without incurring any obligation to mod-
ify units previously sold.
The description of the models shown in this manual has been made in accordance with
the technical specifications known as of the date of design of this document.

Printed in France
Case Cre 7-80183GB November 1999
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

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 operators 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 manufacturers
instructions on how to operate and maintain
the machine. It is your responsibility to follow
applicable rules and regulations. Service and
Operators 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 Operators 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 operators seat. If you are not in the
! operators 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.

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 Operators 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.

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.

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- tors 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.

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

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

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

1001-10
METAL CAP REFERENCES

To SAE J518 specifications
NP 250 bar NP 400 bar Part number

ND 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

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

1001-12

1002
Section
1002
SPECIFICATIONS
Crawler excavators

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
Components made from plastic or resin ............................................................................................................... 5
GENERAL MACHINE SPECIFICATIONS................................................................................................................. 6
Engine .................................................................................................................................................................. 6
Hydraulic system ................................................................................................................................................... 8
Electrical system .................................................................................................................................................. 9
Upperstructure ..................................................................................................................................................... 9
Cab .......................................................................................................................................................................9
Operation ............................................................................................................................................................. 9
Undercarriage (depending on version) ...............................................................................................................10
Safety devices ....................................................................................................................................................10
Indicators ............................................................................................................................................................10
Warning and indicator lamps ..............................................................................................................................10
Attachments .......................................................................................................................................................10
Noise level ..........................................................................................................................................................10
Vibration level in operators compartment ..........................................................................................................10
Ground pressure ................................................................................................................................................11
Travel .................................................................................................................................................................11
WEIGHTS................................................................................................................................................................12
Machine ..............................................................................................................................................................12
Attachments .......................................................................................................................................................15
Counterweight ....................................................................................................................................................15
Cab .....................................................................................................................................................................15
788 AND 788 "PLUS" BUCKETS ............................................................................................................................16
988 AND 988 "PLUS" BUCKETS ............................................................................................................................17
788 AND 788 "PLUS" CLAMSHELLS .....................................................................................................................18
MACHINE OVERALL DIMENSIONS.......................................................................................................................20
TRANSPORTATION OVERALL DIMENSIONS ......................................................................................................22
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.

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
-20C to +60C
Temperate climates
Extreme pressure grease EP NLGI grade 2 with molyb-
-20C to +40C denum disulphide.
Fluid type ISO VG 46
CASE reference: POHYDR Cold climates
-40C to +20C
Hot climates
Extreme pressure grease EP NLGI grade 0.
0C to +60C
CASE reference: POHYDC
Cold climates
-40C to +20C
CASE reference: POHYPF
These various grades of fluid must be in conformity
with CASE France specification P9903201Z.
Temperate climate biodegradable fluid:
This yellow fluid is compatible with standard fluid. If
adopted, it is advisable to drain the circuit completely.
CASE reference: CASYNTH46
This grade of fluid must be in conformity with CASE
France specification P9903203B
Transmission component oil

Extreme pressure oil used for transmission compo-
nents inside sealed housings.
Extreme pressure oil TYPE API GL5 GRADE 80W90 or
ISO VG 150

1002-4
Engine oil
CASE engine oil N1 is recommended for your
engine. This oil ensures correct lubrication of your
engine in all working conditions.
If CASE N1 Multiperformance or Performance
engine oil is not available, use oil corresponding to
category API/CG/CF.
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) ARCTIC
(*) SHOWS THAT AN ENGINE OIL HEATER OR ENGINE COOLANT SOLUTION HEATER MUST BE USED.

1002-5
Fuel Environment
Use fuel that is to ASTM (American Society for Test- Before carrying out any servicing operation on this
ing and Materials) D975 standard. machine and before disposing of used fluids or lubri-
cants, always think of the environment. Never throw
Use Grade No N2 fuel. The use of other types of fuel
fluid or oil on the ground and never keep them in leak-
can result in a loss of power and may cause high fuel
ing receptacles.
consumption.
Consult your local ecological recycling centre to
In cold weather, the use of a mixture of fuels N1 and
obtain information on the appropriate means of dis-
N2 is temporarily permitted. Consult your fuel sup-
posing of these substances.
plier.
If the temperature falls below the fuel cloud point Components made from plastic or
(point at which wax begins to form) the wax crystals resin
will cause power loss or will prevent the engine from
starting. When cleaning polycarbonate windows, the console,
the instrument panel, the gauges, etc., do not use
IMPORTANT: In cold weather, fill the fuel tank at the petrol (gasoline), paraffin (kerosene), paint solvents,
end of the days work, in order to prevent the formation etc. Use only water, soap and a soft cloth.
of condensation.
The use of petrol (gasoline), paraffin (kerosene),
Fuel storage paint solvents, etc, will cause discoloration, cracking
Long storage can lead to the accumulation of impuri- or deformation of these components.
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.
In environments with a temperature higher than
-36C, use a mixture of 50% ethylene-glycol based
anti-freeze.
For areas where the temperature is below -36C, it is
advisable to use a blend of 40% water and 60% anti-
freeze.

1002-6
GENERAL MACHINE SPECIFICATIONS

Engine
(788 and 788 "Plus")
788 788 "Plus"
Make and type ........................................................... CASE 4T 390............................ .......................CASE 4TA 390
4 stroke, 4 cylinder ............................................................... ...................... turbo-charged diesel
Capacity................................................................................ ...............................3920 cm3
Bore ...................................................................................... ................................102 mm
Stroke ................................................................................... ................................120 mm
Cooling ................................................................................. ............................ water-cooled
Staring: 2 x 12 volt batteries, 24 V........................................ ................................ 120 A/h
Working specifications
Engine speed........................................................................ ...............................2000 rpm
Horsepower: SAE J1995......................................68.6 kW (93 hp).......................... .......................81 kW (110 hp)
DIN 70020 - DIN 6271 ..................... 65 kW (88 hp)........................... ...................... 76 kW (103 hp)
EEC 80/1269 - ISO 9249................. 65 kW (88 hp)........................... ...................... 76 kW (103 hp)
Specifications maintained up to an altitude of
3000 m at a temperature of 25C.
Capacities: Engine oil sump .......................................... ...................................10 L
Fuel tank..................................................... ..................................249 L
Electric fuel filler pump ......................................................... ....................... optional equipment
Average consumption per hour ....................................... 10 L/h.................................. ..................................14.5 L/h
Engine and pump assembly mounted on rubber blocks.
Heavy-duty dust filtration.

1002-7
(988 and 988 "Plus")
988 988 "Plus"
Make and type ...................................................................... ........................... CASE 6T 590
Total SAE horsepower at 2800 rpm...................................... ........................126.4 kW (172 hp)
4 stroke, 6 cylinder ............................................................... ......................turbo-charged diesel
Capacity................................................................................ ...............................5880 cm3
Bore ...................................................................................... ................................102 mm
Stroke ................................................................................... ................................120 mm
Engine speed........................................................................ ...............................2000 rpm
Horsepower: SAE ................................................ 91 kW (124 hp).......................... ................... 92 kW (125.7 hp)
DIN 70020 - DIN 6271 .................... 86 kW (116 hp).......................... ...................... 90 kW (122 hp)
EEC 80/1269 - ISO 9249 ................ 86 kW (116 hp).......................... ...................... 90 kW (122 hp)
Specifications maintained up to an altitude of 3000 m at a temperature of 25C.
Capacities: Engine oil sump .......................................... ................................. 14.3 L
Fuel tank ..................................................... ..................................249 L
Electric fuel filler pump ......................................................... ....................... optional equipment

1002-8
Hydraulic system
Variable output system with independent and simultaneous operation of all functions.
Electronic regulation of hydraulic power ("Powersensor" system) for optimal use of engine power.
3 regulation modes:
"FINE": For jobs requiring high precision.
"ECO": For normal jobs.
"MAX": In this position, the operator has the full power of the machine at his disposal.
Engine automatically reverts to idle speed if the operator wishes.
(788 and 788 "Plus")
788 788 "Plus"
Working pressure ................................................................. ................................ 350 bar
Capacity of hydraulic reservoir ............................................. .................................. 115 L
Total system capacity ....................................................... 184 L.................................. ...................................... 187 L
Double body pump:
Variable displacement body for travel and attachment functions.
Flow ...............................................................................210 L/min............................... ............................... 214 L/min
Fixed displacement body for upperstructure swing function.
Flow ................................................................................44 L/min................................ .............................. 41.7 L/min
Installed hydraulic power ..........................................60 kW (81.5 hp).......................... ................... 73.5 kW (100 hp)
(988 and 988 "Plus")
988 988 "Plus"
Capacity of hydraulic reservoir ............................................. ..................................180 L
Total system capacity ........................................................... ..................................288 L
Pumps:
One double-body variable displacement pump for supplying travel motors and attachments.
Flow ...................................................................................... .............................. 320 L/min
A fixed displacement pump for supplying the upperstructure swing function.
Flow ................................................................................56 L/min................................ .............................. 54.9 L/min
Installed hydraulic power .......................................... 81 kW (110 hp).......................... ....................86.3 kW (117 hp)
(788, 788 "Plus", 988 and 988 "Plus")
Fixed pumps for pilot systems.
Parallel, closed centre type attachment and travel control valves.
Flow rates per function, independent of pressures.
Oil cooler with air cooling from engine.
Multispiral high pressure hoses with minimum safety factor of ............................. 2 to 4 times the working pressure
Self-lubricating hydraulic swivel.

1002-9
Electrical system
Circuit voltage circuit ............................................................................................................... 24 volt, negative earth
Batteries ..........................................................................................................two low-maintenance 12 volt 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 walkway giving access to the various components.
Sound-proofed, lockable cowling meeting all current regulations.
Tool box with tool set.
Swing
Hydraulic motor with reduction gear and automatic static brake.
788, 788 "Plus", 988 "Plus" 988
Rotational speed............................................................. 7.7 rpm................................ ...................................8.8 rpm
Turntable............................................................................... .......... Alternating rollers and internal teeth
Centralised bearing surface and tooth lubrication
Cab
Removable, sound-proofed, on flexible mounting blocks.
Up and over windshield.
Tinted windshield.
Pre-fitted for radio installation.
Transparent roof hatch ................................................................................................................. optional equipment
Sliding door window...................................................................................................standard since November 1999
Polycarbonate windows................................................................................................................ optional equipment
Cab safety guards .......................................................................................................................available on request
Elevated cab................................................................................................................................available on request
Ant-vandal cab.............................................................................................................................. optional equipment
Operation
De-luxe seat with armrests and multi-position adjustment (vibration level III/ISO 7096).
Hydraulically assisted controls.
Attachment and swing ........................................................................................................................ 2 control levers
Travel............................................................................................................................................................. 2 pedals
Speed programmer which also automatically changes speed range on the two-speed version.
Single-speed windshield wiper, plus intermittent action, windshield washer, heating, de-frosting, two-speed ventilation,
cab light, cigarette lighter, sun shield.
Working lights:
On upperstructure ...............................................................................................................................2 x 70/75 W
On attachment ............................................................................................................................................... 70 W
Front and rear (on cab) ............................................................................................................ optional equipment
Rear (on cab) ................................................................................................................................................. 70 W
Air conditioning ............................................................................................................................. optional equipment
Cab sun-shield.............................................................................................................................. optional equipment
Cab blower ................................................................................................................................... optional equipment

1002-10
Undercarriage (depending on version)

One-piece undercarriage chassis with welded components.
Lifetime lubricated rollers.
Tractor type tracks; grease cylinder type track tension; shock absorber for shock absorption.
Removable sprocket tooth rings.
Front chain guide (optional rear).
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, horn.
Safety valves ................................................................................................................................ optional equipment
Overload indicator ........................................................................................................................ optional equipment
Roller type seat belt...................................................................................................................... optional equipment
Fire extinguisher ........................................................................................................................... optional equipment
Rotary light ...................................................................................................................... special for certain countries
Indicators
Engine coolant solution temperature, hydraulic fluid temperature, fuel level and hourmeter.
Warning and indicator lamps

Engine oil pressure, battery charge, hydraulic and engine air filter start of restriction indicator.
Warning/indicator lamp test.
Attachments
Sealed linkages, greasing of all linkages possible from the ground, double acting cylinders fitted with end-of-stroke
shock absorbers.
Bucket linkage with side-play compensation system (988 Series only).
Noise level
Certified by the manufacturer.
In accordance with European directive 86/662/EEC.
788 788 "Plus" 988 988 "Plus"
Inside operators compartment (LpA) ................................. 79..................... 76..................... 81..............78 decibels
Outside machine (LwA) ..................................................... 105................... 103................... 108...........103 decibels
Vibration level in operators compartment

Upper members....................................................................................................................level lower than 2.5 m/s2
Body .....................................................................................................................................level lower than 0.5 m/s2

1002-11
Ground pressure
(788 and 788 "Plus")
788 788 "Plus"
With attachment: 4.30 m boom, 2.10 m dipper and 560 L bucket
Machine with 0.50 m track width ......................................... ...............................0.455 bar ........................0.466 bar
(988 and 988 "Plus")
988 988 "Plus"
With attachment: 4.80 m boom, 2.10 m dipper and 760 L bucket
Travel
Sprockets driven by hydraulic motors.
Independent drive to each track.
Manual controlled travel block providing precise adjustment of travel speed regardless of pressure exerted on travel ped-
als.
Braked motors (automatic static brake).
Hydraulic speed limiter, automatic when descending slopes.
(788 and 788 "Plus")
Travel speeds:
(single 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
Gradeability ..........................................................................................................................................................74%
Tractive force ............................................................................................................................................ 10,310 daN
(988 and 988 "Plus")
Travel speeds:
(single speed machine), max. speed ...........................................................................................from 0 to 3.3 kph
(two-speed machine), max. speed ........................................................................... First speed: from 0 to 3.3 kph
Second speed: from 0 to 5.5 kph
Gradeability ..........................................................................................................................................................77%
Tractive force ............................................................................................................................................ 13,500 daN

1002-12
WEIGHTS
Machine
(788 CK)
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.85 m
1.50 m 14 090 14 300 14 510 14 830
Monoblock 2.10 m 14 110 14 320 14 530 14 850
2.65 m 14 165 14 375 14 585 14 905
1.50 m 14 315 14 525 14 735 15 055
Adjustable 2.10 m 14 335 14 545 14 755 15 175
2.65 m 14 390 14 600 14 810 15 130
1.50 m 14 440 14 650 14 860 15 180
Backhoe offset 2.10 m 14 460 14 670 14 880 15 200
2.65 m 14 515 14 725 14 935 15 255
1.50 m 14 425 14 635 14 845 15 165
Articulated 2.10 m 14 445 14 655 14 865 15 185
2.65 m 14 500 14 710 14 920 15 240
NOTE: These values are given in kg, with 560 L backhoe bucket.
(788 CK "Plus")
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.85 m
1.50 m 14 490 14 720 14 945 15 280
Monoblock 2.10 m 14 505 14 730 14 955 15 295
2.65 m 14 560 14 785 15 010 15 350
1.50 m 14 725 14 950 15 175 15 515
Adjustable 2.10 m 14 740 14 965 15 190 15 525
2.65 m 14 795 15 020 15 245 15 580
1.50 m 14 855 15 080 15 305 15 640
Backhoe offset 2.10 m 14 865 15 090 15 320 15 655
2.65 m 14 920 15 145 15 375 15 710
1.50 m 14 825 15 050 15 275 15 615
Articulated 2.10 m 14 840 15 065 15 290 15 625
2.65 m 14 895 15 120 15 345 15 680
NOTE: These values are given in kg, with 560 L backhoe bucket

1002-13
(788 LC "Plus")
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.90 m
1.50 m 15 415 15 655 15 895 16 375
Monoblock 2.10 m 15 425 15 665 15 910 16 390
2.65 m 15 480 15 720 15 965 16 445
1.50 m 15 645 15 885 16 130 16 610
Adjustable 2.10 m 15 660 15 900 16 140 16 625
2.65 m 15 715 15 955 16 195 16 680
1.50 m 15 775 16 015 16 255 16 740
Backhoe offset 2.10 m 15 785 16 025 16 270 16 750
2.65 m 15 840 16 080 16 325 16 805
1.50 m 15 745 15 985 16 230 16 710
Articulated 2.10 m 15 760 16 000 16 240 16 725
2.65 m 15 815 16 055 16 295 16 780
NOTE: These values are given in kg, with 760 L backhoe bucket
(988 CK)
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.90 m
1.60 m 16 925 17 150 17 375 17 825
Monoblock 2.10 m 16 970 17 195 17 420 17 870
2.70 m 17 095 17 320 17 545 17 995
1.60 m 17 260 17 485 17 710 18 160
Adjustable 2.10 m 17 305 17 530 17 755 18 205
2.70 m 17 430 17 655 17 880 18 330
1.60 m 17 435 17 660 17 885 18 335
Backhoe offset
2.10 m 17 480 17 705 17 930 18 380
1.60 m 17 505 17 730 17 955 18 405
Articulated 2.10 m 17 550 17 775 18 000 18 450
2.70 m 17 675 17 900 18 125 18 575
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.90 m
Handling 4.50 m 17 025 17 250 17 475 17 925

1002-14
(988 CK "Plus")
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.90 m
1.60 m 17 490 17 715 17 940 18 390
2.10 m 17 535 17 760 17 985 18 435
Monoblock
2.70 m 17 655 17 880 18 105 18 560
3.10 m 17 690 17 915 18 140 18 595
1.60 m 17 955 18 180 18 405 18 860
Backhoe offset
2.10 m 18 000 18 225 18 450 18 905
1.60 m 18 080 18 305 18 530 18 985
2.10 m 18 130 18 355 18 580 19 030
Articulated
2.70 m 18 250 18 475 18 700 19 150
3.10 m 18 285 18 510 18 735 19 185
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m 0.90 m
Handling 4.50 m 17 025 17 250 17 475 17 925
(988 CKE "Plus")
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m
1.50 m 17 460 17 685 17 910
2.10 m 17 505 17 730 17 955
Monoblock 5.20 m
2.70 m 17 625 17 850 18 075
3.10 m 17 690 17 885 18 110
1.60 m 17 925 18 150 18 375
Backhoe offset
2.10 m 17 975 18 200 18 425
1.60 m 18 055 18 280 18 505
2.10 m 18 100 18 325 18 550
Articulated
2.70 m 18 220 18 445 18 670
3.10 m 18 255 18 480 18 705
Track pads
Boom Dipper
0.50 m 0.60 m 0.70 m
Handling 4.50 m 16 995 17 220 17 445

1002-15
Attachments
(788 and 788 "Plus")
Booms (with dipper cylinder)
One-piece................................................................................................................................................... 1035 kg
Adjustable .................................................................................................................................................. 1335 kg
Backhoe-offset ........................................................................................................................................... 1460 kg
Articulated .................................................................................................................................................. 1610 kg
Dipper (with yoke, connecting link and bucket cylinder)
1.50 m .......................................................................................................................................................... 545 kg
2.10 m .......................................................................................................................................................... 560 kg
2.65 m .......................................................................................................................................................... 615 kg
(988 and 988 "Plus")
One-piece................................................................................................................................................... 1375 kg
Adjustable .................................................................................................................................................. 1600 kg
Articulated .................................................................................................................................................. 1970 kg
Handling boom ............................................................................................................................................... 1350 kg
1.60 m .......................................................................................................................................................... 650 kg
2.10 m .......................................................................................................................................................... 735 kg
2.70 m .......................................................................................................................................................... 860 kg
3.10 m .......................................................................................................................................................... 895 kg
Handling dipper ................................................................................................................................................ 515 kg
Counterweight
(788) 2950 kg
(788 "Plus") 3150 kg
(988) 3550 kg
(988 "Plus") 3550 kg
Cab
295 kg

1002-16
788 AND 788 "PLUS" 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 (See "Density of various spoils and materials").
Earthmoving buckets
Width SAE heaped capacity Weight
0.60 m...........................................................................380 L .......................................................................... 390 kg
0.75 m...........................................................................505 L .......................................................................... 420 kg
0.85 m...........................................................................590 L .......................................................................... 445 kg
0.95 m...........................................................................675 L .......................................................................... 475 kg
1.05 m...........................................................................765 L .......................................................................... 520 kg
1.20 m...........................................................................900 L .......................................................................... 770 kg
All earthmoving buckets are equipped with teeth with removable tooth tips and pins with side play take-up system.
Heavy duty supplement optional (add 5% to the capacity shown).
Side cutters optional (add 8 cm to the width shown).
Trench buckets with ejector

0.35 m...........................................................................195 L .......................................................................... 375 kg
0.45 m...........................................................................270 L .......................................................................... 410 kg
Ditch cleaning buckets equipped with teeth

Width CECE heaped 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)

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
0.35 - 2.10 m ................................................................340 L .......................................................................... 330 kg
0.50 - 2.60 m ................................................................400 L .......................................................................... 395 kg
(1) Small profile
(2) Large profile

1002-17

Earthmoving buckets
0.60 m...........................................................................430 L .......................................................................... 450 kg
0.75 m...........................................................................570 L .......................................................................... 510 kg
0.85 m...........................................................................670 L .......................................................................... 535 kg
0.90 m...........................................................................710 L .......................................................................... 545 kg
1.00 m...........................................................................810 L .......................................................................... 575 kg
1.15 m...........................................................................960 L .......................................................................... 625 kg
1.30 m..........................................................................1100 L.......................................................................... 675 kg

0.35 m...........................................................................225 L .......................................................................... 465 kg
0.45 m...........................................................................315 L .......................................................................... 465 kg

Width CECE capacity Weight
2.20 m (1) .....................................................................310 L .......................................................................... 550 kg
2.40 m (1) .....................................................................340 L .......................................................................... 530 kg
1.80 m (2) .....................................................................800 L .......................................................................... 560 kg

2.40 m (1) .....................................................................340 L .......................................................................... 585 kg
1.80 m (2) .....................................................................800 L .......................................................................... 600 kg
V-shaped bucket
0.50 - 3.00 m ................................................................670 L .......................................................................... 615 kg
(1) Small profile
(2) Large profile

1002-18
788 AND 788 "PLUS" 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
0.79 m.................................................... 1.36 m .........................................250 L ............................................ 535 kg
0.96 m.................................................... 1.48 m .........................................400 L ............................................ 635 kg
Rehandling clamshells
0.97 m.................................................... 1.40 m .........................................400 L ............................................ 525 kg
1.08 m.................................................... 1.47 m .........................................550 L ............................................ 530 kg
1.22 m.................................................... 1.64 m .........................................800 L ............................................ 605 kg
Cylindrical boring clamshell

Opening diameter Capacity Weight
1.23 m...........................................................................175 L .......................................................................... 565 kg
Rectangular boring clamshells

0.43 m.................................................... 0.69 m ..........................................70 L ............................................. 430 kg
0.60 m.................................................... 1.11 m .........................................130 L ............................................ 465 kg
Sugar beet clamshell

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)

1.35 m............................................................................................................. ................................................. 600 kg
Timber grab
0.72 m.................................................... 2.30 m .................................... 0.1 - 0.9 m2 ....................................... 650 kg

1002-19

0.45 m.................................................... 1.57 m .........................................180 L ............................................ 670 kg
0.65 m.................................................... 1.57 m .........................................240 L ............................................ 740 kg
0.85 m.................................................... 1.57 m .........................................400 L ............................................ 760 kg
1.05 m.................................................... 1.57 m .........................................550 L ............................................ 810 kg
1.34 m.................................................... 1.60 m .........................................800 L ............................................ 850 kg
1.34 m.................................................... 1.77 m ........................................1000 L ........................................... 925 kg
Boring clamshell
1.20 m...........................................................................160 L .......................................................................... 770 kg

1.57 m.................................................... 2.50 m ........................................1750 L ......................................... 1240 kg
1.81 m.................................................... 2.50 m ........................................2050 L ......................................... 1305 kg

1.90 m............................................................................................................. ............................................... 1100 kg
1.90 m (1) ....................................................................................................... ............................................... 1200 kg
Scrap metal 5 tine grab

2.00 m............................................................................................................. ............................................... 1025 kg
Timber grab
0.70 m.................................................... 2.75 m ........................................ 1.2 m2 ......................................... 1050 kg

1002-20
MACHINE OVERALL DIMENSIONS

(788 and 788 "Plus")
CS95N446
(Type CK) (Type LC)

A (with 0.50 m track pads).................................................... .................................2.47 m ..............................2.65 m
A (with 0.85 m track pads).................................................... .................................2.92 m
B ........................................................................................... .................................1.97 m ..............................2.15 m
C ........................................................................................... .................................0.43 m ..............................0.45 m
D ........................................................................................... .................................2.94 m ..............................2.95 m
E ........................................................................................... .................................2.44 m ..............................2.44 m
F (radius) .............................................................................. .................................2.05 m ..............................2.05 m
G........................................................................................... .................................0.86 m ..............................0.87 m
H ........................................................................................... .................................0.96 m ..............................0.97 m
J............................................................................................ .................................2.49 m ..............................2.50 m
K ........................................................................................... .................................2.78 m ..............................3.03 m
L............................................................................................ .................................3.55 m ..............................3.82 m
M........................................................................................... .................................3.82 m ..............................3.96 m
N (steps lowered) ................................................................. .................................2.60 m ..............................2.78 m

1002-21
(988 and 988 "Plus")
PDH1162
Type CK Type CKE

B ........................................................................................... .................................2.15 m ..............................1.97 m
C ........................................................................................... .................................0.45 m ..............................0.45 m
D ........................................................................................... .................................2.98 m ..............................2.98 m
E ........................................................................................... .................................2.44 m ..............................2.44 m
F (radius) .............................................................................. .................................2.42 m ..............................2.42 m
G........................................................................................... .................................0.99 m ..............................0.99 m
H ........................................................................................... .................................2.42 m ..............................2.42 m
J............................................................................................ .................................3.03 m ..............................3.03 m
K ........................................................................................... .................................3.82 m ..............................3.82 m
L............................................................................................ .................................4.32 m ..............................4.32 m
M (steps lowered) ................................................................. .................................2.88 m ..............................2.70 m

1002-22
TRANSPORTATION OVERALL DIMENSIONS
PDH0256
NOTE: For top of cab to ground, see "Overall dimensions".

788 and 788 "Plus" 988 and 988 "Plus"
Boom Dipper A B Boom Dipper A B
1.50 m 2.50 7.70 1.60 m 2.95 9.45
Monoblock 2.10 m 2.70 7.55 2.10 m 3.05 9.10
Monoblock
2.65 m 3.00 7.50 2.70 m 3.35 9.00
1.50 m 2.65 7.75 3.10 m 3.60 8.90
Adjustable 2.10 m 2.75 7.65 1.60 m 3.00 9.05
Backhoe offset
2.65 m 2.95 7.65 2.10 m 3.15 8.70
1.50 m 2.50 7.70 1.60 m 3.15 9.20
Backhoe
2.10 m 2.70 7.55 2.10 m 3.15 8.85
offset Articulated
2.65 m 3.00 7.50 2.70 m 3.55 8.80
1.50 m 2.75 8.00 3.10 m 3.45 8.70
Articulated 2.10 m 2.85 7.85 Handling Handling 2.80 9.55
2.65 m 2.95 7.80
NOTE: These values are given in metres.

1002
Section
1002
SPECIFICATIONS
Wheeled excavators

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
Components made from plastic or resin ............................................................................................................... 5
GENERAL MACHINE SPECIFICATIONS................................................................................................................. 6
Engine .................................................................................................................................................................. 6
Hydraulic system ................................................................................................................................................... 8
Electrical system .................................................................................................................................................. 9
Upperstructure ..................................................................................................................................................... 9
Cab .......................................................................................................................................................................9
Operation ............................................................................................................................................................. 9
Undercarriage (depending on version) ...............................................................................................................10
Tyres ..................................................................................................................................................................10
Brakes ................................................................................................................................................................10
Safety devices ....................................................................................................................................................10
Indicators ............................................................................................................................................................10
Warning and indicator lamps ..............................................................................................................................10
Travel .................................................................................................................................................................11
Attachments .......................................................................................................................................................11
Noise level ..........................................................................................................................................................11
Vibration level in operators compartment ..........................................................................................................11
WEIGHTS................................................................................................................................................................12
Machine ..............................................................................................................................................................12
Attachments .......................................................................................................................................................14
Counterweight ....................................................................................................................................................14
Cab .....................................................................................................................................................................14
788 AND 788 "PLUS" BUCKETS ............................................................................................................................15
988 AND 988 "PLUS" BUCKETS ............................................................................................................................16
MACHINE OVERALL DIMENSIONS.......................................................................................................................19
P Version ............................................................................................................................................................19
PL Version ..........................................................................................................................................................20
P2A Version .......................................................................................................................................................21
P2AL Version .....................................................................................................................................................22
P2A+2A Version .................................................................................................................................................23
TRANSPORTATION OVERALL DIMENSIONS ......................................................................................................24
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.

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
-20C to +60C
Temperate climates
Extreme pressure grease EP NLGI grade 2 with molyb-
-20C to +40C denum disulphide.
CASE reference: POHYDR Cold climates
-40C to +20C
Hot climates
Extreme pressure grease EP NLGI grade 0.
0C to +60C
CASE reference: POHYDC
Cold climates
-40C to +20C
CASE reference: POHYPF
These various grades of fluid must be in conformity
with CASE France specification P9903201Z.
Temperate climate biodegradable fluid:
This yellow fluid is compatible with standard fluid. If
adopted, it is advisable to drain the circuit completely.
CASE reference: CASYNTH46
This grade of fluid must be in conformity with CASE
France specification P9903203B
Transmission component oil

Extreme pressure oil used for transmission compo-
nents inside sealed housings.
Extreme pressure oil TYPE API GL5 GRADE 80W90 or
ISO VG 150

1002-4
Engine oil
CASE engine oil N1 is recommended for your
engine. This oil ensures correct lubrication of your
engine in all working conditions.
If CASE N1 Multiperformance or Performance
engine oil is not available, use oil corresponding to
category API/CG/CF.
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) ARCTIC
(*) SHOWS THAT AN ENGINE OIL HEATER OR ENGINE COOLANT SOLUTION HEATER MUST BE USED.

1002-5
Fuel Environment
Use fuel which is to ASTM (American Society for Before carrying out any servicing operation on this
Testing and Materials) D975 standard. machine and before disposing of used fluids or lubri-
cants, always think of the environment. Never throw
Use Grade No N2 fuel. The use of other types of fuel
fluid or oil on the ground and never keep them in leak-
can result in a loss of power and may cause high fuel
ing receptacles.
consumption.
Consult your local ecological recycling centre to
In cold weather, the use of a mixture of fuels N1 and
obtain information on the appropriate means of dis-
N2 is temporarily permitted. Consult your fuel sup-
posing of these substances.
plier.
If the temperature falls below the fuel cloud point Components made from plastic or
(point at which wax begins to form) the wax crystals resin
will cause power loss or will prevent the engine from
starting. When cleaning polycarbonate windows, the console,
the instrument panel, the gauges, etc., do not use
IMPORTANT: In cold weather, fill the fuel tank at the petrol (gasoline), paraffin (kerosene), paint solvents,
end of the days work, in order to prevent the formation etc. Use only water, soap and a soft cloth.
of condensation.
The use of petrol (gasoline), de paraffin (kerosene),
Fuel storage paint solvents, etc, will cause discoloration, cracking
Long storage can lead to the accumulation of impuri- or deformation of these components.
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.
In environments with a temperature higher than
-36C, use a mixture of 50% ethylene-glycol based
anti-freeze.
For areas where the temperature is below -36C, it is
advisable to use a blend of 40% water and 60% anti-
freeze.

1002-6
GENERAL MACHINE SPECIFICATIONS

Engine
(788 and 788 "Plus")
788 788 "Plus"
Make and type ........................................................... CASE 4T 390............................ .......................CASE 4TA 390
4-stroke, 4-cylinder .............................................................. ..................... turbo-charged diesel
Cubic capacity ...................................................................... ...............................3920 cm3
Bore ...................................................................................... ................................102 mm
Stroke ................................................................................... ................................120 mm
Starting: 2 x 12 volt batteries, 24 V....................................... ................................ 120 A/h
Engine speed........................................................................ ...............................2000 rpm
Horsepower: SAE J1595......................................68.6 kW (93 hp).......................... ...................... 81 kW (100 hp)
DIN 70020 - DIN 6271 ..................... 65 kW (88 hp)........................... ...................... 76 kW (103 hp)
EEC 80/1269 - ISO 9249................. 65 kW (88 hp)........................... ...................... 76 kW (103 hp)
Specifications maintained up to an altitude of
3000 m at a temperature of 25C.
Capacities: Engine oil sump .......................................... ...................................10 L
Fuel tank..................................................... ..................................249 L
Electric fuel tank filler pump.................................................. ....................... optional equipment

1002-7
(988 and 988 "Plus")
988 988 "Plus"
Make and type ...................................................................... ........................... CASE 6T 590
Total SAE horsepower at 2800 rpm...................................... ........................126.4 kW (172 hp)
4 stroke, 6 cylinder ............................................................... ......................turbo-charged diesel
Capacity................................................................................ ...............................5880 cm3
Bore ...................................................................................... ................................102 mm
Stroke ................................................................................... ................................120 mm
Engine speed........................................................................ ...............................2000 rpm
Horsepower: SAE ................................................ 91 kW (124 hp).......................... ................... 92.5 kW (126 hp)
DIN 70020 - DIN 6271 .................... 86 kW (116 hp).......................... ...................... 90 kW (122 hp)
EEC 80/1269 - ISO 9249 ................ 86 kW (116 hp).......................... ...................... 90 kW (122 hp)
Specifications maintained up to an altitude of 3000 m at a temperature of 25C.
Capacities: Engine oil sump .......................................... ................................. 14.3 L
Fuel tank ..................................................... ..................................249 L
Electric fuel filler pump ........................................................ ....................... optional equipment

1002-8
Hydraulic system
Variable output system with independent and simultaneous operation of all functions.
Electronic regulation of hydraulic power ("Powersensor" system) for optimal use of engine power.
3 regulation modes:
"FINE": For jobs requiring high precision.
"ECO": For normal jobs.
"MAX": In this position, the operator has the full power of the machine at his disposal.
Engine automatically reverts to idle speed if the operator wishes.
(788 and 788 "Plus")
788 788 "Plus"
Capacity of hydraulic reservoir ............................................. .................................. 115 L
Total system capacity ....................................................... 184 L.................................. ...................................... 187 L
Double body pump:
Variable displacement body for travel and attachment functions.
Flow ...................................................................................... .............................. 210 L/min
Fixed displacement body for upperstructure swing function.
Flow ...................................................................................... .............................. 41.7 L/min
Installed hydraulic power ..........................................60 kW (81.5 hp).......................... ..................... 73.5 kW (97 hp)
(988 and 988 "Plus")
988 and 988 "Plus"
Working pressure ............................................................................................................................................350 bar
Capacity of hydraulic reservoir ........................................................................................................................... 180 L
Total system capacity ......................................................................................................................................... 288 L
Pumps:
One double-body variable displacement pump for supplying travel motors and attachments.
Flow ............................................................................................................................................................. 320 L/min
A fixed displacement pump for supplying the upperstructure swing function.
Flow ............................................................................................................................................................ 54.9 L/min
Installed hydraulic power ..................................................................................................................86.3 kW (117 hp)
(788, 788 "Plus", 988 and 988 "Plus")
Fixed pumps for pilot systems.
Parallel, closed centre type attachment and travel control valves.
Flow rates per function, independent of pressures.
Oil cooler with air cooling from engine.
Multispiral high pressure hoses with minimum safety factor of ............................. 2 to 4 times the working pressure
Self-lubricating hydraulic swivel.

1002-9
Electrical system
Circuit voltage circuit ............................................................................................................... 24 volt, negative earth
Batteries ..........................................................................................................two low-maintenance 12 volt 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 walkway giving access to the various components.
Sound-proofed, lockable cowling meeting all current regulations.
Tool box with tool set.
Swing
Hydraulic motor with reduction gear and automatic static brake.
788, 788 "Plus", 988 "Plus" 988
Rotational speed............................................................. 7.7 rpm................................ ...................................8.8 rpm
Turntable............................................................................... .......... Alternating rollers and internal teeth
Centralised bearing surface and tooth lubrication
Cab
Removable, sound-proofed, on flexible mounting blocks.
Tilting steering column.
Up and over windshield.
Tinted windshield.
Pre-fitted for radio installation.
Transparent roof hatch ................................................................................................................. optional equipment
Sliding door window...................................................................................................standard since November 1999
Polycarbonate windows................................................................................................................ optional equipment
Elevated cab................................................................................................................................available on request
Ant-vandal cab.............................................................................................................................. optional equipment
Operation
De-luxe seat with armrests and multi-position adjustment (vibration level III/ISO 7096).
Hydraulically assisted controls.
Attachment and swing ........................................................................................................................ 2 control 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 lights:
On upperstructure ...............................................................................................................................2 x 70/75 W
On attachment ............................................................................................................................................... 70 W
Front (on cab)................................................................................................................................................. 70 W
Rear (on cab) ................................................................................................................................................. 70 W
Air conditioning ............................................................................................................................. optional equipment
Cab sun-shield.............................................................................................................................. optional equipment
Cab blower ................................................................................................................................... optional equipment

1002-10
Undercarriage (depending on version)

Modular load design which enables a dozer blade or two stabilizers to be installed at the front.
Stabilizers with articulated pads which can be locked for uneven ground.
Oscillating front axle ....................................................................................................................................... + 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 boxes.
Tyres
4 wheels 18-19.5XF
8 wheels 10.00-20 (with dual wheel spacer)
Brakes
Single-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.
Safety valves ................................................................................................................................ optional equipment
Overload indicator ........................................................................................................................ optional equipment
Roller type seat belt...................................................................................................................... optional equipment
Fire extinguisher ........................................................................................................................... optional equipment
Rotary light ...................................................................................................................... special for 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.

1002-11
Travel
Hydro-mechanical transmission with variable displacement hydraulic motor and range selector providing
infinite speed variation ....................................................................................from 0 to 7.5 kph (work-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.
788 788 "Plus" 988 988 "Plus"
Gradeability (continuous).................................................. 40% .................38% ..................43% .......................49%
Outer turning radius......................................................... 6.18 m ..............6.50 m ..............6.44 m .................7.28 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.
Bucket linkage with side-play compensation system (988 Series only).
Noise level
Certified by the manufacturer.
In accordance with European directive 86/662/EEC.
788 788 "Plus" 988 988 "Plus"
Inside operators compartment (LpA) ................................. 79 ..................... 76..................... 81..............78 decibels
Outside machine (LwA) ..................................................... 105................... 103................... 108...........103 decibels
Vibration level in operators compartment

Upper members....................................................................................................................level lower than 2.5 m/s2
Body .....................................................................................................................................level lower than 0.5 m/s2

1002-12
WEIGHTS
Machine
788
Versions
Boom Dipper
P PL P2A P2AL P2A+2A
1.50 m 13240 13855 14470 15085 15700
Monoblock 2.10 m 13255 13870 14485 15100 15715
2.65 m 13310 13925 14540 15155 15770
1.50 m 13465 14080 14695 15310 15925
Adjustable 2.10 m 13480 14095 14710 15325 15940
2.65 m 13535 14150 14765 15380 15995
1.50 m 13590 14205 14820 15435 16050
Backhoe offset 2.10 m 13605 14220 14835 15540 16065
2.65 m 13660 14275 14890 15505 16120
1.50 m 13575 14190 14805 15420 16035
Articulated 2.10 m 13590 14205 14820 15435 16050
2.65 m 13645 14260 14875 15490 16105
NOTE: Loads shown are in kg for machine in 4 wheel configuration 18-19.5XF with 560 L backhoe bucket (for
8 wheel configuration 10.00-20: add 355 kg).
788 "Plus"
Versions
Boom Dipper
1.50 m 13 575 14 240 14 830 15 490 16 080
Monoblock 2.10 m 13 590 14 250 14 840 15 505 16 090
2.65 m 13 645 14 305 14 895 15 560 16 145
1.50 m 13 810 14 470 15 060 15 725 16 310
Adjustable 2.10 m 13 825 14 485 15 075 15 735 16 325
2.65 m 13 880 14 540 15 130 15 790 16 380
1.50 m 13 940 14 600 15 190 15 850 16 440
Backhoe offset 2.10 m 13 950 14 615 15 200 15 865 16 455
2.65 m 14 005 14 670 15 265 15 920 16 510
1.50 m 13 910 14 570 15 160 15 825 16 410
Articulated
2.10 m 13 925 14 585 15 175 15 835 16 425

1002-13
Machine weight (continued)
988
Versions
Boom Dipper
1.60 m 14925 15535 16230 16845 17540
Monoblock 2.10 m 14970 15580 16275 16890 17585
2.70 m 15095 15705 16400 17015 17710
1.60 m 15260 15870 16565 17180 17875
Adjustable 2.10 m 15305 15915 16610 17225 17920
2.70 m 15430 16040 16735 17350 18045
1.60 m 15435 16045 16740 17355 18050
Backhoe offset
2.10 m 15480 16090 16875 17400 18095
1.60 m 15505 16115 16810 17425 18120
Articulated 2.10 m 15550 16160 16855 17470 18165
2.70 m 15675 16285 16980 17595 18290
988 "Plus"
Versions
Boom Dipper
1.60 m 15 155 15 815 16 505 17 170 17 860
2.10 m 15 200 15 860 16 550 17 215 17 905
Monoblock
2.70 m 15 320 15 985 16 675 17 335 18 025
3.10 m 15 355 16 020 16 710 17 370 18 060
1.60 m 15 620 16 285 16 975 17 635 18 325
Backhoe offset
2.10 m 15 670 16 330 17 020 17 680 18 370
1.60 m 15 750 16 410 17 100 17 760 18 450
2.10 m 15 795 16 455 17 145 17 810 18 500
Articulated
2.70 m 15 915 16 580 17 270 17 930 18 620
3.10 m 15 950 16 615 17 305 17 965 18 655
NOTE: Loads shown are in kg for machine in 4 wheel configuration 18-19.5XF with 760 L (575 kg) backhoe bucket
(for 8 wheel configuration 10.00-20: add 400 kg).
988 "Plus"
Versions
Boom Dipper
Handling 4.50 m 14 640 15 300 15 990 16 650 17 340
NOTE: Loads shown are in kg for machine in 4 wheel configuration 18-19.5XF (for 8 wheel configuration 10.00-20:
add 400 kg).

