Chapter 2: Service and Troubleshooting

TXL-838/929/121
Chapter 2: Service and Troubleshooting

Table of contents
Chapter 2 / Section 2: Troubleshooting ...................................................................................................... 3

I. Diagnostic Center ........................................................................................................................................4
I.A. What the Diagnostic Center Can Do ...................................................................................................................................... 6
I.B. Diagnostic center overview .................................................................................................................................................... 7
I.C. Menus quick reference ........................................................................................................................................................... 8
I.C.1. Menu F1 – OPERATIONS .............................................................................................................................................. 10
I.C.2. Menu F2 – DIAGNOSTIC................................................................................................................................................ 11
I.C.3. Menu F3 – CONFIGURATION........................................................................................................................................ 15
I.C.3.a DRIVE MAX SPEED SETTING (828/929/121) .............................................................................................................. 18
I.C.3.b PROPORTIONAL VALVES THRESHOLD SETTING (828/929/121).............................................................................. 19
I.C.3.c CONVEYOR SPEEDS (838/929/121)............................................................................................................................ 20
I.C.3.d ELEVATOR MINIMUM/MAXIMUM HEIGHT ADJUST (121 ONLY)................................................................................ 21
I.C.3.e BRIDGE TRANSDUCER ADJUST (121 ONLY) ............................................................................................................ 22
I.C.3.f BRIDGE TRANSDUCER RESET (838/929 ONLY) ........................................................................................................ 23
I.C.3.g JOYSTICKS NETWORK ID ............................................................................................................................................ 24
I.C.4. Menu F4 – ERROR LOG ................................................................................................................................................ 25
I.C.5. Menu F5 – INFORMATION............................................................................................................................................. 44
I.C.6. Menu OPTIONS SETUP ................................................................................................................................................. 45
II. Troubleshooting Strategy..........................................................................................................................49
II.A. Electrical Switches and Controls (Inputs)............................................................................................................................. 49
II.A.1. Joysticks.......................................................................................................................................................................... 50
II.B. Switches modules ................................................................................................................................................................ 53
II.B.1. Wiring .............................................................................................................................................................................. 53
II.B.2. Status Light ..................................................................................................................................................................... 54
II.C. CAN Bus Network Overview ................................................................................................................................................ 55
II.D. CAN Bus Network Troubleshooting Strategy ....................................................................................................................... 58
II.E. Feedback Transducers......................................................................................................................................................... 59
II.E.1. Bridge Rear Cargo Stops Calibration.............................................................................................................................. 60
II.F. Elevator Overtravel Protection – functionality validation (when installed) ............................................................................ 61
II.F.1 Straddle Interlock ........................................................................................................................................................................ 62
II.G Troubleshooting Flowchart ............................................................................................................................................................ 63
II.G.1. Cargo System – MDWs one side .................................................................................................................................... 63
II.G.2. MDWs both sides ............................................................................................................................................................ 64
II.G.3. MDWs Slow..................................................................................................................................................................... 65
II.G.4. Hydraulic Pump............................................................................................................................................................... 66
II.G.5. Excessive heat ................................................................................................................................................................ 67
II.G.6. Vehicle Drive ................................................................................................................................................................... 68
Service and Troubleshooting Chapter 2

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II.G.7. Vehicle Drive ................................................................................................................................................................... 69

II.G.8. Vehicule drive.................................................................................................................................................................. 70
II.G.9. Elevator Lift ..................................................................................................................................................................... 71
II.G.12. Elevator Lift and Vehicle Drive ........................................................................................................................................ 75
II.G.13. Bridge Cargo Stops Transducers.................................................................................................................................... 76
II.G.14. Elevator Rear Stop/Side Guides ..................................................................................................................................... 77
III. Control Modules.........................................................................................................................................78
III.A. Replacing Inputs/Outputs Modules ...................................................................................................................................... 78
III.B. Replacing Main Controller Module ....................................................................................................................................... 79
III.C. Programming of the Main Controller Module........................................................................................................................ 80
IV. Pump Setup Procedure and Drive Circuit Pressure Setting...................................................................88
IV.A. Pump Setup Procedure, Big Block Loaders, 838/929 ................................................................................................................. 88
IV.A. Pump Setup Procedure, Big Block, continued............................................................................................................................. 90
IV.B. Drive Circuit Pressure Setting, Big Block Loaders ...................................................................................................................... 91
IV.B. Drive Circuit Pressure Setting, Big Block, continued................................................................................................................... 92
IV.C. More on Pump Setup, Big Block Loaders ................................................................................................................................... 92
V. Parking Brake Pressure Release Setup ...................................................................................................93
VI. Auto-Level Option Troubleshooting.........................................................................................................94
V.A Autolevel Test Setup Procedure........................................................................................................................................... 96
VII. Deceleration settings (see section VI.B. for valve location):....................................................................97
X. Fastening Torque Values...............................................................................................................................98
X.A. Imperial fasteners Value in Foot-pounds without Lube ........................................................................................................ 98
X.B. Metric fasteners Value in Foot-pounds without lube. ........................................................................................................... 99
X.C. Hydraulic Fittings and Cartridges Value in Foot-pounds. ..................................................................................................... 99