1002-14
Attachments
788 and 788 "Plus"
Monoblock.................................................................................................................................................. 1035 kg
Adjustable .................................................................................................................................................. 1335 kg
Articulated .................................................................................................................................................. 1610 kg
1.50 m .......................................................................................................................................................... 545 kg
2.10 m .......................................................................................................................................................... 560 kg
2.65 m .......................................................................................................................................................... 615 kg
988 and 988 "Plus"
Monoblock.................................................................................................................................................. 1375 kg
Adjustable .................................................................................................................................................. 1600 kg
Articulated .................................................................................................................................................. 1970 kg
Handling boom ............................................................................................................................................... 1530 kg
1.60 m .......................................................................................................................................................... 690 kg
2.10 m .......................................................................................................................................................... 735 kg
2.70 m .......................................................................................................................................................... 860 kg
3.10 m .......................................................................................................................................................... 895 kg
Handling dipper (with standard universal joint)................................................................................................. 655 kg
Counterweight
(788) 2900 kg
(788 "Plus") 3150 kg
(988) 3150 kg
(988 "Plus") 3550 kg
Cab
295 kg

1002-15

addition to the compactness and structure of the ground.
Earthmoving buckets
0.60 m...........................................................................380 L .......................................................................... 390 kg
0.75 m...........................................................................505 L .......................................................................... 420 kg
0.85 m...........................................................................590 L .......................................................................... 445 kg
0.95 m...........................................................................675 L .......................................................................... 475 kg
1.05 m...........................................................................765 L .......................................................................... 520 kg
1.20 m...........................................................................900 L .......................................................................... 600 kg
All earthmoving buckets are equipped with teeth with removable tooth tips.

0.35 m...........................................................................195 L .......................................................................... 375 kg
0.45 m...........................................................................270 L .......................................................................... 410 kg

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

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
0.35 - 2.10 m ................................................................340 L .......................................................................... 330 kg
0.50 - 2.60 m ................................................................400 L .......................................................................... 395 kg
(1) Small profile
(2) Large profile

1002-16

Earthmoving buckets
0.60 m...........................................................................430 L .......................................................................... 450 kg
0.75 m...........................................................................570 L .......................................................................... 510 kg
0.85 m...........................................................................670 L .......................................................................... 535 kg
0.90 m...........................................................................710 L .......................................................................... 545 kg
1.00 m...........................................................................810 L .......................................................................... 575 kg
1.15 m...........................................................................960 L .......................................................................... 625 kg
1.30 m..........................................................................1100 L ......................................................................... 675 kg

0.35 m...........................................................................225 L .......................................................................... 465 kg
0.45 m...........................................................................315 L .......................................................................... 465 kg

2.20 m (1) .....................................................................310 L .......................................................................... 550 kg
2.40 m (1) .....................................................................340 L .......................................................................... 530 kg
1.80 m (2) .....................................................................800 L .......................................................................... 560 kg

2.40 m (1) .....................................................................340 L .......................................................................... 585 kg
1.80 m (2) .....................................................................800 L .......................................................................... 600 kg
V-shaped bucket
0.50 - 3.00 m ................................................................670 L .......................................................................... 615 kg
(1) Small profile
(2) Large profile

1002-17

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
0.79 m.................................................... 1.36 m .........................................250 L ............................................ 535 kg
0.96 m.................................................... 1.48 m .........................................400 L ............................................ 635 kg
0.97 m.................................................... 1.40 m .........................................400 L ............................................ 525 kg
1.08 m.................................................... 1.47 m .........................................550 L ............................................ 530 kg
1.22 m.................................................... 1.64 m .........................................800 L ............................................ 605 kg
Cylindrical boring clamshell

1.23 m...........................................................................175 L .......................................................................... 565 kg
Rectangular boring clamshells

0.43 m.................................................... 0.69 m ..........................................70 L ............................................. 430 kg
0.60 m.................................................... 1.11 m .........................................130 L ............................................ 465 kg

1.33 m.................................................... 2.50 m ........................................1450 L ......................................... 1100 kg

Opening diameter .............................................................................................................................................Weight
1.55 m............................................................................................................................................................... 820 kg
1.56 m (1) ......................................................................................................................................................... 940 kg
5-tine scrap grab (tines controlled by central cylinder)

1.35 m............................................................................................................................................................... 600 kg
Timber grab
0.72 m.................................................... 2.30 m .................................... 0.1 - 0.9 m2 ....................................... 650 kg

1002-18

0.45 m.................................................... 1.57 m .........................................180 L ............................................ 670 kg
0.65 m.................................................... 1.57 m .........................................240 L ............................................ 740 kg
0.85 m.................................................... 1.57 m .........................................400 L ............................................ 760 kg
1.05 m.................................................... 1.57 m .........................................550 L ............................................ 810 kg
1.34 m.................................................... 1.60 m .........................................800 L ............................................ 850 kg
1.34 m.................................................... 1.77 m ........................................ 1000 L ........................................... 925 kg
Boring clamshell
1.20 m...........................................................................160 L .......................................................................... 770 kg

1.57 m.................................................... 2.50 m ........................................ 1750 L ......................................... 1240 kg
1.81 m.................................................... 2.50 m ........................................ 2050 L ......................................... 1305 kg

1.90 m............................................................................................................................................................. 1100 kg
1.90 m (1) ....................................................................................................................................................... 1200 kg
Scrap metal 5 tine grab

2.00 m............................................................................................................................................................. 1025 kg
Timber grab
0.70 m.................................................... 2.75 m ........................................ 1.2 m2 ......................................... 1050 kg

1002-19
MACHINE OVERALL DIMENSIONS

P Version
A E
B
F
C H
D J
K
L
CS95N242
788 788 "Plus" 988 988 "Plus"

A ...................................................................................... 2.44 m ..............2.44 m ..............2.44 m .................2.44 m
B ...................................................................................... 3.23 m ..............3.23 m ..............3.24 m .................3.25 m
C ...................................................................................... 0.34 m ..............0.34 m ..............0.33 m .................0.33 m
D ...................................................................................... 2.47 m ..............2.47 m ..............2.46 m .................2.46 m
E (radius) ......................................................................... 2.05 m ..............2.08 m ..............2.40 m .................2.45 m
F ...................................................................................... 2.67 m ..............2.79 m ..............2.66 m .................2.68 m
G...................................................................................... 1.26 m ..............1.26 m ..............1.47 m .................1.26 m
H ...................................................................................... 0.95 m ..............0.95 m ..............1.03 m .................1.13 m
J....................................................................................... 2.30 m ..............2.30 m ..............2.50 m .................2.60 m
K ...................................................................................... 4.01 m ..............4.04 m ..............4.48 m .................4.53 m
L....................................................................................... 3.53 m ..............3.55 m ..............3.96 m .................4.09 m

1002-20
PL Version
A E
B
F
G
H
C K
D L M J
N
P
CS95N243
788 788 "Plus" 988 988 "Plus"

A ...................................................................................... 2.44 m .............. 2.44 m ..............2.44 m .................2.44 m
B ...................................................................................... 3.23 m .............. 3.23 m ..............3.24 m .................3.25 m
C ...................................................................................... 0.34 m .............. 0.34 m ..............0.33 m .................0.33 m
D ...................................................................................... 2.48 m .............. 2.48 m ..............2.48 m .................2.46 m
E (radius) ......................................................................... 2.05 m .............. 2.08 m ..............2.40 m .................2.45 m
F ...................................................................................... 2.67 m .............. 2.79 m ..............2.66 m .................2.68 m
G...................................................................................... 1.26 m .............. 1.26 m ..............1.47 m .................1.26 m
H ...................................................................................... 0.59 m .............. 0.59 m ..............0.59 m .................0.49 m
J....................................................................................... 0.18 m .............. 0.18 m ..............0.18 m .................0.18 m
K ...................................................................................... 0.95 m .............. 0.95 m ..............1.03 m .................1.13 m
L....................................................................................... 2.30 m .............. 2.30 m .............. 2.50m..................2.60 m
M...................................................................................... 1.15 m .............. 1.15 m ..............1.15 m .................1.23 m
N ...................................................................................... 4.06 m .............. 4.14 m ..............4.48 m .................4.53 m
P ...................................................................................... 4.15 m .............. 4.26 m ..............4.58 m .................4.81 m

1002-21
P2A Version
A F
B G
C J
D K L
E M
N
CS95N244
788 788 "Plus" 988 988 "Plus"

A ...................................................................................... 2.44 m ..............2.44 m ..............2.44 m .................2.44 m
B ...................................................................................... 3.23 m ..............3.23 m ..............3.24 m .................3.25 m
C ...................................................................................... 0.34 m ..............0.34 m ..............0.33 m .................0.33 m
D ...................................................................................... 2.49 m ..............2.49 m ..............2.49 m .................2.49 m
E ...................................................................................... 3.70 m ..............3.71 m ..............3.70 m .................3.71 m
F (radius) ......................................................................... 2.05 m ..............2.08 m ..............2.40 m .................2.45 m
G...................................................................................... 2.67 m ..............2.79 m ..............2.66 m .................2.68 m
H ...................................................................................... 1.26 m ..............1.26 m ..............1.47 m .................1.26 m
J....................................................................................... 0.95 m ..............0.95 m ..............1.03 m .................1.13 m
K ...................................................................................... 2.30 m ..............2.30 m ..............2.50 m .................2.60 m
L....................................................................................... 1.07 m ..............1.07 m ..............1.07 m .................1.07 m
M...................................................................................... 4.01 m ..............4.04 m ..............4.48 m .................4.53 m
N ...................................................................................... 4.07 m ..............4.10 m ..............4.50 m .................4.65 m

1002-22
P2AL Version
A F
B
G
P
H
C J
Q
D K L
E M
N
CS95N245
788 788 "Plus" 988 988 "Plus"

A ...................................................................................... 2.44 m .............. 2.44 m ..............2.44 m .................2.44 m
B ...................................................................................... 3.23 m .............. 3.23 m ..............3.24 m .................3.25 m
C ...................................................................................... 0.34 m .............. 0.34 m ..............0.33 m .................0.33 m
D ...................................................................................... 2.49 m .............. 2.49 m ..............2.49 m .................2.49 m
E ...................................................................................... 3.70 m .............. 3.71 m ..............3.70 m .................3.71 m
F (radius) ......................................................................... 2.05 m .............. 2.08 m ..............2.40 m .................2.45 m
G...................................................................................... 2.67 m .............. 2.79 m ..............2.66 m .................2.68 m
H ...................................................................................... 1.26 m .............. 1.26 m ..............1.47 m .................1.26 m
J....................................................................................... 0.95 m .............. 0.95 m ..............1.03 m .................1.13 m
K ...................................................................................... 2.30 m .............. 2.30 m ..............2.50 m .................2.60 m
L....................................................................................... 1.07 m .............. 1.07 m ..............1.07 m .................1.07 m
M...................................................................................... 4.63 m .............. 4.70 m ..............4.83 m .................5.00 m
N ...................................................................................... 4.65 m .............. 4.76 m ..............5.12 m .................5.25 m
P ...................................................................................... 0.59 m .............. 0.52 m ..............0.59 m .................0.49 m
Q...................................................................................... 0.18 m .............. 0.18 m ..............0.18 m .................0.18 m

1002-23
P2A+2A Version
A F
B
G
C J
D K N
E L
M
CS95N246
788 788 "Plus" 988 988 "Plus"

A ...................................................................................... 2.44 m ..............2.44 m ..............2.44 m .................2.44 m
B ...................................................................................... 3.23 m ..............3.23 m ..............3.24 m .................3.25 m
C ...................................................................................... 0.34 m ..............0.34 m ..............0.33 m .................0.33 m
D ...................................................................................... 2.49 m ..............2.49 m ..............2.49 m .................2.49 m
E ...................................................................................... 3.70 m ..............3.71 m ..............3.70 m .................3.71 m
F (radius) ......................................................................... 2.05 m ..............2.08 m ..............2.40 m .................2.45 m
G...................................................................................... 2.67 m ..............2.79 m ..............2.66 m .................2.68 m
H ...................................................................................... 1.26 m ..............1.26 m ..............1.47 m .................1.26 m
J....................................................................................... 0.95 m ..............0.95 m ..............1.03 m .................1.13 m
K ...................................................................................... 2.30 m ..............2.30 m ..............2.50 m .................2.60 m
L....................................................................................... 4.55 m ..............4.55 m ..............4.75 m .................4.85 m
M...................................................................................... 4.57 m ..............4.60 m ..............5.05 m .................5.09 m
N ...................................................................................... 1.07 m ..............1.07 m ..............1.07 m .................1.07 m

1002-24
TRANSPORTATION OVERALL DIMENSIONS
B
PDH0126
NOTE: For top of cab to ground, see "Overall dimensions".
788
P - PL and P2A Versions P2AL and P2A+2A Versions
1.50 m 2.85 7.85 1.50 m 2.85 7.85
Monoblock 2.10 m 2.85 7.65 Monoblock 2.10 m 3.10 7.60
2.65 m 3.10 7.65 2.65 m 3.25 7.55
1.50 m 3.45 7.05 1.50 m 3.60 6.90
Adjustable 2.10 m 3.70 6.75 Adjustable 2.10 m 3.80 6.85
2.65 m 3.85 6.65 2.65 m 3.90 6.50
1.50 m 2.90 7.85 1.50 m 2.90 7.85
Backhoe Backhoe
2.10 m 3.00 7.70 2.10 m 3.10 7.65
offset offset
2.65 m 3.15 7.65 2.65 m 3.45 7.55
1.50 m 3.05 7.80 1.50 m 3.05 7.80
Articulated 2.10 m 3.10 7.60 Articulated 2.10 m 3.10 7.65
2.65 m 3.65 7.70 2.65 m 3.30 7.55
NOTE: These values are given in metres.

1002-25
788 "Plus"
P - PL and P2A Versions P2A+2A Version
1.50 m 2.65 7.60 1.50 m 2.70 7.65
Monoblock 2.10 m 2.80 7.55 Monoblock 2.10 m 3.00 7.50
2.65 m 3.10 7.55 2.65 m 3.35 7.40

1.50 m 3.50 6.85
1.50 m 3.30 6.85
Adjustable
Adjustable 2.10 m 3.70 6.60
2.10 m 3.60 6.60 (retracted)
(retracted) 2.65 m 3.95 6.40
2.65 m 3.80 6.45
1.50 m 2.80 7.70
1.50 m 2.65 7.65
Backhoe offset 2.10 m 2.95 7.50
Backhoe
2.10 m 2.75 7.55
offset 2.65 m 3.35 7.40
2.65 m 3.00 7.55 1.50 m 4.25 6.10
1.50 m 4.25 6.20 Articulated
2.10 m 4.15 6.05
(retracted)
Articulated
2.10 m 4.20 6.00 2.65 m 4.00 6.30
(retracted)
2.65 m 4.00 6.30 NOTE: These values are given in metres.
P2AL Version
Boom Dipper A B
1.50 m 2.75 7.70
Monoblock 2.10 m 3.05 7.45
2.65 m 3.40 7.35
1.50 m 3.50 6.80
Adjustable
2.10 m 3.75 6.65
(retracted)
2.65 m 3.95 6.45
1.50 m 2.80 7.70
Backhoe offset 2.10 m 3.00 7.45
2.65 m 3.45 7.35
1.50 m 4.25 6.10
Articulated
2.10 m 4.15 6.10
(retracted)
2.65 m 4.00 6.30

1002-26
988 988 Plus

P - PL and P2A Versions P - PL and P2A Versions
1.60 m 3.10 8.90 1.60 m 3.05 9.45
Monoblock 2.10 m 3.00 8.60 2.10 m 3.10 9.05
Monoblock
2.70 m 3.30 8.70 2.70 m 3.40 9.05
1.60 m 3.90 7.00 3.10 m 3.65 9.00
Adjustable 2.10 m 3.95 6.85 Backhoe off- 1.60 m 3.10 9.05
2.70 m 4.00 6.50 set 2.10 m 3.15 8.65
Backhoe 1.60 m 3.20 9.00 1.60 m 3.35 9.20
offset 2.10 m 3.30 8.70 Articulated 2.10 m 3.30 8.80
1.60 m 3.35 8.70 (retracted) 2.70 m 3.40 8.85
Articulated 2.10 m 3.35 8.50 3.10 m 3.50 8.80
2.70 m 3.45 8.50 Handling 4.50 m 2.60 9.60
P2AL and P2A+2A Versions P2A+2A Version
1.60 m 3.10 8.90 1.60 m 3.05 9.45
Monoblock 2.10 m 3.00 8.60 2.10 m 3.10 9.05
Monoblock
2.70 m 3.50 8.60 2.70 m 3.40 9.05
1.60 m 3.90 6.70 3.10 m 3.65 8.95
Adjustable 2.10 m 4.00 6.65 Backhoe 1.60 m 3.10 9.05
2.70 m 4.20 6.70 offset 2.10 m 3.65 8.95
Backhoe 1.60 m 3.20 9.00 1.60 m 3.35 9.20
offset 2.10 m 3.30 8.70 2.10 m 3.30 8.80
Articulated
1.60 m 3.35 8.70 (retracted) 2.70 m 3.50 8.80
Articulated 2.10 m 3.35 8.50 3.10 m 3.80 8.65
2.70 m 3.50 8.45 Handling 4.50 m 2.60 9.60
NOTE: These values are given in metres. P2AL Version
Boom Dipper A B
1.60 m 3.05 9.45
2.10 m 3.10 9.05
Monoblock
2.70 m 3.40 9.05
3.10 m 3.75 8.90
Backhoe 1.60 m 3.10 9.05
offset 2.10 m 3.75 8.90
1.60 m 3.35 9.20
Articulated 2.10 m 3.30 8.80
(retracted) 2.70 m 3.55 8.75
3.10 m 3.85 8.60
Handling 4.50 m 2.60 9.60

4001
Section
4001
ELECTRICAL SCHEMATICS
788/988 Crawler Excavators

Printed in U.K.
Case Cre 7-80040GB June 1996
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 EQUIPMENT) ............................................. 4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL EQUIPMENT) .............................. 6
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL EQUIPMENT) ............................................... 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 EQUIPMENT) ............................................................................................................................... 15
ELECTRICAL SCHEMATIC (PLATE 2) ................................................................................................................ 16
CAB FLOOR WIRING (STANDARD EQUIPMENT).............................................................................................. 29
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD EQUIPMENT) ........................................ 29
ELECTRONIC SYSTEM WIRING ......................................................................................................................... 30
ELECTRONIC SYSTEM WIRING ......................................................................................................................... 31
CAB FLOOR WIRING (OPTIONAL EQUIPMENT) ............................................................................................... 33
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL EQUIPMENT) .......................................... 33
CAB AND CAB OPTIONAL EQUIPMENT WIRING .............................................................................................. 34
INDEX.................................................................................................................................................................... 35
SPECIFICATIONS
System voltage ..........................................................................24 Volts negative earth and 12 Volts negative earth
Batteries .......................................................................................2 x 12 Volt 120 A/hour low maintenance batteries
Alternator ........................................................................................................................ BOSCH, 28 Volts, 45 Amps
Starter motor...................................................................................................................... BOSCH, 24 Volts, 4.0 kW
Cre 7-80040GB Issued 06-96 Printed in U.K.

4001-3
SCHEMATIC SYMBOLS Local earth
A (n) Radio/housings
B (n) Indicators/pressure switches/loudspeakers/pressostats/senders/heat sender/gauge Wire number
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators Closed circuit
H (n) Warning devices (visible and audible)
K (n) Relays
M (n) Motors 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
NOTE : The (n) shows the component number.
Example : K2 is relay N2. 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 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 red paint marking.
1
4
Cre7-80040GB Issued 06-96 Printed in U.K.

4001-4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD EQUIP-
EQUIPMENT) MENT)
2 4 terminal bar
5 37 V12 7 1 Harness 10-way connector, floor harness

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
10A
F1 30A
F13 5A
F16
43 1 1
F23 5A F24
20 Harness, 6-way connector, cab power connection
5A 5A
k2 k1 F17
V5
V6
k5 5A
F12
26 Harness, 6-way connector, windshield wiper (K20 intermittent action)
38 3 F22 F18
1
AA
10A
S4
5A 5A S2 27 Harness, 2-way connector, windshield washer
k9
3 F33
V11 30 Harness, 6-way connector, electronic control box
7,5A
AAA
5 2
F7 F32 F30 F26 F15
31
4
V2 31 Harness, 3-way connector, troubleshooting test socket
10A 10A 15A 7,5A 15A
AAA K 53 F6
AAA
15A 44 k4
F8 F2 V18
15A 5A 30
1 Harness, 8-way connector, common harness
AAA
V1 V16
4 3
F5 4 Harness, 8-way connector, engine
10A 23
F31
15A
F4
5A
F3 F10 F11
7,5A 15A 7,5A
F27
5A
AA
AA 1
S7 V17 V19
V21
k6
k7
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
4 N 2 27
1 2 3 4 5 20 30
N 3
26
2
F14 5A
AA 2
6 7 9 11 12 14 16 28 42 8 V4
PDH0231
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 K4 Electrical control box supply relay
F3 7.5A Fuse, instrument panel K5 Horn relay
F4 5A Fuse, driving position lighting, horn relay K6 Upperstructure and attachment working light
F6 15A Fuse, upperstructure working lights relay
F7 10A Fuse, horn K20 Windshield wiper intermittent action
F8 15A Fuse, upperstructure power point K21 LH control arm pilot safety relay
F9 10A Fuse, windshield washer, windshield wiper K53 Fuel heater relay
F10 15A Fuse, ventilation, heater, Fuel heater Sh2, Sh3, Sh4 Shunt
F11 7.5A Fuse, cigar lighter Sh1, Sh5, Sh6, Sh7, Sh8 Not used
F12 10A Fuse, pilot safety V1 General contact diode
F15 F16 Not used 2 Starter connection
F31 15A Fuse, windshield wiper intermittent action 4 Printed circuit earth
F32 10A Fuse, not used 5 Upperstructure power line connection
F33 7.5A Fuse, supply to electronic control box
1 Electronic control box supply wire
H14 Diagnostic LED

4001-5
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
200 201
234
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 31
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 k1
V23
5 F20 5A F21 5A
24 21
AA
AAA
F25 V9 5
7,5A
AAA
144 0 141 F9
9
K 20 40 136 142 10A
43 1
AAA
F13 5A 1
F1 30A F16 F23 5A F24
5A V6 5A
AAA
AA AAA AAA
AAA AAAA
k2 k1 V5
F17
k5 5A
AAA AAAA
F12 1 2 3 4 5 6 7 8
38 3 F22 F18
3 2
26
10A
5A 5A S2
S
A
4 k9
V11
3 F33 29 31 167 147
7,5A
5 2 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
4 3
10A
23
A AAAA
14 k7
33 33
AAAA
K 53 S7 V17 V19 k6
1 V21
F31 F4 F3 F10 F11 F27
6
3 2 5 1 15A 5A 7,5A 15A 7,5A 5A N 1
S5 S6 S3 6
7 1 1 1 1 1 1 1 1 1 1 2 2 4 8 k3
1 2 3 4 5 7 9 9 9 9 2 8 2
V22 k2
0 0 14 14 20 1
4 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
1 2 3 4 5 6
A 1 2 3 4 5 6 7 8
A 5
1 2
AA 1 2 3 4 5 6 7 8
A 2
229 224 234 0 0 70 16 137 36 0 40 18 14 11 4

18 200 201 55 33 19 15
138 14 23 13
0
0 33
AA
AA 8
AAA
AAA 27
30 AAAAAAA
AAAAAAA 1 AAAAAAAA
AAAAAAAA 4
PDH0232

4001-6
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL ELECTRICAL CABINET PRINTED CIRCUIT WIRING (OPTIONAL EQUIP-
EQUIPMENT) MENT)
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 Bars (specific to certain countries)
4 Harness quick-attach control
5 37 V12 7
10 33
39 40
5 Harness quick-attach control switch
V8 F19
S8
K 20
V20 V7 V10 5A
Cable adjustable boom raising height limiter (to terminal N3)
35 36 2 V3
V13 K50
6 16
k15
24 21
V23
F20 5A F21 5A
6 Harness, adjustable boom, (specific for Germany)
F25
7,5A
V9 5 7 Harness, hood lighting (optional)
9
F13 5A
F9
10A
43 1 1
9 Harness, cold start assistance (optional)
F1 30A F16 F23 5A F24
k2 k1
5A
F17
V5
V6 5A
10 Harness, adjustable boom, (specific for Germany)
k5 5A
F12
38 3 F22 F18
12 Harness, fuel heating device (optional)
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
5 2
F7
10A
F32
10A
F30
15A
F26
7,5A
F15
15A
4
V2
22 Harness, cold start assistance glow plug (optional)
K51 F6
15A 44 k4 23 Harness, cold start assistance heating element (optional)
F8 F2 V18
V1
15A 5A
V16
30
24 Harness, cab front working lights and rear working light (optional)
3
K53
F5
4
33 Harness, overload indicator (optional)
10A
23
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 4 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 LED (optional)

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

4001-7
23
5 37 V12 7
1 2 10 33
K53
39 40
V8 F19
S8
V10 5A 3 2 5 1
V20 V7
123 119 35 36 V3
2
V13
k15 6 16
V23
F20 5A F21 5A 41 41
24 21
F25 V9 5
7,5A
9 F9
10A
23 F13 5A
F16
43 1 1
F24
F1 30A F23 5A
5A V6 5A
V5
k2 k1 F17
k5 5A
K51 K50
F12
38 3 F22 F18
10A
S4 5A 5A S2 85 86 30 87A 87 85 86 30 87A 87
k9
V11
a3 F33
7,5A
5 2 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
123 119
3 S7 V17 V19
k7
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
4 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
0
0 26
4 5
41 0
59
12 10 33 24 7 6 16 22
CM95F047.PCT

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 Electronic control box 24 volt supply and troubleshooting test socket 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, working lights and rotary light relay (specific to certain countries) V5 Diode, Not used
F6 15A Fuse, uperstructure working lights V6 Diode, Not used
F7 10A Fuse, horn V7 Diode, Not used
F8 15A Fuse, upperstructure power point V8 Diode, Not used
F9 10A Fuse, windshield wiper, windshield washer V9 Diode, Not used
F10 15A Fuse, ventilation, heater, fuel oil heating V10 Diode, Not used
F11 7.5A Fuse, cigarette lighter V11 Diode, Not used
F12 10A Fuse, pilot safety V16, V17, V18, V19 Diode, Not used
F13 5 A Fuse, overload indicator (optional) V20 Diode, Not used
F14 5A Fuse, radio (optional) V21 Overload indicator diode (optional)
F15 Not used V22 Rotary light diode (specific to certain countries)
F16 Not used V23Diode, Not used
F17 Not used
F18 Not used 2 Starter connection
F19 Not used 4 Printed circuit earth
F20 Not used 5 Upperstructure power line connection
F21 Not used
F22 Not used
F23 Not used : see page 4
F24 Not used
F25 Not used
F26 Not used
F27 5A Fuse, adjustable and articulated boom (optional)
F30 15A Fuse, cab working lights (optional)
F31 15A Fuse, Windshield wiper intermittent action
F32 10A Fuse, Not used
F33 7.5A Fuse, electronic control box
H14 Diagnostic LED
K1 Starter motor
K2 24V, 50A General contact relay
K3 Hourmeter relay
K4 Electrical control box supply relay
K5 Horn relay
K6 Working light relay
K7 Not used
K9 Not used
K10 Not used
K20 Windshield wiper intermittent action
K21 Left-hand control arm pilot safety relay
K52 Not used

4001-9
F9
CM95F016.PCT

4001-10
P10 INSTRUMENT PANEL ELECTRICAL SCHEMATIC (PLATE 1)
AAA A AAA
B3 B5 C4 C6 F2
A AAAAAAA
A4 C2 D3 A7 A2
AA B1
AA
+
AA
AA

+
A AAAAAAAA
(30s)
8 7 9 6 11
AA AAAA AAA
AAA
13 12 14 15
(2s)
AA AAA
AAA A5 AA AA
AA
AAA
AA
A
2 1
A 3
AAA A AA
AAA
AA
AAAAAAAAA
AA
AAA
+ P2
AA
AAAAAAAA + P1
AA A
AAAA
+ P3
AAA A
B4 B7 B6 A3
A PDH0233
A2 Minimum pilot pressure red warning lamp connector 1 Stop alarm red warning lamp
A3 Hydraulic oil temperature indicator connector 2 Alarm orange warning 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 Volt supply
9 Hydraulic oil filters restriction red warning lamp
B3 Earth
11 Minimum pilot pressure red warning lamp
B4 Fuel level indicator connector
12 Overload indicator orange warning lamp (optional)
B5 Gauge lighting connector
13 Indicator lighting 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 (optional)
P1 Engine coolant temperature indicator
P2 Fuel level gauge
P3 Hydraulic oil temperature indicator

4001-11
INSTRUMENT PANEL WIRING INSTRUMENT PANEL (FRONT FACE)

A B
1 2 3
5 4 5 4
6 7 3 6 7 3
1 2
A B 1 2
P3
140 23 17 138 13
C
5 4
6 7 3
1 2
C D 5 4
D
6 7 3
1 2
29 18 11 137 0 19 P1
AAAAAA
AAA
STOP
13
15 168 16
C
F
P2
5 4
6 7 3
1 2
F
8
E 1/2
167
6
AA A
A AA
AA
AA
AA
9
AA AAA
A 7-way connector : minimum pilot pressure red warning lamp, hydraulic oil temperature indicator, battery
charge red warning lamp, audible warning cut-out push button, engine oil pressure red warning lamp, alarm
PDG0235
11
AA 7
orange warning lamp, stop alarm red warning lamp.

B 7-way connector : 24 Volt supply, earth, fuel level gauge, indicator lighting, engine coolant temperature indica-
tor.
15
12
C 7-way connector : air filter restriction red warning lamp, overload indicator orange warning lamp (optional).
PDG0234
D 7-way connector : hydraulic oil filter restriction red warning lamp.
1 Stop alarm red warning lamp P1 Engine coolant temperature indicator
F 7-way connector : rotary light orange indicator lamp (optional). 2 Alarm orange warning lamp P2 Fuel level indicator
3 Audible warning cut-out push button P3 Hydraulic oil temperature indicator
6 Engine oil pressure red warning lamp
7 Air filter restriction red warning lamp
9 Hydraulic oil filter restriction red warning lamp
12 Overload indicator orange warning lamp
(optional)
13 Indicator lighting lamp

4001-12
38
29
1 9 0
H11 0
AAA 141
AAA
8
136
AAA
6 5
S6 37
AAA
4 3
H15
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
S3
AAA
5
AAAAAAA AA
AAA
22
S26
AA
AAAAAAAAAAAA
AAAAA AA
1 37
AAA 40
45
29
10 9 0
H13
5
S27 3 1
46
41
28
29
H10 10 9 0
S1 powersensor
5
S4
S24 7 1
6
5 29
C C C C
105 105 64 147 6 7
6 2
PDH0236

4001-13
RIGHT-HAND CONTROL ARM, LEFT-HAND CONTROL ARM (STANDARD

EQUIPMENT)
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
S22 Control panel (see Section 4002)
S24 Pilot safety switch
S26 Windshield washer switch
S27 Heater blower switch
Floor harness

4001-14
V52 V51 H15
H31 S25
AA
101
AA
29
+ -
H53 10 9
AA
AA
101 0 10 9 0
AA 8
AA V50
5 100 102 140
6 5 28
S53 AA 4 3
1
AA 1 31
229
AA
AA
229 128
AA
H30
10 9 0
127
AAAAAAA AA
AAAAAAAAAAA
AA
S20 5 3
AA
AAAAA
AAAAA
AAAA
AAAA
AA
3
1 62
S30
56
90 59
H58 S56 0 powersensor
0
H32 229 10 9
229 10 9
5
7 100 S21
5 1
3 56
1 102 145 91
24 16 6 6
9
CM95F048.PCT

4001-15
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING

(OPTIONAL EQUIPMENT)
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 alarm
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 switch (optional)
S56 Quick-attach control switch (optional)
V50 Quick-attach diode (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 working lights, rear working light harness (optional)

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
F33 7.5A Fuse, supply to electronic control box
ENGINE
K1 Starter motor relay
K2 General contact relay 24 Volts, 50A G2 Alternator
G1 Y1 K3 Hourmeter relay M1 Starter motor
G2
R11 K4 Electronic control box supply relay R11 Cold start assistance glow plug
K15 Cold start assistance relay Y1 Engine shut-down solenoid valve
S1 M1
R10 0.85 Ohm Resistor
Sh1 Shunt not used
V1 General contact diode
FLOOR
S1 Key switch
S20 Cold start assistance momentary switch (optio-
nal)
: see page 4.
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
C See schematic plate 7 page 26 J See schematic plate 3 page 18
D See schematic plate 7 page 26 K See schematic plate 5 page 22
S2 E See schematic plate 4 page 20 L1 See schematic plate 7 page 26
F See schematic plate 3 page 18 N1 See schematic plate 6 page 24
F1 - F2 - F33 - Sh1 - K1 - K2 G See schematic plate 3 page 18

K3 - K4 - K15 - R10 - V1
S20
H30
PDH0237

4001-17
CONTACT SWITCH
BATTERIES BATTERY RELAY THERMOSTART ENGINE SHUT-
BATTERY MASTER SWITCH ALTERNATOR
MOTOR STARTER COLD START ASSISTANCE DOWN CONTROL
DIAGNOSTIC SOCKET ELECTRONIC BOX
+12 V +12 V 97
K
+24V +24V 2
97 J
1
2 +24V 9
1 2 I
3 F1
F2
5A Sh1 30A
237
G1
8 3
F33 11
1 2 7.5A H
V1
5 236 2 9
S20 9 (2)
2 (5)
H30 13
S1
9 5
G
3
0
R012
58 50 1 10 1 3
1
5 K3
9 (1)
3 (9) 2 (9) 2 K 5 4
62 3 24
4 7 13 14 F
6 2 3
K15
5 K1 1 1 3 K4 1 4 1 K15 5 4 4 (8)
2 4 (6)
4 123 4 (4)
3 K1 2 2 K4 5 2 K2 3 K2
30 B+ D+ W
23 (1) G2
M1 234
50 R1
S
2 0
23 (2)
119 2
22 Y1 24
9 22 1
0
9
R1
1
A B L1 4 4 C D E N1
CM95F020

4001-18

INSTRUMENT PANEL FLOOR
P10 Instrument panel (See schematic plate 1) B3 Pilot pressure pressostat
ELECTRICAL CABINET
P4 Hourmeter
F3 7.5A Fuse, instrument panel S3 Horn relay
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 sensor
B4 E1 Cab lighting H26 Horn
P10 E10 - S10
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 sensor
B1
WIRING CONNECTION BETWEEN SCHEMATICS
See schematic plate 2 page See schematic plate 5 page See schematic plate 4 page
F M T
16 22 20
G N U
16 20 20
H P V
16 20 22
B2
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) L S J1
22 20 26
See schematic plate 6 page

H26 M1 24
F3 - F4 - F7 - K5
S3 P4
B3
PDH0237

4001-19
INSTRUMENT PANEL
INSTRU-
BATTERY HYDR. OIL HYDRAU-
HOURMETER AIR FIL- PILOT ENGINE MENT PA- CAB LIGHTING HORN
CHARGE FILTER FUEL RESERVE LIC OIL ENGINE TEMPERATU-
TER RES- PRESSU- OIL PRES- NEL
WARNING RES- WARNING LIGHT TEMPERA- RE
TRICTION RE SURE AUDIBLE
LAMP TRICT. TURE
ALARM
2 +24V +24V 2
J U
9 +24V +24V 9
I T
F3 F4 F7
7.5 5A 10A
A
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
G A4 P10 B3 22
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) 16 3 (5) 20 (1) K5
7
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 30 (2) S10
B21 B22
B1 B2 B3 B4 H1 H2
5 6
P11 X10 (C)
0
Q
0
P
4
M1 L M X J1 N
CM95F021

4001-20

INSTRUMENT PANEL
CAB
H57 Rotary light (optional)
M2 Windshield wiper motor
E : Blue
J : White
L : Grey
M : Black
X1 (F) Rotary light cab floor/cab connector (optional)
X1 (E), (L), (M), (J) Windshield wiper motor cab floor/
cab connector
E7 H57 S27 Heater blower switch
FLOOR
ELECTRICAL CABINET
E7 Cigarette lighter
M2 F5 10A Fuse, working light, rotary light relay (optio-
M3 Windshield washer motor
nal)
M4 Heater blower motor
F6 15A Fuse, upperstructure working lights
F9 10A Fuse, windshield washer, windshield wiper UPPERSTRUCTURE
F10 15A Fuse, ventilation, heater
E2 Attachment working light (on boom)
F11 7.5A Fuse, cigarette lighter
E3 Upperstructure working light
F31 15A Fuse, windshield wiper intermittent action
X5 (A), (C) Attachment working light connector
Sh3 Shunt
Sh6 Shunt
V22 Rotary light indicator lamp (optional)
1 Strip
: see page 4.
B See schematic plate 2 page 16 Y See schematic plate 6 page 24

E3
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)
Q See schematic plate 3 page 18 C1 See schematic plate 5 page 22
E3
M3 S See schematic plate 3 page 18 D1 See schematic plate 5 page 22
M4
F5 - F6 - F9 - F10
F11 - F31 - K6 - K20
T See schematic plate 3 page 18 E1 See schematic plate 6 page 24
V22 - Sh3 - Sh6
U See schematic plate 3 page 18 F1 See schematic plate 5 page 22
H10 - H11 - H12 - H13 - H31
S4 - S6 - S25 - S26 - S27
X See schematic plate 3 page 18 K1 See schematic plate 2 page 16
P1 See schematic plate 5 page 22
PDH0237B

4001-21
WORKING LIGHTS BLOWER HEATER AIR

ROTATING LIGHT (OPTIONAL) WINDSHIELD WIPER WINDSHIELD WASHER CIGARETTE LIGHTER
UPPERSTRUCTURE ATTACHMENT 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 12
6 (1)
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)
40
6 (3) 142
20 (3)
26 (6) 2
me
1 re
20 (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 1 K6 5 4 K 3B X1 (E) M3 M4
(F) 6 (5) 33 6 K20 5B X1 (L)
1B X1 (J)
X1 (M)
1(10) 8 1(4)
1 X5 (C)
H5
16 M2
7
7
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
CM95F022

4001-22

INSTRUMENT PANEL CAB
F8 15A Fuse, upperstructure power line connection 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 lights (optional) E51 Rear working light (optional)
V4 Radio diode (optional) M6 Blower motor (optional)
E50 V21 Overload indicator diode (optional) S29 Blower switch (optional)
M6 - S29 - X14(1),(2) E51 X1(A),(B),(C),(D) RH and LH loudspeaker connector
INSTRUMENT PANEL
Y51 - Y52 (optional)
B5 E12 - S28 H32 Overload indicator switch lighting (optional) X1(H),(G) Front working light, rear working light con-
X2 S21 Overload indicator switch (optional) nectors (optional)
X14 (1),(2) Blower motor connectors (optional)
FLOOR
UPPERSTRUCTURE
A1 Radio (optional)
H53 Front working light switch lighting (optional) B23 Overload indicator pressostat on boom foot
H58 Quick-attach control switch lighting (optional) (optional)
S53 Front working light switch (optional) X2 Upperstructure power line connection
S56 Quick-attach control switch (optional) Y51 Quick attach solenoid valve (optional)
V50 Quick-attach diode (optional) Y52 Quick-attach solenoid valve (optional)
ENGINE
1 4 terminal bar E12 Engine compartment light (optional)
S28 Engine compartment lighting switch (optional)
: voir page 4.
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),(G),(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 P1 See schematic plate 4 page 20
H58 - H56 A1
PDH0237

4001-23
UPPERSTRUCTURE CAB WORKING LIGHTS

HOOD LIGHTING CAB VENTILATION
POWER LINE CONNEC- FUEL FILLER PUMP OVERLOAD INDICATOR (OPTIONAL) RADIO QUICK-ATTACH
FRONT REAR (OPTIONAL) (OPTIONAL)
TION
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
1 0 2
H32 S53
9 5 9 5
7 V4
36 92
10 1 10 1 3 10
2 (8) S56 229
16 (1) H58
+ 56 E1
229 145
24 (3)
33 (1) A1
128 G1
5 -
1 (7) 1 (8) 1 (6) 1 (9) 102 100
21 (1)
132 134 133 135
P B23 1 1
Y53 X1 (H) X1 (G) 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 E51 0 - -
V21 X14 (2) B5 HPD B6 HPG

6 (2)
168 33 0
16 7 14
F1 W P1 Z
CM95F023

4001-24

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

4001-25
ADJUSTABLE OR ARTI-
BOOM RAISING HEIGHT LIMITER (OPTIONAL) PILOT SAFETY FUEL OIL HEATING
CULATED BOOM
A1
9 +24V
H1
F27 F12
5A 10A
49 41
14
56
Sh4
15
2 6 (6)
S30 1
4 S24
3
90 NO NC
B56 3 1 K53
59 3 (7) 6 (7)
126 56 4 5 2
6 (1) 6 (2) 64 147
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
125
2 2 2 1 (2) 6 (8) 14
Y7 1 Y8 1 1 Y50
2
0 0 0 0
1 Y2
0
6
G1 Y A R 12 M1 N1
CM95F024

4001-26

H14 Diagnostic lamp (LED) B7 Swing detection pressostat
B10 Swing motor speed detector
CAB
B11 Hydraulic pressure sender
A2 Electronic control box Y5 Upperstructure swing brake release control
S22 Control panel solenoid valve
X3 35-way Connector Y6 Travel motor displacement change solenoid
X4 Diagnostic socket valve (two-speed excavators only)
FLOOR ENGINE
Y5 - Y6 B10 - X7 B8 Travel detection pressostat B9 Engine speed detector
S22 M5 - X9 - P12 M5 Injection pump servo-motor
P12 Servo-motor potentiometer
X6 Engine speed detector connector
X7 Engine speed connector
Y4 X8 Hydraulic pressure sender connector
X9 Injection pump servo-motor connector
Y4 DRE4 proportional pressure reduction valve
NOTE : For cab, cab floor, upperstructure and engine module wiring, see Section 4002.
C See schematic plate 2 page 16
D See schematic plate 2 page 16
J1 See schematic plate 3 page 18
K1 See schematic plate 4 page 20
L1 See schematic plate 2 page 16
B9 - X6
A2 - X3
X4
B7 H14
B8 - B11 - X8
PDH0269

4001-27
SWING PRESSURE SWITCH DIA- +28V

SWING UPPERSTRUC-
BRAKE RE- WA- GNOS- INSTRU-
TROUBLESHOOTING ENGINE SPEED PRESURE TRAVEL DISP. TURE SWING 0V +28V
INJECTION PUMP SERVO-MOTOR LEASE SO- TER TIC MENT PA- CONTROL PANEL PRESSURE SENDER
TEST SOCKET DETECTOR REDUCER SWING TRAVEL CHANG. SPEED DETEC- BATT. BATT.
LENOID T LAMP NEL
DRE4 TOR
VALVE (LED) LIGHTING
A2
X3
23 6 22 5 15 32 14 9 27 21 4 3 29 13 12 20 31 10 28 24 1 2 19 11 26 7 25 8 18 17 35
200 201 205 206 202 20 204 20 208 20 210 211 213 214 215 219 18 222 22 224 0 234 234 229 225 22 227 22 230 23 232
3 7 9 3 6 8 1
30 (4)
31 (1)
C 30 (3)
3 3
30 (6) H14
P P
B7 B8
31 (2) 31 (3) 1 1
1 2 5 6 7 A B A B C A B
X9 X6 X7 X8
234 2
2
+ - B3 A1 B1 B2
+ - + 0 - + -
B 1 Y 1 Y6
B9 2 B10
5 S22
A C 30 (5) 30 (1)
M 1 Y4
X 5
P12
4
B11

J1 L1 30 K1
D
CM95F025

4001-28
CAB FLOOR WIRING (STANDARD EQUIPMENT) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD EQUIPMENT)
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
0 C
S26
X10
0 H15
S3 H13
Y2
S27
F
E
H10
22 22
S4
0 140
55 0
1 8
4 1
B3 X2
M3 P4 M4
1 2 3 X4 36 0
16
17 148 S1 B2 S2
40 0 24 11 45 46 0 S22
+ -
- +
powersensor
7 5 B21 G1
6 G1
S24
0 138 Y1
105 14 31
132 4 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
A1 15 0 B+
2 B4
M1 D+
135 26 38 0 W
128
92
23 0 2 14 13
135 2 4
0 133
20 30
40 21
27 1 2 3 6 134
27 20 31
0 132
PDH0238

4001-29
CAB FLOOR WIRING (STANDARD EQUIPMENT) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD EQUIP-
ELECTRICAL CABINET MENT)
20, 20, 21, 27, 27, 31, 30 : see page 4 ELECTRICAL CABINET
24 Volts supply before contact
1, 2, 3, 6 0 : see page 4
FLOOR 1, 4 8 : see page 4
A1 Radio (optional) UPPERSTRUCTURE

B3 Pilot pressure pressostat B1 Air filter restriction pressostat
E3 Upperstructure working light B2 Hydraulic oil filter restriction pressostat
E7 Cigarette lighter B21 Hydraulic oil temperature sender
H10 Working light switch lighting E2 Attachment working light
H11 Windshield wiper switch lighting E3 Upperstructure working light
H12 Windshield washer switch lighting G1 Batteries
H13 Heater blower switch lighting P11 Fuel level indicator
H15 Instrument panel audible warning S2 Battery master switch
H26 Horn X2 Upperstructure power line connection
M3 Windshield washer motor X5 Attachment working light power connection
M4 Heater blower motor X10 Fuel level indicator connector
P4 Hourmeter Y2 Pilot safety solenoid switch
P10 Instrument panel
S1 Key switch ENGINE
S3 Horn switch B4 Engine oil pressure pressostat
S4 Working light switch B22 Engine coolant temperature sender
S6 Windshield wiper switch G2 Alternator
S22 Control panel M1 Starter motor
S24 Pilot safety switch Y1 Engine shut-down solenoid valve
X1 Cab floor/cab power connector
X4 Troubleshooting test socket

4001-30
ELECTRONIC SYSTEM WIRING
X9
4
227 225
228 226 1 Y4 6
2 B22
3
B1 B2 B3 A1
B10
X6
S22 5
powersensor
B9
M5 - P12
232
231 230 227 225 X7
228 226
AB C Y5
7
222 223 B10
X3
A B 8
A2 3
219 2 1 0 X4
4 (2) 30 31 X7 28
X4
222 223
B7
B11
232 B8 Y6 219 9
B7 231 230 207208
0 Y6
214 215 211
213 214 X8
0
9
A B Y5
3
211 2 1 0 25 27 10
213 214 1 2
3 3 26 B8
2 1 214 24 12
215 18
11 10
207 X6 202
203 X9
23 0
208 204 4
0
205 22
209 210 206
A2 31
M5 21
P12 30
Y4 B9
20
16 X8
210 1
3
2 209
0 B22 19 B11
18
X3
17 S22
14
B 203
B 202 13
4 5
6
B 3
2 17
206
B 205
B 204
15
PDH0489 PDH0490

4001-31

A2 Electronic control box 1 O ring
B7 Swing detection pressostat 2 Bushing
B8 Travel detection pressostat 3 Washer
B9 Engine speed detector 4 Lock
B10 Swing motor speed detector 5 Plug
B11 Hydraulic pressure sender 6 Clamp
B22 Engine coolant temperature sender 7 Pressure reduction valve
M5 Injection pump servo-motor 8 Electronic harness
P12 Servomotor potentiometer 9 Screw
S22 Control panel 10 O ring
X3 35-way Connector 11 Travel block
X4 Troubleshooting socket 12 Swing block
X6 Connector 13 Printed circuit card
X7 Connector 14 Decal
X8 Connector 15 Control panel fixing hardware
X9 Connector 16 Nut
Y4 DRE4 proportional pressure reduction valve 17 Washer
Y5 Travel motor upperstructure brake release con- 18 Rivet
trol solenoid valve 19 Screw
Y6 Displacement change solenoid valve (two- 20 Support
speed excavators only) 21 Nuts
22 Washers
23 Screws
30 Electronic control box six-way connector har-
24 Handle
ness
25 Screw
31 Troubleshooting socket three-way connector
26 Washer
harness
27 Troubleshooting socket harness
4(2) Engine eight-way connector harness
28 Engine harness

4001-32
CAB FLOOR WIRING (OPTIONAL EQUIPMENT) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL EQUIPMENT)
V51
AA
101 B23
AA
AA
+ - H15
AA
V52 101 0
145 146
100 102 V50
AA
AA
140
Y53
A
A A
A AA
AAA
AA
AAA
AAA AA
AA 90
0 Y7
7 K53
5
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
126 B56
90 59 0 125
Y50
0
+
- +
E12 26
41
-
R50
powersensor 0
R11 S28
119
H32
S21
9 24 6 16 15 6
102
100
14 19 14 1
CM95F049.PCT

4001-33
CAB FLOOR WIRING (OPTIONAL EQUIPMENT) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL EQUIP-
ELECTRICAL CABINET MENT)
1 4 unit strip ELECTRICAL CABINET
6, 9, 14, 16, 19, 24, 15, 14 6 1 4 unit strip
INSTRUMENT PANEL 7, 10, 12, 22, 23 (1) (2), 33

H30 Cold start assistance switch lighting UPPERSTRUCTURE
H31 Rotary switch lighting B23 Overload indicator
H32 Overload indicator switch lighting B56 Boom raising range limitation detector
H53 Front working light switch lighting K50 Boom raising range limitation relay
H58 Quick-attach switch lighting K51 Adjustable boom lowering range limitation relay
S20 Cold start assistance switch K53 Fuel heater relay
S21 Overload indicator switch R50 Fuel oil heating device
S25 Rotary light switch (specific to certain countries) Y7 Adjustable or articulated boom extending electro-valve
S30 Adjustable or articulated boom switch Y8 Adjustable boom solenoid valve
S53 Front working light switch Y50 Adjustable boom raising range limitation solenoid valve
S56 Quick-attach switch Y51 Quick-attach solenoid valve
V50 Quick-attach diode Y52 Quick-attach solenoid valve
V51 Quick-attach diode
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

4001-34
CAB AND CAB OPTIONAL EQUIPMENT 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
J
144 E
M
K
38 2 (7)
B6 132 D L
A 135 B5
C B
133
- -
132
135 134
+ 142 134 133 26 +
0 31 0 33
H57 E51 PDH0228
A White wire X1 (A) (B) (C) (D) Cab floor/cab RH and LH louds-
B Grey wire peaker power connector
C Blue wire X1 (H) (G) Cab floor/cab front and rear working light
D Black wire power connector (optional)
E1 Cab lighting X1 (E) (J) (M) (L) Cab floor/cab windshield wiper and
E7 Cigarette lighter (see wiring pages 28) working light power connector
E50 Front working lights (optional) X1 (F) Cab floor/cab rotary light power connector
E51 Rear working light (optional) X1 (K) Cab floor/cab lighting power connector
H57 Rotary light (optional) X14 (1) (2) Cab blower plug (optional)
B5 RH Loudspeaker (optional) 2 (7) 10-way connector (see printed circuit wiring
B6 LH Loudspeaker (optional) page 5)
M6 Cab blower motor (optional)
S10 Cab lighting switch
S29 Cab blower switch (optional)

4001-35
INDEX
A C
Adjustable boom control switch ..............................15 Cigarette lighter.................................... 20, 21, 29, 34
Adjustable boom lowering range Cold start assistance.............................................. 17
limitation relay ......................................6, 8, 24, 33 Cold start assistance glow plug ....................... 16, 33
Adjustable boom raising height Cold start assistance momentary switch................ 16
limitation relay ......................................................8 Cold start assistance relay............................. 6, 8, 16
Adjustable boom raising height limiter relay .............6 Cold start assistance resistor................................. 33
Adjustable boom raising range Cold start assistance switch............................. 15, 33
limitation detector ...............................................24 Cold start assistance switch lighting .......... 15, 16, 33
Adjustable boom raising range Connector .............................................................. 31
limitation solenoid valve ...............................24, 33 Connector (35-way) ......................................... 26, 31
Adjustable boom solenoid valve .............................33 Contact switch........................................................ 17
Adjustable or articulated boom ...............................25 Control panel.................................. 13, 26, 27, 29, 31
Adjustable or articulated boom
D
extending electro-valve ................................24, 33
Adjustable or articulated boom Description of electrical cabinet printed circuit
retracting electro-valve .......................................24 (optional equipment) ............................................ 6
Adjustable or articulated boom switch ..............24, 33 Description of electrical cabinet printed circuit
Air filter restriction...................................................19 (standard equipment) .......................................... 4
Air filter restriction pressostat ...........................18, 29 Diagnostic lamp (LED) ..................................... 26, 27
Alternator ....................................................16, 17, 29 Diagnostic LED .................................................... 4, 8
Attachment working light ........................................29 DRE4 proportional pressure
Attachment working light (on boom) .......................20 reduction valve ............................................ 26, 31
Attachment working light connector........................20
E
Attachment working light power connection ...........29
Audible alarm..........................................................15 Electrical cabinet printed circuit wiring
Audible warning ......................................................33 (optional equipment) ............................................ 6
Electrical cabinet printed circuit wiring
B
(standard equipment) .......................................... 4
Batteries .....................................................16, 17, 29 Electrical control box supply relay........................ 4, 8
Battery charge warning lamp..................................19 Electrical schematic (plate 2) ................................. 16
Battery master switch .................................16, 17, 29 Electrical schematic (plate 3) ................................. 18
Battery relay ...........................................................17 Electrical schematic (plate 4) ................................. 20
Blower motor ..........................................................22 Electrical schematic (plate 5) ................................. 22
Blower motor connectors........................................22 Electrical schematic (plate 6) ................................. 24
Blower switch..........................................................22 Electrical schematic (plate 7) ................................. 26
Blower, heater, air conditioning ..............................21 Electronic box ........................................................ 17
boom raising height limiter......................................25 Electronic control box....................................... 26, 31
Boom raising range limitation detector ...................33 Electronic control box six-way connector
Boom raising range limitation relay ..................24, 33 harness .............................................................. 31
Electronic control box supply relay ........................ 16
C
Electronic control box supply wire............................ 4
Cab and cab optional equipment wiring .................34 Electronic system wiring ........................................ 30
Cab blower motor ...................................................34 Electronique system wiring .................................... 31
Cab blower switch ..................................................34 Engine compartment light ................................ 22, 33
Cab floor wiring (optional equipment)...............32, 33 Engine compartment lighting switch ...................... 22
Cab floor wiring (standard equipment) .............28, 29 Engine compartment working light switch.............. 33
Cab floor/cab power connector...............................29 Engine coolant temperature sender................. 29, 31
Cab lighting.................................................18, 19, 34 Engine coolant temperature sensor ....................... 18
Cab lighting switch............................................18, 34 Engine eight-way connector harness..................... 31
Cab ventilation........................................................23 Engine module and upperstructure wiring
Cab working lights (front)........................................23 (optional equipment) .................................... 32, 33
Cab working lights (rear) ........................................23 Engine module and upperstructure wiring
Cab/cab floor, cab lighting connector .....................18 (standard equipment) .................................. 28, 29

4001-36
E F
Engine oil pressure.................................................19 Fuse, windshield wiper, windshield
Engine oil pressure pressostat .........................18, 29 washer (10A) ....................................................... 8
Engine shut-down control .......................................17 Fuse, working light, rotary light relay (10A)............ 20
Engine shut-down solenoid valve .....................16, 29 Fuse, working lights and rotary light
Engine speed connector.........................................26 relay (10A) ....................................................... 6, 8
Engine speed detector................................26, 27, 31
G
Engine speed detector connector...........................26
Engine temperature ................................................19 General contact diode.................................... 4, 8, 16
General contact relay............................................... 4
F
General contact relay (24V, 50A)....................... 8, 16
Front working light switch ...........................15, 22, 33
H
Front working light switch lighting...............15, 22, 33
Front working light, rear working light Heater blower motor ........................................ 20, 29
connectors..........................................................22 Heater blower switch.................................. 13, 20, 29
Front working lights ..........................................22, 34 Heater blower switch lighting ..................... 13, 20, 29
Fuel filler pump .......................................................23 Hood lighting .......................................................... 23
Fuel heater relay...................................4, 6, 8, 24, 33 Horn ........................................................... 18, 19, 29
Fuel level indicator............................................18, 29 Horn relay ...................................................... 4, 8, 18
Fuel level indicator connector.................................29 Horn switch ...................................................... 13, 29
Fuel level indicator connectors ...............................18 Hourmeter .................................................. 18, 19, 29
Fuel oil heating .......................................................25 Hourmeter relay ............................................. 4, 8, 16
Fuel oil heating device......................................24, 33 Hydraulic oil filter restriction pressostat ........... 18, 29
Fuel reserve............................................................19 Hydraulic oil temperature ....................................... 19
Fuse, adjustable and articulated Hydraulic oil temperature sender ........................... 29
boom (5A) ......................................................8, 24 Hydraulic oil temperature sensor ........................... 18
Fuse, adjustable or articulated boom (5A)................6 Hydraulic pressure sender ............................... 26, 31
Fuse, cab lighting, horn relay (5A)......................8, 18 Hydraulic pressure sender connector .................... 26
Fuse, cab working lights (15A) .......................6, 8, 22 Hydraulique oil filter restriction............................... 19
Fuse, cigar lighter (7.5A) ..........................................4
I
Fuse, cigarette lighter (7.5A) ..................................20
Fuse, cold start assistance (30A) .......................8, 16 Injection pump servo-motor ....................... 26, 27, 31
Fuse, cold start assistance (optional) (30A) .............6 Injection pump servo-motor connector................... 26
Fuse, driving position lighting, horn relay (5A) .........4 Instrument panel ........................................ 18, 19, 29
Fuse, electronic control box (7.5A)...........................8 Instrument panel (front face).................................. 11
Fuse, horn (10A).............................................4, 8, 18 Instrument panel audible alarm.............................. 19
Fuse, instrument panel (7.5A) ........................4, 8, 18 Instrument panel audible warning .............. 13, 18, 29
Fuse, overload indicator (5A) .........................6, 8, 22 Instrument panel lighting........................................ 27
Fuse, pilot safety (10A)...................................4, 8, 24 Instrument panel wiring.......................................... 11
Fuse, radio (5A)..............................................6, 8, 22
K
Fuse, starter switch (5A).................................4, 8, 16
Fuse, supply to electronic Key switch.................................................. 13, 16, 29
control box (7.5A) ...........................................4, 16
L
Fuse, uperstructure working lights (15A)..................8
Fuse, upperstructure power line Left-hand control arm pilot safety relay.................... 8
connection (15A) ................................................22 LH control arm pilot safety relay .............................. 4
Fuse, upperstructure power point (15A) ...............4, 8 LH Loudspeaker..................................................... 34
Fuse, upperstructure working lights (15A)..........4, 20 LH loudspeaker...................................................... 22
Fuse, ventilation, heater (15A) ...........................4, 20
M
Fuse, ventilation, heater, fuel oil heating (15A) ........8
Fuse, windshield washer, windshield Motor starter........................................................... 17
wiper (10A).....................................................4, 20
O
Fuse, Windshield wiper intermittent
action (15A) ..........................................................8 Overload indicator............................................ 23, 33
Fuse, windshield wiper intermittent Overload indicator diode .................................... 8, 22
action (15A) ....................................................4, 20 Overload indicator lamp ........................................... 6

4001-37
O S
Overload indicator pressostat Schematic symbols .................................................. 3
on boom foot ......................................................22 Servo-motor potentiometer .................................... 26
Overload indicator switch ...........................15, 22, 33 Servomotor potentiometer ..................................... 31
Overload indicator switch lighting ...............15, 22, 33 Shunt.............................................................. 4, 8, 20
Shunt, Pilot safety relay ......................................... 24
P
Specifications........................................................... 2
P10 instrument panel electrical schematic Starter motor ................................................ 8, 16, 29
(plate 1) ..............................................................10 Starter motor relay ............................................. 4, 16
Pilot pressure..........................................................19 Swing brake release solenoid valve....................... 27
Pilot pressure pressostat ..................................18, 29 Swing detection pressostat .............................. 26, 31
Pilot safety ..............................................................25 Swing motor speed detector ............................ 26, 31
Pilot safety relay .....................................................24 Swing presure reducer DRE4 ................................ 27
Pilot safety solenoid switch.....................................29
T
Pilot safety solenoid valve ......................................24
Pilot safety switch .......................................13, 24, 29 Thermostart............................................................ 17
Pressure sender .....................................................27 Travel detection pressostat.............................. 26, 31
Pressure switch (swing)..........................................27 Travel motor displacement change solenoid
Pressure switch (Travel).........................................27 valve (two-speed excavators only) .................... 26
Printed circuit schematic guide.................................8 Travel motor upperstructure brake release
control solenoid valve ........................................ 31
Q
Troubleshooting socket.......................................... 31
Quick attach solenoid valve....................................22 Troubleshooting socket three-way
quick-attach ............................................................23 connector harness ............................................. 31
Quick-attach control switch.....................................22 Troubleshooting test socket ............................. 27, 29
Quick-attach control switch (optional).....................15
U
Quick-attach control switch lighting ........................22
Quick-attach diode............................................15, 22 Upperstructure and attachment working
Quick-attach solenoid valve..............................22, 33 light relay ............................................................. 4
Quick-attach switch ................................................33 Upperstructure power line connection ....... 22, 23, 29
Quick-attach switch lighting ..............................15, 33 Upperstructure swing brake release
control solenoid valve ........................................ 26
R
Upperstructure swing speed detector .................... 27
Radio ..........................................................22, 23, 29 Upperstructure working light ............................ 20, 29
Radio diode ........................................................8, 22
W
Radio LED ................................................................6
Rear working light.............................................22, 34 Warning light .......................................................... 19
Resistor (0.85 ohm) ........................................6, 8, 16 Water temperature ................................................. 27
RH and LH loudspeaker connector ........................22 Windshield washer................................................. 21
RH Loudspeaker.....................................................34 Windshield washer motor................................. 20, 29
RH loudspeaker......................................................22 Windshield washer switch.......................... 13, 20, 29
Right-hand and left-hand control arm Windshield washer switch lighting ............. 13, 20, 29
wiring (optional equipment) ................................15 Windshield wiper.................................................... 21
Right-hand control arm, left-hand Windshield wiper intermittent action .............. 4, 8, 20
control arm (standard equipment) ......................13 Windshield wiper motor.................................... 20, 34
Rotary light .......................................................20, 34 Windshield wiper motor cab floor/cab
Rotary light cab floor/cab connector .......................20 connector ........................................................... 20
Rotary light diode......................................................8 Windshield wiper switch............................. 13, 20, 29
Rotary light indicator lamp ..................................6, 20 Windshield wiper switch lighting ................ 13, 20, 29
Rotary light switch ............................................15, 20 Working light rela ..................................................... 8
Rotary light switch Working light relay ................................................. 20
(specific to certain countries) .............................33 Working light switch ................................... 13, 20, 29
Rotary light switch lighting ................................15, 20 Working light switch lighting....................... 13, 20, 29
Rotary switch lighting..............................................33 Working lights (attachment) ................................... 21
Rotating light...........................................................21 Working lights (upperstructure).............................. 21

4001
Section
4001
Crawler excavators

Printed in France
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 6) (788C/988C/1188C) ............................................................................... 24
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

4001-3
B (n) Indicators/pressure switches/loud-speakers/detectors/thermal detector/gauge Wire number
F (n) Fuses
H (n) Warning devices (lighted and audible)
K (n) Relays
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
Y (n) Solenoid valves, solenoid shut-off valves
NOTE: The (n) shows the component number.
Example: K2 is relay N2. Link with following plate

A
Bulbs
Test bulb

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
3 2
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
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
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

4001-5
PDH0232

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
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
K59 Air conditioning compressor relay
K60 Air conditioning condenser relay
K61 Battery relay (heater/air conditioner)
R10 Resistor, 0.85 Ohms

4001-7
1 3 2
CM99K019

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
F19 Not used S6 Night lighting (switch)
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

4001-9
CM99K032

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
B1 24 volt power supply
B3 Earth
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
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

4001-11
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
12 Overload indicator orange warning lamp
(optional)

4001-12
H11
S6
H15
H12
S3 S26
H13
S27
H10
S4
S1 S22
S24
CM99K020

4001-13
RIGHT-HAND CONTROL ARM AND LEFT-HAND CONTROL ARM WIRING

(STANDARD)
H10 Working brake switch lighting
S1 Key switch
S3 Horn switch
S22 Control keyboard (788-988-1188)
Floor harness
30 Electronic harness

4001-14
H31
H53
H30
S25
S53
S20
S30
H58
S56
H32
S21
CM99K021

4001-15
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)

H53 Cab front working light switch lighting (optional)
H58 Quick coupler switch lighting (optional)
S30 Adjustable or articulated boom control switch (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

4001-16

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)
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

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

4001-18

INSTRUMENT PANEL UPPERSTRUCTURE
B1 Air filter restriction pressure switch
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
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
B22 H32 Overload indicator switch lighting (optional)
P11 S4 Working light switch
B1
B23
B2
B21
P10 F3 - F12
S24 K21
V21 - V26 - V30
H15
B3 SH4 - SH6
CM99K022

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

4001-20

INSTRUMENT PANEL V22 Rotary light diode on instrument panel
H10 Working brake switch lighting CAB
E1 Cab lighting
E50 Cab front working lights
E51 Cab rear working light
H57 Standard or Italian rotary light
E50 E1-S10 E51 H57 S25 Rotary light switch (optional)
E Blue
J White
ELECTRICAL CABINET L Grey
M Black
F4 Fuse, 5 A, cab lighting, horn (control), hood
M2 P10 Instrument panel
lighting
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
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
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

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

4001-22

ELECTRICAL CABINET CAB
B5 RH loudspeaker (optional)
F2 Fuse, 5 A, starter key switch
B6 LH loudspeaker (optional)
lighting
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)
A1 Radio
Y53 G3 Step-down transformer 24V / 12V
X5 12V accessories socket
B6
S4-S27
H13
F2-F4-F8-F10-F11-F13-F14
Sh6
G3
X5
M4
E7 A1
CM99K022

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

4001-24
ELECTRICAL SCHEMATIC (PLATE 6) (788C/988C/1188C)

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)
B9-X6
F2-F32
K4
A2 - X3 H14
V1
B10-X7
Sh6
B7
B11-X8 X4
CM99K022

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

4001-26

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-
tro-valve (optional)
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
S30 Adjustable or articulated boom control switch
(optional)
F27
K50-K51
V52
Sh6
S56-H58
CM99K022

4001-27
ADJUSTABLE BOOM
ADJUSTABLE BOOM
OR QUICK TOOL COUPLER
RANGE LIMITATION
ARTICULATED BOOM
CM99K014

4001-28

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

4001-29
STARTER KEY SWITCH AIR CONDITIONER
CM99K015

4001-30
CAB FLOOR WIRING (STANDARD)
See page 4
FLOOR
A1 Radio
B25 Threshold detector (788)
G3 Step-down transformer 24V / 12V
H26 Horn
P4 Hourmeter
S1 Key switch
S3 Horn switch
X1 Cab floor/cab connector
X4 Troubleshooting test socket (788-988-1188)
CM99K023

4001-31
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)
See page 4
UPPERSTRUCTURE
B21 Hydraulic oil temperature sender
G1 Batteries
S2 Battery master switch
X5 Attachment working light power connection
X10 Fuel level indicator connector
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

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

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
28 Engine harness
CS99K546
* Wire 219, only on two-speed excavators

X3 35-pin connector

4001-34
CAB FLOOR WIRING (OPTIONAL)

ELECTRICAL CABINET
1 Connecting strip
See page 6
INSTRUMENT PANEL
S53 Front working lights switch (optional)
CM99K024

4001-35
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)

ELECTRICAL CABINET
1 Connecting strip
2 Air conditioner
See page 6
UPPERSTRUCTURE
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)
ENGINE
E12 Engine compartment light (optional)
R11 Cold start assistance plug (optional)
CM99K028

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)
CM99J052

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
(optional) .......................................................15, 26, 34
Adjustable or articulated boom extending electro-
valve (optional)...................................................26, 35
Electrical schematic (Plate 6) (788C/988C/1188C).24
Adjustable or articulated boom retracting electro-valve
(optional) .............................................................26, 35
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
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

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

4001
Section
4001
788/988 Wheeled Excavators
988 series: CGG0127801 to CGG0128301 CGG0128304 to CGG0128313.
988 series Plus: CGG0128302, CGG0128303, CGG0128314 and after

Printed in U.K.
Case Cre 7-80021GB May 1996 (RvisionFebruary 1998)
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 AND
COMBINATION SWITCH WIRING (STANDARD) .................................................................................................13
RIGHT-HAND AND LEFT-HAND CONTROL ARM WIRING (OPTIONAL)............................................................ 15
ELECTRICAL SCHEMATIC (PLATE 2) .................................................................................................................16
ELECTRICAL SCHEMATIC (PLATE 10) ...............................................................................................................32
ELECTRICAL SCHEMATIC (PLATE11) ................................................................................................................34
ELECTRICAL SCHEMATIC (PLATE 12) ...............................................................................................................36
CAB FLOOR WIRING (STANDARD) .....................................................................................................................39
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD EQUIPMENT) ..........................................39
ELECTRONIC SYSTEM WIRING .......................................................................................................................... 40
ELECTRONIC SYSTEM WIRING ..........................................................................................................................41
CAB FLOOR WIRING (OPTIONAL)....................................................................................................................... 43
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL) .................................................................43
CAB AND CAB OPTION WIRING ..........................................................................................................................44
ALPHABETICAL INDEX..........................................................................................................................................45
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
Motor starter ...................................................................................................................... BOSCH, 24 Volts, 4.0 kW

4001-3
A(n) Radio/housings
B (n) Indicators/pressure switches/loudspeakers/pressures switches/senders/heat sender/gauge 1 Wire number
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
NOTE : The (n) shows the component number. 1
Example : K2 is relay No. 2. Link with following plate
1

Bulbs
Test bulb

Regulator
1 or 1 or 1 Harness identification
1(1) or 1(1) or 1 (1) Harness identification followed by path identification number
3 2
1 2 3 4 5 6 7 8 9 10
harness connector (1). This position is completed when the path 1 line is
4 1

4001-4
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (STANDARD V1 General contact diode V18 Axle unlocking indicator lamp diode
V2 K3 relay diode V20 RH direction indicator diode
EQUIPMENT) V3 Dipped headlight indicator lamp diode V23 Hazard warning diode
V6 Main beam headlight indicator lamp diode 2 Starter motor - solenoid control connection
V7 RH direction indicator green indicator lamp 4 Printed circuit earth
5 37 V12 7
V8 LH direction indicator green indicator lamp 5 Upperstructure power line connection
10 33 39 40
V9 Hazard warning diode
S8
V8 F19 1 Electronic control box supply wire
V20 V7 V10 5A V10 LH direction indicator diode
K 20 35 36 2 V3 2 K53 relay base
V13 K 53
k15 6 16
V23
3 Connecting strip
F20 5A F21 5A
24 21
F25 V9 5
7,5A
1 9
F13 5A
F9
10A
43 1 1
ELECTRICAL CABINET PRINTED CIRCUIT WIRING (STANDARD)
F1 30A F16 F23 5A F24
5A V6 5A
k2 k1
k5
F17
5A
V5
1 Harness 10-way connector, floor harness
F12
10A
38 3 F22
5A
F18
5A S2
2
K 14
S4
k9
a3 F33
7,5A
V11
31
5 2
F7 F32 F30 F26 F15 4
10A 10A 15A 7,5A 15A
F6 6 Harness 8-way connector, floor harness

15A 44 k4
F8
15A
F2
5A 30
V1
K 10 V16
4 3
F5
10A 23
5 Harness, 3 way connector, direction indicator, hazard warning

k7
S7 V17 V19 k6
a1 V21
F31
15A
F4
5A
F3 F10 F11 F27
7,5A 15A 7,5A 5A N 1
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
20
V22 k21
28 Safety clips, working brake, parking brake
4 27
N 2
30 Harness, 6-way connector, electronic control box
1 2 3 4 5 20 30 38
2
31 Harness, 3-way connector, troubleshooting test socket
N 3 26
F14 5A
a2
37 Harness, 5 way connector, two-speed
6 7 9 11 12 14 16 28 42 8 V4 44 Harness, 3 way connector, flasher unit
CM97G025 F24 Fuse, 5 A, LH main beam headlight
1 24 Volts supply before contact F25 Fuse, parking brake (7.5 A) 1 Harness, 8-way connector, common harness
2 12 Volts supply before contact (radio) F26 Fuse, 7.5 A, direction indicators, hazard warning 2 Harness, 10 way connector, lighting and electro
3 Electronic control box 24 volt supply and trou- F31 Fuse, 15 A, windshield wiper momentary action 3 Harness, 6 way connector, brake unit
bleshooting test socket F32 Fuse, 10 A, not used 4 Harness, 8-way connector, engine
F2 Fuse, 5 A, starter switch F33 Fuse, 7.5 A, electronic control box
F3 Fuse, 7.5 A, instrument panel 1 Clip, common harness
H14 LED troubleshooting
F4 Fuse, 5 A, cab lighting, horn relay 2 Clip, lighting and solenoid valve
F6 Fuse, 15 A, upperstructure working lights K1 Starter motor relay 3 Clip, brake unit
F7 Fuse, 10 A, horn K2 General contact relay 24 V, 50 A 4 Clip, engine
F8 Fuse, 15 A, upperstructure power line connec- K3 Hourmeter relay
K4 Electrical control box supply relay 28 Clip, working brake, parking brake
tion
K5 Horn relay 5 Clip, direction indicator, hazard warning
F9 Fuse, 10 A, windshield washer, windshield wiper
K6 Attachment and cab rear working light relay 20 Clip, cab power connection
F10 Fuse, 15 A, ventilation, heater, fuel heater
F11 Fuse, 7.5 A, cigarette lighter K7 Upperstructure headlight and working light relay
F12 Fuse, 10 A, pilot safety K9 Axle unlocking relay
F15 Fuse, 15 A, main beam headlights K10 Flasher unit relay
F16 Fuse, 5 A, RH brake lights K52 Speed change relay
F17 Fuse, 5 A, LH brake light K20 Windshield wiper intermittent action
F18 Fuse, 5 A, RH front side light K21 LH control arm pilot safety relay
F19 Fuse, 5 A, LH front side light Sh2, Sh4, Sh5 Shunt
F20 Fuse, 5 A, RH front dipped headlight Sh1, Sh3, Sh6, Sh7, Sh8 Not used
F21 Fuse, 5 A, LH front dipped headlight
F23 Fuse, 5 A, RH main beam headlight

4001-5
1 2 3
1 2 3
1 2 3 4 5 6 7 8 9 10
68 165
200 201
1 2 3 4 5 6 1 2 3 4 5 6 71
234
99 87 88 160 165
71 89 162 163 165
0 26 144 142 128 133 134
31 38 132 135
31
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
6 16 82 83 86 94 79 50 72 74 166 164
k15
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
k9
V11 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
5 2 31
V2
F7 F32 F30 F26 F15 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
0 49 106 F8
15A
F2
5A 30
V18
V1 V16
3
K 52 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
4 N 2 27 168 38 105 148 141 28 41 92 22
219
2
98
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
98 219
3
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 0
0 94 33 0 0 0 0 0 0 0
0 0 219
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 1 2 3 4 5 6
5 2
70 16 137 36 0 40 14 11 0 4 66 83 82 67 106 70 73 50 229 224 234

2 1 2 3 4 5 55 33 19 138
18
15 23 13 63 84 65 58 52 169 51 78 18 200 201
0
14
0
14
28 27
1 4 3 2 30
CM97G026

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 Connecting strip (specific to certain countries)
5 37 V12 7
4 Quick coupler control harness
10 33
39 40 5 Quick-coupler electro-control harness
S8
V20 V7 V10
V8 F19
5A 8 Fuel pump supply cable (optional)
35 36 2 V3
V13 K50
k15 6 16
V23
Cable, adjustable boom raising height limiter (to terminal No. 3)
F20 5A F21 5A
24 21
F25
7,5A
V9 5
6 Harness, adjustable boom (PM version, special for Germany)
F9
9
F13 5A
10A
F16
43 1 1
F24
7 Hood lighting harness (optional)
F1 30A F23 5A
k2 k1
5A
F17
V5
V6 5A
K51 9 Harness, cold start assistance (optional)
k5 5A
F12
38 3 F22 F18
10Harness, adjustable boom (PM version, special for Germany)
10A
S4 5A 5A S2
k9
11Rear fog light harness (specific to certain countries)
V11
a3 F33
7,5A
12Harness, fuel heating device (optional)
5 2 31
F7
10A
F32
10A
F30
15A
F26
7,5A
F15
15A
4
V2
14Wire to terminal No. 1, adjustable boom raising and lowering range limitation (specific to certain countries)
F6
15A 44 30 k4 16Harness, overload indicator (optional)
F8 F2
15A 5A
17Harness, upperstructure rotary light (specific to certain countries)
V1
V16
4 3 3 22Harness, cold start assistance glow plug (optional)
F5
10A 23
K53 23Harness, cold start assistance resistor (optional)

k7
S7 V17 V19
24Harness, front working lights on cab (optional)
k6
F31
15A
F4
5A
F3 F10 F11 F27
7,5A 15A 7,5A 5A
a1
N 1
V21
33Harness, overload indicator (optional)
S5 S6 S3 6
38Harness, pilot system cancellation (specific to certain countries)
7 11 12 13 14 15 17 19 19 19 19 22 28 42 8 k3
6 43Rear fog light harness (specific to certain countries)

V22 k21
R 10 4 N 2 27
20
19Cable, registration plate light (optional)
2
1 2 3 4 5 20 30 38
N 3 26
F14 5A
a2
7
6 7 9 11 12 14 16 28 42 8 V4
CM97G027
F1 Fuse, 30 A, cold start assistance (optional) V4 Radio diode (optional)

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

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 K50 K53
43 1 1 K51
23 F1 30A
F13 5A
F16 F23 5A F24
5A V6 5A
V5
k2 k1 3 2 5 1
F17 85 86 30 87A 87 85 86 30 87A 87
k5 5A
F12
38 3 F22 F18
10A
S4 5A 5A S2
k9 0 126 59 124 0 126 56 125 41 41
V11
a3 F33
2 7,5A
36 31
5 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
15A 5A 30
V1 V16
3 4 3
F5
10A 23
123 119 k7
S7 V17 V19 k6 56 56 56 126 59 0 0 0

a1 V21
F31 F4 F3 F10 F11 F27
15A 5A 7,5A 15A 7,5A 5A N 1
100 102 S5 S6 S3 6
k3
2
R 10 7 11 12 13 14 15 17 19 19 19 19 22 28 42 8
V22 k21
4 N 2 27
20
3
100 102
2
1 2 3 4 5 20 30 38
a2
F14 5A
6 7 9 11 12 14 16 28 42 8
N 3 26
1
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 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 26 0 0
0 0 0 0 0 56 229 229 229
56 31 229 119
43 10 33 9 24 6 16 38
1 2 1 2
1 2 1 2 1 2 1 2 3 1 2
1 2 3
4 5 76 75 0 90 59 59 145 146 62 3 127 128 90 59 91 145 8 106 105

109
31 0 26
11 12 43 10 33 24 17 7 6 16 22 19
9 38
CM97G028

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 Electronic control box 24 volt supply and troubleshooting test socket Sh8 Shunt (pilot system cancellation) remove shunt Sh4 and install it at Sh8
F1 Fuse, 30 A, cold start assistance (optional) V1 General contact diode
F2 Fuse, starter switch (5 A) V2 K3 relay diode
F3 Fuse, instrument panel (7.5 A) V3 Dipped headlight indicator lamp diode
F4 Fuse, cab lighting, horn relay (5 A) V4 Radio diode (optional)
F5 Fuse, 10 A, headlight and rotary light relay (specific to certain countries) V5 Rear fog light indicator lamp diode (specific to certain countries)
F6 Fuse, upperstructure headlights (15 A) V6 Main beam headlight indicator lamp diode
F7 Fuse, horn (10 A) V7 RH direction indicator green indicator lamp
F8 Fuse, upperstructure power line connection (15 A) V8 LH direction indicator green indicator lamp
F9 Fuse, windshield washer, windshield wiper (10 A) V9 Hazard warning diode
F10 15 A Fuse, ventilation, heater, fuel heater V10 LH direction indicator diode
F11 Fuse, 7.5 A, cigarette lighter V11 Pilot system cancellation diode (specific to certain countries)
F12 Fuse, 10 A, pilot safety V16, V17, V19 Pilot system cancellation diode (specific to certain countries)
F13 Fuse, 5 A, overload indicator (optional) V18 Axle unlocking indicator lamp diode (specific to certain countries)
F14 Fuse, 5 A, radio (optional) V20 RH direction indicator diode
F15 Fuse, 15 A, main beam headlight V21 Overload indicator diode (optional)
F16 Fuse, 5 A, RH stop light V22 Rotary light indicator diode (specific to certain countries)
F17 5 A Fuse, LH stop light V23 Hazard warning diode
F18 Fuse, 5 A, RH front position light
F19 Fuse, 5 A, LH front position light 2 Connection, starter motor - starter motor solenoid valve control
F20 Fuse, 5 A, RH front dipped headlight 4 Printed circuit earth
F21 Fuse, 5 A, LH front dipped headlight 5 Connection, upperstructure socket - fuel filler pump (optional)
F22 Fuse, 5 A, Rear fog light (specific to certain countries)
F23 Fuse, 5 A, RH main beam headlight
F24 Fuse, 5 A, LH main beam headlight : see page 4
F25 Fuse, 7.5 A, parking brake
F26 Fuse, 7.5 A, direction indicators, hazard warning
F27 Fuse, 5 A, adjustable or articulated boom
F30 Fuse, 15 A, cab working lights (optional)
F31 Fuse, 15 A, windshield wiper intermittent action
F32 10 A fuse, not used
F33 Fuse, 7.5 A, electronic control box
H14 LED troubleshooting
K1 Starter motor relay
K2 General contact relay 24 V, 50 A
K3 Hourmeter relay
K4 Electrical control box supply relay
K5 Horn relay
K6 Attachment and cab rear working light relay
K7 Upperstructure headlight and working light relay
K9 Axle unlocking relay
K10 Flasher unit relay
K21 LH control arm pilot safety relay