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Chapter 2 / Section 2: Troubleshooting

BRIDGE
ELEVATOR
ELEVATOR 2 (I/O) modules
(under platform)

(under platform)
BRIDGE 1 and BRIDGE 2
inputs/outputs (I/O) modules
(under platform)
(under platform)
Main controller and ELEVATOR 4 (I/O) modules
diagnostic center (under platform)
Figure 2.2.1.1 : Electronic modules localisation (838 shown)
Main controller
Diagnostic Center Display.

Located on main box door.
Figure 2.2.1.2: Diagnostic center

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I. Diagnostic Center
The Diagnostic Center is located in the main electric box. The Diagnostic Center facilitates the troubleshooting electric and
hydraulic problems. The Diagnostic Center can also be used for parameters adjustments (see procedures in chapter 2.1).
The Diagnostic Center has the same priority than loader controls (for example, switches and joysticks). If a switch or joystick is
used to control a function, release that function before using the Diagnostic Center OPERATIONS menu.
NOTE: Both emergency stop buttons must be pulled out, and the network between
the main controller and the Diagnostic Center must be working in order to be able to
use the Diagnostic Center.
If the display shows MAIN CONTROLLER NO SIGNAL, it is possible to move the network termination
resistor on one of the elevator module to the back of the display (spare connector) in order to get the
network running between the main controller and the diagnostic.
Network termination resistor:
Figure 2.2.1.3: Network diagram

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As it depends what is the network failure, just moving the network termination resistor might not work. If not, bridge network (MB-
6) and elevator network (MB-7) connectors at the back of the main box (the two smaller connectors) can be disconnected so that
the CAN OPEN network will be only between the main controller and the diagnostic center creating a very small network between
the main controller and the diagnostic center..
Figure 2.2.1.4: Network diagram
Make sure both platforms are clear before pressing anything on the panel.
Loader functions can be test-run inadvertently and cargo can be
transferred off the deck.
Make sure all personnel are clear of loader before using the Diagnostic
Center. Loader functions can be test-run inadvertently and cause serious
injury or death.

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I.A. What the Diagnostic Center Can Do

Short and open wires: The Diagnostic Center identifies short and open wires during operations, even “remembering” an intermittent
short or open wire. When a problem is found, it is placed in the error log in the diagnostic center and a red error light on the console
will lit as long as a problem is active or present.
Test Modes:
• Individual Test-run: It is possible to operate any available loader function from the Diagnostic Center, even if the
corresponding control switch has failed.
• The real-time value of each input can be monitored.
• Each output can be forced ON to test the components.
Adjustments:
• Engine RPM
• Adjustment of proportional valves threshold.
• Adjust cargo transfer speeds, elevator lift speeds, drive speeds from the Diagnostic Center.

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I.B. Diagnostic center overview

Note: Loader ignition switch (starter) must be ON, and both emergency stop buttons pulled out to use Diagnostic Center.
The Diagnostic Center is divided into 5 sections which are

independent:
F1 – OPERATION: This menu is used to operate the
loader with the diagnostic center display.
F2 – DIAGNOSTIC: This menu is used to test all loader

INPUTS and OUTPUT. It is also possible to force any
OUTPUTS from this menu if necessary.
F1 – OPERATION
F3 – CONFIGURATION: This menu is used to configure F2 – DIAGNOSTIC
loader parameters. See next page for a list of all F3 – CONFIGURATION
parameters that can be adjusted from the diagnostic F4 – ERROR LOG
center display. F5 – INFORMATION
F4 – ERROR LOG: This menu identifies and records the

different errors found on the unit.
F5 – INFORMATION: This menu gives information

about the engine, system and history of the loader.
Figure 2.2.1.5: Diagnostic Center
Navigation through menus:
Press ( ↑ ) or ( ↓ ) button to move up or down one line.
Press (→) or (←) button to see next or previous page.
Press (ok) to select parameter or function.
Press (esc) to go back in any time one menu level at the time.