4001-9
CS97G035

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
AA
A
A5
A AA 2 1
A AAAAAAAAAAAAA
AAA
AA
A AAAAA
AAAAAAAA
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
CM97G029
E1 Minimum braking 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 warning lamp connector 11 Minimum pilot pressure red warning lamp
A3 Hydraulic oil temperature indicator connector E3 Parking brake red warning lamp connector 12 Overload indicator orange indicator lamp (optional)
A4 Battery charge red warning lamp connector E5 Rear fog light orange indicator lamp connector (specific to certain countries) 14 Pilot system cancellation green indicator lamp (specific to certain countries)
A5 Audible warning red, orange indicator lamp connector E6 RH direction indicators green warning lamp connector 16 Front axle unlocking orange indicator lamp
A6 Front axle unlocking orange indicator lamp connector 24 Rotary light orange indicator lamp (specific to certain countries)
F1 LH direction indicators green indicator lamp connector
A7 Engine oil pressure red warning lamp connector 25 Minimum steering pressure red warning lamp
F2 Rotary light orange indicator lamp connector (specific to certain countries)
26 Parking brake and working brake red warning lamp
B1 24 Volts supply F5 Side light green indicator lamp connector
27 Minimum braking pressure red warning lamp
B3 Earth F6 Main beam blue indicator lamp connector
28 Rear fog light orange indicator lamp (specific to certain countries)
B4 Fuel level indicator connector F7 Minimum steering pressure red warning lamp connector
29 LH direction indicator green indicator lamp
B5 Indicator lighting connector
P1 Engine coolant temperature indicator 30 Main beam blue indicator lamp
B6 Engine coolant temperature indicator connector
P2 Fuel level indicator 31 Side light green indicator lamp
B7 Fuel minimum level connector
P3 Hydraulic oil temperature indicator 32 Hazard warning red warning lamp
C2 Air filter restriction red warning lamp connector 33 RH direction indicator green indicator lamp
1 Stop alarm red warning lamp
C4 Overload indicator orange warning lamp connector (optional) 39 Instrument panel lamp
2 Alarm orange indicator lamp
D2 Pilot system cancellation green indicator lamp connector (specific to cer- 3 Audible warning stop push button
tain countries) 6 Engine oil pressure red warning lamp
D3 Hydraulic oil filter restriction red warning lamp connector 7 Air filter restriction red warning lamp

4001-11

A B
1 2 3
5 4 5 4
6 7 3 6 7 3
1 2
A B 1 2
P3
C D
P1
140 159 23 17 138 13 71 18 11 137 0 19
5 4 C D 5 4
6 7 3 6 7 3 39
1 2 1 2
15 168
E F
156 16 6
P2
5 4 5 4
6 7 3 6 7 3
1 2 1 2
F
7
E
161 162 84 164 83 160 166 163 82 167 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).
CS97G034
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 indicator lamp 28 Rear fog light orange indicator lamp (specific to
brake red warning lamp, rear fog light orange indicator lamp (specific to certain countries), RH direction indica- 3 Audible warning stop push button certain countries)
tors green indicator lamp. 6 Engine oil pressure red warning lamp 29 LH direction indicator green indicator lamp
7 Air filter restriction red warning lamp 30 Main beam blue indicator lamp
F 7 way connector : LH direction indicator green indicator lamps, rotary light orange indicator lamp (specific to 8 Battery charge red warning lamp 31 Side light green 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 32 Hazard warning red warning lamp
red warning lamp. 11 Minimum pilot pressure red warning lamp 33 RH direction indicator green indicator lamp
12 Overload indicator orange indicator lamp 39 Instrument panel lamp
(optional)
P1 Engine coolant temperature indicator
14 Pilot system cancellation green indicator lamp
P2 Fuel level indicator
(specific to certain countries)
16 Front axle unlocking orange indicator lamp
24 Rotary light orange indicator lamp (specific to
certain countries)
25 Minimum steering pressure red warning lamp
26 Parking brake red warning lamp

4001-12
SC1 V14 V15 38
A SC4 0
A
A
AA
AA
H11 10 9 71
AA
141
8
AA 6 5 136
AA
SC2
B52 H15 AA
AA
S6 4 3
1
37
AA
V V
C C
140 0
AA
38
141
SC3
AA
0 40
0
AA
65 66
AA H12 10 9 71
22 22
S3 0
AA AA AA
AAA
AA
84
B51
AA AA AA
AAA
AA
22 0 22
AA AA AA
AAA
AA
82 0 5
AAAAAA AAA
AA
S26 1
10 9
H51 37
B53 45
0
6 5
S51 10 9 71
2 1
0 3
H13
63
5
A
0 S22 3
H50 10 9
B
83 S27 1
8 46
41
6
B50 28
S50 4 3
0
Y15
AA H10
2 1 10 9 71
powersensor
AA
S1
5 7 AA
AA
5
S4
6
1 29
C C C C
105 105 64 147 63 71 0 63 99 94 94 48 86 71 0 86 89 165 5 6 7
6 1 6 1 6 1
5 2
J14 5 2
J13 5 2
J15 0
4 3 4 3 4 3 10 9 71
0
H31
6 1 86 6 1 65 6 1 105 5 28
10 9 71
0 5 2 87 77 5 2 69 54 5 2 50
H55
22 4 3 88 65 4 3 72 53 4 3 51
S25 1 31
5 75
S24
S55 1 76
CM97G033

4001-13

COMBINATION SWITCH WIRING (STANDARD)
B50 Parking brake pressure switch
B51 Stop light pressure switch
B52 Minimum braking pressure switch
B53 Steering pressure switch
H31 Rotary switch lighting
H50 Working brake and parking brake switch lighting
H51 Hazard warning switch lighting
H55 Rear fog light switch lighting
J13 Steering column connector
S1 Key switch
S3 Horn switch
S50 Parking brake and working brake switch
S51 Hazard warning switch
S22 Control panel (see Section 4002)
S25 Rotary light switch
S55 Rear working lights switch
SC1 Combination switch for direction indicator (commodo), dipped headlights, headlights main beam, 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

4001-14
V52 H15
AA
101
82 0 H53 10 9
AA
AA
+ -
AA
101 0
5 100 102AA
AA
140
S53
AA
82 0
V50
0
1
AA
AA
H30 229
AA
229 128
AA
AAA
AA AA
AAAAAA
AA
127
10 9 0 3
AA
AAA AA
S20 5 3
AA
AAA
AA AA
AAAAAA
AAA AAAA
V51
1 62
S30
56
H52 90 59
229
0
H32
10 9
0 powersensor
H58 7 105
0 5 106
229 10 9
S52 1 109
229 10 9
5
7 100
S21
1
3 56
S56 1 102 145 91
38 24 16 6
9
1
2
CM97G034

4001-15

H52 Pilot system cancellation switch lighting (specific to certain countries)
H53 Front working light switch lighting (optional)
H15 Audible warning
S52 Pilot system cancellation switch (specific to certain countries)
S53 Front working lights switch (optional)
V50 Quick coupler diode (optional)
1 Steering brake harness (specific to certain countries)
2 Quick coupler harness (optional)
3 Braking unit harness (standard)
6 Adjustable boom control harness (specific to certain countries)
9 Cold start assistance harness (optional)
16 Overload indicator harness (optional)
24 Front working lights harness (optional)
38 Pilot system cancellation harness (specific to certain countries)

4001-16

F1 Fuse, 30 A, cold start assistance G1 Batteries
F2 Fuse, starter switch (5 A) S2 Battery master switch
F3 Fuse, 7.5 A, injection pump solenoid valve, Y53 Fuel filler pump (optional)
hourmeter
ENGINE
Y1 G2 F8 Fuse, 15 A, fuel filler pump
R11 F10 Fuse, 15 A, fuel heater G2 Alternator
S1 S2
R50 F19 Fuse, 5 A, switch lighting M1 Starter motor
P10 K1 Starter motor relay R11 Pre-heater plug
K2 General contact relay 24 Volts, 50 A R50 Fuel heater (optional)
Y53 M1 K3 Hourmeter relay Y1 Injection pump solenoid
CAB
K15 Cold start assistance relay
R10 Resistor 0.85 Ohm P4 Hourmeter
Sh5 Shunt P10 Instrument panel (See page 19)
V1 General contact diode SC1 Combination switch for direction indicator (com-
modo),dipped headlights, headlights main beam,
2, 4, 5 : see page 4
sidelights, headlight flasher and horn
FLOOR
S1 Key switch
A
S20 Cold start assistance momentary switch
(optional)
G1
F1 - F2 - F3 - F8
F10 - F19
SC1 K1 - K2 - K3
S20 - H30 K15 - K53
P4 R10 - V1 - Sh5
CM97G035

4001-17
MASTER
BATTERY CHARGE
SWITCH STARTER KEY SWITCH COLD START ASSISTANCE ALTERNATOR FUEL FILLER PUMP COMBINATION
MASTER MAIN RELAY ENGINE SHUT DOWN WARNING FUEL HEATER (OPTIONAL)
STARTER STARTER MOTOR RELAY (OPTIONAL HOURMETER (OPTIONAL) SWITCH (COMMODO)
SWITCH LAMP
MOTOR
97 + 12V 97
2 + 24V 2
2
2 9
1
9 +24V
F2 F1 F3 F10 SC1
5A 30A 7.5A 15A
G1 A4
8 3 11 41 F8
0123
3 (1) 15A
1 2
V1 12
5 2 J13 (2)
3 (3) P10
9 (2) 5 (9)
2 (5) S20
11 69
S1 H30
30 9 5 3
1 F19
K53
36 5A
R012 4 5 2
58 50 15 10 1 3
1 K3 14 71
9 (1)
3 (9) 2 (9) 2 5 4
62
4 13 14
6 7 2 3
K15 R50 Sh5
5 1 1 4
1 K15 5 4 4 (8) 229
2 4 (6)
123 4 (4) 5
3 2 2 3 T
30 K1 K2 B+ D+ W
23 (1) 19 19 19
M1 G2
50 R10
S2
23 (2)
2 Y53
119
229 Y1
22 1
0 24
9 h P4 M
R11
0 0 0 0 3 (10)
0
0
4 12 4
CM97G036

4001-18

P10 Instrument panel (see schematic plate 1 page 8) B50 Parking brake pressure switch
H32 Overload indicator switch lighting (optional) B52 Brake pressure switch
S21 Overload indicator switch (optional) B53 Orbitrol pressure switch
P10 B22 ELECTRICAL CABINET
B4
P11 - X10 B1 UPPERSTRUCTURE
F3 Fuse, instrument panel (7.5 A)
F13 Fuse, 5 A, overload indicator B1 Air filter restriction pressostat
F19 Fuse, 5 A, switch lighting B2 Hydraulic oil filter pressostat
Sh5 Shunt B21 Hydraulic oil temperature sender
V21 Overload indicator diode (optional) B23 Overload indicator pressure switch (optional)
P11 Fuel level indicator
see page 4
X10 (A) (B) (C) Fuel level indicator connectors.
CAB
ENGINE
SC1 Combination switch for direction indicator (com- B4 Engine oil pressure switch
modo),dipped headlights, headlights main beam, B22 Engine coolant temperature sender
sidelights, headlight flasher and horn
B23
H15
B52 - B53 B21

B2
S21 - H32 SC1 B50 F3 - F13 - F19
V21 - Sh5
CM97G035

4001-19
INSTRUMENT PANEL
HYDRAULIC INST. PANEL PARKING BRAKE
AIR FILTER ENGINE FUEL LEVEL ORBITROL OVERLOAD INDICATOR COMBINATION SWITCH
OIL FILTER HYD. OIL AUDIBLE BRAKE MINIMUM
RESTRIC- OIL RESERVE ENGINE TEMPERATURE PRESSURE (OPTIONAL) (COMMODO)
RESTRIC- TEMP. WARNING PRESURE PRESSURE
TION PRESSURE WARNING
TION DEVICE
97 +12V 97
2 +24V 2
9 +24V 9
F3
7.5A SC1
F13
11 5A 0123
84 83 82 168
3 (3) 91
J13 (2)
16 (2) 5 (9)
B1 E1 E3 F7 C4 4 (2) 4 (4) 4 (3) S21
H32 69
P10 B3 9 5
B6 F19
C2 D3 A7 B7 B4 A3 A5 5A
82 83 84 10 1
71
3 (4) 1 (4) 3 (2) 1 (2) 1 (3) 1 (1) 3 (5) 16 (1)
168 229 145
15 16 23 137 19 138 140 18 3 (5) 3 (3) 3 (4)
33 (1) Sh5
4 (5) 1 (5) 4 (7) 1 (7) 1 (6) 1 (8) 4 (2) 229
X10 (B) X10 (A)
P P P
B53 B50 B52 19 19 19
P P P 30 (2) P B23
B21 B22
B1 B2 B4 H15
P11 X10 (C)
146
33 (2)
V21
0
0 6 (2)
168
0 0 0 0 0
4 3 16
CM97G038

4001-20

F12 Fuse, 10 A, pilot safety Y2 Pilot safety solenoid valve
F19 Fuse, 5 A, switch lighting Y11 Gear box solenoid valve (first speed)
Y2 - Y11 - Y12 F25 Fuse, parking brake (7.5 A) Y12 Gear box solenoid valve (second speed)
SC2 - SC3 - SC4 Y13 - Y26 - Y27 K9 Front axle unlocking relay Y13 Front axle unlocking solenoid valve
Y16 K21 Pilot safety relay Y15 Parking brake and working brake control sole-
K52 Speed change relay noid valve
V14 - V15 Sh4 Shunt (standard equipment) Y16 Working brake solenoid valve (Standard)
V18 Axle unlocking diode Y26, Y27 Stabilizer solenoid valves
Sh2 Shunt
CAB
1 Connecting strip
4 : see page 4
SC1 Combination switch for direction indicator (com-
FLOOR modo), dipped headlights, headlights main
beam, sidelights, headlight flasher and horn
A2 Electronic control box
SC2 Front axle automatic and manual unlocking
switch
SC3 Front axle locking and unlocking switch (in
unlocked position)
A
SC4 Stabilizer raising and lowering momentary
inverter switch
B54 Front axle unlocking pressure switch
J13 Steering column connectors
S24 Pilot safety switch (hand control lever shown in
raised position)
V14-V15 Stabilizer solenoid valve diodes (in combi-
nation switch (commodo)
X3(20) Connector, 35-way
F12 - F19 - F25

P10 K9 - K21 - K52
Sh2 - Sh4
V18 - 1
S24
J13 - J15
B54
SC1
B3 Y15
A2 - X3 S50 - H50
CM97G035

4001-21
AXLE PILOT
SECOND SPEED FIRST SPEED
UNLOCKING PRESSURE AXLE UNLOCKING COMBINATION SWITCH STANDARD WORKING
SOLENOID SOLENOID TWO-SPEED RELAY PILOT SAFETY SYSTEM STABILIZERS AXLE UNLOCKING CONTROL PARKING BRAKE
INDICATOR WARNING SOLENOID VALVE (COMMODO) BRAKE
VALVE VALVE
LAMP LAMP
97 +12V 97
2 +24V 2
9 +24V 9
F12 SC1
F25
10A
7.5A
0123 99
49
Sh4 105
7 (1)
6 (6) J13 (2)
37 (2) 39 (1) 219
0
5 (9)
K52 3 1 J15 (1)
S24 69
K52
4 5 2
2 me 1 re NO NC 57
SC4 SC2 F19 H50 10 1 7 2 8
37 (5) 37 (4) 3 (7) 6 (7) S50
SC3 5A
1 0 1 0
64 147 V15 71
V14 9 5 6
7 (2)
J15 (2) J15 (3) J15 (4) J15 (5)
3 5 (2) 5 (3) 53 105 71
3 S2 1
X3 (20) K21 5 (1)
2 54
5 4 5 4 P B54
K9
V18 1
4 (5) 4 (8)
2
K9 63 94
4 (7) 3 (2) 28
159 58 55 148 50 51
52 106
A6 P10 A2
2 (4) 2 (3) 2 2
2 (2) 1 (2) 6 (8) 2 (9) 2 (8)
2 2 A2 2 2 2 2 1 1
0 Y15 Y16
P
1 1 17 1 Y13 1 Y2 B3 1 Y26 1 Y27
Y12 Y11
0 0 0 0
0
2 4 3 28
CM97G040

4001-22

F4 Fuse, 5 A, driving position lighting, torque con- B51 Stop light pressure switch
verter relay H26 Horn
F7 Fuse, 10 A, horn J13 Steering column connectors
F15 Fuse, 15 A, main beam headlights J14 Steering column connectors
F16 Fuse, 5 A, RH brake lights X5(B) Steering brake pressure switch
F17 Fuse, 5 A, LH brake lights
UPPERSTRUCTURE
F18 Fuse, 5 A, RH front position light
E10 - E13 - E21 F19 Fuse, 5 A, LH front position light E10 RH rear stop light
SC1 S3 F20 Fuse, 5 A, RH front dipped headlight E11 LH rear stop light
P10 F21 Fuse, 5 A, LH front dipped headlight E12 Front RH side light
F23 Fuse, 5 A, RH main beam headlight E13 Rear RH side light
F24 Fuse, 5 A, LH main beam headlight E14 Front LH side light
E31 F26 Fuse, 7.5 A, direction indicator, hazard warning E15 Rear LH side light
lights E16 Front RH dipped headlight
K5 Horn relay E17 Front LH dipped headlight
K7 Upperstructure and attachment working light E18 RH main beam headlight
relay E19 LH main beam headlight
K10 Flasher unit E20 RH front direction indicator
Sh5 Shunt E21 RH rear direction indicator
V3 Dipped headlight indicator lamp diode E22 LH rear direction indicator
A
V6 Main beam headlight indicator lamp diode E23 LH front direction indicator
V7 RH direction indicator green indicator lamp E31 RH front side mounted direction indicator
V8 LH direction indicator green indicator lamp E32 LH front side mounted direction indicator
V10 LH direction indicator diode
V20 RH direction indicator diode
: see page 4
CAB
P10 Instrument panel (See page 19)
E20 S3 Horn switch
SC1 Direction indicator (commodo), main beam and
E12 - E16 dip switch, side lights and headlight flasher switch
E18
E11 - E15 - E22
X5 F4 - F7 - F15 - F16
F17 - F18 - F19 - F20
B51 F21 - F23 - F24 - F26
S51 - H51 K5 - K7 - K10 - Sh5
H26 E32 V3 - V6 - V7 - V8 - V9 - V10
J13 - J14 V20 - V23
E23
E14 - E17
E19
CM97G035

4001-23
COMBINATION SWITCH
HORN BRAKE LIGHT SIDE LIGHT DIPPED HEADLIGHTS MAIN BEAM HEADLIGHTS DIRECTION INDICATOR LIGHTS HAZARD WARNING LIGHTS
(COMMODO)
97 +12V 97
2 +24V 2
9 +24V 9
F4 F7 F15
5A 10A 15A
65 85
F26
22 7.5A
4 (1) 49 31
26 34 SC1 J13 (1) J14 (4) K10
3 (6) 49A
44 (2)
44 (1)
2 (10) 44 (3)
P 0123
4 (6)
B51 66 86
22 72 77
J13 (2) J14 (1)
3 (1) J13 (3) J13 (5) J14 (5) S51 6 5
5 (9) SC1 10
S3 5 (4) 5 (7) H51
69 0 0
1
0
1
2 K5 3 F20 F21 F22 F23 F24 J14 (2) J14 (3)

K5 F16 F17 F18 F19 8 2 7 1 9
5 4 5A 5A 5A 5A 5A 5A 5A 5A 5A 162
1
67 1 7 (6) 7 (3) 7 (5) 7 (8) 7 (4) 7 (9)
35 71 75
68 2 K7 87 88
3 (8) 43 (2) V7 V8
5 (1) 1 (3) 2 (5) 7 (2) 2 (10) 4 (10)
89
2 (1) 5 (2) V10 163
70 V3 V6
165
Sh5 V20
H26 229
160 78 79 166
V23
V9
2 (6) 5 (3) 7 (10)
19 19 19 19 7 (7) 2 (7) 5 (6) 5 (8)
5(10) 71 0
73 74
E10 E14
164 0
0 0
E11 E12 E13 E15 E16 E17 E18 E19
30 (1)
0 0 0 0 0 0 0 0 0 0 E20 E31 E21 E22 E23 E32
F5 F6 E6 F1 E2 B5
2 5 4
P10
CM97G042

4001-24

H10 Working light switch lighting E1 Cab interior light
H11 Windshield wiper switch lighting E50 Front cab working lights (optional)
H12 Windshield washer switch lighting E51 Rear cab working lights
H31 Rotary light switch lighting (optional) M2 Windshield wiper motor
H53 Front cab working light switch lighting (optional) cable item 144 = blue cable
S4 Working light switch cable item 142 = grey cable
E1 - S10 S6 Windshield wiper switch cable item 0 = black cable
E51 H57 S25 Rotary light switch (optional) cable item 38 = white cable
H50
M2 S26 Windshield washer switch P10 Instrument panel (See page 19)
S53 Front cab working light switch lighting (optional) S10 Cab interior light
ELECTRICAL CABINET
dip switch, side lights and headlight flasher
F4 Fuse, 5 A, cab interior light switch
F5 Fuse, 10 A, headlight and rotary light relay (spe- X1 (E) Cab floor/Cab windshield wiper motor blue
cific to certain countries) connector
F6 Fuse, 15 A, upperstructure working lights X1 (G) Cab floor/cab connector
F9 Fuse, 10 A, windshield washer, windshield wiper X1 (J) Cab floor/Cab windshield wiper motor white
F18 Fuse, 5 A, K7 relay coil connector
F19 Fuse, 5 A, switch lighting X1 (K) Cab floor/cab connector
A
F30 Fuse, 15 A, front cab working lights X1 (L) Cab floor/Cab windshield wiper motor grey
F31 Fuse, 15 A, windshield wiper intermittent action connector
K6 Working light relay X1 (M) Cab floor/Cab windshield wiper motor black
K7 Upperstructure and attachment working light connector
relay X1 (F) Cab floor/Cab rotary light connector (optional)
FLOOR
Sh5 Shunt
V22 Rotary light indicator lamp diode (specific to M3 Windshield washer motor
certain countries)
UPPERSTRUCTURE
4 : see page 4
H57 Standard rotary light (optional)
X5 (A), (C) Attachment working light power connection
X1
X5
E2
F4 - F5 - F6 - F9
F18 - F19 - F30 - F31
K6 - K7 - K20
P10 V22
S4 - S6 - S25 - S26 - S53 SC1 Sh5
M3
H10 - H11 - H12 - H31 - H53
CM97G035

4001-25
ROTARY
ROTARY LIGHT ATTACHMENT COMBINATION SWITCH FRONT CAB WORKING
CAB LIGHTING LIGHT REAR CAB WORKING LIGHT WINDSHIELD WIPER WINDSHIELD WASHER
INDICATOR LAMP WORKING LIGHT (COMMODO) LIGHTS (OPTIONAL)
(OPTIONAL)
97 +12V 97
2 +24V 2
9 +24V 9
SC1
F4 F5 F6 F31 F9 F30
5A 10A 15A 15A 10A 15A
0123
28 32 144 37
127
26 2 (4) 1 (5) J13 (2)
24 (1)
5 (9)
S4 S6 S26 69 H53
S25 S53
H31 H10 H11 H12
9 5 9 5 9 2 6 1 5 9 1 F18 F19 9 5
2 1 0 2 1 0
5A 5A
10 1 10 1 10 4 8 3 7 10 5 10 1
136 38 7 (2)
31 29 2 (3) 6 (4) 2 (2)
20 (1) 142 26 (6) 40 24 (3)
6 (3) 6 (1) 20 (3) 229
26 (4) 26 (5)
3 1 20 (6) 2 (1) 128
K7 141 26 (1)
X1 (K) 167 19
4 5 2 K7 26 (2) 27 (2) 21 (1)
E1 20 (2) V22 30
2 3 2B
4B
5 4 1A 20 (5) X1 (H)
S10 X1 (F) 1 K6 K6 3B X1 (E) M3
6 (5) 33 K20 5B X1 (L)
1B X1 (J) 70
1(4) 8 X1 (M)
31
X5 (C) X1 (G) E50
H57
M2
F2
E2 E51
0 0 0 0 0
P10 X5 (A) 0
0 0
0 0
0
20 26 (3)
27 (1)
4
CM97G044

4001-26

F8 Fuse, 15 A, upperstructure power line connec- B5 Right-hand loudspeaker (optional)
tion B6 Left-hand loudspeaker (optional)
F10 Fuse, 15 A, blower, heater M6 Blower motor (optional)
F11 Fuse, 7.5 A, cigarette lighter/cab blower (optional) X1(A),(B),(C),(D) Cab floor/cab LH and RH loud-
F14 Fuse, 5 A, radio speaker connector (optional)
F19 Fuse, 5 A, switch lighting X14 (1),(2) Blower motor connector (optional)
V4 Radio diode (optional)
B5 B6 UPPERSTRUCTURE
M6 - S29 - X14 5 : see page 4
X2 Upperstructure power connection
INSTRUMENT PANEL
SC1
X2 H13 Blower/heater switch lighting
S27 Blower/heater switch
S29 Blower switch (optional)
FLOOR
A1 Radio (optional)
M4 Blower/heater motor
A
switch
X1
F8 - F10 - F11 - F14

F19
V4
S27 - H13 A1
M4 E7
CM97G035

4001-27
UPPERSTRUCTURE
CIGARETTE CAB BLOWER COMBINATION SWITCH
RADIO (OPTIONAL) POWER LINE VENTILATION/HEATING
LIGHTER (OPTIONAL) (COMMODO)
CONNECTION
97 +12V
2 +24V 2
9 +24V 9
SC1
F10 F11
97 15A 7.5A
F14 F8 41 48 0123
5A 15A
2 (6) 2 (7) J13 (2)
S27 5 (9)
93 H13
69
9 3 48
F19
5A
10 5 1 E7 X14 (1)
V4
92 36 7 (2)
2 (8)
2 me 1 re
+ 45
A1 46
- 5
1 (7) 1 (8) 1 (6) 1 (9)
132 134 133 135 M4
S29
21 (4) 21 (5) 21 (3) 21 (6)
M6
X1 (D) X1 (C) X1 (B) X1 (A)
4
+ + X14 (2)
0 - - 1 X2
B5 B6
0 0 0 0 0
CM97G046

4001-28

F2 Fuse, 5 A, starter switch B7 Swing detector pressure switch
F19 Fuse, 5 A, switch lighting B10 Swing motor speed detector
F33 Fuse, 7.5 A, electronic control box B11 Hydraulic pressure sender
H14 Diagnostic (LED) lamp B57 Speed change pressure switch
K3 Hourmeter relay G1 Batteries
K52 Speed change relay S2 Battery master switch
M5 - X9 - P12 K4 Electrical control box supply relay Y5 Upperstructure brake release control solenoid
Y5 B10 - X7 S2
S22 Sh5 Shunt valve
SC1 G2 V1 General contact diode
B22 ENGINE
V2 K3 relay diode
1 Connecting strip B9 Engine speed detector
Y4 B22 Engine coolant temperature sender
CAB
G2 Alternator
A2 Electronic control box M5 Injection pump servo-motor
S22 Control panel P12 Servo-motor potentiometer
SC1 Direction indicator (commodo), main beam and X6 Engine speed detector connector
dip switch, side lights and headlight flasher switch X7 Upperstructure swing speed detector connector
X3 35 -way connector X8 Hydraulic pressure sender connector
X4 Troubleshooting socket X9 Injection pump servo-motor connector
A
Y4 DRE 4 proportional pressure reduction valve
FLOOR
B8 Travel detector pressure switch
S1 Key switch
4 : see page 4
B9 - X6
B57 X4 G1
F2 - F19 - F33
K3 - K4 - K52
B7 V1 - V2
B8 H14
Sh5 - 1
S1 A2 - X3 B11 - X8
CM97G035

4001-29
PRESSURE SWITCH UPPER-

DRE4 SWING
STRUC- DIAG +28V
ENGINE PRES- BRAKE TRAVEL 0V +28V SPEED CHANGE
INJECTION PUMP WATER TURE NOS- INST.
TROUBLESHOOTING SOCKET SPEED SURE RELEASE SPEED BAT- BAT- CONTROL PANEL PRESSURE SENDER PRESSURE
SERVO-MOTOR SWING TRAVEL T SWING TIC PANEL
DETECTOR REDUCING SOLENOID RELAY TERY TERY SWITCH
SPEED LED LIGHTG
VALVE VALVES
DETECTOR
A2
X3
23 6 22 5 15 32 14 9 27 21 4 3 29 13 12 20 31 10 28 24 1 2 19 11 26 7 25 8 18 17 35 30
200 201 205 206 202 203 204 207 208 209 210 211 213 214 215 219 18 222 223 224 0 234 234 229 225 226 227 228 230 231 232 237
30 (4)
31 (1)
30 (3)
3 3 2
30 (6) H14 P
P P
1 B7 1 B8 1 B57
31 (2) 31 (3)
1 2 5 6 7 A B A B C A B
X9 X6 X7 X8 98
234
2
+ - B3 A1 B1 B2
+ - + 0 - + -
B 1 Y5
B9 2 30 (2) B10 37 (3)
A C S22
30 (5) 30 (1)
M5 1 Y4
V2
X4 P12 SC1
B11 24
2 +24V 0123
2 (5)
S1
1
30 J13 (2)
1 5 (9) 0 1 K3 3
K3
5 F2 1
R012 3 5 4
5A 69 2
58 50 15
1
8 237 G1 14
2 (9) K52 B22
2 229 F19
7 V1 5A 4 (8)
F33 S2
13 4 (4)
1 3 K4 7.5A 71
0 B+ D+ W
2
K4 4 236 G2
2 5
0 0 0 0 Sh5
0 0
4 30
19 19
CM97G048

4001-30

F19 Fuse, 5 A, switch lighting B56 Adjustable boom raising range limitation detec-
F27 Fuse, 5 A, adjustable boom and adjustable tor (optional)
boom range limitation Y7 Adjustable or articulated boom extending elec-
K50 Adjustable boom raising range limitation relay tro-valve
(optional) Y8 Adjustable or articulated boom retracting elec-
K51 Adjustable boom lowering range limitation relay tro-valve
(optional) Y50 Adjustable boom raising height limiter solenoid
Y51 - Y52 Y50 B56 Sh5 Shunt valve (optional)
1-2 Connecting strip Y51 Quick coupler attach solenoid valve (optional)
Y7 - Y8 Y52 Quick coupler attach solenoid valve (optional)
see page 4
S30 INSTRUMENT PANEL
CAB
P10 H58 Quick coupler switch lighting (optional)
SC1 Direction indicator combination switch (com-
V50 Quick coupler diode
modo) (dipped headlights, main beam head-
lights, parking lights and headlight flasher
selection)
H15
F19 - F27
V50 - V51 - V52 K50 - K51
Sh5
SC1 1-2
S56 - H58
CM97G035

4001-31
ADJUSTABLE BOOM
OR ADJUSTABLE BOOM RANGE LIMITATION COMBINATION SWITCH
QUICK COUPLER (OPTIONAL)
ARTICULATED BOOM (OPTIONAL) (COMMODO)
(OPTIONAL)
2 +24V 2
9 +24V 9
F27
5A
SC1
V51
14 102
56 101
100 0123
15
2 V52
S30 7 1 9 J13 (2)
1
1
5 (9)
4 0 2
69
3 P10
90
B56
59 F19
126 56 A5 5A
3 10
6 (1) 6 (2) S56 229
H58 71
V50 140 56
10 (1)
10 (2) Sh5
K51 K50
229
30 86 86 30 102 100
19 19 19
85 85 87 87A H15
87A 87 1 2
2 2 2
2 2 1 Y50 1 1
Y51 Y52
1 Y7 Y8 1
0 0 0 0 0 0
14
6
CM97G050

4001-32
Supplement for Italy UPPERSTRUCTURE
ELECTRICAL CABINET E29 Registration plate lighting (Italy)

H56 Upperstructure rotary light (Italy)
F5 Fuse, 10 A , Headlight/rotary light relay (Italy) Y2 Pilot safety solenoid valve
F12 Fuse, 10 A, pilot safety Y11 Gear box solenoid valve (first speed)
F19 Fuse, 5 A, switch lighting Y12 Gear box solenoid valve (second speed)
F25 Fuse, 7.5 A, parking brake Y13 Front axle unlocking solenoid valve
H56 K9 Front axle unlocking relay Y15 Parking brake and working brake control sole-
SC2 - SC3 - SC4 H57
Y2 - Y11 - Y12 K52 Speed change relay noid valve
V14 - V15
Y13 - Y26 - Y27 Sh2 Shunt Y16 Working brake solenoid valve (Standard)
P10 Sh4 Shunt (not used) Y26, Y27 Stabilizer solenoid valves
Sh5 Shunt
Sh8 Shunt (pilot cancellation option special for Italy), CAB
remove shunt Sh4 and install it at Sh8) H31 Rotary switch lighting
V11 Pilot system cancellation indicator lamp (spe- H57 Cab rotary light (Italy)
cific to certain countries) P10 Instrument panel (See page 19)
V16, V17, V19 Pilot system cancellation indicator SC1 Direction indicator (commodo), main beam and
lamps (specific to certain countries) dip switch, side lights and headlight flasher
1 Connecting strip switch
S25 Rotary light switch
A
4: see page 4
X1 (F)Cab floor/cab connector
FLOOR
B55 Steering brake pressure switch (Italy)
H52 Pilot system cancellation switch lighting (spe-
cific to certain countries)
SC2 Front axle automatic and manual unlocking
switch
SC3 Front axle locking and unlocking switch (locked
axle shown)
SC4 Stabilizer raising and lowering momentary
inverter switch
E29 S24 Pilot safety switch (hand control lever shown in
X1
raised position)
F5 - F12 - F19 - F25 S52 Pilot system cancellation switch (specific to cer-
S25 - H31 S24 K9 - K52 tain countries)
B55 Sh2 - Sh4 - Sh5 - Sh8 V14-V15 Stabilizer solenoid valve diodes (in combi-
B54 V11 - V16 - V17 - V19 nation switch)
Y16 1 X3(20) A2 electronic control box 35-way connector
J13 - J15 S50 - S52 Y15
A2 - X3
H50 - H52
SC1
CM97G035

4001-33
SECOND AXLE
FIRST SPEED REGISTRA- STEERING
SPEED TWO-SPEED RELAY UNLOCKING PILOT AXLE UNLOCKING WORKING ROTARY CAB ROTARY
SOLENOID STABILIZER PARKING BRAKE TION PLATE - BRAKE
SOLENOID ROAD POSITION - ITALY SOLENOID SAFETY CONTROL BRAKE - ITALY LIGHT - ITALY LIGHT
VALVE ITALY PRESSURE
VALVE VALVE
2 +24V 2
9 +24V 9
F12 SC1
F25
10A 7.5A F5
10A
99 0123
49 28
105
7 (1) 2 (4)
J13 (2)
37 (2) 39 (1) 219 6 (6)
S25 5 (9)
K52 3 H31
1 J15 (2) 69 P10
S24
K52 9 5
4 5 2
2 me 1 re NO NC 57
SC4 SC2 F19
37 (5) 37 (4) 3 (7) 6 (7) 5A
10 1
SC3 F7
64 V15 H50
105 S50 71
V14 31 4 (2)
10 1 7 2 8
38 (1) J15 (3) J15 (4) J15 (5) J15 (6) 6 (3)
1 0 1 0 Sh5
K9 105
10 5 6
3 5 (2) 5 (3) 53 229
9 5 6
0 H52 5 (1)
Sh8 S52 Sh2 54 82
1 0 1 0
5 4 P B54 17 20 (2)
9 1 7 2 8
0
19 19
1
3 (5)
2 X1 (F)
38 (2) 38 (3) K9 4 (5) 4 (8)
159
109 63 94
4 (7)
V19 V16 V17 V11 58 55 50 51 3 (2) 28
106 52
H56 H57 E29
42 4 (9)
2 (3) 2 (4) P B55
2 (2) 1 (2) 2 (9) 2 (8)
2 2
2 2 2 2 2 2
1
1 Y11 1 Y12 156 1 Y13 1 Y2 1 Y26 1 Y27 1 1
Y15 Y16
0 0 0 0 0 0 0 0 0 0
X3(20)
P10
A6 1 2 4 3 28
A2
D2
CM97G052

4001-34
ELECTRICAL SCHEMATIC (PLATE11)

Supplement for Switzerland Supplement for Belgium
ELECTRICAL CABINET ELECTRICAL CABINET
F11 Fuse, 7.5 A, cigarette lighter/brake (Germany) F15 Fuse, 15 A, combination switch
F25 Fuse, 7.5 A, working brake/parking brake F19 Fuse, 5 A, switch lighting
Sh5 Shunt F22 Fuse, 5 A, rear fog light
CAB Sh5 Shunt
V5 Rear fog light diode
E12 - S28 E29 P10 Instrument panel FLOOR
S50 Parking brake and working brake switch J13 Steering column connector
FLOOR CAB
B55 Steering brake pressure H55 Rear fog light switch lighting
UPPERSTRUCTURE P10 Instrument panel (See page 19)
E20 RH front direction indicator dip switch, side lights and headlight flasher
E23 LH front direction indicator switch
Y15 Parking brake solenoid valve S55 Rear working lights switch
Y17 Working brake solenoid valve (Germany)
A
Y18 Working brake solenoid valve (Germany) UPPERSTRUCTURE
E25 Rear fog light
E29 Registration plate lighting
4: see page 4
Supplement for Northern Europe
ELECTRICAL CABINET
F4 Fuse, 5 A, engine compartment lighting
Sh5 Shunt
ENGINE
E12 Engine compartment light
S28 Engine compartment lighting
E20
E25
B55 F4 - F11 - F15 - F19

P10 F22 - F25
Sh5
Y15 V5
S55 - H55 Y17 - Y18
J13 S50 - H50
E23
SC1
CM97G035

4001-35
ENGINE COMPART-
FRONT RIGHT-HAND FRONT LEFT-HAND REAR FOG LIGHT
STEERING BRAKE MENT LIGHTING - REGISTRATION PLATE LIGHTING -
WORKING BRAKE - SWITZERLAND PARKING BRAKE DIRECTION INDICATOR DIRECTION INDICATOR LIGHT INDICATOR LAMP - FOG LIGHT - BELGIUM
PRESSURE NORTHERN BELGIUM
LIGHT - SWITZERLAND - SWITZERLAND BELGIUM
EUROPE
2 +24V 2
9 +24V 9
F25 F4 F15
7.5A 5A 15A
F11
7,5A 99 65
4 (1)
7 (1)
48 SC1 J13 (1) F22
26 5A
13 P10
0123 72 75
H50 10 3 7 4 8
J13 (3)
S50 J13 (2)
1 0 1 0 F7 7 5 (4)
2 2 5 (9)
4 (2) 69 43 (2)
9 1 5 2 6
F19
5A P10
10 5
S55
2 (6) 5 (3) 7 (10) H55
82
9 1
Sh5 E5
4 (8) 4 (5) 229 76
169 165
3 (5)
94 63
28 3 (2)
19 19 43 (1)
S28
V5
2 2 2 E20 E23
E12 5 (5) 11
P B55
1 1 1
Y18 Y17 Y15
E29 E25
0 0 0 0 0 0 0 0
0
28 3 3 2 4
7 11
CM97G054

4001-36
Supplement for Germany Supplement for Austria

F11 Fuse, 7.5 A, cigarette lighter/brake (Germany) P10 Instrument panel (See page 19)
F15 Fuse, 15 A, combination switch
FLOOR
F18 Fuse, 5 A, dipper lighting
F25 Fuse, 7.5 A, working brake/parking brake B55 Steering brake pressure switch
CAB
switch
4: see page 4
A
FLOOR
B55 Steering brake pressure switch
UPPERSTRUCTURE
E24 Dipper lighting
X5(A), X5(B) Dipper lighting connector
Y15 Parking brake solenoid valve
Y17 Working brake solenoid valve (Germany)
P10 Y18 Working brake solenoid valve (Germany)
P10
E24 - X5
B55 F11 - F15 - F18 - F25
P10 Y15
Y17 - Y18
J13 S50 - H50
SC1
CM97G035

4001-37
STEERING BRAKE STEERING BRAKE

WORKING BRAKE - GERMANY PARKING BRAKE DIPPER LIGHTING - GERMANY
PRESSURE PRESSURE - AUSTRIA
2 +24V
9 +24V
F25
7.5A F15
15A
F11
7,5A 99
4 (1)
7 (1)
48 J13 (1)
13 65
P10 P10
SC1
H50 10 3 7 4 8
S50 0 F7 F7
1 1 0
2 2 0123
9 1 5 2 6 4 (2) 4 (2)
J13 (2
5 (9)
69
82 82
F18
5A
4 (8) 4 (5)
3 (5) 3 (5)
94 63 70
28 3 (2) 1 (3)
X5 (B)
2 2 2
P B55 P B55
1 1 1
Y18 Y17 Y15 E24
X5 (A)
0 0 0 0 0
28 3 3 1 3
CM97G056

4001-38
CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)
E23 E19 - E17 - E14 H26

E32 E2
0 0 165 0 79 74 71 35 0
165
E12 - E16 - E18
E20
B51 B52 B53
J14 B A X5
4 3
1 86
5 2 33 0 7078 73 0 169 0 E31
6 1 0 5 2 87 65 66 84 0 82 0
22 4 3 88 169
0
35 6 1 79 J13 J15 H11
0 5 2 74 1 65 1 105 P10 S6
165 4 3 71
77 5 2 69 54 5 2 50 A B Y27 Y12
65 4 3 72 53 4 3 51 H12 P11
S26
C
19 A
D
H13 137 B
S27 51 0 52 0 0 C
Y13 Y26 Y11 Y2 X10
H10
0 S4
S3 F
E
H51 H31
S51 S25 58 0 50 0 1060 55 0
22 22
H50 H55
S50 S55 5 1 2 28 Y16
1 Y17 Y18
4
P4 B3 0
M4 H15 X2
140
94
0
94
94
0
0
Y15
B50 24 11 17 148 S22 S1 16
36 0
46 45 0
B2 S2
powersensor
83 0 7 5
+ -
63 0
- +
B54 6 B21 G1
144 31 0 138 Y1
53 105 132
M3 E7 11
142 X1
D E F
134 C L M
33 4 3 B22 18 3
105 133 B
G
48 B1
40 0 X4 K H
A J 0 2 2
6 1 G2 6 1
A1
64 105 0 15 0 B+
147 135 26 38 128 0 6 1 68 2 B4 0 6 1 67
M1 D+
2 71 W 2 70
92
S24 76 4 3 165 3 169
135 23 0 2 14 13
3 3 0 133 2 4
31 21 30
0 20
40 4 134 E10 - E13 - E21
1 2 3 E11 -E15 - E22
27 27 20 E25
132
43 5 6 7
CM97G057

4001-39
CAB FLOOR WIRING (STANDARD) ENGINE MODULE AND UPPERSTRUCTURE WIRING

(STANDARD EQUIPMENT)
3, 3, 20, 20, 21, 27, 31, 30,
1, 2, 3, 4, 5, 6, 7, 0, 43 1 24 volt supply before contact
FLOOR 1, 2, 4, 5 and 28
A1 Radio (optional)
B3 Pilot pressure pressostat UPPERSTRUCTURE
B51 Stop light pressure switch B1 Air filter restriction pressostat
B52 Braking minimum pressure switch B2 Hydraulic oil filter pressostat
B53 Steering pressure switch B21 Hydraulic oil temperature sender
B54 Front axle unlocking pressure switch E2 Attachment working light on boom
E7 Cigarette lighter E10 RH rear stop light
E14 Front LH side light E11 LH rear stop light
E17 Front LH dipped headlight E12 Front RH side light
E19 LH main beam headlight E13 Rear RH side light
E23 LH front direction indicator E15 Rear LH side light
E32 LH side-mounted direction indicator E16 Front RH dipped headlight
H10 Working light switch lighting E18 RH main beam headlight
H11 Windshield wiper switch lighting E20 RH front direction indicator
H12 Windshield washer switch lighting E21 RH rear direction indicator
H13 Heater blower switch lighting E22 LH rear direction indicator
H15 Instrument panel audible warning E25 Rear fog light
H26 Horn E31 RH side-mounted direction indicator
H31 Rotary switch lighting G1 Batteries
H50 Working brake and parking brake switch lighting P11 Fuel level indicator
H51 Hazard warning switch lighting S2 Battery master switch
H55 Rear fog light switch lighting X2 Upperstructure power connection
J13 Steering column connector (commodo) X5 Attachment working light power connection
J14 Steering column connector (commodo) X10 Fuel level indicator connector
J15 Steering column connector (commodo) Y2 Pilot safety solenoid valve
M3 Windshield washer motor Y11 Gear box solenoid valve (first speed)
M4 Heater blower motor Y12 Gear box solenoid valve (second speed)
P4 Hourmeter Y13 Front axle unlocking solenoid valve
P10 Instrument panel Y16 Working brake solenoid valve (Standard)
S1 Key switch Y17-Y18 Working brake solenoid valves (specific to certain countries)
S3 Horn switch Y26-Y27 Stabilizer raising and lowering solenoid valves
S4 Working light switch ENGINE
S22 Control panel (see Section 4002) B4 Engine oil pressure pressostat
S24 Pilot safety switch B22 Engine coolant temperature sender
S25 Rotary light switch (optional) G2 Alternator
S26 Windshield washer switch M1 Starter motor
S27 Heater blower switch Y1 Engine stop solenoid valve
S55 Rear working lights switch
X1 Cab floor/cab power connector
X4 Troubleshooting socket

4001-40
X9
227 225
6
228 226 1 2
3 4 B22
B1 B2 B3 A1 Y4
B10 5
S22
X6
237
powersensor
222 223
3
2 1 98 A B
232
231 230 227 225
228 226 X7 7
ABC M5 - P12
A2 X3 B10
B9
B57 9
K52 8
37
4 (2) 30 31 29 X7 Y5
X4 237 98
222 223 X4
B11
232 B8 28 9
B7 231 230 207 208
214 215 211 B8 B7
213 214 X8
Y5 0
A B
3 9
211 0
B57
2 1
27 10
213 214 1 2 25
3 3
2 1 214 26 10
215
24 12
11 10
207 X6 202
208 203 X9 23
204
205 4
209 210 206 22
M5 31
P12
21 A2 18
Y4 B9 30 30
16 37
20 B11
210 1
3
2 209
0 B22 14
18
19
K52
X3 17 X8
S22
B 203
B 202
4 5
6
B 3
2 17
206 13
B 205
B 204
15 29
CM97G058 CS97G033

4001-41

A2 Electronic control box 1 O-ring
B7 Swing detector pressure switch 2 Ring
B8 Travel detector pressure switch 3 Washer
B9 Engine speed detector 4 Lock
B10 Swing motor speed detector 5 Plug
B11 Hydraulic pressure sender 6 Clamp
B22 Engine coolant temperature sender 7 Pressure reduction valve
B57 Brake pressure switch 8 Electronic harness
K52 Speed change relay 9 Screw
M5 Injection pump servo-motor 10 O-ring
P12 Servo-motor potentiometer 11 Travel block
S22 Control panel 12 Swing block
X3 35 -way connector 13 Printed circuit card
X4 Troubleshooting socket 14 Decal
X6 Engine speed detector connector 15 Control panel fixing hardware
X7 Upperstructure swing speed detector connector 16 Nut
X8 Hydraulic pressure sender connector 17 Washer
X9 Injection pump servo-motor connector 18 Rivet
Y4 DRE 4 proportional pressure reduction valve 19 Screw
Y5 Upperstructure brake release control solenoid 20 Bracket
valve 21 Nuts
22 Washer
23 Screw
30Harness, 6-way connector, electronic control
24 Handle
box
25 Screw
31Harness, 3-way connector, troubleshooting test
26 Washer
socket
4 Harness, 8-way connector, engine
28 Engine harness
37Harness, 5-way connector, speed change
29 Strip
30 Harness, speed change

4001-42
CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)
E24
B23
AA
101 H15 X5
AA
0 70
V51 H56
AA
+ - 145 146
31
AA
101 0
V52
100 102 36
AA
V50
140
AA
82 82 0
AAAAAAAAA
0 0 Y53
AA
A AA
AAAAAAA 1
5
K50 125
H58 H52 H30 H53 11 7 K51 124 33
S56 S52 S20 S53 1 23 (1) 0
22
R10 19 K53 10
23 (2) 12 17 90
Y7
0
56 S30 59
Y8
0
102
90 59 56 Y51
56 0
125 B56 100
B55 Y50 126 Y52
0 0 0
0
E12
+
82
- +
41 0 26
-
R50
powersensor 0
R11
119 S28
H32
S21
0
229
38 9 3 24 15 6 16
102
100 E29
229 0
14 19 14 1
E29
CM97G060

4001-43
CAB FLOOR WIRING (OPTIONAL) ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)
1 Connecting strip 1 Connecting strip
3, 6, 9, 14, 14, 15, 16, 19, 24 and 38 1, 4, 6, 10, 11, 12, 19, 22 23 (1) (2) , 33, 17, 7, 5
INSTRUMENT PANEL UPPERSTRUCTURE
B55 Steering brake pressure switch B23 Overload indicator
H30 Cold start assistance switch lighting B56 Boom raising range limitation detector
H32 Overload indicator switch lighting E24 Dipper lighting
H52 Pilot system cancellation switch lighting E29 Registration plate lighting
H53 Front working light switch lighting Belgium : left-hand rear centre lighting
H58 Quick coupler switch lighting Italy : left-hand rear lighting
S20 Cold start assistance switch H56 Upperstructure rotary light (Italy)
S21 Overload indicator switch K50 Adjustable boom raising range limitation relay
S30 Adjustable or articulated boom switch K51 Adjustable boom lowering range limitation relay
S52 Pilot system cancellation switch K53 Fuel heater relay
S53 Front working lights switch R50 Fuel heating device
S56 Quick coupler switch Y7 Adjustable or articulated boom extending electro-valve
V50 Quick coupler diode Y8 Adjustable or articulated boom retracting electro-valve
V51 Quick coupler diode Y50 Adjustable boom raising range limitation solenoid valve
V52 Quick coupler diode Y51 Quick coupler solenoid valve
H15 Audible warning Y52 Quick coupler solenoid valve
Y53 Fuel filler pump
X5 Steering column connector
ENGINE
R10 Cold start assistance resistor
R11 Cold start assistance glow plug
S28 Engine compartment working light switch

4001-44

E50 E50
128 0 128 0
M2
C A
D B
38
142
144
0
S29
M6
0 26
AA
E1 S10 X14 (2) X14 (1)
AA
0 E7 48
0 33 X1
2 (7)
31 F
G H 128
M J
144 E K 38
132 D L
A 135
B6 C B B5
133
- - 132
135 134
+ 142 134 133 26 +
0 31 0 33
H57 E51
CM97G061
A White wire X1 (A) (B) (C) (D)Cab floor/cab LH and RH loud-

B Grey wire speaker connector (optional)
B5 Right-hand loudspeaker (optional) X1 (E) (J) (M) (L) Cab floor/cab windshield wiper
B6 Left-hand loudspeaker (optional) motor connector
E1 Cab lighting X1 (F) Cab floor/cab rotary light connector (specific to
E7 Cigarette lighter (See Wiring, page 38) certain countries)
E50 Front working lights (optional) X1 (K) Cab floor/cab operators compartment lighting.
E51 Rear working light X14 (1) (2) Cab blower plug (optional)
H57 Standard cab or Italy (option) 2 (7) Connector 10 way (see printed circuit wiring

4001-45
ALPHABETICAL INDEX
A C
Adjustable boom.................................................... 31 Cab and cab option wiring .................................... 44
Adjustable boom lowering range Cab blower............................................................ 27
limitation relay ......................................... 6, 30, 43 Cab blower motor.................................................. 44
Adjustable boom raising height limiter................... 31 Cab blower plug .................................................... 44
Adjustable boom raising height limiter Cab blower switch................................................. 44
detector ............................................................. 30 Cab floor wiring (Optional) .............................. 42, 43
Adjustable boom raising height limiter relay ............ 6 Cab floor wiring (standard).............................. 38, 39
Adjustable boom raising height limiter Cab floor/cab connection ...................................... 32
solenoid valve ............................................. 30, 43 Cab floor/cab connector.................................. 24, 39
Adjustable boom raising range Cab floor/cab LH and RH loudspeaker
limitation relay .............................................30, 43 connector .................................................... 26, 44
Adjustable or articulated boom control Cab floor/Cab rotary light connector ..................... 24
switch ................................................................ 43 Cab floor/Cab windshield wiper motor
Adjustable or articulated boom extending black connector ................................................ 24
electro-valve ................................................ 30, 43 Cab floor/Cab windshield wiper motor
Adjustable or articulated boom lowering blue connector .................................................. 24
solenoid valve ................................................... 30 Cab floor/Cab windshield wiper motor
Adjustable or articulated boom retracting grey connector .................................................. 24
electro-valve ......................................................43 Cab floor/Cab windshield wiper motor
Adjustable or articulated boom switch ............. 15, 30 white connector ................................................ 24
Air filter restriction.................................................. 19 Cab front working light switch ............................... 24
Air filter restriction pressure switch.................. 18, 39 Cab front working light switch lighting................... 24
Alternator ............................................. 16, 17, 28, 39 Cab interior light.................................................... 24
Alternator charge warning lamp............................. 17 Cab interior light switch......................................... 24
Articulated boom ....................................................31 Cab lighting ............................................... 18, 25, 44
Attachment and cab rear working Cab lighting switch .......................................... 18, 44
light relay ......................................................... 4, 8 Cab rear working light ..................................... 24, 25
Attachment working light ....................................... 25 Cab rotary light................................................ 32, 33
Attachment working light on boom .................. 24, 39 Cab/cab floor connector........................................ 18
Attachment working light power Can front working lights .................................. 24, 25
connection ................................................... 24, 39 Cigarette lighter................................... 26, 27, 39, 44
Audible warning ............................................... 15, 43 Cold start assistance............................................. 17
Axle unlocking diode.............................................. 20 Cold start assistance heater element.................... 43
Axle unlocking indicator lamp ................................ 21 Cold start assistance momentary switch
Axle unlocking indicator lamp diode .................... 4, 8 (optional)........................................................... 16
Axle unlocking relay............................................. 4, 8 Cold start assistance plug..................................... 43
Axle unlocking solenoid valve................................ 33 Cold start assistance relay............................ 6, 8, 16
Axle unlocking solenoid valve shunt Cold start assistance switch............................ 15, 43
(Excavators Italy only) ......................................... 6 Cold start assistance switch lighting ............... 15, 43
Cold start assistance switch lighting (optional) ..... 16
B
Combination switch
Batteries .............................................. 16, 17, 28, 39 (commodo) ......................... 17, 19, 21, 25, 27, 31
Battery master switch .......................... 16, 17, 28, 39 Combined switch for direction indicator (commodo),
Blower switch......................................................... 26 dipped headlights, headlights main beam, sidelights,
Blower/heater switch ............................................. 26 headlight flasher and horn.......... 13, 16, 18, 20
Blower/heating switch lighting ............................... 26 Connecting strip .................................. 20, 28, 30, 32
Boom raising range limitation detector ..................43 Connector, 35-way.............................. 20, 28, 32, 41
Brake ..................................................................... 33 Contact switch....................................................... 17
Brake light pressure switch.................................... 22 Control panel................................. 13, 28, 29, 39, 41
Brake minimum pressure....................................... 19
Brake pressure switch ......................... 13, 18, 39, 41

4001-46
D F
Description of electrical cabinet printed First speed solenoid valve .................................... 21
circuit (optional equipment) ................................. 6 Flasher unit ........................................................... 22
Description of electrical cabinet printed Flasher unit relay ................................................ 4, 8
circuit (standard equipment)................................ 4 Fog light ................................................................ 35
Diagnostic (LED) lamp........................................... 28 Front axle automatic and manual
Dipped headlights indicator lamp diode......... 4, 8, 22 unlocking switch ................................... 13, 20, 32
Dipper lighting............................................ 36, 37, 43 Front axle locking and unlocking switch.......... 20, 32
Direction indicator combination switch (commodo), Front axle locking switch....................................... 13
main beam and dip switch, side lights and headlight Front axle unlocking pressure switch ........ 20, 32, 39
flasher switch ........... 22, 24, 26, 28, 32, 34, 36 Front axle unlocking relay ............................... 20, 32
Direction indicator combination switch (commodo) (dipped Front axle unlocking solenoid valve .......... 20, 32, 39
headlights, main beam headlights, parking lights and Front LH dipped headlight............................... 22, 39
headlight flasher selection) .......................... 30 Front LH side light........................................... 22, 39
DRE4 proportional pressure Front RH dipped headlight .............................. 22, 39
reduction valve ............................................ 28, 41 Front RH side light .......................................... 22, 39
Front working light switch lighting ................... 15, 43
E
Front working lights............................................... 44
Electrical cabinet printed circuit wiring Front working lights switch.............................. 15, 43
(optional equipment) ........................................... 6 Fuel filler pump ......................................... 16, 17, 43
Electrical cabinet printed circuit wiring Fuel heater...................................................... 16, 17
(standard equipment) .......................................... 4 Fuel heater relay ......................................... 6, 16, 43
Electrical schematic (plate 10)............................... 32 Fuel level gauge.............................................. 18, 39
Electrical schematic (plate 11)............................... 34 Fuel level indicator connector ............................... 39
Electrical schematic (plate 12)............................... 36 Fuel level indicator connectors ............................. 18
Electrical schematic (plate 2)................................. 16 Fuel oil heating...................................................... 43
Electrical schematic (plate 3)................................. 18 Fuel reserve .......................................................... 19
Electrical schematic (plate 4)................................. 20 Fuse 5 A, engine compartment lighting ................ 34
Electrical schematic (plate 5)................................. 22 Fuse, 10 A, headlight and rotary light relay .. 6, 8, 24
Electrical schematic (plate 6)................................. 24 Fuse, 10 A, horn ........................................... 4, 8, 22
Electrical schematic (plate 7)................................. 26 Fuse, 10 A, not used........................................... 4, 8
Electrical schematic (plate 8)................................. 28 Fuse, 10 A, pilot safety ........................... 4, 8, 20, 32
Electrical schematic (plate 9)................................. 30 Fuse, 10 A, windshield washer,
Electronic control box .......................... 20, 28, 32, 41 windshield wiper ....................................... 4, 8, 24
Electronic control box supply relay ................ 4, 8, 28 Fuse, 10 A, working light/rotary lights (Italy) ......... 32
Electronic control box supply wire ........................... 4 Fuse, 15 A, blower, heater.................................... 26
Electronic system wiring .................................. 40, 41 Fuse, 15 A, cab front working lights.................. 6, 24
Engine compartment light................................ 34, 43 Fuse, 15 A, cab working lights ................................ 8
Engine compartment light switch........................... 43 Fuse, 15 A, combination switch (commodo) ... 34, 36
Engine compartment lighting switch ...................... 34 Fuse, 15 A, fuel filler pump ................................... 16
Engine coolant solution temperature sender. ........39 Fuse, 15 A, fuel heater.......................................... 16
Engine coolant temperature sender .......... 18, 28, 41 Fuse, 15 A, main beam headlights ............... 4, 8, 22
Engine hood lighting .............................................. 35 Fuse, 15 A, upperstructure power line
Engine module and upperstructure wiring connection ................................................ 4, 8, 26
(optional) ..................................................... 42, 43 Fuse, 15 A, upperstructure working lights..... 4, 8, 24
Engine module and upperstructure wiring Fuse, 15 A, ventilation, heater, fuel heater ......... 4, 8
(standard).................................................... 38, 39 Fuse, 15 A, windshield wiper intermittent
Engine oil pressure................................................ 19 action ........................................................ 4, 8, 24
Engine oil pressure switch............................... 18, 39 Fuse, 30 A, cold start assistance ...................... 8, 16
Engine shut down control ...................................... 17 Fuse, 30 A, cold start assistance (optional) ............ 6
Engine shut down solenoid valve .......................... 39 Fuse, 5 A, adjustable or articulated boom .... 6, 8, 30
Engine speed detector............................... 28, 29, 41 Fuse, 5 A, cab interior light ................................... 24
Engine speed detector connector ....................28, 41 Fuse, 5 A, cab lighting, horn relay ................ 4, 8, 22
Engine temperature ............................................... 19 Fuse, 5 A, dipper lighting ...................................... 36
Fuse, 5 A, K7 relay coil ......................................... 24
Fuse, 5 A, LH brake light .............................. 4, 8, 22

4001-47
F H
Fuse, 5 A, LH front dipped headlight ............. 4, 8, 22 Hydraulic pressure sender .............................. 28, 41
Fuse, 5 A, LH front side light ......................... 4, 8, 22 Hydraulic pressure sender connector ............. 28, 41
Fuse, 5 A, LH main beam headlight .............. 4, 8, 22
I
Fuse, 5 A, overload indicator......................... 6, 8, 18
Fuse, 5 A, radio ............................................. 6, 8, 26 Injection pump servo-motor ...................... 28, 29, 41
Fuse, 5 A, rear fog light ................................. 6, 8, 34 Injection pump servo-motor connector............ 28, 41
Fuse, 5 A, RH brake light .............................. 4, 8, 22 Injection pump solenoid ........................................ 16
Fuse, 5 A, RH front dipped headlight ................ 8, 22 Instrument
Fuse, 5 A, RH front side light......................... 4, 8, 22 panel ........... 16, 18, 19, 20, 22, 30, 32, 34, 36, 39
Fuse, 5 A, RH main beam headlight.............. 4, 8, 22 Instrument panel (front face)................................. 11
Fuse, 5 A, starter switch .......................... 4, 8, 16, 28 Instrument panel audible
Fuse, 5 A, switch warning ..................................... 13, 18, 19, 30, 39
lighting ............... 16, 18, 20, 24, 26, 28, 30, 32, 34 Instrument panel lighting....................................... 29
Fuse, 7.5 A, cigar lighter...................................... 4, 8 Instrument panel wiring......................................... 11
Fuse, 7.5 A, cigarette lighter/brake.................. 34, 36
K
Fuse, 7.5 A, cigarette lighter/cab blower ............... 26
Fuse, 7.5 A, direction indicator/hazard K53 relay base ........................................................ 4
warning lights .................................................... 22 Key switch........................................... 13, 16, 28, 39
Fuse, 7.5 A, direction indicators,
L
hazard warning................................................ 4, 8
Fuse, 7.5 A, electronic control box ................ 4, 8, 28 Left-hand control arm pilot safety relay............... 4, 8
Fuse, 7.5 A, injection pump solenoid LH direction indicator diode .......................... 4, 8, 22
valve/hourmeter ................................................ 16 LH direction indicator green
Fuse, 7.5 A, instrument panel........................ 4, 8, 18 indicator lamp ........................................... 4, 8, 22
Fuse, 7.5 A, parking brake ...................... 4, 8, 20, 32 LH front direction indicator .................. 22, 34, 35, 39
Fuse, 7.5 A, working brake/parking brake ....... 34, 36 LH front side mounted direction
indicator ............................................................ 22
G
LH loudspeaker............................................... 26, 44
Gear box solenoid valve .................................. 20, 32 LH main beam headlight ................................. 22, 39
Gear box solenoid valve (first speed) .................... 39 LH rear brake light .......................................... 22, 39
Gear box solenoid valve (second speed) .............. 39 LH rear direction indicator............................... 22, 39
General contact diode ............................. 4, 8, 16, 28 LH side-mounted direction indicator ..................... 39
General contact relay 24 Volts, 50 A ..................... 16
M
General contact relay 24 V, 50 A......................... 4, 8
Main beam headlight indicator
H
lamp diode ................................................ 4, 8, 22
Hazard warning diode.......................................... 4, 8 Main beam position............................................... 33
Hazard warning light diode ............................ 4, 8, 22 Main relay ............................................................. 17
Hazard warning switch .............................. 13, 22, 39 Minimum braking pressure switch......................... 13
Hazard warning switch lighting .................. 13, 22, 39 Motor starter.............................................. 16, 17, 39
Heater blower motor ..............................................39
O
Heater blower switch ....................................... 13, 39
Heater blower switch lighting........................... 13, 39 Orbitrol pressure ................................................... 19
Horn................................................................. 22, 39 Orbitrol pressure switch ........................................ 18
Horn relay ...................................................... 4, 8, 22 Overload indicator........................................... 19, 43
Horn switch................................................ 13, 22, 39 Overload indicator diode ............................... 6, 8, 18
Hourmeter........................................................ 16, 39 Overload indicator pressure switch....................... 18
Hourmeter relay....................................... 4, 8, 16, 28 Overload indicator switch.......................... 15, 18, 43
Hydraulic oil filter restriction................................... 19 Overload indicator switch lighting ............. 15, 18, 43
H P
Hydraulic oil filter restriction pressure P10 instrument panel electrical schematic
switch .......................................................... 18, 39 (plate 1) ............................................................ 10
Hydraulic oil temperature....................................... 19 Parking brake...................................... 21, 33, 35, 37
Hydraulic oil temperature sender..................... 18, 39

4001-48
P R
Parking brake and working brake control RH front side mounted direction indicator............. 22
solenoid valve ....................................... 13, 20, 32 RH loudspeaker .............................................. 26, 44
Parking brake and working brake RH main beam headlight ................................ 22, 39
switch .................................. 13, 20, 32, 34, 36, 39 RH rear brake light.......................................... 22, 39
Parking brake pressure ......................................... 19 RH rear direction indicator .............................. 22, 39
Parking brake pressure switch .................. 13, 18, 39 RH side-mounted direction indicator..................... 39
Parking brake solenoid valve..................... 34, 36, 39 Right-hand and left-hand control arm
Pilot pressure switch........................................ 20, 39 wiring (optional) ................................................ 15
Pilot pressure warning lamp .................................. 21 Right-hand control arm, left-hand
Pilot safety ............................................................. 21 control arm and combination
Pilot safety relay .................................................... 20 switch wiring (standard) .................................... 13
Pilot safety solenoid valve ......................... 20, 32, 39 Rotary light............................................................ 25
Pilot safety switch ................................ 13, 20, 32, 39 Rotary light indicator diode ................................. 6, 8
Pilot safety system solenoid valve......................... 33 Rotary light indicator lamp .................................... 25
Pilot system cancellation diode ........................... 6, 8 Rotary light indicator lamp diode........................... 24
Pilot system cancellation diode Rotary light switch............................... 13, 24, 32, 39
(specific to certain countries) .............................. 6 Rotary light switch lighting .................. 13, 24, 32, 39
Pilot system cancellation indicator lamp................ 32
S
Pilot system cancellation indicator lamps .............. 32
Pilot system cancellation switch ................ 15, 32, 43 Schematic symbols ................................................. 3
Pilot system cancellation switch lighting.... 15, 32, 43 Second speed solenoid valve ............................... 21
Pre-heater plug...................................................... 16 Second speed travel indicator lamp shunt
pressure sender..................................................... 29 (Excavators Italy only) ........................................ 6
Pressure switch ..................................................... 29 Servo-motor potentiometer ............................. 28, 41
Pressure switch for minimum braking pressure..... 39 Shunt............. 4, 8, 16, 18, 20, 22, 24, 28, 30, 32, 34
Printed circuit schematic guide................................ 8 Shunt (pilot system cancellation) ........................ 6, 8
Specifications.......................................................... 2
Q
Speed change pressure switch....................... 28, 29
Quick couple.......................................................... 31 Speed change relay ........................ 4, 20, 28, 32, 41
Quick coupler solenoid valve................................. 43 Stabilizer lowering and raising momentary
Quick coupler switch.................................. 15, 30, 43 inverter switch................................................... 13
Quick coupler switch lighting ..................... 15, 30, 43 Stabilizer raising and lowering momentary
Quick coupler unlocking solenoid valve inverter switch............................................. 20, 32
(optional) ........................................................... 30 Stabilizer raising and lowering
solenoid valves ................................................. 39
R
Stabilizer solenoid valve diodes ................ 13, 20, 32
Radio ......................................................... 26, 27, 39 Stabilizer solenoid valves................................ 20, 32
Radio diode ................................................... 6, 8, 26 Stabilizers ............................................................. 21
Rear fog light ......................................................... 34 Standard cab or Italian cab ................................... 44
Rear fog light diode ............................................... 34 Standard rotary light (optional).............................. 24
Rear fog light indicator lamp.................................. 35 Standard working brake ........................................ 21
Rear fog light indicator lamp diode ...................... 6, 8 Starter motor relay .................................. 4, 8, 16, 17
Rear fog light switch ............................ 15, 30, 39, 43 Steering brake pressure...................... 33, 34, 35, 37
Rear fog light switch lighting...................... 13, 34, 39 Steering brake pressure switch........... 22, 32, 36, 43
Rear LH side light ............................................ 22, 39 Steering column connector ....................... 13, 36, 43
Rear RH side light ........................................... 22, 39 Steering column connector (commodo) ................ 39
Rear working light.................................................. 44 Steering column connectors ..................... 20, 22, 32
Rear working lights switch ............................... 13, 34 Steering pressure switch................................. 13, 39
Registration plate lighting .............. 32, 33, 34, 35, 43 Swing brake release solenoid valve...................... 29
Relay diode (K3)............................................ 4, 8, 28 Swing detection pressure switch..................... 28, 41
Resistor, 0.85 Ohms.......................................... 6, 16 Swing motor speed detector ........................... 28, 41
RH direction indicator diode .......................... 4, 8, 22 Swing pressure reducer ........................................ 29
RH direction indicator green
indicator lamp............................................ 4, 8, 22
RH front direction indicator ........................ 22, 34, 39

4001-49
T
Travel detector pressure switch .......................28, 41
Travel pressure switch........................................... 29
Travel relay............................................................ 29
Troubleshooting test LED .............................. 4, 8, 29
Troubleshooting test socket................. 28, 29, 39, 41
Two-speed relay .................................................... 21
U
Upperstructure and attachment light relay......... 4, 22
Upperstructure and attachment working
light relay ........................................................... 24
Upperstructure brake release control
solenoid valve ............................................. 28, 41
Upperstructure headlight and working
light relay ............................................................. 8
Upperstructure power line connection ....... 26, 27, 39
Upperstructure rotary light ......................... 32, 33, 43
Upperstructure swing speed detector.................... 29
Upperstructure swing speed detector
connector .................................................... 28, 41
V
Ventilation/heating ................................................. 27
Ventilator motor ..................................................... 26
Ventilator motor connector .................................... 26
W
Warning light.......................................................... 19
Water temperature................................................. 29
Windshield washer ................................................ 25
Windshield washer motor ................................ 24, 39
Windshield washer switch ......................... 13, 24, 39
Windshield washer switch lighting ............. 13, 24, 39
Windshield wiper ................................................... 25
Windshield wiper intermittent action .................. 4, 24
Windshield wiper motor ................................... 24, 44
Windshield wiper switch ............................ 13, 24, 39
Windshield wiper switch lighting ................ 13, 24, 39
Working brake ................................................. 35, 37
Working brake and parking brake
switch lighting ...................... 13, 20, 32, 34, 36, 39
Working brake solenoid valve ........20, 32, 34, 36, 39
Working brake solenoid valve (Standard).............. 39
Working brake switch lighting .......................... 13, 39
Working light relay ................................................. 24
Working light switch................................... 13, 24, 39
Working light switch lighting .................................. 24

4001
Section
4001
Wheeled excavators

Printed in France
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 10) .............................................................................................................. 32
ELECTRICAL SCHEMATIC (PLATE 11) ............................................................................................................... 34
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

4001-3
B (n) Indicators/pressure switches/loud-speakers/detectors/thermal detector/gauge Wire number
F (n) Fuses
H (n) Warning devices (lighted and audible)
K (n) Relays
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
NOTE: The (n) shows the component number.
Example: K2 is relay N2. Link with following plate


Bulbs
Test bulb

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
3 2
harness connector (1). This position is completed when the path 1 line is
4 1

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
tion of travel control, overload indicator + two-speed supply relay 51 Heavy lift solenoid valve harness, clip
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

4001-5
CM99J047

4001-6
DESCRIPTION OF ELECTRICAL CABINET PRINTED CIRCUIT (OPTIONAL) 1 Connection strip
PRINTED CIRCUIT WIRING (OPTIONAL)

7 Hood lighting harness, clip
9 Cold start switch 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

4001-7
1 2 3
CM99J048

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
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 4 (1) printed circuit earth
K4 Electronic supply relay 4 (2) printed circuit earth
K5 Horn relay
K7 Relay authorizing working lights if sidelights on
K9 Pilot safety relay/axle unlocking
K13 Engine stop solenoid relay
K15 Thermostart relay
K52 Speed change relay (except 588)
K54 Frequency threshold detector relay (threshold: 1 = 1600 rpm)
K55 Frequency threshold detector relay (threshold: 2 = 1400 rpm)

4001-9
CM99K032

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
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
4001-11
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

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

4001-13

COMMODO WIRING (STANDARD)
H14 Troubleshooting test LED
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)
S1 Key switch
S3 Horn switch
S12 Two-speed switch (588)
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
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
40 Two-speed control box harness (588)

4001-14
H53
S53
H30
S20
H52 S30
H58
S52
S56
H32
1 S21
CM99J046

4001-15

H30Cold start assistance switch lighting (optional)
H52 Pilot system cancellation switch lighting (optional)
S53 Cab front working light 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

4001-16

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)
Sh5 Shunt Night lighting (switch) + P excavator regi-
stration plate
V24 K54 relay diode
V25 K55 relay diode
FLOOR
S1 Key switch
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

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

4001-18

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
stration plate
V21 Overload indicator lamp diode on instrument panel
V30 Buzzer diode
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

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

4001-20

F12 Fuse, 10 A, two-speed electro, axle unlocking,
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
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
K58 Two-speed supply relay
Sh4 Shunt OK Standard - not Italy
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
B12 Brake pressure switch (588)
B57 Speed change pressure switch
(optional)
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
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

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

4001-22

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
E12 - E16 S3 Horn switch
E18 S51 Hazard warning switch
E11 - E15 - E22 SC1 Direction indicator combination switch (com-
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

4001-23
COMBINATION SWITCH DIPPED MAIN BEAM

HORN BRAKE LIGHTS SIDE LIGHTS INDICATOR LIGHTS HAZARD WARNING LIGHTS
(COMMODO) HEADLIGHTS HEADLIGHTS
CM99H004

4001-24

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
ELECTRICAL CABINET
lighting
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)
K6 Working light relay FLOOR
K7 Relay authorizing working lights if sidelights on
Sh5 Shunt Night lighting (switch) + P excavator regi- UPPERSTRUCTURE
stration plate
V22 Rotary light diode on instrument panel
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

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

4001-26

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
SC1 H13 Heater blower switch lighting Y53 Fuel filler pump (optional)
X2 S27 Heater blower switch
FLOOR
A1 Radio (optional)
X1
F8 - F10 - F11 - F14

F19
G3
S27 - H13 A1 X5
M4 E7
CM99K025

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

4001-28

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)
Y4 B22 Engine coolant temperature sender
K58 Two-speed supply relay
G2 Alternator
M5 Injection pump servo-motor (788-988-1188)
stration plate
P12 Servo-motor potentiometer (788-988-1188)
X6 Engine speed detector connector (788-988-1188)
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)
X3 35-way connector (788-988-1188)
FLOOR
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

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

4001-30

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
S30 H58 Quick coupler switch lighting (optional)
V30 Buzzer diode
P10 modo), main beam and dip switch, side lights
S30 Adjustable or articulated boom control switch
(optional)
H15
F19 - F27
K50 - K51
Sh5
SC1 V30 - V52
S56 - H58
CM99K025

4001-31
ADJUSTABLE BOOM
ADJUSTABLE BOOM RANGE
OR QUICK COUPLER (OPTIONAL)
LIMITATION (OPTIONAL)
ARTICULATED BOOM (OPTIONAL)
CM99H008

4001-32

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
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
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

4001-33
CM99H009

4001-34
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
+ 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
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
B55 Steering brake pressure switch (optional)
E29 (optional)
X1 H52 Pilot system cancellation switch lighting (optional)
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

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

4001-36

Supplement for Switzerland Supplement for Belgium
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
S50 Parking brake and working brake switch (optional) H55 Rear fog light switch lighting
FLOOR SC1 Direction indicator combination switch (com-
B55 Steering brake pressure switch (optional) modo), main beam and dip switch, side lights
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
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

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

4001-38
Supplement for Germany Supplement for Austria

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
(optional)
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)
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

4001-39
STEERING BRAKE STEERING BRAKE

WORKING BRAKE FOR GERMANY PARKING BRAKE DIPPER LIGHTING FOR GERMANY
PRESSURE PRESSURE FOR AUSTRIA
CM99H012

4001-40
CAB FLOOR WIRING (STANDARD)

See page 4
FLOOR
A1 Radio (optional)
B12 Brake pressure switch (588)
B25 Threshold detector (788)
B51 Brake light pressure switch
B52 Pressure switch for minimum braking pressure
B53 Steering pressure switch
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
H26 Horn
H31 Rotary light switch lighting
H50 Working brake and parking brake switch lighting (optional)
K10 Flasher unit relay
P4 Hourmeter
S1 Key switch
S3 Horn switch
S12 Two-speed switch (588)
S50 Parking brake and working brake switch (optional)
S55 Rear fog light switch
CM99J049

4001-41
ENGINE MODULE AND UPPERSTRUCTURE WIRING (STANDARD)
See page 4
UPPERSTRUCTURE
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
S2 Battery master switch
X5 Attachment working light power connection
X10 Fuel level indicator connector
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
G2 Alternator
M1 Starter motor
Y1 Engine shut-down solenoid valve
CM99K029

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

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
28 Engine harness
X3
CS99K546

4001-44
CAB FLOOR WIRING (OPTIONAL)

ELECTRICAL CABINET
1 Connecting strip
See page 6
INSTRUMENT PANEL
B55 Steering brake pressure switch (optional)
H52 Pilot system cancellation switch lighting (optional)
K50 Adjustable boom raising limiter relay (optional)
K51 Adjustable boom retracting limitation relay (optional)
S53 Cab front working light switch (optional)
CM99J051

4001-45
ENGINE MODULE AND UPPERSTRUCTURE WIRING (OPTIONAL)

ELECTRICAL CABINET
1 Connecting strip
2 Air conditioner
See page 6
UPPERSTRUCTURE
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)
ENGINE
R11 Cold start assistance plug (optional)
CM99K030

4001-46
A White wire X1 (A) (B) (C) (D) Cab floor/cab LH and RH loud-
B Grey wire speaker connector
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
CM99J052

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
Adjustable or articulated boom extending electro-
(optional).............................................................. 6
valve (optional) .............................................30, 45
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
Battery relay (heater/air conditioner) ........4, 8, 16, 32
Blower motor connector (optional)..........................26
Blower speed resistor .............................................32
Electrical schematic (plate 2) ................................. 16
Boom raising range limitation detector (optional) ..30,
45
Brake light pressure switch...............................22, 40
Brake pressure switch (588).............................20, 40
Buzzer diode.............................................4, 8, 18, 30
C Electrical schematic (plate 8) ................................. 28
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

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

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

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

4002
Section
4002
ELECTRONIC AND
TROUBLESHOOTING SYSTEM
Crawler excavators

Printed in France
4002-2
TABLE OF CONTENTS
TOOLS REQUIRED ............................................................................................................................................... 3
ELECTRONIC SYSTEM ......................................................................................................................................... 4
General ............................................................................................................................................................... 4
Components connected to electronic system ..................................................................................................... 4
Location of components on the excavator .......................................................................................................... 5
Electronic control box ...................................................................................................................................... 5
Swing detection pressure switch..................................................................................................................... 5
Travel detector pressure switch ...................................................................................................................... 5
Engine speed detector .................................................................................................................................... 6
Swing motor speed detector ........................................................................................................................... 6
Hydraulic pressure sender .............................................................................................................................. 6
Engine coolant temperature sender ................................................................................................................ 7
Led diagnostic (LED) ...................................................................................................................................... 7
Servo-motor (injection pump lever control) ..................................................................................................... 7
Control panel ................................................................................................................................................... 8
Troubleshooting test socket ............................................................................................................................ 8
Proportional pressure reduction valve DRE4 .................................................................................................. 9
Upperstructure brake release control solenoid valve ...................................................................................... 9
Travel motor displacement change electro-control valve (Two-speed excavators only) ................................ 9
ELECTRONIC SYSTEM DIAGNOSIS .................................................................................................................. 10
General ............................................................................................................................................................. 10
Defect code 01 .................................................................................................................................................. 11
Defect code 02: Components associated with engine electrical acceleration ................................................... 11
Defect code 03: Components associated with the measurement of hydraulic pressure (L.S.) ......................... 13
Defect code 04: Components associated with the measurement of engine speed .......................................... 14
Defect code 05: Components associated with the measurement of water temperature ................................... 15
Defect code 06: Components associated with pressure reduction ................................................................... 16
Defect code 07: Components associated with the control of travel motor displacement
(two-speed excavators only) ......................................................................................................................... 17
Defect code 08: Components associated with the upperstructure braking and brake release ......................... 18
Defect code 09: Components associated with the control keyboard ................................................................ 19
Defect code 10, 12 and 13: Components associated with the control box ....................................................... 20
Defect code 11: Calibration impossible ............................................................................................................. 21
Settings ............................................................................................................................................................. 23
Electric acceleration (M5) mechanical adjustment - old type fitting (graduations centred on the gauge) .......... 23
Electric acceleration (M5) mechanical adjustment - new type fitting (graduations offset 15 on the gauge) ..... 24
Mechanical adjustment of electrical acceleration (M5) on "low emissions" models ........................................... 26
Electric acceleration calibration.......................................................................................................................... 28
Adjusting the engine speed detector (B10) ........................................................................................................ 28
Adjusting the engine speed detector (B9) .......................................................................................................... 28
This symbol is used in this manual to indicate important safety messages. Whenever you see this sym-
bol, carefully read the message that follows, as there is a risk of serious injury.
Turn the battery master switch to the "Off" position before carrying out any service work on the circuit.

4002-3
TOOLS REQUIRED
PD00012
1. PHOTO-DIGITAL TACHOMETER CAS 10449
2. AEROSOL M1703414
(For cleaning and de-oxidation of electrical con-
tacts)

4002-4
ELECTRONIC SYSTEM
General
Some of the machines functions are managed and checked electronically. The functions concerned are as follows:
- Cold start assistance.
- Electric acceleration.
- Automatic return to idle.
- Engine overheating safety system.
- Engine / hydraulic system power regulation: "Speed sensing".
- Swing braking and brake release.
- Automatic travel sequencing (Two-speed excavators only).
- Electronic system diagnosis.
Components connected to electronic system
X4 E F
B11
Y4
B9
B22 M5
A2
B10 Y5
B7
H14
B8
Y6
C
PDH0471
S22
PH0732A

B7 Swing detector pressure switch S22 Control keyboard
B8 Travel detector pressure switch X4 Diagnostic socket
B9 Engine speed detector Y4 Proportional pressure reduction valve DRE4
B10 Swing motor speed detector Y5 Upperstructure brake release electro-control
B11 Hydraulic pressure detector valve
B22 Engine coolant temperature sender Y6 Travel motor displacement change electro-con-
H14 Correct operation indicator light (LED) trol valve (two-speed excavators only)
C Lighting 28 volts
E Earth
F 28 volt battery

4002-5
Location of components on the excavator

PDH0472 PE09306
Located to the right of the operators seat, it contains the electronic card through which all information passes. The
card is connected to the other components by means of a 35-pin connector.
B7 Swing detection pressure switch
PDH0472 PDH08504
Located on the rear panel of the cab floor, it closes at about 6 bar (RH or LH swing pilot pressure).
PDH0472 PH08504
Located on the rear panel of the cab floor, it closes at about 6 bar (travel brake release pilot pressure).

4002-6
B9 Engine speed detector
PDH0472 PH00918
Mounted in line with the starter ring teeth, it delivers a signal with a frequency corresponding to the time interval
between the passage of two consecutive teeth.
PDH0472 PH01002
Located behind the hydraulic motor housing and opposite a sprocket, it delivers a signal with a frequency corre-
sponding to the passage of two consecutive teeth.
PDH0472 PH01034
Located under the cab floor, it measures the highest pressure (Load-Sensing) in the excavator attachment and
travel hydraulic systems.

4002-7
PDH0472 PH00917
Mounted on the engine block, it delivers a pressure of between 0 and 28 volts. It is the ratio between this voltage
and the battery voltage which is used for information processing purposes
H14 Led diagnostic (LED)
PDH0472 CD99J017
This consists of a red warning lamp (Light-Emitting Diode) mounted on the printed circuit board. This indicator lamp
is continuously "on" when the circuit is trouble-free. It starts to flash on and off if one or more defects occur in the
system. Such defects can be identified by means of a lighting code system (See page 10).
M5 Servo-motor (injection pump lever control)
PDH0472 PH08508
Mounted on the engine, it control the injection pump lever.