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I.C. Menus quick reference
F1 – OPERATIONS
F2 – DIAGNOSTIC
F3 – CONFIGURATION
F4 – ERROR LOG
F5 – INFORMATION
F1 F2 F3
OPERATIONS DIAGNOSTIC CONFIGURATION
BRIDGE UP SLOW INPUTS ELEV UP FAST SPEED
BRIDGE UP FAST ANALOG OUTPUTS ELEV DOWN FAST SPEED
ELEVATOR UP SLOW DIGITAL OUTPUTS ELEV UP SLOW SPEED
BRIDGE CARGO TRANSFER NETWORK ELEV DOWN SLOW SPEED
(↓)
Select ↑, ↓ and
Select ↑, ↓ and press OK
BRIDGE UP SLOW press OK
BRIDGE UP FAST
ELEVATOR UP SLOW
BRIDGE CARGO TRANSFER
ELEV DOWN SLOW SPEED
SPEED (0-250): 200
(ok) TEST ELEVATOR LANDING
DOWN TO THE FRAME
OPERATIONS ADJUST←→ MOVE ↑↓
BRIDGE UP FAST
↑
←↓→
USE ARROWS
FOR TRANSFER
MOVEMENTS
INPUTS
J-5 BRIDGE DOWN 800
LS-04 EL NEAR FRAME 0
LS-28 OVERTRAVEL* 1
SW-11 DRIVE FWD 0
MOVE ↑, ←, ↓, → ANALOG OUTPUTS OUTPUTS NETWORK

EP-1 BRIDGE 0 L-26 BRIDGE BEACON 0 BRIDGE 1 MODULE 1
EP-31 ELEV FRONT 0 SV-01 BRIDGE FWD 1 BRIGDE 2 MODULE 0
EP-32 ELEV REAR 0 SV-02 BRIDGE REV 0 SWM-1 CARGO 1
EP-61 ELEV/DRIVE 205 SV-03 BRIDGE LEFT 0 ELEVATOR 1 MODULE 1
MOVE ↑, ←, ↓, → MOVE ↑, ←, ↓, → MOVE ↑, ←, ↓, →

and press ok to force
Figure 2.2.1.6: Quick reference menu

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I.C. Menus quick reference (continued)
F1 – OPERATIONS
F2 – DIAGNOSTIC
F4 – ERROR LOG
F5 – INFORMATION
F4 F5
ERROR LOG INFORMATION
1-DISPLAY ERRORS (0) 1-ENGINE
2-ERASE ALL ENTRIES 2-SYSTEM STATUS
3-ENGINE CODES (0) 3-HISTORY
4-VERSION
Select ↑, ↓ and
Select ↑, ↓ and press OK
press OK
Line 3
INFORMATION
ENGINE STARTS 112
Line 1 Line 3 ELEV CYCLES (k) 2
A/C SERVED (k) 1
DRIVE TIME ( h) 15
ERROR LOG ENGINE CODES
ACCELERATOR PEDAL ENGINE FAULT MOVE ↑, ↓
OUT OF RANGE SPN: 113
OCCURRENCE : 2 FMI : 2
ACTIVE: TRUE OCCURRENCE: 3
USE ARROWS TO Line 1 Line 2

USE ARROWS TO
SEE THE OTHER SEE THE OTHER
ERRORS IF ANY INFORMATION INFORMATION
ERRORS IF ANY ENGINE HOURS 22 MODE: LOAD
ENGINE SPEED 1159 STRADDLE NOT ENGAGED
COOLANT TEMP (C) 55 HIGH DEMAND REQUEST
OIL PRESSURE 51 OVERTRAVEL OK
Line 2
MOVE ↑, ↓ MOVE ↑, ↓
ERROR LOG
ALL ENTRIES WILL Line 4
BE ERASED
INFORMATION
PRESS OK TO CONFIRM MAIN CONTROLLER
059100-0010 v1.03
DIAGNOSTIC CENTER
PRESS OK TO ERASE 059101-0003 v1.02
ALL ERROR ENTRIES
Figure 2.2.1.7: Quick reference menu