4002-8
S22 Control panel
PDH0472 PH07328
Located near the right-hand control lever, it has a front face covered with a silk-screened plastic film, an electronic
circuit board with six momentary-action push-buttons, eight LED type indicator lamps, electronic components and a
connector.
The functions of the control panel can be classified under four modes:
- The "Work" mode, consisting of the following push-buttons: "FINE" 1580 to 1620 rpm (low flow work, handling),
"ECO" 1880 to 1920 rpm (economical, digging) and "MAX" 2180 to 2220 rpm (maximum power, hard work).
- The "Idle" mode consisting of the following push-buttons: "LOW" 900 to 1000 rpm (low idle) and "AUTO" 1180 to
1220 rpm (automatic idle).
- The "Travel" mode (two-speed excavators only) has two indicator lamps: "POSITION 1" (low speed) and "POSI-
TION 2" (high speed).
- The "Pre-heat" mode has an indicator lamp: a flashing lamp shows the machine has not yet reached its normal
operating temperature. When that lamp goes out the machine is ready to work.
PDH0472 PH010834D
Located in the cab, behind the seat, it is protected by a trim panel. It is for use connected to a dialogue console
which can perform in-depth diagnosis of the machine and which is also used for reading and modifying the "exca-
vator parameters".

4002-9
Y4 Proportional pressure reduction valve DRE4
PDH0472 PH00918
Mounted on the main pump, it delivers an output pressure which is proportional to the current passing through it,
thus enabling a check to be made of the variable flow pump hydraulic torque.
NOTE: The photo shows the DRE4 reduction valve on the 988 excavator. On the 788 the DRE4 reduction valve is
identical, but is mounted in a different manner.
Y5 Upperstructure brake release control solenoid valve
PDH0472 PH08422
Located behind the cab on the valve bank partition, it is actuated to release the upperstructure brake. It brakes the
upperstructure when not actuated.
Y6 Travel motor displacement change electro-control valve
(Two-speed excavators only)
PDH0472 PH08524
Located behind the cab on the valve bank partition, it selects high speed (low displacement) when it is actuated, or
low speed (high displacement) when it is not actuated.
4002-10
ELECTRONIC SYSTEM DIAGNOSIS

Diagnosis without console
General
The machine is equipped with an integrated diagnostic system which is designed to locate problems which may
occur in the system. Such defects are displayed by means of an indicator lamp (LED) inserted in the printed circuit
located in the cab behind the operators seat This indicator lamp (LED) is on continuously when the system is fault-
free. It starts to flash when one or more defects appear.
The defect signalling code is as follows:
The indicator lamp lights up for half a second, then goes out for half a second, a number of times equal to the code.
At the end of the cycle the indicator lamp lights up for 5 seconds, the cycle starts again.
Example: 1 defect to be displayed:
- Servo-motor failure: Associated defect code 02
0.5 s 5s
02 02
On
Off
2.5 s 2.5 s
0.5 s
1 flash sequence Separator 1 flash sequence

PDH0474
One flashing sequence may contain more than one defect, in which case they will be listed in numerical sequence
and coded as shown in the example below:
Example: 2 defects to be displayed:
- Failure of components connected with the measurement of water temperature: Associated defect code 05.
- Failure of components connected with the engine electrical acceleration: Associated defect code 02.
02 05 02 05
On
Off
2.5 s 2.5 s 2.5 s
1 flash sequence Separator

1 flash sequence
PDH0475
The defect codes are as follows:

Defect code 01 Not used
Defect code 02 Components connected with the engine electrical acceleration
Defect code 03 Components associated with the measurement of hydraulic pressure
Defect code 04 Components associated with the measurement of engine speed
Defect code 05 Components associated with the measurement of water temperature
Defect code 06 Components associated with pressure reduction
Defect code 07 Components associated with the control of travel motor displacement (two-speed excavators
only)
Defect code 08 Components associated with upperstructure braking and brake release
Defect code 09 Components associated with the control keyboard
Defect code 10 Components associated with the control box
Defect code 11 Calibration impossible
4002-11
Defect code 01
Not used.
Defect code 02: Components associated with engine electrical acceleration

Problems found:
- Engine returns automatically to idle (lever against the injection pump minimum stop)
- Control keyboard completely off except travel mode on two-speed excavators only
- The code appears regardless of the type of electric motor failure (short-circuit or open circuit)
Illustration of the indicator lamp signal
5s
02 02
On
Off
2.5 s 2.5 s
PDH0491
Check the connection of the connector (X9) If there are traces

which connects the servo-motor to of oxidation, spray with the
the electronic harness. NO appropriate product.
Connection 1. 2. 5. 6 and 7 on (M5) Reconnect the
connector (X9) correctly.
YES
Make a visual check of the condition of the

servo-motor cable. Is it in good condition? Change the servo-motor
(with no traces of crushing or cutting) NO (M5)
YES

electronic harness. Repair or change the
Is it in good condition? NO harness.
(with no traces of crushing or cutting)
YES
Check the length of the servo-motor

connecting rod.
Is the length 171 mm 1? NO
YES Ensure that the system

for mechanical transmis-
Actuate the fuel injection pump lever back and
sion of movement is in Adjust the length of
forth from one stop to the other.
good condition. the connecting rod,
Is the movement correct? NO Change the servo-motor see page 23 or 24.
(no seizing or stiff places)
(M5) if the fault persists.
YES Calibrate the servo-

motor (M5),
(continued on next page) see page 25.
4002-12
NOTE: After each corrective action, switch off and on again to reset the system.
(continued from previous page)
Switch on without starting the engine.

Select "LOW" speed. Select "MAX" speed.
Does the defect appear as soon as the
Does the defect appear? Does the defect appear?
system is switched on? NO NO
YES YES
Lengthen the servo-motor Shorten the servo-motor

connecting rod (M5) by connecting rod (M5) by
one turn, then calibrate, one turn, then calibrate
and start again if and start again if
YES
necessary. necessary.
Change the servo-motor (M5).

Is there any movement of the servo- Adjust the length of the connecting rod to
motor cursor (M5)? 171 mm 1. See page 23 or 24 and cali-
NO brate the servo-motor (M5), see page 25.
Is the defect still present?
YES
YES
Change the control box (A2) and cali-

brate the servo-motor (M5), see page 25.
brate it, see page 25.
YES
YES

Adjust the length of the connecting rod to Change the electronic harness.
171 mm 1. See page 23 or 24 and cali- (if that has not already been done).
brate the servo-motor (M5), see page 25.
YES
Change the electronic harness.

(if that has not already been done)
NOTE: Switch off and on again after each corrective action to reset the system. In the event of a servo-motor fail-
ure, a temporary repair solution is possible consisting of fixing the control connecting rod into one of the holes in
the graduated strip, thus allowing the engine to run at constant speed. Disconnect the servo-motor plug (X9). If this
temporary solution is used, it is essential that the connecting rod fastening is disconnected before stopping the
engine, to allow it to run at idle (otherwise there is a danger of damaging the turbo-charger).

4002-13
Defect code 03: Components associated with the measurement of hydraulic

pressure (L.S.)
Problems found:
- "Auto" (automatic idle) inoperative
- Automatic travel speed system inoperative
- This defect is indicated in all cases of failure of the pressure detector (B11) (short-circuit, open circuit etc.)
5s
03 03
On
Off
2.5 s 2.5 s
PDH0476
Check the connection of the connector (X8)

connecting the hydraulic pressure detector
(B11) to the electronic harness. Reconnect the connector (X8) correctly
Connection A, B and C on detector (B11) NO
Is the connection correct?
YES

hydraulic pressure detector cable (B11).
Is it in good condition? Change the hydraulic pressure detector (B11).
NO
YES

electronic harness.
Repair or change the harness.
Is it in good condition? NO
YES
Change the control box (A2) and calibrate the

servo-motor (M5), see page 25.
YES

4002-14
Defect code 04: Components associated with the measurement of engine

speed
Problems found:
- Reduced hydraulic power, DRE4 pressure fixed when swing is not actuated
- Engine speed safety system inoperative
- Engine starts up directly in "ECO" mode and stays there
- No Auto Idle
NOTE: The failure is more often detected by these symptoms than by the LED flashing.
5s
04 04
On
Off
2.5 s 2.5 s
PDH0477

from the engine speed detector (B9) to the
electronic harness. Reconnect the connector (X6) correctly.
Connection A and B on detector (B9) NO
YES

engine speed detector cable (B9). Is it in good Change the engine speed detector (B9).
condition? NO
YES

electronic harness. Repair or change the harness.
YES
Adjust the position of the engine speed

detector (B9), see page 25.
YES Change the control box (A2) and calibrate the

Change and adjust the position of the engine servo-motor (M5), see page 25.
speed detector (B9), see page 25. Is the defect still present?
Is the defect still present? NO
YES

4002-15
Defect code 05: Components associated with the measurement of water

temperature
Problems found:
- Indicator on instrument panel inoperative
- When starting up from cold, warm-up time reduced to one minute
- Over-heating safety system inoperative
- Short-circuits and open circuits on following items cause this failure: sender, wire, indicator and printed circuit board
5s
05
On
Off
2.5 s 2.5 s
PDH0478
Is it possible to select speeds other than Battery voltage too low: recharge or
"LOW" and "FINE") change.
NO
at the control keyboard (S22)?
YES
Check the connection connecting the water

temperature sender (B22) to the electronic
harness. Reconnect correctly.
Connector 30 (2) NO
(see schematic in Section 4001)
YES

electronic harness.
YES
Change the water temperature sender (B22).

YES

YES


4002-16
Defect code 06: Components associated with pressure reduction

Problems found:
- Engine stalls under load
- Zero pressure at valve
NOTE: This defect is indicated by valve short-circuits and open circuits.
5s
06
On
Off
2.5 s 2.5 s
PDH0479
Check the connection from the proportional

pressure reduction valve DRE4 (Y4) and the Reconnect correctly.
NO
electronic harness.
YES

NO
Is it in good condition?
YES
Change the proportional pressure reduction

valve DRE4 (Y4).
YES

YES


4002-17
Defect code 07: Components associated with the control of travel motor
displacement (two-speed excavators only)
Problems found:
- Speed change inoperative (control panel locked in 1st speed)
NOTE: This defect is indicated if the displacement change solenoid valve (Y6) is short-circuited or cut off.
Travel pressure switch failure
- No defect indicated on the LED
- Open circuit: 1st and 2nd speeds operate but no automatic return to 2nd speed 1
- Circuit broken: Automatic return from 2nd 1st when the attachment circuit pressure increases
- No Auto Idle
5s
07
On
Off
2.5 s 2.5 s
PDH0480
Check the line connecting the travel motor dis-

placement control solenoid valve (Y6) to the Reconnect correctly.
NO
electronic harness.
YES

YES
Change the solenoid valve (Y6).

YES

YES


4002-18
Defect code 08: Components associated with the upperstructure braking

and brake release
Problems found:
- Upperstructure swing impossible
- No brake release
Brake release solenoid valve defective:
- Short circuit and open circuit detected by electronics
Swing pressure switch failure:
- Not detected by electronics
- Short circuit: continuous brake release
- Open circuit: no brake release
5s
08
On
Off
2.5 s 2.5 s
PDH0481
Check the connection from the upperstructure

Reconnect correctly.
brake release solenoid valve (Y5) to the elec- NO
tronic harness.
YES
Make a visual check of the condition of the Repair or change the harness.
NO
electronic harness.
YES

YES

YES


4002-19
Defect code 09: Components associated with the control keyboard

Problems found:
- Control keyboard jammed, generally "off" except travel and "LOW IDLE" in certain cases
- Machine on "FINE" and travel on position 2.
5s
09
On
Off
2.5 s 2.5 s
PDH0482
Check the connection from the control key-

board (S22) to the electronic harness. NO
Connection A1. B1. B2 and B3 on (S22).
YES

YES
Change the control keyboard (S22).

YES

YES


4002-20
Defect code 10, 12 and 13: Components associated with the control box
5s
10
On
Off
2.5 s 2.5 s
PDH0483
5s
12
On
Off
2.5 s 2.5 s
PDH0484
5s
13
On
Off
2.5 s 2.5 s
PDH0485

from the control box (A2) to the electronic har- Reconnect correctly.
ness. NO
YES

YES

YES


4002-21
Defect code 11: Calibration impossible

5s
11
On
Off
2.5 s 2.5 s
PDH0486
Defect appearing after the calibration procedure
Disconnect the servo-motor (M5)

and use tachometer CAS 10449 to check the Check the engine and adjust if nec-
engine speed by actuating the injection pump essary, check and, if necessary,
lever manually. repair the air supply circuit and the
NO
Is the engine speed equal to or lower than 900 fuel supply circuit.
rpm at the idle stop and equal to or lower than
2200 rpm at the maximum speed stop?
YES
Check the length of the connecting rod.

171 mm 1.
Is the length correct? NO
YES
Actuate the fuel injection pump lever back and Overhaul and repair the control
forth from one stop to the other. linkage.
Is the movement correct? Change the servo-motor (M5) if the
NO
(no seizing, no stiff places, etc.) defect still remains.
Adjust the length of the

YES connecting rod to 171 mm 1.
See page 23 or 24.
Calibrate the servo-motor

(continued on next page) (M5), see page 25.
NOTE: Switch off and on again after each corrective action to reset the system. and start the calibration procedure
again.

4002-22
Check the connection of the
connector (X6) from the engine
Carry out the calibration Does defect speed detector (B9) to the Reconnect the
procedure again. Does the code 02 electronic harness. connector (X6)
speed range stabilize at NO appear? NO Connection A and B on NO correctly.
950 30 rpm? detector (B9)
Is the connection
YES YES correct?
Lengthen the servo-motor Adjust the position of the engine speed

(M5) connecting rod, see page detector (B9), see page 25.
23 by one turn, start again if Is the defect still present?
necessary.
YES
YES Change and adjust the engine speed
Change the servo-motor (M5). detector (B9), see page 25.
Adjust the length of the Is the defect still present?
connecting rod, see page 23
or 24 and calibrate YES
the servo-motor (M5), Change the control box (A2).
see page 25. Is the defect still present?
YES
Are the following speeds

stable:
Does defect code 04 appear? Is any position unstable?
1200, 1600, 1800 NO NO
and 2000 rpm? YES
YES
YES Adjust the position of the
engine speed detector (B9),
The defect appears after Adjust the length of the con-
see page 25.
2100 rpm (servo-motor necting rod and calibrate the
jammed on maximum stop) servo-motor (M5),
NO
YES see page 25.

YES Is the defect still present?
Change and adjust the engine
Shorten the servo-motor (M5) speed detector (B9),
connecting rod by one turn. YES
see page 25.
Start again if necessary. Is the defect still present? Change the control box (A2).
YES
Change the control
box (A2).
YES
Change the electronic
harness.
NOTE: If the calibration procedure is not completed after 300 seconds: Calibration impossible. Switch off and on
again after each corrective action to reset the system. and start the calibration procedure again.

4002-23
Settings
Electric acceleration (M5) mechanical adjustment - old type fitting (graduations centred
on the gauge)
CM99J036
171 1mm
PDH0487
PH08508
STEP 1 STEP 3
Turn the battery master switch to the "Off" position. Adjust the connecting rod (2) to the following
length: 171 1 mm.
STEP 2
Make sure that the servo-motor (1) axis mark is cor-
rectly positioned.

4002-24
Electric acceleration (M5) mechanical adjustment - new type fitting (graduations offset
15 on the gauge)
2 5
CM95F018
1
3
4
171 1mm
PDH0487
PH08508
PH08508
PH08508
STEP 1 STEP 5
Turn the battery master switch to the "Off" position. Place the injection pump lever (6) in the "idle" posi-
tion (LH stop), mark its position and then place the
STEP 2 lever in the "accelerated" position (RH stop) and
Make sure that the servo-motor (1) axis mark is cor- mark its position.
rectly positioned.
STEP 6
STEP 3 Check if the two marks previously noted are located
Adjust the connecting rod (2) to the following on the same graduation but with opposite signs. If
length: 171 1 mm. this is not the case, use the connecting rod (2) to
make the "idle/accelerated" positions more symmetri-
STEP 4 cal and then tighten the two lock-nuts (4) and (5).
Install the connecting rod (2) on the lever (3) of the
acceleration motor.

4002-25
This page is intentionally left blank

4002-26
Mechanical adjustment of electrical acceleration (M5) on "low emissions" models
788
1
mm
85
4
3
CM99J036
6
2
5
1
7
CD99J001
988/1188
988: 140 mm 1
1188: 145 mm 1
6
4 CM99J035
1
7
CD99J002

4002-27
STEP 1 STEP 6
Turn the battery master switch to the "Off" position. Place the injection pump lever (6) in the "idle" posi-
tion (LH stop), mark its position on the gauge and
STEP 2 then place the lever (6) in the "accelerated" position
Make sure that the lever (3) of the Servo-motor (1) is (RH stop) and mark its position on the gauge.
correctly positioned (letter F facing the operator).
STEP 7
Position bracket (7) on the engine block, with the on the same graduation but with opposite signs. If
apertures centred. this is not the case, change the position of the
bracket (7) on the engine block and lock the screws.
STEP 4
STEP 8
Adjust the connecting rod (2) to the recommended
length for the excavator model concerned: Change the length of the connecting rod to make the
"idle/accelerated" positions more symmetrical.
788: 85 mm 1
988: 140 mm 1
1188: 145 mm 1
STEP 5
acceleration motor.

4002-28
Electric acceleration calibration
STEP 1 STEP 5
Start the engine and warm it up to normal operating Wait for the LEDs on the keyboard, except for the
temperature, then press the "LOW" (low idle) key. "ECO" key, to go out, and then release the keys.
Switch off the engine.
STEP 6
STEP 2
Start the engine. The "LOW" and "MAX" indicator
Place the LH control arm in the "Safety" position. lamps should flash, showing that the calibration
phase is starting.
STEP 3
NOTE: This phase lasts less than six minutes. The
Using the left hand, press simultaneously on the engine will run successively at 950, 1200, 1600,
"LOW" and "MAX" keys on the control panel. 1800, 2000 and 2240 rpm, and will then stay at
STEP 4 "medium idle" speed (not shown on control panel),
which is 1200 rpm.
Using the right hand, switch on the machine.
STEP 7
Check that the printed circuit board indicator lamp
(LED) stays on continuously.
If this is not the case, note the defect code(s) and
refer to the corresponding page.
If defect code 11 is displayed (calibration impossible)
refer to page 4002-21.
Adjusting the engine speed detector (B10)
STEP 1
Disconnect the connector (X7).
STEP 2
Check the condition of the seal and that the washers
X7 are present. Loosen the lock-nut and screw the
detector up to the stop, then unscrew it one turn.
B10 STEP 3
Tighten the lock-nut to a torque of 10 Nm and recon-
nect the connector (X7).
PH01002
STEP 1
B9
STEP 2
Loosen the lock-nut and screw the detector up to the
stop, then unscrew it one turn.
STEP 3
X7
PH00918

4002
Section
4002
ELECTRONIC AND
TROUBLESHOOTING SYSTEM
Wheeled excavators

Printed in France
4002-2
TABLE OF CONTENTS
TOOLS REQUIRED ............................................................................................................................................... 3
ELECTRONIC SYSTEM ......................................................................................................................................... 4
General ............................................................................................................................................................... 4
Components connected to electronic system ..................................................................................................... 4
Location of components on the excavator .......................................................................................................... 5
Electronic control box ...................................................................................................................................... 5
Swing detection pressure switch ..................................................................................................................... 5
Travel detector pressure switch ...................................................................................................................... 5
Engine speed detector .................................................................................................................................... 6
Swing motor speed detector ........................................................................................................................... 6
Hydraulic pressure sender .............................................................................................................................. 6
Brake pressure switch (speed change) .......................................................................................................... 7
Engine coolant temperature sender ................................................................................................................ 7
Led diagnostic (LED) ...................................................................................................................................... 7
Servo-motor (injection pump lever control) ..................................................................................................... 8
Control panel .................................................................................................................................................. 8
Troubleshooting test socket ............................................................................................................................ 9
Proportional pressure reduction valve DRE4 .................................................................................................. 9
Upperstructure brake release control solenoid valve ..................................................................................... 9
ELECTRONIC SYSTEM DIAGNOSIS .................................................................................................................. 10
General ............................................................................................................................................................. 10
Defect code 01 .................................................................................................................................................. 11
Defect code 02: Components associated with engine electrical acceleration ................................................... 11
Defect code 03: Components associated with the measurement of hydraulic pressure (L.S.) ......................... 13
Defect code 04: Components associated with the measurement of engine speed .......................................... 14
Defect code 05: Components associated with the measurement of water temperature ................................... 15
Defect code 06: Components associated with pressure reduction ................................................................... 16
Defect code 07: Components associated with the speed change control ......................................................... 17
Defect code 08: Components associated with the upperstructure braking and brake release ......................... 18
Defect code 09: Components associated with the control keyboard ................................................................ 19
Defect code 10, 12 and 13: Components associated with the control box ....................................................... 20
Defect code 11: Calibration impossible ............................................................................................................. 21
Settings ............................................................................................................................................................. 23
Electric acceleration (M5) mechanical adjustment - old type fitting (graduations centred on the gauge) ......... 23
Electric acceleration (M5) mechanical adjustment - new type fitting (graduations offset 15 on the gauge) .... 24
Mechanical adjustment of electrical acceleration (M5) on "low emissions" models .......................................... 26
Electric acceleration calibration ......................................................................................................................... 28
Adjusting the engine speed detector (B10) ....................................................................................................... 28
Adjusting the engine speed detector (B9) ......................................................................................................... 28
This symbol is used in this manual to indicate important safety messages. Whenever you see this sym-
bol, carefully read the message that follows, as there is a risk of serious injury.
Turn the battery master switch to the "Off" position before carrying out any service work on the circuit.

4002-3
TOOLS REQUIRED
PD00012
1. PHOTO-DIGITAL TACHOMETER CAS 10449
2. AEROSOL M1703414
(For cleaning and de-oxidation of electrical con-
tacts)

4002-4
ELECTRONIC SYSTEM
General
Some of the machines functions are managed and checked electronically. The functions concerned are as follows:
- Cold start assistance.
- Electric acceleration.
- Automatic return to idle.
- Engine overheating safety system.
- Engine / hydraulic system power regulation: "Speed sensing".
- Swing braking and brake release.
- Speed change.
- Electronic system diagnosis.
Components connected to electronic system
X4 E F
B11 K52
B9 Y4
B22
A2 M5
B10
Y5
B7
H14
B8
B57
C
PDH0471
S22
PH07328A

B7 Swing detector pressure switch S22 Control keyboard
B8 Travel detector pressure switch X4 Diagnostic socket
B9 Engine speed detector Y4 Proportional pressure reduction valve DRE4
B10 Swing motor speed detector Y5 Upperstructure brake release electro-control
B11 Hydraulic pressure detector valve
B57 Brake pressure switch C Lighting 28 volts
B22 Engine coolant temperature sender E Earth
H14 Correct operation indicator light (LED) F 28 volt battery
K52 Two-speed relay

4002-5
Location of components on the excavator

PDH0472 PE09306
Located to the right of the operators seat, it contains the electronic card through which all information passes. The
card is connected to the other components by means of a 35-pin connector.
B7 Swing detection pressure switch
PDH0472 PDH08504
Located on the rear panel of the cab floor, it closes at about 6 bar (RH or LH swing pilot pressure).
PDH0472 PH08504
Located on the rear panel of the cab floor, it closes at about 6 bar (travel brake release pilot pressure).

4002-6
B9 Engine speed detector
PDH0472 PH00918
Mounted in line with the starter ring teeth, it delivers a signal with a frequency corresponding to the time interval
between the passage of two consecutive teeth.
PDH0472 PH01002
Located behind the hydraulic motor housing and opposite a sprocket, it delivers a signal with a frequency corre-
sponding to the passage of two consecutive teeth.
PDH0472 PH01034
Located under the cab floor, it measures the highest pressure (Load-Sensing) in the excavator attachment and
travel hydraulic systems.

4002-7
B57 Brake pressure switch (speed change)
PDH0472 PH01012
Located under the upperstructure and the undercarriage frame, it closes at about 40 bar (brake circuit pressure).
PDH0472 PH00917
Mounted on the engine block, it delivers a pressure of between 0 and 28 volts. It is the ratio between this voltage
and the battery voltage which is used for information processing purposes
H14 Led diagnostic (LED)
PDH0472 CD99J017
This consists of a red warning lamp (Light-Emitting Diode) mounted on the printed circuit board. This indicator lamp
is continuously "on" when the circuit is trouble-free. It starts to flash on and off if one or more defects occur in the
system. Such defects can be identified by means of a lighting code system (See page 10).

4002-8
M5 Servo-motor (injection pump lever control)
PDH0472 PH08508
Mounted on the engine, it control the injection pump lever.

S22 Control panel
PDH0472 PH07328
Located near the right-hand control lever, it has a front face covered with a silk-screened plastic film, an electronic
circuit board with six momentary-action push-buttons, eight LED type indicator lamps, electronic components and a
connector.
The functions of the control panel can be classified under four modes:
- The "Work" mode, consisting of the following push-buttons: "FINE" 1580 to 1620 rpm (low flow work, handling),
"ECO" 1880 to 1920 rpm (economical, digging) and "MAX" 2180 to 2220 rpm (maximum power, hard work).
- The "Idle" mode consisting of the following push-buttons: "LOW" 900 to 1000 rpm (low idle) and "AUTO" 1180 to
1220 rpm (automatic idle).
- The "Travel" mode (two-speed excavators only) has two indicator lamps: "POSITION 1" (low speed) and "POSI-
TION 2" (high speed).
- The "Pre-heat" mode has an indicator lamp: a flashing lamp shows the machine has not yet reached its normal
operating temperature. When that lamp goes out the machine is ready to work.

4002-9
PDH0472 PE10834
Located in the cab, behind the seat, it is protected by a trim panel. It is for use connected to a dialogue console
which can perform in-depth diagnosis of the machine and which is also used for reading and modifying the "exca-
vator parameters".
Y4 Proportional pressure reduction valve DRE4
PDH0472 PH00918
Mounted on the main pump, it delivers an output pressure which is proportional to the current passing through it,
thus enabling a check to be made of the variable flow pump hydraulic torque.
NOTE: The photo shows the DRE4 reduction valve on the 988 excavator. On the 788 the DRE4 reduction valve is
identical, but is mounted in a different manner.
Y5 Upperstructure brake release control solenoid valve
PDH0472 CD99J018
Located behind the cab on the valve bank partition, it is actuated to release the upperstructure brake. It brakes the
upperstructure when not actuated.
4002-10
ELECTRONIC SYSTEM DIAGNOSIS

Diagnosis without console
General
The machine is equipped with an integrated diagnostic system which is designed to locate problems which may
occur in the system. Such defects are displayed by means of an indicator lamp (LED) inserted in the printed circuit
located in the cab behind the operators seat This indicator lamp (LED) is on continuously when the system is fault-
free. It starts to flash when one or more defects appear.
The defect signalling code is as follows:
The indicator lamp lights up for half a second, then goes out for half a second, a number of times equal to the code.
At the end of the cycle the indicator lamp lights up for 5 seconds, the cycle starts again.
Example: 1 defect to be displayed:
- Servo-motor failure: Associated defect code 02
0.5 s 0.5 s 5s
02 02
On
Off
2.5 s 2.5 s
0.5 s
1 flash sequence Separator 1 flash sequence

PDH0474
One flashing sequence may contain more than one defect, in which case they will be listed in numerical sequence
and coded as shown in the example below:
Example: 2 defects to be displayed:
- Failure of components connected with the measurement of water temperature: Associated defect code 05.
- Failure of components connected with the engine electrical acceleration: Associated defect code 02.
5s
02 05 02 05
On
Off
2.5 s 2.5 s 2.5 s
1 flash sequence Separator

1 flash sequence
PDH0475
The defect codes are as follows:

Defect code 01 Not used
Defect code 02 Components connected with the engine electrical acceleration
Defect code 03 Components associated with the measurement of hydraulic pressure
Defect code 04 Components associated with the measurement of engine speed
Defect code 05 Components associated with the measurement of water temperature
Defect code 06 Components associated with pressure reduction
Defect code 07 Components associated with speed change control
Defect code 08 Components associated with upperstructure braking and brake release
Defect code 09 Components associated with the control keyboard
Defect code 11 Calibration impossible

4002-11
Defect code 01
Not used.
Defect code 02: Components associated with engine electrical acceleration

Problems found:
- Engine returns automatically to idle (lever against the injection pump minimum stop)
- Control keyboard completely off except travel mode on two-speed excavators only
- The code appears regardless of the type of electric motor failure (short-circuit or open circuit)
Illustration of indicator lamp
5s
02 02
On
Off
2.5 s 2.5 s
PDH0491
Check the connection of the connector (X9) If there are traces of

which connects the servo-motor to the oxidation, spray with the
electronic harness. appropriate product.
Connection 1. 2. 5. 6 and 7 on (M5) NO Reconnect the
connector (X9) correctly.
YES

servo-motor cable. Is it in good condition? Change the servo-
(no traces of crushing or cutting) NO motor (M5)
YES

electronic harness. Repair or change the
Is it in good condition? NO harness
(no traces of crushing or cutting)
YES
Check the length of the servo-motor

connecting rod.
Is the length 171 mm 1? NO
YES Ensure that the system

for mechanical
Move the injection pump lever manually from
transmission of Adjust the length of
one stop to the other.
movement is in good the connecting rod,
Is the movement correct? NO condition. see page 23 or 24.
(no seizing or stiff places)
Change the servo-motor
(M5) if the fault persists.
YES Calibrate the
servo-motor (M5),
(continued on next page) see page 25.

4002-12
NOTE: After each corrective action, switch off and on again to reset the system.
Switch on without starting the engine.

Select "LOW" speed. Select "MAX" speed.
Does the defect appear
NO Does the defect NO Does the defect
as soon as the system is
appear? appear?
switched on?
YES YES
Lengthen the servo-motor Shorten the servo-motor

connecting rod (M5) by connecting rod (M5) by
one turn, then calibrate, one turn, then calibrate
and start again if and start again if
YES
necessary. necessary.

Is there any movement of the Adjust the length of the connecting rod to
servo-motor cursor (M5)? 171 mm 1. See page 23 or 24 and cali-
NO brate the servo-motor (M5), see page 25.
YES
YES

Change the control box (A2) and
brate the servo-motor (M5),
calibrate it, see page 25.
see page 25.
YES
YES
Adjust the length of the connecting rod to
171 mm 1. See page 23 or 24 and cali- Change the electronic harness.
brate the servo-motor (M5), see page 25. (if that has not already been done).
YES

NOTE: Switch off and on again after each corrective action to reset the system. In the event of a servo-motor fail-
ure, a temporary repair solution is possible consisting of fixing the control connecting rod into one of the holes in
the graduated strip, thus allowing the engine to run at constant speed. Disconnect the servo-motor plug (X9). If this
temporary solution is used, it is essential that the connecting rod fastening is disconnected before stopping the
engine, to allow it to run at idle (otherwise there is a danger of damaging the turbo-charger).

4002-13
Defect code 03: Components associated with the measurement of hydraulic

pressure (L.S.)
Problems found:
- Automatic travel speed system inoperative
- This defect is indicated in all cases of failure of the pressure detector (B11) (short-circuit, open circuit etc.)
Illustration of indicator lamp signal
5s
03 03
On
Off
2.5 s 2.5 s
PDH0476

connecting the hydraulic pressure detector
(B11) to the electronic harness. Reconnect the connector (X8) correctly
Connection A, B and C on detector (B11) NO
YES

hydraulic pressure detector cable (B11).
Change the hydraulic pressure detector (B11).
YES

electronic harness.
YES

YES

4002-14
Defect code 04: Components associated with the measurement of engine

speed
Problems found:
- Reduced hydraulic power, DRE4 pressure fixed when swing is not actuated
- Engine speed safety system inoperative
- Engine starts up directly in "ECO" mode and stays there
- No Auto Idle
NOTE: The failure is more often detected by these symptoms than by the LED flashing.
Illustration of indicator lamp signal
5s
04 04
On
Off
2.5 s 2.5 s
PDH0477

which connects the engine speed detector
(B9) to the electronic harness. Reconnect the connector (X6) correctly.
Connection A and B on detector (B9) NO
YES

engine speed detector cable (B9). Is it in good Change the engine speed detector (B9).
condition? NO
YES

YES
Adjust the position of the engine speed detec-

tor (B9), see page 25.
YES Change the control box (A2) and

Change and adjust the position of the engine calibrate the servo-motor (M5),
speed detector (B9), see page 25. see page 25.
Is the defect still present? NO Is the defect still present?
YES

4002-15
Defect code 05: Components associated with the measurement of water

temperature
Problems found:
- Indicator on instrument panel inoperative
- When starting up from cold, warm-up time reduced to one minute
- Over-heating safety system inoperative
- Short-circuits and open circuits on following items cause this failure: sender, wire, indicator and printed circuit board
- Open circuits: sender, unconnected wires, no defect code 5. Each time the engine is stopped, there is 5 minutes pre-
heating time
5s
05
On
Off
2.5 s 2.5 s
PDH0478
Is it possible to select speeds other than Battery voltage too low: recharge or
"LOW" and "FINE") change.
NO
at the control keyboard (S22)?
YES
Check the connection connecting the water

temperature sender (B22) to the electronic
harness. Reconnect correctly.
Connector 30 (2) NO
(see schematic in Section 4001)
YES

electronic harness.
(no traces of crushing or cutting)
YES
Change the water temperature sender (B22).

YES

YES

4002-16
Defect code 06: Components associated with pressure reduction

Problems found:
- Engine stalls under load
- Zero pressure at valve
NOTE: This defect is indicated by valve short-circuits and open circuits.
5s
06
On
Off
2.5 s 2.5 s
PDH0479
Check the connection from the proportional

pressure reduction valve DRE4 (Y4) and the Reconnect correctly.
NO
electronic harness.
YES

NO
YES
Change the proportional pressure reduction

valve DRE4 (Y4).
YES

YES


4002-17
Defect code 07: Components associated with the speed change control
Problems found:
- Speed change inoperative (the excavator is stuck in second speed)
NOTE: The electronic system does not detect failures in the K52 relay. Open circuit or short-circuit
Travel pressure switch failure
- Open circuit: Impossible to change speed when pressing brake pedal
- Circuit broken: It is possible to change speed without pressing the brake pedal
Solenoid valve failure (not displayed on the LED)
- It should always be excited (at one side or the other) as soon as the machine is switched on
- If it is supplied with current but does not move, change it.
- If it is not supplied with current and no failure is indicated, check the contacts in the relay K52
5s
07
On
Off
2.5 s 2.5 s
PDH0480
Check the connection from the relay K52 to

the electronic harness. Reconnect correctly.
NO
YES

YES
Change the relay (K52).

YES

YES


4002-18
Defect code 08: Components associated with the upperstructure braking

and brake release
Problems found:
- Upperstructure swing impossible
- No brake release
Brake release solenoid valve defective:
- Short circuit and open circuit detected by electronics
Swing pressure switch failure:
- Not detected by electronics
- Short circuit: continuous brake release
- Open circuit: no brake release
5s
08
On
Off
2.5 s 2.5 s
PDH0481
Check the connection from the upperstructure

brake release solenoid valve (Y5) to the elec- NO
tronic harness.
YES
Make a visual check of the condition of the Repair or change the harness.
NO
electronic harness.
YES

YES

YES


4002-19
Defect code 09: Components associated with the control keyboard

Problems found:
- Control keyboard jammed, generally "off" except travel and "LOW IDLE" in certain cases
- Machine on "FINE" and travel on position 2.
5s
09
On
Off
2.5 s 2.5 s
PDH0482
Check the connection from the control key-

board (S22) to the electronic harness. NO
Connection A1. B1. B2 and B3 on (S22).
YES

YES
Change the control keyboard (S22).

YES

YES


4002-20
Defect code 10, 12 and 13: Components associated with the control box
5s
10
On
Off
2.5 s 2.5 s
PDH0483
5s
12
On
Off
2.5 s 2.5 s
PDH0484
5s
13
On
Off
2.5 s 2.5 s
PDH0485

from the control box (A2) to Reconnect correctly.
the electronic harness. NO
YES

YES

YES


4002-21
Defect code 11: Calibration impossible

5s
11
On
Off
2.5 s 2.5 s
PDH0486
Defect appearing after the calibration procedure
Disconnect the servo-motor (M5)

and use tachometer CAS 10449 Check the engine and adjust
to check the engine speed by actuating the if necessary, check and,
injection pump lever manually. if necessary, repair the air supply
Is the engine speed equal to or lower NO circuit and the fuel
than 900 rpm at the idle stop and equal to or supply circuit.
lower than 2200 rpm at the maximum
speed stop?
YES
Check the length of the connecting rod.

171 mm 1.
Is the length correct? NO
YES
Actuate the fuel injection pump lever back and Overhaul and repair the control
forth from one stop to the other. linkage.
Is the movement correct? Change the servo-motor (M5) if the
NO
(no seizing, no stiff places, etc.) defect still remains.
Adjust the length of the connect-

YES ing rod to 171 mm 1.
See page 23 or 24.
Calibrate the servo-motor

(continued on next page) (M5), see page 25.
NOTE: Switch off and on again after each corrective action to reset the system. and carry out the calibration proce-
dure again.

4002-22
Check the connection of
the connector (X6) from
Carry out the calibration Reconnect the
Does defect the engine speed detector (B9)
procedure again. Does the connector (X6)
code 02 to the electronic harness.
speed range stabilize at NO NO NO correctly.
appear? Connection A and B
950 30 rpm? on detector (B9)
Is the connection
YES YES correct?
Lengthen the servo-motor Adjust the position of the engine speed

(M5) connecting rod, detector (B9), see page 25.
see page 23 by one turn, start Is the defect still present?
again if necessary.
YES
YES Change and adjust the engine speed
Change the servo-motor (M5). detector (B9), see page 25.
Adjust the length of Is the defect still present?
the connecting rod,
see page 23 or 24 and cali- YES
brate the servo-motor (M5), Change the control box (A2).
see page 25 Is the defect still present?
YES
Are the following speeds

stable:
Does defect code 04 appear? Is any position unstable?
1200, 1600, 1800 NO NO
and 2000 rpm ? YES
YES
YES Adjust the position of the
engine speed detector (B9),
The defect appears after Adjust the length of the con-
see page 25.
2100 rpm (servo-motor necting rod and calibrate the
jammed on maximum stop) servo-motor (M5),
NO
YES see page 25.

YES Is the defect still present?
Change and adjust the engine
Shorten the servo-motor (M5) speed detector (B9), YES
connecting rod by one turn. see page 25.
Start again if necessary. Is the defect still present? Change the control box (A2).
YES
Change the control box (A2).

YES
Change the electronic
harness.
NOTE: If the calibration procedure is not completed after 300 seconds: Calibration impossible. Switch off and on
again after each corrective action to reset the system. and start the calibration procedure again.

4002-23
Settings
Electric acceleration (M5) mechanical adjustment - old type fitting (graduations centred
on the gauge)
2
CM99J036
171 1mm
PDH0487
PH08508
STEP 1 STEP 3
Turn the battery master switch to the "Off" position. Adjust the connecting rod (2) to the following
length: 171 1 mm.
STEP 2
Make sure that the servo-motor (1) axis mark is cor-
rectly positioned.

4002-24
Electric acceleration (M5) mechanical adjustment - new type fitting (graduations offset
15 on the gauge)
2 5
CM95F018
1
3
4
171 1mm
PDH0487
PH08508
PH08508
PH08508
STEP 1 STEP 5
Turn the battery master switch to the "Off" position. Place the injection pump lever (6) in the "idle" position
(LH stop), mark its position and then place the lever
STEP 2 in the "accelerated" position (RH stop) and mark its
Make sure that the servo-motor (1) axis mark is cor- position.
rectly positioned.
STEP 6
STEP 3 Check if the two marks previously noted are on the
Adjust the connecting rod (2) to the following same graduation but with opposite signs. If this is not
length: 171 1 mm. the case, use the connecting rod (2) to make the
"idle/accelerated" positions more symmetrical and
STEP 4 then tighten the two lock-nuts (4) and (5).
acceleration motor.

4002-25

4002-26
Mechanical adjustment of electrical acceleration (M5) on "low emissions" models
788
1
mm
85
4
3
CM99J036
6
2
5
1
7
CD99J001
988/1188
988: 140 mm 1
1188: 145 mm 1
6
4 CM99J035
1
7
CD99J002

4002-27
STEP 1 STEP 6
Turn the battery master switch to the "Off" position. Place the injection pump lever (6) in the "idle" position
(LH stop), mark its position on the gauge and then
STEP 2 place the lever (6) in the "accelerated" position
Make sure that lever (3) of the servo-motor (1) is cor- (RH stop) and mark its position on the gauge.
rectly positioned (letter F facing the operator).
STEP 7
Position bracket (7) on the engine block, with the on the same graduation but with opposite signs. If
apertures centred. this is not the case, change the position of the
bracket (7) on the engine block and lock the screws.
STEP 4
STEP 8
Adjust the connecting rod (2) to the recommended
length for the excavator model concerned: Change the length of the connecting rod to make the
"idle/accelerated" positions more symmetrical.
788: 85 mm 1
988: 140 mm 1
1188: 145 mm 1
STEP 5
acceleration motor.