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Diagnostic center menus

I.C.1. Menu F1 – OPERATIONS
• 00-BRIDGE UP/DN SLOW
Move the bridge platform up or down slowly.
• 01-BRIDGE UP/DN FAST
Move the bridge platform up or down fast.
• 02-ELEVATOR UP/DN SLOW
Move the elevator platform up or down slowly.
• 03-ELEVATOR UP/DN FAST
Move the elevator platform up or down fast.
• 06-BRIDGE TRANSFERS
Operate bridge longitudinal and tangential
movements.
• 07-ELEV FRONT TRANSFERS
Operate elevator front section longitudinal and
tangential movements. OPERATIONS
• 08-ELEV REAR TRANSFERS BRIDGE UP SLOW
Operate elevator rear section longitudinal and BRIDGE UP FAST
tangential movements. ELEVATOR UP SLOW
BRIDGE CARGO
• 09-ELEV REAR ROTATE
Operate elevator rear rotate movement.
• 10-ELEV CENTER ROTATE
Operate elevator center rotate movement.
• 12-LEFT SIDE GUIDE DOWN
Operate elevator left side guide (force it down).
• 13-RIGHT SIDE GUIDE DOWN
Operate elevator right side guide (force it down).
• 14-REAR ELEV STOP DOWN
Operate elevator rear stop (force it down).
• 15-REAR CHASSIS (121 only)
Operate rear chassis up and down.
• 16-LOW DEMAND
Request low demand RPM to the engine and
activate the pump enable valve. Figure 2.2.1.8: Diagnostic Center - Operations
• 17-HIGH DEMAND
Request high demand RPM to the engine and activate
the pump enable valve.
•18-FORCE DRIVE MODE (121 only)
Under specific circonstances to force drive mode.
NOTE: Not all menus may be shown depending on the loader model and options.
Procedure:
• Open the main box and locate diagnostic center panel—located on main box door.
• Press (F1) to select OPERATIONS menu.
• Press ( ↑ ) or ( ↓ ) or (→) or (→) button to select the function and then press (ok).
• Use ( ↑ ) or ( ↓ ) or (→) or (→) button to activate the function, e.g. up to move elevator up, left to side shift, etc. The
available arrows will be lit when active.
• Press (esc) to go back to OPERATIONS menu.

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I.C.2. Menu F2 – DIAGNOSTIC

4 functions are available in the diagnostic menu:
• INPUTS
All inputs are listed in this section. Real-time values are shown here.
• OUTPUTS ANALOG
All analog outputs are listed in this section. Real-time values and short/open are shown here.
• OUTPUTS DIGITAL
All digital outputs are listed in this section. Real-time values and short/open are shown here.
• NETWORK
This section shows what are the modules on the network at are communicating properly.
FUNCTION INPUTS
Procedure:
• Open the main box and locate diagnostic center panel—
located on main box door.
• Press (F2) to select DIAGNOSTIC menu.
• Press ( ↑ ) or ( ↓ ) button to select the function and then
press (ok).
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to scroll through
the inputs list. Real-time values are shown at the end of
each line.
INPUTS
Example for reading the display on this page: J-5 BRIDGE DOWN 800
LS-04 EL NEAR FRAME 0
• Line 1 shows a joystick value (J-5) for bridge down. LS-28 OVERTRAVEL* 1
Value 800 indicates that the joystick is activated at 80% SW-11 DRIVE FWD 0
of the full stroke. 0 would be Joystick Bridge down not
activated.
• Line 2 shows a proximity switch value (LS-04) for
Elevator near frame (24 in / 60 cm above the frame).
The value is 0 so it means that the elevator is above 24
inches. 1 would mean that the elevator is below that
point.
• Line 3 shows another proximity switch for elevator
overtravel. This proximity switch is normally closed, so
there is a “ * “ at the end of the description to indicate
that the value “1” means “nothing in front of the sensor”.
A “1” corresponds to voltage at the input. A “1” also
corresponds to a proximity sensor light ON.
• Line 4 shows the status of a switch on the console, it
tells that the drive forward switch is not active.
Figure 2.2.1.9: Diagnostic Center - Inputs

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FUNCTION OUTPUTS ANALOG

Procedure:
• Open the main box and locate diagnostic center panel—located on main box door.
• Press ( ↑ ) or ( ↓ ) button to select the function and then press (ok).
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to scroll through the outputs list. Real-time values are shown at the end of
each line.
Example for reading the display on this page:

• Lines 1, 2 and 3 show proportional valves values for
bridge and elevator. Value 0 indicates that they are
OFF. When in cargo mode, the proportional valves are
at the threshold point (about 100).
NOTE: There is no feedback loop for EP-1, EP- OUTPUTS

31 and EP-32 so the value displayed might not EP-1 BRIDGE 0
be the actual value at the valve. There is no EP-31 ELEV FRONT 0
EP-32 ELEV REAR 0
short/open monitoring but the outputs are EP-61 ELEV/DRIVE 205
short protected.
• Line 4 shows proportional valve value EP-61 for

elevator/drive speed control. Value 205 is the
threshold value. If elevator up is activated, this value
will show approximately 650.
NOTE: There is a feedback loop for EP-61 and

EP-62 so the value displayed are the actual
current value in mA at the valve. There is a
short/open monitoring and the valve will be
turned OFF when there is a short detected.
Figure 2.2.1.10: Diagnostic Center – Outputs analog
The symbol will appear at the end of the line corresponding to the valve with an open circuit.
The symbol will appear at the end of the line corresponding to the valve with short circuit.
The status of the open/short circuit is reset every 30 seconds. A valve with an intermittent short or open circuit could work fine,
then OFF for 30 seconds, and then if the problem disappears, it will be ON again and so on. The fault will be displayed in the F4 -
ERROR LOG menu and the trouble light on the cargo console will be ON indicating an entry in the error log.

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FUNCTION OUTPUTS DIGITAL

Procedure:
press (ok).
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to scroll through OUTPUTS
the outputs list. Real-time values are shown at the end L-26 BRIDGE BEACON 0
SV-01 BRIDGE FWD 1
of each line.
SV-02 BRIDGE REV 0
SV-03 BRIDGE LEFT 0
• Line 1 shows the console bridge flashing beacon status,
ON or OFF.
• Lines 2, 3 and 4 show hydraulic valves values for bridge
cargo. Line 2 shows that SV-01 or bridge forward is
active.
Figure 2.2.1.11: Diagnostic Center – Outputs digital
The symbol will appear at the end of the line corresponding to the valve with an open circuit.
The symbol will appear at the end of the line corresponding to the valve with short circuit.
The status of the open/short circuit is reset every 30 seconds. A valve with an intermittent short or open circuit could work fine,
then OFF for 30 seconds, and then if the problem disappears, it will be ON again and so on. The fault will be displayed in the F4 -
ERROR LOG menu and the trouble light on the cargo console will be ON indicating an entry in the error log.
NOTE: On the same I/O module, if there is a short on one of the outputs, the output
will be turned OFF. If there is another output shorted, this output will also be turned
OFF. However, if there is an open circuit, the other short or open circuit on this same
I/O module will not be detected. Note that the outputs are still short protected but it
won’t show the error on the diagnostic center.

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FUNCTION NETWORK
Procedure:
press (ok).
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to scroll through
the network devices list.
NETWORK
• A “1” at the end of the line indicates that the network BRIDGE 1 MODULE 1
device is communicating properly with the main BRIGDE 2 MODULE 0
controller. SWM-1 CARGO 1
ELEVATOR 1 MODULE 1
• Lines 1, 3 and 4 show that the network device is working
properly. However, line 2 shows that BRIDGE 2
MODULE is not communicating with the main controller.
(See diagnostic section (sec II.E) on how to troubleshoot
the network.)
Figure 2.2.1.12: Diagnostic Center – Network

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I.C.3. Menu F3 – CONFIGURATION
There are no flow control valves to adjust for elevator lift and cargo transfer speeds except for the side roller on the 929-C. Adjust
speeds with the Diagnostic Center Display located in the main electric box.
Make sure all personnel are clear of loader before using the Diagnostic
Center. Loader functions can be test-run inadvertently and cause serious
injury or death.
A well-tunned loader does NOT need frequent adjustment. A loader

constantly going out of adjustment signals a different problem possibly
hydraulic or mechanical. Identify the root cause of the problem
Figure 2.2.1.13: Diagnostic Center in Main Electrical Box
NOTE: Loader ignition switch (starter) must

be ON, and both emergency stop buttons
pulled out to use Diagnostic Center.
The Diagnostic Center is divided into 5 sections which are
independent:
F1 – OPERATION: This menu is used to operate the F1 – OPERATION

loader with the diagnostic center display. F2 – DIAGNOSTIC
F2 – DIAGNOSTIC: This menu is used to test all loader F4 – ERROR LOG
INPUTS and OUTPUTS. It is also possible to force any F5 – INFORMATION
OUTPUTS from this menu if necessary.
F3 – CONFIGURATION: This menu is used to configure
loader parameters. See next page for the list of all
parameters that can be adjusted from the diagnostic
center display.
F4 – ERROR LOG: This menu identifies and records the
different errors found on the unit.
F5 – INFORMATION: This menu gives information about
the engine, system and history of the loader.
Figure 2.2.1.14: Diagnostic Center – Configuration