4002-28
Electric acceleration calibration
STEP 1 STEP 5
Start the engine and warm it up to normal operating Wait for the LEDs on the keyboard, except for the
temperature, then press the "LOW" (low idle) key. "ECO" key, to go out, and then release the keys.
Switch off the engine.
STEP 6
Do not actuate any of the controls during this Start the engine. The "LOW" and "MAX" indicator
procedure. lamps should flash, showing that the calibration
phase is starting.
STEP 2 NOTE: This phase lasts less than six minutes. The
engine will run successively at 950, 1200, 1600,
Place the LH control arm in the "Safety" position. 1800, 2000 and 2240 rpm, and will then stay at
STEP 3 "medium idle" speed (not shown on control panel),
which is 1200 rpm.
Using the left hand, press simultaneously on the
"LOW" and "MAX" keys on the control panel. STEP 7
STEP 4 Check that the printed circuit board indicator lamp
(LED) stays on continuously.
Using the right hand, switch on the machine. If this is not the case, note the defect code(s) and
refer to the corresponding page.
If defect code 11 is displayed (calibration impossible)
refer to page 4002-21.
STEP 1
STEP 2
Check the condition of the seal and that the washers
X7 are present. Loosen the lock-nut and screw the
detector up to the stop, then unscrew it one turn.
B10 STEP 3
PH01002
STEP 1
B9
STEP 2
Loosen the lock-nut and screw the detector up to the
stop, then unscrew it one turn.
STEP 3
X7
PH00918

8001
Section
8001
TESTS, ADJUSTMENTS
AND HYDRAULIC SCHEMATICS
Crawler excavators

Printed in France
8001-2
TABLE OF CONTENTS
TOOLS REQUIRED ................................................................................................................................................. 3
TOOLS TO BE MANUFACTURED .......................................................................................................................... 5
788C GENERAL HYDRAULICS............................................................................................................................... 6
788C PLUS GENERAL HYDRAULICS .................................................................................................................... 7
788CGENERAL HYDRAULIC SYSTEM .................................................................................................................. 9
788C PLUS GENERAL HYDRAULIC SYSTEM..................................................................................................... 11
788C GENERAL HYDRAULIC SYSTEM ............................................................................................................... 13
988C GENERAL HYDRAULICS............................................................................................................................. 16
988C PLUS GENERAL HYDRAULICS .................................................................................................................. 17
SETTING THE PRESSURES ON THE 788C ........................................................................................................ 26
SETTING THE PRESSURES ON THE 788C PLUS .............................................................................................. 27
SETTING THE PRESSURES ON THE 988C ........................................................................................................ 28
SETTING THE PRESSURES ON THE 988C PLUS .............................................................................................. 29

8001-3
TOOLS REQUIRED
1. TEST EQUIPMENT Two pressure measurements, pressure peaks, pres-
There are three possible choices: sure differential (Delta P), temperature, temperature
a) Multi-Handi test kit 2051.........................E5444449 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 220 V 50 Hz power supply ................... D5344467
1 cigarette lighter cable.............................. E5344468
CP96E001 1 instruction manual.................................... -------------
1 carry-case ............................................... P5344477
The Multi-Handi test kit is recommended as the basic
tool of the mechanic. c) Multi-System 5000 test kit ..................... U5344459
The Multi-Handi can carry out the following tests:
Two pressure measurements, pressure peaks, pres-
sure differential (Delta P), temperature, rotational
speed and volumetric flow.
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 ................................... -------------
1 carry-case............................................... N5344476 The Multi-System is recommended for specialist
departments (Engineering Design Office and tests at
b) Multi-Test 4020 test kit .......................... T5344458 customers premises).
The Multi-System can carry out the following tests:
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.
1 Multi-System 5000 unit ........................... R5344456
CP96E003 1 rotational speed detector ........................ Z5344463
1 temperature sender................................. A5344464
The Multi-Test is recommended to carry out in-depth 2 double PT cables .................................... B5344465
diagnostics. Values read can be recorded in its mem- 4 cables length 5 m.................................... E3144472
ory and transferred to a PC and a printer. 1 x 220 V 50 Hz power supply ................... D5344467
The Multi-Test can carry out the following tests: 1 cigarette lighter cable.............................. E5344468
1 instruction manual.................................... -------------
1 carry-case ............................................... P5344477

8001-4
CP96E004 PG04005
2. TEMPERATURE SENDER A5344464 6. ONE PRESSURE TEST POINT M14 X 1.5

A3237549
Use with Multi-Handi 2051 test kit
3. MAGNETIC BASE G5344470
Use with Multi-Handi 2051, Multi-Test 4020 and Multi-
System 5000 test kits
PE18402
7. TWO MINIMESS HOSES LENGTH 2500 mm

P2144487
TWO HOSE UNIONS C5144412
PF01410
4. 600 LITRES FLOWMETER, ORDER THE FOL-

LOWING:
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
5. ONE HIGH PRESSURE HOSE DN19 Q5931990
ONE LOW PRESSURE HOSE DN12 B8031969
PG04006
8. TWO PLUGS 27 X 200 Q3337452

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

8001-5
PDH0505 PDH0506
9. TWO REDUCTION GEARS DN25 - DN19 G1037352 10.ONE SPECIAL UNION W5137530
TOOLS TO BE MANUFACTURED
PDG0239
1. ONE SPACER TO LIMIT THE STROKE OF THE

CONTROL LEVER SPOOLS

8001-6
788C GENERAL HYDRAULICS

788C hydraulic system
Location of hydraulic components
3 - Low flow options control valve (clamshell rotation, articulated boom)
6 - High pressure pump with:
1 fixed flow body for the swing function
1 variable flow body for the attachment, travel and options
7 - Low pressure pump for the pilot system
8 - Hose/accumulator on variable flow pump LS information circuit
10 - Anti-surge valve on pump LS circuit
22a - Foot control valve for the RH travel function
22b - Foot control valve for the LH travel function
23 - Manual travel control block (INCHING)
26 - Pilot systems supply and return circuit manifold
41 - Swing control valve block
42 - Hydraulic swing motor
43 - Swing safety and force-feed flange
61 - Electro-control valve including:
61a - Control arm safety electro-control valve
61b - Swing automatic braking and brake release electro-control valve
61c - Pressure limiter P35
62 - Hydraulic travel motor displacement change control electro-control valve (two-speed excavators)
63 - Electrically controlled proportional reducing valve (DRE4)
81 - Attachment control valve block (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)
103 - Travel drift control block
104 - Variable displacement hydraulic travel motors (two-speed excavators)
M1 - Pressure test point for attachment/travel and options (if any)
M2 - Pressure test point for the swing function
M3 - Pressure test point for LS circuit
M4 - Pressure test point for pilot circuits
M6 - Pressure test point for travel manual control block outlet
M7 - Pressure test point for swing braking and brake release
M17 - Pressure test point for travel on speed limiter
M27 - Pressure test point for proportioning valve outlet
CM99J025

8001-7
788C PLUS GENERAL HYDRAULICS

788C Plus hydraulic system
3 - Low flow options control valve (clamshell rotation, articulated boom)
1 fixed flow pump for the swing
7 - Low flow pump for pilot system
8 - Hose/accumulator on the variable flow pump LS information circuit
10 - Anti-surge valve on attachment LS circuit
12 - Filter on pilot circuit
22a - Foot control block for RH travel function
22b - Foot control block for LH travel function
23 - Manual travel control block (INCHING)
26 - Pilot systems supply and return circuit manifold
43 - Swing safety and force-feed flange
61b - Automatic swing braking and brake release electro-control valve
61c - Pressure limiter P35
61d - Hydraulic travel motor displacement change electro-control valve (two-speed excavators)
63 - Electrically controlled proportional reducing valve (DRE4)
102 - Fixed displacement travel hydraulic motors (single speed excavators)
M2 - Pressure test point for the swing function
M4 - Pressure test point for pilot systems
CM99J026

8001-8
CM99J029

8001-9
788C GENERAL HYDRAULIC SYSTEM 65a - Swing pilot pressure switch (6 bar)
65b - Travel pilot pressure switch (6 bar)
Single-speed 788C B general hydraulic system 66 - Electronic control box
67 - Swing motor speed detector (for braking function)
Description
1 - Reservoir 82 - P10 counter-pressure valve
2 - Reservoir filler cap with self-pressurizing valve and screen filter 83 - Flow limiter on dipper cylinder small chamber
3 - Return manifold with element type filters and restriction indicator 84 - Dipper cylinder with dashpot on large and small chambers
4 - Magnetic filter 85 - Backhoe / clamshell selector block
5 - LS detector information selector block with filter on travel LS information 86 - Bucket cylinder with dashpot on the small chamber
6 - High pressure hydraulic pump with: 87 - Boom cylinder supply distribution block with flow limiter on cylinder large chambers
1 fixed flow body for the swing function 88 - Boom cylinders with dashpot on the large chambers
1 variable flow body for attachment, travel and options 89 - Pressure selector between the attachment/options and travel LS information circuits
7 - Fixed flow low pressure pump for pilot circuit 90 - Hydraulic swivel
8 - Hose/accumulator
9 - Pressure test point
101a - Anti-excess flow valve
M1 - Pressure test point for attachment, travel and options (if any)
101b - Hydraulic travel motor automatic brake release valve
M2 - Pressure test point for swing
101c - Speed limiter
102 - Fixed displacement hydraulic travel motors (with static brake)
110 - Hydraulic oil cooler
M15 - Pressure test point for swing pilot system
M17 - Pressure test point travel brake release on speed limiter
10 - Anti-surge valve and filter on LS information (attachment/options)
21 -
Boom and bucket (or clamshell) manual control block)
22a -
RH travel control block
22b -
LH travel control block
23 -
Manual travel control block
24 -
Travel pilot pressure selector block (AUTO-IDLE)
25 -
Pressure release pump (foot control)
26 -
Pilot circuit manifold
27 -
Pilot circuit minimum pressure switch
28 -
Swing pilot pressure information selector block (swing braking and brake release function + AUTO-IDLE func-
tion)
29 - Dipper and swing function manual control block
42 - Hydraulic swing motor with static brake
43 - Safety/force-feed flange on swing function
44 - 3 bar counter-pressure valve
45 - Braking check valves on swing control valve spool pilot systems
46 - 0.5 b check valve on force-feed circuit (mounted on swing control valve)
47 - Double spring type accumulator
61c - P35 pressure limiter
63 - Electro-hydraulic proportioning valve (DRE4)
64 - LS information pressure detector

8001-10
CM99J031

8001-11
788C PLUS GENERAL HYDRAULIC SYSTEM 65a - Swing pilot pressure switch (6 bar)
Single-speed 788C B general hydraulic system 66 - Electronic control box
67 - Swing motor speed detector (for braking)
Description
3 - Return manifold with element type filters and restriction indicator 84 - Dipper cylinder with dashpot on large and small chamber
4 - Magnetic filter 85 - Backhoe/clamshell selector block
5 - LS detector information selector block with filter on travel LS information 86 - Bucket cylinder with dashpot on small chamber
6 - High pressure hydraulic pump with: 87 - Boom cylinder supply distribution block with flow limiter on cylinder large chambers
1 fixed flow body for the swing function 88 - Boom cylinders with dashpot on large chambers
1 variable flow body for attachment, travel and options 89 - Pressure selector between attachment/options and travel LS information circuits
7 - Fixed flow low pressure pump for the pilot circuit 90 - Hydraulic swivel
M6 - Pressure test point for manual travel control block outlet
M17 - Pressure test point for travel brake release on speed limiter
11 - Pilot circuit filter
12 - Work/heavy lift position selector
21 -
Boom and bucket (or clamshell) manual control block
22a -
22b -
23 -
24 -
25 -
Pressure release block (foot control)
26 -
27 -
28 -
Swing pilot pressure information selector block (swing braking and brake release function + AUTO-IDLE func-
tion)
30 - Jet in swing circuit
43 - Safety / force-feed flange on swing function

8001-12
CM99J030

8001-13
Two-speed 788C B general hydraulic system 66 - Electronic control box
67 - Swing motor speed detector (for braking function)
1 - Reservoir
2 - Reservoir filler cap with self-pressurizing valve and screen filter 81 - Attachment control valve block (boom, dipper, bucket)
3 - Return manifold with element type filters and restriction indicator 82 - P10 counter-pressure valve
4 - Magnetic filter 83 - Flow limiter on dipper cylinder small chamber
5 - LS detector information selector block with filter on travel LS information 84 - Dipper cylinder with dashpot on large and small chamber
6 - High pressure hydraulic pump with: 85 - Backhoe/clamshell selector block
1 fixed flow body for the swing 86 - Bucket cylinder with dashpot on the small chamber
1 variable flow body for the attachment, travel and options 87 - Boom cylinder supply distributor with flow limiter on cylinder large chambers
7 - Fixed flow low pressure pump for the pilot circuit 88 - Boom cylinders with dashpot on the large chambers
8 - Hose/accumulator 89 - Pressure selector between the attachment/option and travel LS information circuits
9 - Pressure test point 90 - Hydraulic swivel
M1 - Pressure test point for attachment, travel and options (if any) 101 - Travel control valve block
M2 - Pressure test point for swing 101a - Anti-excess flow valve
M3 - Pressure test point for LS circuit 101b - Hydraulic travel motor automatic brake release valve
M4 - Pressure test point for pilot circuits 101c - Speed limiter
M6 - Pressure test point for manual travel control block outlet 103 - Travel drift control block
M7 - Pressure test point for swing braking and brake release 104 - Variable displacement hydraulic travel motors
M15 - Pressure test point for swing pilot system 110 - Hydraulic oil cooler
21 - Boom and bucket (or clamshell) manual control block
22a - RH travel control block
22b - LH travel control block
23 - Manual travel control block
24 - Travel pilot pressure selector block (AUTO-IDLE)
25 - Pressure release pump (foot control)
26 - Pilot circuits manifold
27 - Pilot circuit minimum pressure switch
28 - Swing pilot pressure information selector block (automatic swing braking and brake release + AUTO-IDLE)
45 - Braking valves on swing control valve spool pilots
46 - 0.5 b valve on the force-feed circuit (mounted on the swing control valve)
47 - Double spring type accumulator
61 - Electro-control valve block consisting of:
61a - Safety control arm electro-control valve
61b -Automatic swing braking and brake release electro-control valve
62 - Hydraulic travel motor displacement change electro-control valve

8001-14
CM99J032

8001-15
Two-speed 788C Plus general hydraulic system 66 - Electronic control box
67 - Hydraulic swing motor speed detector (for braking function)
Description
3 - Return manifold with element type filters and restriction indicator 84 - Dipper cylinder (dashpot on large and small chamber)
5 - LS detector information selector block with filter on travel LS information filter 86 - Bucket cylinder (dashpot on small chamber)
6 - High pressure hydraulic pump with: 87 - Boom cylinder supply distribution block with flow limiter on the cylinder large chambers
1 fixed flow body for swing 88 - Boom cylinders (dashpot on large chambers)
1 variable flow body for the attachment, travel and options 89 - Pressure selector between LS/options and travel
104 - Variable displacement hydraulic travel motors
M6 - Pressure test point for travel manual control point outlet
21 -
Boom and bucket (or clamshell) manual control block
22a -
22b -
23 -
24 -
25 -
Pressure release pump (foot control)
26 -
Manifold for pilot circuits
27 -
28 -
Swing pilot pressure information selector block (swing automatic braking and brake release function + AUTO-
IDLE function)
30 - Jet in swing circuit
46 - 0.5 b check valve on force-feed circuit (mounted on the swing control valve)
61 - Electro-control valve block:
62 - Hydraulic travel motor displacement change electro-control valve

8001-16
988C GENERAL HYDRAULICS

988C hydraulic system
3 - Low flow option control valve (clamshell rotation, articulated boom)
1 fixed flow body for the swing
7 - Low pressure pump for the pilot circuit
8 - Hose/accumulator on the variable flow pump LS information circuit
10 - Anti-surge valve on the attachment LS circuit
22a - Foot control block for the RH travel function
22b - Foot control block for the LH travel function
26 - Manifold for supply circuits and pilot return circuits
43 - Swing function safety and force-feed flange
61a - Automatic swing braking and brake release electro-control valve
61b - Safety control arm electro-control valve
62 - Hydraulic travel motor displacement change electro-control valve (two-speed excavators)
63 - Electrically controlled proportional reduction valve (DRE4)
81 - Attachment control valve
101 - Travel control valve
102 - Fixed displacement hydraulic travel motors (single-speed excavators)
103 - Travel anti-drift block
M17 - Pressure test point for travel on the speed limiter
CM99J027

8001-17
988C PLUS GENERAL HYDRAULICS

988C Plus hydraulic system
6 - High pressure hydraulic pump with:
7 - Low pressure hydraulic pump for the pilot circuit
8 - Hose/accumulator on the variable flow pump LS information
10 - Anti-surge valve on the pump LS circuit
22a - Foot control block for the RH travel function
22b - Foot control block for the LH travel function
26 - Pilot supply and return circuit manifold
41 - Swing control valve
43 - Swing function safety and force-feed flange
62 - Hydraulic travel motor displacement change electro-control valve (two-speed excavators)
63 - Electrically controlled proportional reduction valve (DRE4)
81 - Attachment control valve
82 - P10 counter-pressure block
101 - Travel control valve
102 - Fixed displacement hydraulic travel motors (single-speed excavators)
CM99J028

8001-18
CM99M027

8001-19
65b - travel pilot pressure switch (6 bar)
Single-speed 988C general hydraulic system 66 - Electronic control box
67 - Hydraulic swing motor speed detector
Description
6 - High pressure hydraulic pump with: 87 - Boom cylinder supply distribution block with flow limiter on the cylinder large chambers
1 fixed flow body for the swing circuit 88 - Boom cylinders with dashpot on the large chambers
2 variable flow bodies for the attachment, travel and options 89 - Pressure selector between attachment/option and travel LS information circuits
7 - Low pressure pump for the pilot circuit 90 - Hydraulic swivel
101a - Speed limiter
101b - Automatic hydraulic motor brake release valve
101c - Anti-excess flow valve
11 - Calibrated orifice (: 2.5 mm) on main pump irrigation circuit
21 -
Boom and bucket (or clamshell) function manual control
22a -
22b -
23 -
24 -
25 -
Decompression pump (foot control)
26 -
27 -
Pilot system minimum pressure switch
28 -
Swing pilot pressure information selector block (automatic swing braking and brake release + AUTO-IDLE func-
tion)
44 - 3 bar valve block
47 - Accumulator

8001-20
CM99J033

8001-21
Single-speed 988C Plus general hydraulic system 66 - Electronic control box
67 - Swing motor speed detector (for braking)
Description
2 - Reservoir filler plug with self-pressurizing valve and screen filter 83 - Flow limiter on dipper cylinder small chamber
4 - Filter on return circuit 85 - Backhoe/clamshell selector block
6 - High pressure hydraulic pumps with: 87 - Boom cylinder supply distribution block with flow limiter on the cylinder large chambers
1 fixed flow body for the swing 88 - Boom cylinders with dashpot on the big chambers
2 variable flow bodies for the attachment, travel and the options 89 - Pressure selector between attachment/option and travel LS information circuits
7 - Low pressure fixed flow pump for the pilot circuit 90 - Hydraulic swivel
101 - Travel control valve blocks
101b - Automatic hydraulic travel motor brake release valve
M15 - Pressure test point for swing pilot
11 - Calibrated orifice (: 2.5 mm) on the main pump irrigation circuit
21 -
Boom and bucket (or clamshell) function manual control block
22a -
22b -
23 -
24 -
25 -
26 -
Pilot circuits manifold
27 -
28 -
Swing pilot pressure information selector block (automatic swing braking and brake release + AUTO-IDLE func-
tion)
30 - Jets on swing pilot circuit
44 - 3 bar valve block
46 - 0.5 b valve on force-feed circuit (mounted on swing control valve)
61 - Electro-control valve block including:

8001-22
CM99M028

8001-23
Two-speed 988C general hydraulic system 66 - Electronic control box
Description
81 - Attachment control valve (boom, dipper, bucket)
5 - LS detector information selection block with filter on travel LS information line 86 - Bucket cylinder with dashpot on small chamber
6 - High pressure hydraulic pumps with: 87 - Boom cylinder supply distributor with flow limiter on cylinder large chambers
1 fixed flow body for the swing 88 - Boom cylinders with dashpot on the large chambers
2 variable flow bodies for the attachment, travel and options 89 - Pressure selector between attachment/options and travel LS information circuits
M1 - Pressure test point for attachment, travel and option (if any)
101b - Travel hydraulic motor automatic brake release valve
M6 - Pressure test point for manual travel control block outlet
M7 - Pressure test point for swing brake and brake release
11 - Calibrated orifice (dia: 2.5 mm) on main pump irrigation circuit
21 - Boom and bucket (or clamshell) function manual control block
22a - RH travel control block
22b - LH travel control block
23 - Travel manual control block
24 - Travel pilot pressure selection block (AUTO-IDLE)
25 - Decompression pump (foot control)
27 - Minimum pilot pressure switch
28 - Swing pilot pressure information selector block (swing auto braking and brake release + AUTO-IDLE)
29 - Dipper and swing manual control block
41 - Swing control block
43 - Safety/force-feed flange on swing
44 - 3 bar check valve block
46 - 0.5 b check valve on force-feed circuit (mounted on the swing control valve)
47 - Accumulator
62 - Travel motor displacement change electro-control valve block
63 - Elector-hydraulic proportioning valve (DRE4)

8001-24
CM99J034

8001-25
Two-speed 988C Plus general hydraulic system 66 - Electronic control box
Description
4 - Return circuit filter 85 - Backhoe/clamshell selector block
5 - LS detector information selection block with filter on travel LS information 86 - Bucket cylinder with dashpot on small chamber
6 - High pressure hydraulic pumps with: 87 - Boom cylinder supply distribution block with flow limiter on cylinder large chambers
1 fixed flow body for the swing 88 - Boom cylinders with dashpot on large chambers
2 variable flow bodies for the attachment, travel and options 89 - Pressure selector between attachment/options and travel LS information circuits
7 - Low pressure fixed flow pump for the pilot circuit 90 - Hydraulic swivel
M1 - Pressure test point attachment/travel and options (if any)
101b - Automatic hydraulic travel motor brake release valve
M2 - Swing pressure test point
M3 - LS circuit pressure test point
M4 - Pilot circuit pressure test point
M6 - Travel manual control block outlet pressure test point
M7 - Swing braking and brake release pressure test point
M15 - Swing pilot system pressure test point
M17 - Travel pressure test point on speed limiter
M27 - Proportioning valve outlet pressure test point
10 - Anti-surge valve and filter on LS information LS (attachment/options)
11 - Calibrated orifice (: 2.5 mm) on main pump irrigation circuit
21 -
Boom and bucket (or clamshell) function manual control block
22a -
22b -
23 -
24 -
Travel pilot pressure selection block (AUTO-IDLE)
25 -
26 -
27 -
28 -
Swing pilot pressure information selector block (automatic swing + AUTO-IDLE braking and brake release func-
tion)
30 - Jets on swing pilot circuit
44 - 3 bar block
61b -Automatic swing braking and brake release electro-control valve
62 - Hydraulic travel motor displacement change electro-control valve block

8001-26
SETTING THE PRESSURES ON THE 788C

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 hose
M4 on the manifold
M7 on the swing brake supply hose
M27 on the proportioning valve
Location of pressure test points to be installed
M6 on the manifold
M17 on the speed limiter
Installing the flowmeter on the A1 attachment and travel (pump body)
Disconnect the variable displacement pump body outlet hose A1, from the union block mounted on the power mod-
ule longitudinal member, at the earthing end.
Install the flowmeter (C3744471) using the hose recommended (W5431976) in the tooling list.
Raising circuit temperature to between 50 and 55C
Use the attachment to raise one track.
Operate the bucket or clamshell against the stops.
Checking the engine speeds without load and the pressures supplied by the proportioning valve
Install the tachometer and connect the multitester at M27.
MODES SPEEDS PRESSURES
AUTO - IDLE 1150 to 1250 (rpm) 19.5 to 23.5 (bar)

LOW - IDLE 900 to 1000 (rpm) 19.5 to 23.5 (bar)
FINE 1570 to 1630 (rpm) 13.5 to 17.5 (bar)
ECO 1920 to 1980 (rpm) 8.5 to 12.5 (bar)
MAX 2190 to 2250 (rpm) 5.5 to 9.5 (bar)
If the speeds are outside tolerances, check first of all the servomotor connecting rod geometry (length end-to-
end = 171 + or - 1 mm) and then recalibrate.
CM99J040

8001-27
SETTING THE PRESSURES ON THE 788C PLUS
M3 on the anti-surge valve
M4 on the manifold
M6 on the travel control block circuit
Installing the flowmeter on the A1 pump body (for the attachment and travel)
Disconnect the pump body hose from the port A1 of the pump.
Install the flowmeter (Z5344486) using the hose (W5431976) recommended in the tool list.
Raising the circuit temperature to between 50 and 55C
Checking the engine speeds without load and the pressures delivered by the proportioning valve
Install the tachometer and connect the multitester at M27.
AUTO - IDLE 1170 to 1230 (rpm) 19 to 24 (bar)

LOW - IDLE 900 to 1000 (rpm) 19 to 24 (bar)
FINE 1570 to 1630 (rpm) 19 to 18 (bar)
ECO 1920 to 1980 (rpm) 6 to 11 (bar)
MAX 2190 to 2250 (rpm) 5 to 10 (bar)
If the speeds are not within tolerances, check first of all the geometry of the servomotor connecting rod (see Sec-
tion 4002).
CM99J038

8001-28
SETTING THE PRESSURES ON THE 988C
M4 on the manifold
M6 on the manifold
Disconnect the variable displacement pump body outlet hose A1, on the union block mounted on the power mod-
ule longitudinal member, at the earthing end
Install the flowmeter (C3744471) using the hose (W5431976) recommended in the tool list.
Installer the tachometer and connect the multitester at M27.

FINE 1570 to 1630 (rpm) 15 to 19 (bar)
ECO 1920 to 1980 (rpm) 9.5 to 13.5 (bar)
MAX 2190 to 2250 (rpm) 7.5 to 11.5 (bar)
If the speeds are not within tolerances, check first of all the servomotor connecting rod (length end-to-end = 171 +
or - 1 mm) and then recalibrate.
CM99J041

8001-29
SETTING THE PRESSURES ON THE 988C PLUS
M4 on the manifold
M6 on the manifold

FINE 1570 to 1630 (rpm) 13 to 17 (bar)
ECO 1920 to 1980 (rpm) 6 to 11 (bar)
MAX 2190 to 2250 (rpm) 5 to 10 (bar)
If the speeds are not within tolerances, check first of all the servomotor connecting rod geometry (see
Section 4002).
CM99J039

8001-30

8001-31
Pressure settings (continued) Checking the maximum flow from the
WARNING! All checks and adjustments are carried variable displacement pump, using one
out at various engine speeds and at a temperature of flowmeter only
50C. Set the MAX mode.
WARNING! The flows specified on the 988 are Connect the multitester for flow measurement.
those read on the flowmeter (1 pump body). Retract the dipper and close the bucket simultane-
ously.
Checking the pilot pressure with the The flow should be greater than 205 (l/min) and the
control arm lowered pressure at M1 lower than 125 (bar) on the 788.
The flow should be greater than 153 (l/min) and the
Connect the multitester to the manifold at M4.
pressure at M1 lower than 100 (bar) on the 988.
Set the MAX mode.
The pressure must be greater than 34 (bar). Checking the flow adjustment valve
If it is not, check the P35 or the electrical circuit. flows
AFTER EACH CHECK, IF THE PARAMETERS ARE Attachment control valves
INCORRECT, ADJUST AT THE COMPONENT
CONCERNED OR CHANGE THE COMPONENT. Supply the large chambers of the boom, bucket and
dipper cylinders, one after another.
Setting the LS valve pressure The flows should be between:
Static test using the same 0/40 bar pressure
gauge: 788C, 788C Plus 988C, 988C Plus
WARNING! Start the engine running, before connect-
140 - 160 l/min 83 - 93 l/min
ing the pressure gauge at M1.
on the boom on the boom
Raise the left-hand control arm as a safety measure.
Set the FINE mode. 90 - 110 l/min 70 - 80 l/min
Connect the pressure gauge at M3. The pressure on the bucket on the bucket
should be between 8 and 12 (bar). If it is not, check
the P10. 115 - 135 l/min 78 - 88 l/min
Connect the pressure gauge at M1. The difference on the dipper on the dipper
between M1 and M3 should be 21 to 25 (bar).
Travel control valve
Dynamic test using multitester:
WARNING! The difference in the flows between the
Assemble the spacer on the boom raising control two tracks should not exceed 4 (l/min).
lever push-rod.
Connect the two outlets from the multitester at M1
Forward travel:
and M3. Select the speed 1 (two-speed excavators).
Operate the boom raising control. Use the attachment to raise each track. Set the inch-
The pressure difference (P) should be between 21 ing valve control lever to maximum.
and 23 (bar). Operate each track in the forward direction.
The flows noted should be between 100 and 120 (l/min)
on the 788 and between 65 and 75 (l/min) on the 988.
If the values noted are between 95 and 125 (l/min) on
the 788 and between 61 and 81 (l/min) on the 988,
adjust the flow adjustment valves.
If not, check the adjustment of the automatic flow dis-
tribution.

8001-32
Using a chronometer:
The number of revolutions of the sprocket must be
between 30 and 36 (rpm) on the 788 and between 28
and 32 (rpm) on the 988.
If the values noted are between 29 and 37 (rpm) on
the 788, and between 27 and 33 (rpm) on the 988,
adjust at the flow adjustment valves.
If not, check the adjustment of the automatic flow dis-
tribution. (A.F.D.) (See page 36).
Reverse travel:
The process is the same as for forward travel.
If the value of flows noted is between 100 and
120 (l/min) on the 788 and between 61 and 81 (l/min)
on the 988, or if the sprocket revolutions are between
30 and 36 (rpm) on the 788 and between 27 and
33 (rpm) on the 988, adjust the mechanical stops in
the control 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.) (See page 36).

8001-33
Checking the hydraulic power supplied by the proportioning valve, with the engine under
load
DRE4 pressure
Engine speed DRE4 pressure Output
with swing
788C
1980 - 2020 11 - 16.5 92 l/min 20 - 27
09/97
988C (1)
1980 - 2020 12 - 17 66 l/min 21 - 27
09/97
788C
1980 - 2020 11 - 16,5 92 l/min 20 - 27
09/97
988C (1)
1980 - 2020 12 - 17 58 l/min 21 - 27
09/97
988C Plus (2) 60 l/min 21 - 27

09/97
788C Plus 1980 - 2020 11 - 16 102 l/min 20 - 26
(1) 988 C not sound-proofed (fan ratio = 1.1 on cooling).

(2) 988 C sound-proofed (fan ratio 0.87 on cooling).
Check or adjustment of all valves
Connect the multitester at M1.
Set to MAX mode.
Overtighten the relief valve by one turn.
Overtighten the attachment and travel flow cancellation valve by two turns.
Safety valves on the attachment control valve
Attachment control valve
788 - 988 - 988 Plus 788 Plus
Attachment limiter 390 - 425 380 - 400
Boom raising 390 - 420 410 - 440
Boom lowering 380 - 410 390 - 420
Extending dipper 380 - 410 395 - 425
Retracting dipper 380 - 410 395 - 425
Extending bucket 380 - 410 395 - 425
Retracting bucket 380 - 410 395 - 425

8001-34
Safety valves on travel control valve Checking or adjusting the swing
Lock the tracks mechanically in both travel directions. Circuit pressure without load
Set to MAX mode, with the inching lever at full travel.
Supply each track, one after another, in both direc- Connect the multitester at M2.
tions Set the MAX mode.
The pressures noted should be between 385 and The pressure noted should be between 15 and
415 (bar) on the 788 and 988 and between 395 and 17 (bar).
425 (bar) on the 788C Plus. If it is not, check the P3.
Relief valve
Adjusting the relief valve
Lock the upperstructure mechanically.
Supply the bucket opening function.
Overtighten one safety valve by one turn.
Untighten the relief valve until the same pressure is
Supply the direction of swing concerned.
obtained as the bucket secondary relief valve.
The pressure noted should be between 370 and
Adjusting the attachment and travel flow 400 (bar) on the 788, and between 375 and 405 (bar)
cancellation valve on the 988.
Untighten this valve two turns. Swing secondary relief valves

Operate the bucket against the stop. Supply the swing in both directions.
Adjust to a value between 355 and 365 (bar). The pressure noted should be between 305 and
Adjusting the flow cancellation valve 330 (bar) on the 788, and between 345 and 365 (bar)
(heavy lift - 788 Plus) on the 988.
Overtighten the attachment control valve relief valve. Checking the swing brake release
Overtighten the boom raising safety valve. Connect the two outlets of the multitester at M2 and
Operate the attachment against the stops. M7.
Set the engine to FINE mode. With the upperstructure immobilised, feather the
Adjust the flow cancellation valve to 450 (bar). swing control lever.
Adjust the boom raising safety valve to its value The pressure at M7 should be 35 (bar) before the
(420 bar). pressure rises at M2.
Adjust the relief valve to its value 390 (bar). If it is not, check the brake release circuit.
Checking the travel brake release
Install a pressure test point at M17.
Connect the two outlets of the multitester at M1 and
M17.
Lock one track mechanically.
Press down fully on the foot pedal concerned.
Feather at the inching valve.
The pressure at M17 should be 11 (bar) before the
pressure rises at M1.
If it is not, check the brake release circuit.

8001-35
Checking the boom and dipper flow METHODS

limiters (Previous type) Use the attachment to raise each track, one after the
When the dipper is retracted, the pressure at M1 other.
should be between 30 and 70 (bar). Push the control lever to maximum on the single
If it is not, adjust the limiter spring to L = 21 mm on speed and to the indexing point on the two-speed.
the 788, and 17 mm on the 988. Operate each track in both directions of travel.
If the boom lowering speed is not correct, adjust the Note the flows at the flowmeter or count the number
spring to L = 26.5 mm. of sprocket revolutions.
The flows should be between:
- 110 and 120 (l/min) on the 788 and between 69 and
L 74 (l/min) on the 988
The number of sprocket revolutions should be
between:
- 33 and 36 (rpm) on the 788 and between 29 and 31
(rpm) on the 988
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.
PDH509 Overtighten the adjusting screw by screwing it fully
Procedure for complete adjustment of home.
single and two-speed excavator travel
2 If a control valve section has been changed if
control valves
the sprocket revolutions do not correspond to
1 The troubleshooting method the indicated values or if a complete overhaul
This method is used for complete adjustment of the is taking place
flow adjustment valves and the anti-excess flow This method is used for complete adjustment of the
valve. flow adjustment valves and the anti-excess flow
This procedure should be applied when the control valve.
valve has been completely misadjusted or when an This procedure should be applied when the control
in-depth inspection is taking place. valve has been completely misadjusted or when an
It can be applied by means of either of the following in-depth inspection is taking place.
methods: It can be applied by means of either of the following
- measuring the flow by means of a flowmeter. methods:
- measuring the number of revolutions per minute. - measuring the flow by means of a flowmeter.
BASIC ASSUMPTIONS - measuring the number of revolutions per minute.
- The following values are correct: BASIC ASSUMPTIONS

a) Maximum engine speed. - The following values are correct:
b) Pilot system pressures. a) Maximum engine speed.
c) p L.S. b) Pilot system pressures.
d) Main pump maximum output. c) p L.S.
e) Spool pilot pressures 24 bar. d) Main pump maximum output.
- The hydraulic oil is at 50C. e) Spool pilot pressures 24 bar.
- The hydraulic oil is at 50C.

8001-36
METHODS Adjusting flows or track speeds in
Preparation for the various adjustments. forward travel
Overtighten the anti-excess flow valve fully home. Assemble the springs and push-rods of the flow
Disassemble the springs and push-rods from the flow adjustment valves on each section.
adjustment valves. Operate each forward travel.
Disconnect the pilot pipes. Adjust the flows between:
Untighten the spool mechanical stops in the caps and - 115 and 125 (l/min) on the 788 and between 89 and
place them in contact with the Installations. 94 (l/min) on the 988.
Reconnect the pilot pipes. The number of sprocket revolutions between:
Measure the flows on each track. - 34 and 38 (rpm) on the 788 and between 38 and 40
(rpm) on the 988.
Use the attachment to raise each track in turn.
Operate each track in both directions of travel. WARNING! Unscrew to increase the flow and vice
Read the flows on the flowmeter or count the number versa.
of sprocket revolutions.
Adjusting the anti-excess flow valve
Note these values.
Remove that valve.
Adjusting so as to provide symmetrical Unscrew the pressure setting screw a quarter of a
flows turn.
TAKE THE LOWEST FLOW READING OR Install the valve.
SPROCKET SPEED INTO CONSIDERATION Operate one forward travel.
For the other three flows: The flows should be between:

Disconnect the pilot line opposite to the spool move- 74 (l/min) on the 988.
ment. The number of sprocket revolutions should be
Operate the direction of travel concerned. between:
Read the flow or count the number of sprocket revo- - 33 and 36 (rpm) on the 788 and between 29 and
lutions. 31 (rpm) on the 988.
Screw in the stop until the flow or the number of revo-
lutions of the sprocket is equal to the value shown for If they are not, adjust the anti-excess flow valve
the slower of the two tracks. again.
Reconnect the pilot line. WARNING! Screw in to increase the flow and vice
NOTE: It is normal to find leaks at the caps during versa.
these adjustments They are due to the pilot system Then carry out a complete check again.
heating system.

8001-37
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 revolutions of the sprockets. Operate each forward travel.
The flows should be between: Adjust the flows between:
- 115 and 125 (l/min) on the 788 and between 89 and - 115 and 125 (l/min) on the 788 and between 89 and
94 (l/min) on the 988. 94 (l/min) on the 988.
The number of revolutions of the sprockets should be The number of sprocket revolutions should be
between: between:
- 34 and 38 (rpm) on the 788 and between 38 and - 34 and 38 (rpm) on the 788 and between 38 and
40 (rpm) on the 988. 40 (rpm) on the 988.
IF THE FLOWS OR THE NUMBER OF REVOLU- WARNING! Unscrew to increase flow and vice versa.
TIONS OF THE SPROCKETS ARE INCORRECT.
Adjusting the anti-excess flow valve
Cancel the effect of the spool stops
Remove the valve.
Disconnect the pilot pipes.
Untighten the pressure adjustment screw a quarter
Unscrew the spool mechanical stops in the caps and
turn.
put them in contact with the installations.
Install the valve.
Reconnect the pilot lines.
Operate one forward travel.
Cancel the action of the flow adjustment valve
The flow should be between:
springs
Remove the springs and push-rods. 94 (l/min) on the 988.
The number of sprocket revolutions should be
Measure the flow on each track.
between:
Use the attachment to raise each track in turn. - 34 and 38 (rpm) on the 788 and between 38 and 40
Operate each track in both directions of travel. (rpm) on the 988.
Read the flows at the flowmeter or count the number
If they are not so, 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.
Adjusting so as to provide symmetrical
flows Then carry out a complete check again.
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.