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The following parameters can be adjusted from this menu. Some menus are HIDDEN in normal operation. To display all
parameters, TURN OFF the power, HOLD IN the F3 key and TURN ON the power untilthe CONFIGURATION menu is displayed
(about 7 seconds)
• 00-ENGINE IDLE RPM

• 01-ENGINE LOW RPM (LOW DEMAND)
• 02-ENGINE HIGH RPM (HIGH DEMAND)
• 03-BRIDGE SLOW SPEED
• 04-BRIDGE FAST SPEED
• 05-ELEVATOR UP FAST SPEED
• 06-ELEVATOR DOWN FAST SPEED
• 07-ELEVATOR UP SLOW SPEED
• 08-ELEVATOR DOWN SLOW SPEED
• 09-LIFT PRESSURE (121 only) CONFIGURATION
05-ELEV UP FAST SPEED
• 23-DRIVE SLOW SPEED FOR AIRCRAFT APPROACH 06-ELEV DOWN FAST SPEED
• 24-DRIVE JOYSTICK FWD 07-ELEV UP SLOW SPEED
• 25-DRIVE JOYSTICK REV 08-ELEV DOWN SLOW SPD
• 26-DRIVE MAX SPEED
Proportional valves thresholds 838 / 929 / 121:

• 30-THRESHOLD EP1
• 36-THRESHOLD EP62 (929/121 only)
Cargo transfer speeds 838 / 929 / 121:

• 11-BRIDGE FWD/REV SPEED
• 12-ELEVATOR FRONT FWD/REV SPEED
• 13-ELEVATOR REAR FWD/REV SPEED Figure 2.2.1.15: Diagnostic Center CONFIGURATION menu
• 14-BRIDGE SIDE SHIFT SPEED
• 15-ELEVATOR FRONT SIDE SHIFT SPEED
• 16-ELEVATOR REAR SIDE SHIFT SPEED
• 17-ELEVATOR CENTER ROTATE SPEED
• 18-ELEVATOR REAR ROTATE SPEED
• 19-EXTENSION SPEED
• 20-EXTENSION SIDE SHIFT SPEED
Elevator height sensor calibration 121:

• 44-ELEVATOR MINIMUM HEIGHT ADJUST
• 45-ELEVATOR MAXIMUM HEIGHT ADJUST
Bridge cargo stops calibration 121:

• 46-BRIDGE TRANSDUCER ADJUST
The next sections give examples of parameter adjustment. Those
Bridge cargo stops calibration 838/929: examples cover all types of adjustments that can be done from
diagnostic center.
• 47-BRIDGE TRANSDUCER RESET

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Cargo joysticks network ID:

• 48-J-1 ID
• 49-J-2 ID
• 50-J-3 ID

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I.C.3.a DRIVE MAX SPEED SETTING (828/929/121)
This parameter determines the maximum vehicule drive speed. If you want to limit the maximum vehicule drive speed, you can
lower this parameter.
NOTE: Cold hydraulic fluid results in slow speeds. Before timing and adjusting speeds, cycle
elevator lift several times until hydraulic oil reaches operating temperature.
NOTE: Loader must be in drive mode with engine running.
• Open main box and locate diagnostic center panel—located on main box door.
• Turn power off.
• Press and hold (F3) key.
• Turn power on.
• Release (F3) key after 10 seconds.
• Press ( ↑ ) or ( ↓ ) button to select the parameter to adjust and
then press (ok).
• Press (→) or (←) button increase or decrease value of
parameter.
26-DRIVE MAX SPEED
SPEED (300-1000) : 1000
NOTE: Parameter value will be automatically saved in system. SPEED (KM/H) : 0.0
PRESS ESC TO GO BACK
ADJUST MOVE
• Press (esc) to go back to CONFIGURATION menu.
Figure 2.2.1.16: Drive Max Speed Setting

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I.C.3.b PROPORTIONAL VALVES THRESHOLD SETTING (828/929/121)

Any time a new main controller module is installed in a loader it is necessary to perform the threshold setup before putting the
loader back into service. Any time a proportional valve is replaced (EP1, EP-31, EP32, EP-61, EP-62), it is also necessary to
perform the threshold setup.
With Diagnostic Center Module, pull emergency stops and start loader. Leave loader in load mode. With Diagnostic Center panel,
operate the elevator lift through 5 cycles (up and down). Leave elevator 30 cm (12”) above frame with engine running.
The threshold adjustement sets the start position of the proportional valve.
Make sure there is no cargo on the platforms and make sure all personnel
are clear of loader before using Diagnostic Center for any of the following
procedures.
NOTE: Loader must be in load mode with engine running.
EP-1, EP-31, EP-32 and EP-33:

• Press (F3) to select CONFIGURATION menu.
• Press ( ↑ ) or ( ↓ ) button to select the parameter to adjust
and than press (ok).
• Press (→) button to increase the value until the
corresponding conveying element moves.
• Press (←) button to decrease value of parameter until the
corresponding conveying element stops. The normal value is
approximately 100 (60-150).
EP1 BRIDGE THESHOLD
SET POINT: 97
EP-61 and EP-62: MOVE VALUE UP AND THEN
• Lift the elevator about 4 feet from the ground. LOWER VALUE UNTIL STOP
ADJUST MOVE
and then press (ok).
• Press (→) button to increase the value until the elevator
moves.
• Press (←) button to decrease value of parameter until the
elevator stop. The normal value is approximately 180 (100-
250).
NOTE: If the final value is 80 and the elevator is still moving, there
is a problem with the hydraulic circuit or the valve.
NOTE: Parameter value will be automatically saved in system.

Figure 2.2.1.17: Valve Threshold Adjustments
NOTE: Changing the threshold of EP-61 might change the elevator slow down speed. Check elevator speed settings.

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I.C.3.c CONVEYOR SPEEDS (838/929/121)

There are different speed adjustments in 3 zones for cargo:
• Bridge:
o 11-FWD/REV Speed (FTC Longitudinal Speed)
o 14-Side Shift Speed (Bridge MDW Tangential Speed)
• Front of elevator
o 12-Front FWD/REV Speed (FTC Longitudinal Speed )
o 15-Front Side Shift Speed (MDW Tangential Speed)
• Rear of elevator
o 13-Rear FWD/REV speed (FTC Longitudinal Speed)
o 16-Rear Side Shift Speed (MDW Tangential Speed)
o 17-Center Rotate speed
o 18-Rear Rotate Speed
o 19-Extension Speed
o 20-Extension Side Shift Speed
Check transfer speeds using wheel tachometer on one of triple flat-top chains for NOTE: See Chap 5 for the complete
each zone or the side roller for side shift speed. Adjust all zones to the speeds found list of recommended speeds.
in Chap 5. Cargo transfer speeds do NOT need to be adjusted often.
A well-running loader does NOT need

frequent adjustment. A loader constantly
going out of adjustment signals a different problem—
possibly hydraulic or mechanical. Identify the root
cause of the problem. Do not damage Diagnostic
Center by over-adjusting.
NOTE: Cold hydraulic fluid results in slow speeds.
Before timing and adjusting speeds, cycle elevator lift
several times until hydraulic oil reaches operating BRIDGE FWD/REV SPEED
temperature. SPEED (0-1000): 800
NOTE: Loader must be in load mode with engine
running.
ADJUST MOVE
• Open main box and locate diagnostic center panel—located on
main box door.
• Press ( ↑ ) or ( ↓ ) button to select the parameter to adjust and
then press (ok).
parameter.
NOTE: Parameter value will be automatically
saved.
• After making small adjustment, press ( ↑ ) or ( ↓ ) button to test
new settings and measure longitudinal and tangential speed
with a wheel tachometer.
• Repeat, as needed, to obtain recommended speeds of Chap 5.
Figure 2.2.1.19: Cargo Transfer Speed Adjustments

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I.C.3.d ELEVATOR MINIMUM/MAXIMUM HEIGHT ADJUST (121 ONLY)

There is a sensor to measure the elevator height in order to determine the height to slow down the elevator when going down, the
height where to stop the elevator when safety props are engaged and also the height of the 60” interlock feature when active.
• Turn power OFF.
• Press and hold F3 key.
• Turn power ON.
• Release F3 key after 10 seconds
PARAMETER: ELEV MIN HEIGHT ADJ

CALIBRATION VERIFICATION
• Press (↓ ) button to lower the elevator platform up to the
frame.
The actual value is displayed and also the actual set point. The two ELEVATOR MIN HEIGHT
values should be within ±25. If not, follow the adjustment procedure. ACTUAL: 501 SET: 511
LOWER ELEVATOR TO
FRAME AND PRESS F6
ADJUSTMENT PROCEDURE
• With the elevator at frame, press F6 key to set the minimum
height position.
PARAMETER: ELEV MAX HEIGHT ADJ

• Press (↑ ) button to raise the elevator platform up to the max
height (the bridge must be raised to max height as well).
The actual value is displayed and also the actual set point. The two
values should be within ±25. If not, follow the adjustment procedure.
• With the elevator at max height, press F6 key to set the
maximum height position.
Note: Parameter value will be automatically saved in system.