8001
Section
8001
TESTS, ADJUSTMENTS
AND HYDRAULIC SCHEMATICS
Wheeled excavators

Printed in France
8001-2
TABLE OF CONTENTS
TOOLS REQUIRED ................................................................................................................................................. 3
TOOLS TO BE MANUFACTURED .......................................................................................................................... 5
788P GENERAL HYDRAULICS............................................................................................................................... 6
788P PLUS GENERAL HYDRAULICS .................................................................................................................... 7
788P GENERAL HYDRAULIC SYSTEM ................................................................................................................. 9
788P PLUS GENERAL HYDRAULIC SYSTEM ..................................................................................................... 11
988P GENERAL HYDRAULICS............................................................................................................................. 12
988P PLUS GENERAL HYDRAULICS .................................................................................................................. 13
988P GENERAL HYDRAULIC SYSTEM ............................................................................................................... 15
988P PLUS GENERAL HYDRAULIC SYSTEM ..................................................................................................... 17
SETTING THE PRESSURES ON THE 788P......................................................................................................... 18
SETTING THE PRESSURES ON THE 788P PLUS .............................................................................................. 19
SETTING THE PRESSURES ON THE 988P......................................................................................................... 20
SETTING THE PRESSURES ON THE 988P PLUS .............................................................................................. 21

8001-3
TOOLS REQUIRED
1. TEST EQUIPMENT Two pressure measurements, pressure peaks, pres-
There are three possible choices: sure differential (Delta P), temperature, temperature
a) Multi-Handi test kit 2051.........................E5444449 differential, rotational speed and volumetric flow,
amperage, voltage, connection to PC and printer,
memory capacity 60000.
1 Multi-Test 4020 unit................................. Q5344455
1 temperature sender................................. B3144469
4 cables length 5 m.................................... E3144472
CP96E001 1 instruction manual.................................... -------------
1 carry-case ............................................... P5344477
The Multi-Handi test kit is recommended as the basic
tool of the mechanic. c) Multi-System 5000 test kit ..................... U5344459
The Multi-Handi can be used to carry out the follow-
ing tests:
sure differential (Delta P), temperature, rotational
speed and volumetric flow.
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
CP96E002
1 cigarette lighter cable ..............................E5344468
1 instruction manual ................................... ------------- The Multi-System is recommended for specialist
1 carry-case............................................... N5344476 departments (Engineering Design Office and tests at
customers premises).
b) Multi-Test 4020 test kit .......................... T5344458
The Multi-System can carry out the following tests:
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.
1 Multi-System 5000 unit ........................... R5344456
CP96E003 1 temperature sender................................. A5344464
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-
ory and transferred to a PC and a printer.
The Multi-Test can be used to carry out the following 1 instruction manual.................................... -------------
tests: 1 carry-case ............................................... P5344477

8001-4
CP96E004 PG04005
2. SONDE DE TEMPERATURE A5344464 6. ONE PRESSURE TEST POINT M14 X 1.5

A3237549
Use with Multi-Handi 2051 test kit
3. MAGNETIC BASE G5344470
Use with Multi-Handi 2051, Multi-Test 4020 and Multi-
System 5000 test kits
PG03824
7. ONE PRESSURE TEST POINT UNION U1237211

AND W1237213
PF01410
4. 600 LITRES FLOWMETER, ORDER THE FOL-

LOWING:
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
5. ONE HIGH PRESSURE HOSE DN19 Q5931990 PE18402
ONE LOW PRESSURE HOSE DN12 B8031969
8. TWO MINIMESS HOSES LENGTH 2500 mm
P2144487
TWO HOSE UNIONS C5144412

8001-5
PDH0506
PG04006
11. ONE SPECIAL UNION W5137530
9. TWO PLUGS 27 X 200 Q3337452
ONE FEMALE UNION 27 X 200 P4237556
ONE MALE/FEMALE UNION D12 L3237536
PDH0505
10. TWO REDUCTION GEARS DN25 - DN19 G1037352
TOOLS TO BE MANUFACTURED
PDG0239
1. ONE SPACER TO LIMIT THE STROKE OF THE

CONTROL LEVER SPOOLS

8001-6
788P GENERAL HYDRAULICS

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
11 - Filter on steering/braking system
22 -
Travel control pedal
23 -
Travel direction reverser (INCHING)
26 -
28 -
Steering box (ORBITROL)
29 -
Braking unit
32a -
Travel pilot pressure switch
(automatic front axle unlocking)
42 - Hydraulic swing motor safety flange
43 - Fixed displacement hydraulic swing motor
61 - Hydraulic pilot block including:
61a - Electro-control valve (Y2 and Y13) for control arm raising safety - front axle locking and unlocking
61c - 35 bar pressure limiter
61d - Travel speed change electro-control valve (Y11: job-site speed - Y12: road speed)
61e - Stabilizer and blade electro-control valve (Y26: raising - Y27: lowering)
91 - 16 passage hydraulic swivel
101 - Travel and stabilizer/blade control valve block
102 - Hydraulic travel motors (with displacement change)
103 - Travel motor force-feed flange
104 - Speed limiter and safety block
105 - Two-speed block with parking brake
109 - Brakes on front axle
110 - Brakes on rear axle
112 - Stabilizer/blade selector lever valve
113 - Union block on stabilizer or rear blade small chamber supply
203 - Flow limiter on stabilizer cylinder small chambers
M8 - Pressure test points for braking circuits
M22 - Pressure test points for hydraulic travel motor displacement change circuit
CM99J015

8001-7
788P PLUS GENERAL HYDRAULICS

1 variable flow body for the attachment and travel
11 - Filter on steering/braking system
13 - FC (Fine Mode) overpressurizing selector block
14 - Parking brake electro-control valve (Y15)
22 -
23 -
26 -
28 -
Steering box (ORBITROL)
29 -
Braking unit
32a -
Travel pilot pressure switch
(automatic front axle unlocking)
43 - Fixed displacement hydraulic swing motor
61a - Electro-control valve (Y2): control arm raising safety
61d - Travel speed change electro-control valve for (Y11: job-site speed - Y12: road speed)
61e - Stabilizers and blade electro-control valve (Y26: raising - Y27: lowering)
61f - Electro-control valve (Y13): for front axle locking and unlocking
105 - Two-speed block with parking brake
113 - Union block on stabilizer or rear blade small chamber supply
M8 - Pressure test point for parking brake electro-control valve
CM99J016
M22 - Pressure test point for hydraulic travel motor displacement change circuit

8001-8
CM99J019

8001-9
788P GENERAL HYDRAULIC SYSTEM

65a - Swing control valve spool pilot pressure switch for swing brake release
788P general hydraulic system 27 - Pilot circuit minimum pressure switch
65b - Travel control valve spool pilot pressure switch for AUTO-IDLE function
List of hydraulic components 28 - Steering box (ORBITROL)
66 - Electronic control box
29 - Braking unit
1 - Reservoir 67 - Swing motor speed detector (for braking)
2 - Reservoir filler cap with self-pressurizing valve 30a - Accumulator on the parking brake circuit
and screen filter 30b - Accumulator on the front axle braking circuit
3 - Return manifold with element type filters and 30c - Accumulator on the rear axle braking circuit
83 - Flow limiter on dipper cylinder small chamber
restriction indicator 31 - Brake pressure switch for travel speed change
84 - Dipper cylinder with dashpot on large and small chamber
4 - Magnetic filter on functional leak return lines 32a - Travel pilot pressure switch (automatic front
85 - Backhoe/clamshell selector lever valve (optional)
5 - LS information selector block for LS information axle unlocking)
86 - Bucket cylinder with dashpot on large chamber
detector and filter on travel/stabilizer LS infor- 32b - Pressure switch (brake lights)
87 - Boom cylinder supply block with flow limiter on the large chambers
mation circuit 33a - Parking brake pressure switch
88 - Boom cylinders with dashpot on large chambers
6 - High pressure pump with: 33b - Braking minimum pressure switch
89 - Lever valve on the boom cylinder large chambers (for the transportation position)
1 fixed flow body for the swing 34 - Minimum steering pressure switch
1 variable flow body for the attachment, travel 35 - Swing spool pilot selector block for automatic 90 - Pressure selector on the attachment and travel/stabilizer LS circuits
and option swing brake release 90b and Pressure selector on the braking circuits
7 - Low pressure pump 36 - Boom - bucket function manual control block 90c - (working brake and dynamic brake)
1 body for the steering/braking system 91 - 16 passage hydraulic swivel
1 body for the pilot systems 42 - Hydraulic swing motor safety/force-feed flange 101 - Travel and stabilizer/blade control valve block
8 - Hose/accumulator on the pump LS information 43 - Fixed displacement hydraulic swing motor (with 102 - Hydraulic travel motors (with displacement change)
circuit static brake) 103 - Travel motor force-feed flange
9 - Pressure test points 44 - 3 bar check valve for swing force-feed 104 - Speed limiter and safety block
M1 - Pressure test point for attachment/ 45 - Braking valves on swing control valve pilots 105 - Two-speed box with parking brake and speed range change cylinder
travel and options (if any) 46 - Double spring-type accumulator on swing con- 106 - Indexing and speed range change safety block
M2 - Pressure test point for swing trol valve spool pilots 107 - Hydraulic travel motor pressure release block (for speed range change)
M3 - Pressure test point for LS circuit 108 - Calibrated orifice on the parking brake circuit
M4 - Pressure test point for pilot circuits 61 - Hydraulic pilot block including:
M6 - Pressure test point for travel manual control 61a - Control arm safety or control arm safety and
- Steering cylinder
block outlet axle locking pressure selector block
M7 - Pressure test point for swing braking and 61b -Automatic swing braking and brake release
111 - Front axle locking cylinder
brake release electro-control valve
M8 - Pressure test point for brake unit 61c - Electro-control valve (Y2 and Y13: control
113 - Union block on stabilizer or rear blade cylinder small chamber supply
M22 -Pressure test point for for hydraulic travel arm safety, front axle locking and unlock-
motor displacement change circuit ing) 201 - Blade cylinder
M27 -Pressure test point for proportioning valve 61d - 35 bar pressure limiter (P35) 202 - Calibrated orifice on blade cylinder large chamber
outlet 61e - Travel speed change electro-control valve 203 - Flow limiter on stabilizer cylinder small chambers
10 - Anti-surge valve on the attachment LS circuit (Y11: job-site speed - Y12: road speed) 204 - Stabilizer cylinders
11 - Steering/braking system filter 61f - Stabilizer and blade electro-control valve 205 - Stabilizer cylinder piloted check valve (on the small chambers)
(Y26: raising - Y27: lowering)
21 - Dipper and swing function manual control 62 - Working brake electro-control valve (Y15)
block 63 - Electro-hydraulic proportioning valve (DRE4)
22 - Travel control pedal 64 - LS information detector
23 - Travel direction reverser (INCHING)
24 - Travel spool pilot selector block for the AUTO-
IDLE function

8001-10
2 F5
T
0,4 bar 3 16 F3
3,1 bar
B2 F1
P 120 43 F M1 82
L G1 F2
F4
B
+
F6
A
T2
4 40 42 T3 T4
T1 T5
X M2
M
M1
1 G B 9 P3
B10 V P2
P1 P4
B21 T
3bar
10
LS 87
67 44
V
B9 T
7 B1 T1 A1 T
A1 B1
Zb1 B
R2 10
6 M A1 A S1
Za1 A1
R1 T2 36 B2
88
S B B1 A A2
16 T
107
P
12 M3 P 89
4
9 10 2 A2
X8 C 1 B1
Zb2
B
B2
8 41 3 Za2
B A 85 86
B2 A A2
21
90 9 A1
X3 Zb1 Za1
M2 P
9
64 45 T
1 4
A3
Zb3
X4 A B
M15
3 2 Za3 83
A B P 66
8 13 84
Y4
B11 Z1 37 B3
209
P Z2 Z3
210 35 5
9
M3 LS P
A
81
B7 A1
63
213 214
M 27
65a
B
11 9
C1
C
61a
P F
61
F12 55
K9
26 T7
1(6) 58 P2 P3 P5 T0 T5 T3 T9 T4
B1 P0
+ 49 23
54 55 P1 P7 P4 P8 P6 T11 T2 T8 T1 T10 T6
A1
64
105 9 F 1
108
M4
S24 2,35 T
61b 17 P
10
B2 A P
54 P 12
SC 3 27
A2 B5 25 A
9 B P
57 61c B3 7
M7 22 32a B
105
A3 53
manu SC 2 8 B
106 C
auto 4 A
54 61d 16
A4 A
53 15 107
B4 T M 18 Z
214 B8
M
9 MB F G G T G P
6 P
106 B
M6
P
52 219 215 B'

53 B1 B
A5 65b 9 Za1
105 SC 4 29 5
50 R Zb1 A
61e B5
51 24
K52
184
14 A1 A
2 3
34 105
101 A'
61f B6 P3 Y G G'
K58 P B53
LS
MF MA
MP 82
B2 X
49 184 63 P Za2
2
33a 104 103
DS Y15
3 Zb2 113 M 22 110
P PP A2' A2 F2 F1 A4 A1 P1 P S
63 63
49 P P
A
83 II
237 M8
84 91 A2 B
9h
Sh 102
49 W B50 9 65
66
33b I
ALTER
B12 I A B
+ B52 III
203
P
94 (12V) B51 30b II

98
11 T1 A
112 B
III
F P
K3
31 30a A
111
94 9
203
62 203
Y16
202
MF MP
B 201
: 2,5
P
90b 90c 32b L 14
28
T
109 204
205
R 13
205 204 204 205 204
CM99J013

8001-11
788P PLUS GENERAL HYDRAULIC SYSTEM

65a - Swing control valve spool pilot pressure switch for swing brake release
788P Plus general hydraulic system 28 - Steering box (ORBITROL)
65b - Travel control valve spool pilot for AUTO-IDLE function
List of hydraulic components 29 - Braking unit
30a - Accumulator on front axle braking circuit
1 - Reservoir 67 - Swing motor speed detector (for braking)
30b - Accumulator on rear axle braking circuit
2 - Reservoir filler cap with self-pressurizing valve 31 - Braking pressure switch for travel speed 81 - Attachment control valve block (boom, dipper, bucket)
and screen filter change 82 - P10 counter-pressure valve
3 - Return manifold with element type filters and 32a - Travel pilot pressure switch (automatic front 83 - Flow limiter on dipper cylinder small chamber
restriction indicator axle unlocking) 84 - Dipper cylinder with dashpot on large and small chambers
4 - Magnetic filter on functional leak return lines 32b - Pressure switch (brake lights) 85 - Backhoe/clamshell selector lever valve (optional)
5 - LS information selector block for LS information 33a - Parking brake pressure switch 86 - Bucket cylinder with dashpot on large chamber
detector and filter on the travel/stabilizer LS 33b - Minimum braking pressure switch 87 - Boom cylinder supply block with flow limiter on the large chambers
circuit 34 - Minimum steering pressure switch 88 - Boom cylinders with dashpot on large chambers
6 - High pressure pump with: 35 - Swing spool pilot selector block for automatic 89 - Lever valve on the boom cylinder large chambers (for the transportation position)
1 fixed flow body for the swing swing brake release
1 variable flow body for the attachment, travel 90 - Pressure selector on the attachment and travel/stabilizer LS circuits
36 - Manual control block for
and options 90b and Pressure selector on the brake circuits
boom - bucket
7 - Low pressure pump: 90c - (working brake and dynamic brake)
37 - Calibrated union
1 body for the steering/braking circuit 91 - 16 passage hydraulic swivel
1 body for the pilot systems 41 - Swing control valve block
8 - Hose/accumulator on the pump LS information 42 - Hydraulic swing motor safety/force-feed flange
circuit 43 - Fixed displacement hydraulic swing motor (with
9 - Pressure test points static brake)
M1 - Pressure test point for attachment/travel 44 - 3 bar check valve for swing force-feed
105 - Two-speed block with parking brake and speed range change cylinder
and options (if any) 45 - Braking valves on swing control valve pilot cir-
106 - Indexing and speed range change safety block
M2 - Pressure test point for swing cuits
107 - Hydraulic travel motor pressure release block (for speed range change)
M3 - Pressure test point for LS circuit 61 - Hydraulic pilot block 108 - Calibrated orifice on parking brake circuit
M4 - Pressure test point for pilot circuits consisting of: 109 - Brakes on front axle
M6 - Pressure test point for travel manual con- 61a - Electro-control valve (Y2) for control arm - Steering cylinder
trol block outlet safety 110 - Brakes on rear axle
M7 - Pressure test point for swing braking and 61b - Electro-control valve (Y5) for automatic 111 - Front axle locking cylinder
brake release swing braking and brake release 112 - Stabilizer/blade selector lever valve
M8 - Pressure test point for braking unit 61c - 35 bar pressure limiter (P35) 113 - Union block on stabilizer or rear blade small chamber supply
M22 - Pressure test point for hydraulic travel 61d - Travel speed change electro-control valve
motor displacement change circuit 201 - Blade cylinder
(Y11: road speed - Y12: job-site speed)
M27 - Pressure test point for proportioning valve 202 - Calibrated orifice on blade cylinder large chamber
61e - Stabilizer and blade electro-control valve
outlet 203 - Flow limiter on stabilizer cylinder small chambers
(Y26: raising - Y27: lowering)
10 - Anti-surge valve and filter on the attachment LS 204 - Stabilizer cylinder
61f - Electro-control valve (Y13) for axle locking
circuit 205 - Stabilizer cylinder piloted check valve (on the small chambers)
62 - Working brake electro-control valve (Y16)
11 - Steering/braking system filter 63 - Electro-hydraulic proportioning valve (DRE4)
12 - Pilot circuit filter 64 - LS information detector
21 -
Manual control block for dipper and swing
22 -
23 -
24 -
Travel spool pilot selector block for the AUTO-
IDLE function

8001-12
988P GENERAL HYDRAULICS

988P hydraulic system
6 - High pressure pump with 1 fixed flow body for swing and
2 variable flow bodies for the attachment, travel and any options
10 - Anti-surge valveand filter on the attachment LS circuit
11 - Filter on the steering/braking circuit
22 - Travel control pedal
28 - Steering box (ORBITROL)
29 - Braking unit
32a - Travel pilot pressure switch (automatic front axle unlocking)
42 - Fixed flow hydraulic swing motor
61a - Electro-control valve (Y2 and Y13) control arm safety - front axle locking and unlocking
61b - Circuit selector flange for control arm safety - front axle locking and unlocking
61c - 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)
105 - Two-speed box with parking brake
113 - Union block on stabilizer or rear blade cylinder small chambers
M8 - Pressure test point for brake system
CM99J017

8001-13
988P PLUS GENERAL HYDRAULICS

988P Plus hydraulic system
6 - High pressure pump with 1 fixed flow body for the swing
2 variable flow bodies for the attachment, travel and any options
11 - Filter on the steering/braking system
14 - Parking brake electro-control valve
29 - Braking unit
32a - Travel pilot pressure switch (automatic front axle unlocking)
42 - Fixed flow hydraulic swing motor
61a - Electro-control valve (Y2): for control arm safety
61c - Pressure limiter
61d - Travel speed change electro-control valve (Y11: job-site speed - Y12: road speed)
61e - Stabilizer and blade electro-control valve (Y26: raising - Y27: lowering)
61f - Front axle locking and unlocking electro-control valve (Y13)
105 - Two-speed box with parking brake
113 - Union block stabilizer or rear blade small chamber supply
M8 - Pressure test point for parking brake electro-control valve
CM99J018

8001-14
CM99J020
8001-15
988P GENERAL HYDRAULIC SYSTEM

65a - Pressure switch for swing control valve spool pilot system pressure for release of swing brake and for the
988P general hydraulic system 27 - Pilot circuit minimum pressure switch
AUTO-IDLE function.
List of hydraulic components 65b - Pressure switch for travel control valve spool pilot system pressure for the AUTO-IDLE function.
29 - Braking unit
1 - Reservoir 30a - Accumulator on the parking brake circuit 67 - Hydraulic swing motor speed detector
2 - Reservoir filler cap with self-pressurizing valve 30b - Accumulator on the front axle braking circuit
and screen filter 81 - Attachment control valve (boom, dipper, bucket)
30c - Accumulator on the rear axle braking circuit
3 - Return manifold with element type filters and 82 - P10 counter-pressure valve
31 - Braking pressure switch for travel speed
restriction indicator 83 - Flow limiter block on dipper cylinder small chamber
change
4 - Element type filter on the functional leak return 84 - Dipper cylinder with dashpot on large and small chamber
32a - Travel pilot pressure switch (automatic front
line 85 - Backhoe/clamshell selector lever valve (optional)
axle unlocking)
5 - Information selector block for LS detector and 86 - Bucket cylinder with dashpot on large chamber
32b - Pressure switch (brake lights)
filter on travel/stabilizer LS circuit 87 - Boom cylinder supply block with flow limiter on large chambers
33a - Parking brake pressure switch
6 - High pressure pump with: 88 - Boom cylinders with dashpot on large chambers
33b - Minimum braking pressure switch
1 fixed flow body for the swing 89 - Lever valve on the boom cylinder large chambers (for the transportation position).
34 - Minimum steering pressure switch
2 variable flow bodies for the attachment, travel 35 - Swing spool piloting selector block for auto- 90 - Pressure selector on the attachment and travel/stabilizer LS circuits
and options matic swing brake release 90b and Pressure selector on braking circuits
7 - Low pressure pump 36 - Boom - bucket function manual control block 90c - (working brake and dynamic brake)
1 body for the steering/braking system 91 - 16 passage hydraulic swivel
1 body for the pilot system 41 - Swing control valve block
8 - Hose/accumulator on the pump LS information 42 - Hydraulic swing motor safety/force-feed flange 101 - Travel and stabilizer/blade control valve block
circuit 43 - Fixed displacement hydraulic swing motor (with 102 - Hydraulic travel motors (with displacement change)
9 - Pressure test points static brake) 103 - Travel motor force-feed flange
M1 - Pressure test point for attachment/travel 44 - 3 bar check valve for swing force-feed 104 - Speed limiter and safety block
and options (if any) 45 - Braking valves on swing control valve spool 105 - Two-speed box with parking brake and speed range change cylinder
M2 - Pressure test point for swing pilots 106 - Speed range change indexing and safety block
M3 - Pressure test point for LS circuit 46 - Spring type accumulator on swing control valve 107 - Hydraulic travel motor clutch release block (for changing speed range)
M4 - Pressure test point for pilot circuits spool pilot system 108 - Calibrated orifice on the parking brake circuit
M6 - Pressure test point for travel manual con- 109 - Brakes on front axle
61 - Hydraulic piloting block, including:
trol block outlet - Steering cylinder
61a - Circuit selector flange for control arm
M7 - Pressure test point for swing braking and 110 - Brakes on rear axle
raising safety and front axle locking and
brake release 111 - Front axle locking cylinder
unlocking
M8 - Pressure test point for braking circuits 112 - Stabilizer/blade selector lever valve
61b - Electro-control valve (Y2 and Y13: con-
M22 - Pressure test point for hydraulic travel 113 - Union block on supply to stabilizer or blade cylinder small chambers
trol arm raising safety, front axle locking
motor displacement change circuit and unlocking) 201 - Blade cylinder
M27 - Pressure test point for proportioning 61c - Electro-control valve (Y2 and Y13: con- 202 - Calibrated orifice on blade cylinder large chamber
valve outlet trol arm raising safety, front axle locking 203 - Flow limiter on stabilizer cylinder small chambers
10 - Anti-surge valve on the attachment LS circuit and unlocking) 204 - Stabilizer cylinder
11 - Steering/braking circuit filter 61d - 35 bar pressure limiter (P35) 205 - Stabilizer cylinder piloted check valve
12 - Calibrated orifice (dia.: 2.5 mm) on main pump 61e - Travel speed change electro-control
irrigation circuit valve (Y11: job-site speed - Y12: road
21 - Dipper and swing function manual control block speed)
22 - Travel control pedal 61f - Stabilizer and blade electro-control valve
23 - Travel direction reverser (INCHING) (Y26: raising - Y27: lowering)
24 - Travel spool piloting selector block for the 62 - Working brake electro-control valve (Y16)
AUTO-IDLE function 63 - Electro-hydraulic proportioning valve (DRE4)
25 - Pressure release pump (foot control) 64 - LS information detector

8001-16
2
F5 T
0,4 bar 3 3,1 bar 16
F3
F1
B2
P 120 L G2 F2
F
F4
82
+
43 A
F6
T2
4
40 42 T3
T4
T1
X M T5
M1
1 G B 9 P3
B10 V P2
P1 P4
B21
V
B9 3bar
R2 LS 87
A2 R1 S M A1 2,5 S1 67 44
A1
B1 T3 A1 T Zb1 B B1
6
P A1
28 Za1
80 80 T2 36 B2 88
G1
B1 A A2
13 T
12 M3
P
4
89
9 10 2 A2
C 1
12 Zb2 B1
B
B2
X3 0,8 8 3 Za2
41
0,8 7 B A 85 86
G2
X4
90
B2 A A2
21
9 A1
Zb1 Za1
M2 P
9
45 T A3
R3 64 1 4 Zb3
A B
M15 83
3 2 Za3
Y4
63 84
209 210
B11 P Z2 Z3 Z1 B3
35 5
LS P
B7
81
A1 A
9 M27
213 214
65a
B
66
11 C1
61a
P F
F12 61
K9
26 T7
1(6) 58 P2 P3 P5 T0 T5 T3 T9 T4
P0
+ 49 B1 23
54 56 P1 P7 P4 P8 P6 T11 T2 T8 T1 T10 T6
A1
105 9 F 1
M4
108
2,35 T
S24 61b 10
17 P
A P
54 P 12
B2
SC 3 27
B5 25 B P A
57 A2 7
9 22 32a B
B3
61c M7 105
53
manu SC 2 A3 8 B
106 C
auto 4 A
54 16
A
61d 107
A4 15
Z
53 214 B8 9 T 9 MB F G G T G P
B4 6 P M
106 B
P
52 219 215 B'
53
M6 B1 B
105 SC 4 29 65b 5 Za1
50 A5 R A
Zb1
61e B5 K5L 14 35 24 A1 A
51 184
3
34 105
DS 101 A'
K58 Y15 P3
P B53 Y G G'
61f B6 LS
MA
82
49 B2
MP MF P X
63 2 Za2
33a 104 103
2
3 Zb2 112 113 M 22 110
P PP A2' A2 F2 F1 A4 A1 P1 P S
63 63
49 P P A
83 B50 91 II
237 84 A2 B
49
Sh M8 9 65 102 9h B A
W
ALTER
66
33b I
B12 B52
+ III A
P
94 (12V) B51 30b II III

98
11 T1 I A B A
F P K3
31 30a
111 203
94 9
203
62
Y16 B
B 202
MF MP
201
: 2,5
P
90b 90c 32b L 14
28
T
109
R 13
204
205 204
204 205 204
CM99J014

8001-17
988P PLUS GENERAL HYDRAULIC SYSTEM

65a - Swing control valve spool pilot pressure switch for swing brake release and for the AUTO-IDLE function
988P Plus general hydraulic system 28 - Steering box (ORBITROL)
65b - Travel control valve spool pilot pressure switch for the AUTO-IDLE function
29 - Braking unit
List of hydraulic components 66 - Electronic control box
30a - Accumulator on the rear axle braking circuit
1 - Reservoir 30b - Accumulator on the rear axle braking circuit
2 - Reservoir filler cap with self-pressurizing valve 31 - Braking pressure switch for travel speed 81 - Attachment control valve (boom, dipper, bucket)
and screen filter change 82 - P10 counter-pressure valve
3 - Return manifold with element type filters and 32a - Travel pilot pressure switch (automatic front 83 - Flow limiter on dipper cylinder small chamber
restriction indicator axle unlocking) 84 - Dipper cylinder with dashpot on large and small chamber
4 - Element type filter on functional leak return 32b - Pressure switch (brake lights) 85 - Backhoe/clamshell selector lever valve (optional)
lines 33a - Parking brake pressure switch 86 - Bucket cylinder with dashpot on large chamber
5 - Information selector block for LS detector and 33b - Minimum braking pressure switch 87 - Boom cylinder supply block with flow limiter on the large chambers
filter on travel/stabilizer LS circuit 34 - Minimum steering pressure switch 88 - Boom cylinders with dashpot on large chambers
6 - High pressure pump with: 35 - Swing spool pilot selector block for automatic 89 - Lever valve on boom cylinder large chambers (for transportation position)
1 fixed flow body for the swing swing brake release
90 - Pressure selector on attachment and travel/stabilizer LS circuits
2 variable flow bodies for the attachment, travel 36 - Dipper and swing function manual control block
90b and Pressure selector on braking circuits
and options 41 - Swing control valve block 90c - (working brake and dynamic brake)
7 - Low pressure pump: 42 - Hydraulic swing motor safety/force-feed flange 91 - 16 passage hydraulic swivel
1 body for the steering/braking system 43 - Fixed displacement hydraulic swing motor (with
1 body for the pilot systems 101 - Travel and stabilizer/blade control valve block
static brake)
8 - Hose/accumulator on the pump LS information 102 - Variable displacement hydraulic travel motors
44 - 3 bar check valve for swing force-feed
circuit 103 - Travel motor force-feed flange
45 - Braking valves on swing control valve pilot cir-
9 - Pressure test points 104 - Speed limiter and safety block
cuits
M1 - Pressure test point for attachment/travel 105 - Two-speed box with parking brake and speed range change cylinder
46 - Spring type accumulator on swing control valve
and options (if any) 106 - Speed range change indexing and safety block
spool pilot
M2 - Pressure test point for swing 107 - Hydraulic travel motor clutch release block (for speed range change)
M3 - Pressure test point for LS circuit 61 - Hydraulic piloting block including: 108 - Calibrated orifice on the parking brake circuit
M4 - Pressure test point for pilot circuits 61a - Electro-control valve (Y2) for control arm 109 - Brakes on front axle
M6 - Pressure test point for travel manual con- safety - Steering cylinder
trol block outlet 61b - Electro-control valve (Y5) for automatic 110 - Brakes on rear axle
M7 - Pressure test point for swing braking and swing braking and brake release 111 - Front axle locking cylinder
brake release 61c - 35 bar pressure limiter 112 - Stabilizer/blade selector lever valve
M8 - Pressure test point for braking circuits 61d - Travel speed change electro-control 113 - Union block on stabilizer or blade cylinder small chamber supply
M22 - Pressure test point for hydraulic travel valve (Y11: road speed - Y12: job-site
201 - Blade cylinder
motor displacement change circuit speed)
202 - Calibrated orifice on blade cylinder large chamber
M27 - Pressure test point for proportioning 61e - Stabilizer and blade electro-control valve
valve outlet (Y26: raising - Y27: lowering)
204 - Stabilizer cylinder
10 - Anti-surge valve on the attachment LS circuit 61f - Axle locking electro-control valve
205 - Stabilizer cylinder piloted check valve
11 - Steering/braking system filter 62 - Working brake electro-control valve (Y16)
12 - Calibrated orifice (dia.: 2.5 mm) on main pump 63 - Electro-hydraulic proportioning valve (DRE4)
irrigation circuit 64 - LS information detector
13 - Pilot system filter
24 - Travel spool piloting selector for the AUTO-
IDLE function

8001-18
SETTING THE PRESSURES ON THE 788P

M4 on the manifold
M6 on the shuttle ball block (at the back, at the bottom of the cab)
M8 on the braking unit
M22 on the travel motor
M5 on the Orbitrol steering
M10 on the front axle
M11 on the rear axle
M12 on the parking brake
Use the stabilizers and the blade to raise the excavator.
AUTO - IDLE 1150 to 1250 (rpm) 19.5 to 23.5 (bar)

LOW 900 to 1000 (rpm) 19.5 to 23.5 (bar)
FINE 1570 to 1630 (rpm) 13.5 to 17.5 (bar)
ECO 1920 to 1980 (rpm) 8.5 to 12.5 (bar)
MAX 2190 to 2250 (rpm) 5.5 to 9.5 (bar)
If the speeds are out of tolerance, see Section 4002.

168
T
CM99J021

8001-19
SETTING THE PRESSURES ON THE 788P PLUS

M4 on the manifold
M8 on the parking brake electro-control valve

LOW 900 to 1000 (rpm) 19 to 24 (bar)
FINE 1570 to 1630 (rpm) 13 to 18 (bar)
ECO 1920 to 1980 (rpm) 8 to 13 (bar)
MAX 2190 to 2250 (rpm) 5 to 10 (bar)
CM99J022

8001-20
SETTING THE PRESSURES ON THE 988P

M4 on the manifold
M8 on the braking unit
M12 on the parking brake
MEDIUM - IDLE 1150 to 1250 (rpm) 23 to 27 (bar)

FINE 1570 to 1630 (rpm) 15 to 19 (bar)
ECO 1920 to 1980 (rpm) 9.5 to 13.5 (bar)
MAX 2190 to 2250 (rpm) 7.5 to 11.5 (bar)
CM99J023

8001-21
SETTING THE PRESSURES ON THE 988P PLUS
M4 on the manifold
M8 on the parking brake electro-control valve
MEDIUM - IDLE 1170 to 1230 (rpm) 22 to 27 (bar)

FINE 1570 to 1630 (rpm) 13 to 18 (bar)
ECO 1920 to 1980 (rpm) 6 to 11 (bar)
MAX 2190 to 2250 (rpm) 5 to 10 (bar)
CM99J024

8001-22

8001-23
788, 988 pressure setting (continued)
WARNING! All checks and adjustments are carried out at various engine speeds and at a temperature of
50C.
WARNING! The flows specified on the 988 are those read on the flowmeter (1 pump body).
Checking the pilot pressure with the control arm lowered
Connect the multitester to the manifold at M4.
Set the MAX mode.
The pressure should be greater than 34 (bar).
If it is not, check the P35 or the electrical circuit.
AFTER EACH CHECK, IF THE PARAMETERS ARE INCORRECT, ADJUST AT THE COMPONENT CON-
CERNED OR CHANGE THE COMPONENT.
Setting the LS valve pressure
Static test using the same 0/40 bar pressure gauge:
WARNING! Start the engine running, before connecting the pressure gauge at M1.
Raise the left-hand control arm as a safety measure.
Set the FINE mode.
Connect the pressure gauge at M3. The pressure should be between 8 and 12 (bar). If it is not, check the P10.
Connect the pressure gauge at M1. The difference between M1 and M3 should be 21 to 25 (bar).
Dynamic test using multitester:
Assemble the spacer on the boom raising control lever push-rod.
Connect the two outlets from the multitester at M1 and M3.
Operate the boom raising control.
The pressure differential should be between 21 and 23 (bar).
Checking the variable displacement pump maximum flow (using only one flowmeter on
the 988)
Set the MAX mode.
Connect the multitester for flow measurement.
Retract the dipper and close the bucket simultaneously.
The flow should be greater than 205 (l/min) and the pressure at M1 lower than 125 (bar).
The flow should be greater than 153 (l/min) and the pressure at M1 lower than 100 (bar) on the 988.
Checking the flow adjustment valve flows
Attachment control valves
Supply the large chambers of the boom, bucket and dipper cylinders, one after another.
The flows should be between:
788P, 788P Plus 988P, 988P Plus
140 and 160 (l/min) on the boom. 83 and 193 (l/min) on the boom.
90 and 110 (l/min) on the bucket. 70 and 80 (l/min) on the bucket.
115 and 135 (l/min) on the dipper. 78 and 88 (l/min) on the dipper.

8001-24
Travel control valve
Connect the multitester at M6 to check the travel control valve pilot system in forward and reverse travel.
Raise the excavator using the stabilizers and the blade.
Select job-site speed, travel forward and reverse.
The pressures read should be 24 (bar) minimum. If they are not, adjust the pressure regulator or add shims under
the travel reverser spool spring(s).
788P, 788P Plus 988P, 988P Plus
Forward travel 163 and 173 l/min 82 and 87 l/min
Reverse travel 160 and 173 l/min 80 and 87 l/min
Universal joint speed, job-site range, forward 649 and 659 rpm 649 and 659 rpm
Universal joint speed, job-site range, forward, Ger- 547 and 556 rpm 547 and 556 rpm
many
Universal joint speed, job-site range, reverse 627 and 659 rpm 627 and 659 rpm
Universal joint speed, job-site range, reverse, Germany 523 and 556 rpm 523 and 556 rpm
Universal joint speed, road travel range, forward 2166 and 2136 rpm 2166 and 2196 rpm
Universal joint speed, road travel range, forward, Ger- 1825 and 1855 rpm 1825 and 1855 rpm
many
Universal joint speed, road travel range, reverse 2091 and 2196 rpm 2091 and 2196 rpm
Universal joint speed, road travel range, reverse, Ger- 1745 and 1855 rpm 1745 and 1855 rpm
many
Stabilizer and dozer blade control valve. Beam A

When descending a slope, the flow should be:
788P, 788P Plus 988P, 988P Plus
2 pads 45 - 55 l/min
1 blade 45 - 55 l/min
2 pads + blade 45 - 55 l/min
4 pads

8001-25
Stabilizer and dozer blade control valve. Beam B
When descending a slope, the flow should be:
788P, 788P Plus 988P, 988P Plus
2 pads forward and 150 - 180 l/min 75 - 90 l/min

reverse
1 blade 60 - 80 l/min 30 - 40 l/min
2 pads + blade 150 - 180 l/min 80 - 90 l/min
4 pads 150 - 180 l/min 80 - 90 l/min
If not, adjust the balance valve, or check the jet at the large chamber inlet for the blade.
Checking the hydraulic power supplied by the proportioning valve, with the engine under
load
Connect the multitester at M1 and M2.
Set the MAX mode.
Lock an attachment and the swing to check their maximum pressures which should be between 355 and 365 (bar)
for the attachment and between 305 and 330 (bar) on the 788 swing and between 345 and 365 (bar) for the
988 swing.
Adjust the dipper cylinder large chamber safety valve to 300 (bar).
Supply the dipper retracting function only.
a) The pressure delivered by the proportional valve should be between:
DRE4 pressure
Engine speed DRE4 pressure Output
with swing
788P
1980 - 2020 11 - 16.5 88 l/min 20 - 27
09/97
988P
1980 - 2020 12 - 17 66 l/min 21 - 27
09/97
788P
1980 - 2020 11 - 16.5 82 l/min 20 - 27
09/97
988P, 988P Plus

1980 - 2020 12 - 17 61 l/min 21 - 27
09/97
788P Plus 1980 - 2020 11 - 16 102 l/min 20 - 26
WHEN THESE ADJUSTMENTS HAVE BEEN COMPLETED, REMOVE THE FLOWMETER.

8001-26
Check or adjustment of all valves
Connect the multitester at M1.
Set the MAX mode.
Overtighten the relief valve by one turn.
Overtighten the attachment and travel flow cancellation valve by two turns.
Safety valves on the attachment control valve
Attachment control valve
788P, 988P, 988P Plus 788P Plus
Attachment limiter 390 - 425 380 - 400
Boom raising 390 - 420 410 - 440
Boom lowering 380 - 410 390 - 420
Extending dipper 380 - 410 395 - 425
Retracting dipper 380 - 410 395 - 425
Extending bucket 380 - 410 395 - 425
Retracting bucket 380 - 410 395 - 425
Travel safety valve (on speed limiter)

Disconnect the wire 94 (brown colour) at 28, behind the cabinet printed circuit board.
PDH0507
Set the MAX mode.
Apply the parking brake.
Select road speed.
Operate the direction of travel reverser in one direction.
Press the travel pedal.
Repeat the operation in the opposite direction of travel.
The pressures read should be between 380 and 410 (bar) on the 788, 988, 988 Plus, and between 395 and 425
(bar) on the 788 Plus.

8001-27
Secondary relief valves on travel control valve
Operate against the stop, raising and lowering.
The pressures read should be 380 and 410 (bar) on the 788, 988, 988 Plus and 395 to 425 (bar) on the 788 Plus.
Adjusting the relief valve except 788P Plus (see FC adjustment)
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).
Adjusting the flow cancellation valve (heavy lift 788P Plus)
Overtighten the attachment control valve relief valve.
Overtighten the boom raising safety valve.
Operate the attachment against the stops.
Set engine in FINE mode.
Adjust the heavy lift flow cancellation valve to 450 (bar).
Adjust the boom raising secondary relief valve to its value (420 bar).
Adjust the relief valve to its value 395 (bar).
Checking the stabilizer and blade control valve flows (raising)
Beam A: the flow should be:
788 788P Plus 988
2 pads 45 - 55 l/min 45 - 55 l/min 20 - 25 l/min
1 blade 45 - 55 l/min 45 - 55 l/min 20 - 25 l/min
2 pads + blade 45 - 55 l/min 45 - 55 l/min 20 - 25 l/min
4 pads
Beam B: the flow should be:
788 788P Plus 988
1 blade 15 - 30 l/min 15 - 30 l/min 8 - 16 l/min
2 pads + blade 60 - 20 l/min 60 - 20 l/min 31 - 41 l/min
If it is not, check the flow limiter(s) at the front or rear of the chassis for the pads.

8001-28
Hydraulic travel motor displacement Service brake pressures

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 theFINE 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
WARNING! Unscrew to increase pressure. Same as the front axle at M11.
Retighten the travel reverser brake. Checking or adjusting the swing
Reconnect the wire 94.
Checking the circuit pressure without load
Orbitrol steering box relief valve Connect the multitester at M2.
Install a pressure test union (W1237213) at M5 at the Set the MAX mode.
inlet P to the steering box. The pressure read should be between 15 and
Connect the multitester. 17 (bar).
Turn it against the stops in both directions. If it is not, check the P3.
The pressures read should be between 155 and Checking the relief valve
160 (bar).
If they are not, disassemble the steering box and Lock the upperstructure mechanically.
check all the valves. Overtighten one safety valve by one turn.
Supply the direction of swing concerned.
Braking unit disengagement and The pressure read should be between 370 and
engagement pressures 400 (bar) (788) and between 375 and 405 (bar)
Connect the multitester at M8 on the unit. (988).
Operate the parking brake several times. Checking the safety valves
The minimum engagement pressure should be
between 120 and 135 (bar). Supply the swing in both directions.
The maximum disengagement pressure should be The pressure should be between 305 and 330 (bar)
160 (bar). (788) and between 345 and 365 (bar) (988).
If not, check the braking unit. Checking the swing brake release
Parking brake pressure Connect the two outlets of the multitester at M2 and
Install a pressure test union (U1237211) at M12 on M7.
the previous type assembly. With the upperstructure immobilised, feather the
Bleed the parking brake circuit. swing control lever.
Connect the multitester at M8 (new type assembly) or The pressure at M7 should be 35 (bar) before the
at M12 (previous type assembly). pressure rises at M2.
With the parking brake control in the disengaged If it is not, check the brake release circuit.
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.

8001-29
Checking the boom and dipper flow limiters (Previous type)

When the dipper is retracted, the pressure at M1
should be between 40 and 70 (bar).
If it is not, adjust the limiter spring to L = 21 mm on
the 788, and L = 17 mm on the 988.
If the boom lowering speed is not correct, adjust the
spring to L = 26.5 mm.
PDH0509

Case Hydraulics Excavators 788 988 Update 06 2000 Shop Manual PDF

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Case Hydraulics Excavators 788 988 Update 06 2000 Shop Manual PDF

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HYDRAULICS EXCAVATORS

788 & 988

Copyright 1999 Case France

Copyright 1999 Case France

SAFETY, GENERAL INFORMATION

Copyright 1999 Case France

Cre 7-56942GB Issued 11-99

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

WARNING: If you wear loose clothing or if

WARNING: When working close to the fan

WARNING: The machine is built to carry the

Cre 7-56942GB Issued 11-99

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

WARNING: Certain components of this

WARNING: Use proper lifting/hoisting equip-

Cre 7-56942GB Issued 11-99

WARNING: Make sure that all decals on the

Cre 7-56942GB Issued 11-99

Cre 7-56942GB Issued 11-99

CORRECT USE OF TORQUE WRENCHES

1/2 square insert Extension SJ214, for doubling

a - Hold the wrench by the handle

b - When tightening, always keep the

c - Keep one hand on the leverage

d - Tighten progressively in one

e - Position a correctly dimensioned

Cre 7-56942GB Issued 11-99

HARDWARE TIGHTENING ORDER

- Follow the correct order of proce-

- Cross or diagonal pattern tightening.

Always tighten in clockwise order.

Cre 7-56942GB Issued 11-99

STANDARD SCREW A TORQUE SPECIFICATIONS

Steel grade Steel grade

Two-part hydraulic connector

Cre 7-56942GB Issued 11-99

METAL CAP REFERENCES

NP 250 bar NP 400 bar Part number

Cre 7-56942GB Issued 11-99

PLASTIC PLUG AND CAP REFERENCE CHART

Tapped orifices and connectors with tighten-

Unions = Screw-type plugs

Cre 7-56942GB Issued 11-99

Cre 7-56942GB Issued 11-99

Copyright 1999 Case France

Cre 7-80071GB Issued 11-99

FLUIDS AND LUBRICANTS

Transmission component oil

Cre 7-80071GB Issued 11-99

Oil viscosity/Oil range

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99

GENERAL MACHINE SPECIFICATIONS

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99

Undercarriage (depending on version)

Warning and indicator lamps

Vibration level in operators compartment

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99

Cre 7-80071GB Issued 11-99