Figure 2.2.1.23: Elevator min/max height adjust

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I.C.3.e BRIDGE TRANSDUCER ADJUST (121 ONLY)

The bridge stops tranducers adjustment is all done using the
diagnostic center. This menu sets the zero point where the
elevator is interfaced with the bridge to allow smooth slow and
stop of the elevator at the bridge.
Calibration is required regularly to ensure a good interface

and security of the system.
The diagnostic system will detect faulty or out of adjustment

bridge stops transducers most of the time but cannot detect all
cases. This is why a regular verification of the adjustment is
necessary.
Note: Loader must be in drive mode with engine running.
• Turn power OFF.
• Turn power ON.
• Press ( ↑ ) button to lift the elevator platform up to the bridge.
There are two sensors: RFT1 and RFT2 for left and right side. The
actual value is displayed and also the actual set point. The two values CONFIGURATION
should be within ±5. If not, follow the adjustment procedure. RFT1: 564 SET: 564
RFT2: 601 SET: 602
ADJUSTMENT PROCEDURE PRESS F6 TO SET
• Press F6 key and the SET values will set at 100 (default).
• The elevator will stop automatically when it detects that there
is no movement of the bridge stops.
• The elevator will not go up if one of the bridge stop
transducers is out of range.
• The menu should show “STATUS: SETUP OK” at the end.
• If the status is ERROR, troubleshoot the transducers.

Figure 2.2.1.24: Bridge Tranducers Adjust

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I.C.3.f BRIDGE TRANSDUCER RESET (838/929 ONLY)

The bridge stops tranducers adjustment is all done using the
diagnostic center. This menu sets the zero point where the
elevator is interfaced with the bridge to allow smooth slow and
stop of the elevator at the bridge.
Calibration is required regularly to ensure a good interface

and security of the system.
The diagnostic system will detect faulty or out of adjustment

bridge stops transducers most of the time but cannot detect all
cases. This is why a regular verification of the adjustment is
necessary.
• Turn power OFF.
• Turn power ON.
• The elevator will stop when it detects the overtravel proximity CONFIGURATION
switch so make sure that the adjustment is appropriate. RFT1: 564 SET: 564
• The elevator will not go up if one of the bridge stop RFT2: 601 SET: 602
PRESS F6 TO SET
transducers is out of range.
• The menu should show “STATUS: SETUP OK” at the end.
• If the status is ERROR, troubleshoot the transducers.
Figure 2.2.1.25: Bridge Tranducers Reset

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I.C.3.g JOYSTICKS NETWORK ID

There are three configurable parameters joystick network IDs. Those IDs should be adjusted only if the main controller is changed.
To access those parameters follow the following procedures:
• Open main box and locate diagnostic center panel—

• Turn power OFF.
• Turn power ON.
• Release F6 key after 10 seconds CONFIGURATION
• Press ( ↑ ) or ( ↓ ) button to select the parameter to adjust J-1 ID: 1
and then press (ok). TURN POWER OFF.
parameter to set the joystick network ID according to your
electrical schematic.
• Turn power OFF to activate the changes.

Those parameters should be changed only if

requested by TLD service.
Figure 2.2.1.26: Joystick network ID adjustments

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I.C.4. Menu F4 – ERROR LOG

This menu will show the errors list. When there is an error logged, the red indicator light on the cargo console will lit.
Figure 2.2.1.27: Error Warning on Operator’s Panel
Procedure:
• Press (F4) to select ERROR LOG menu.
• Two types of errors are listed here. The first one is a
system error and the second one is engine fault codes.
• The number of errors is indicated at the end of line 1
and 3. It is only possible to see the list of errors when
ERROR LOG
there is at least one error.
1-DISPLAY ERRORS (0)
• Press ( ↑ ) or ( ↓ ) button to scroll through the error 2-ERASE ALL ENTRIES
types and press (ok). 3-ENGINE CODES (0)
• Press (ok) to get more information about the selected
error (extensive description, number of occurrences).
The error can also be cleared.
Figure 2.2.1.28: Diagnostic Center – Error log

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DISPLAY ERRORS:
• When DISPLAY ERRORS is selected, it shows the
errors one page per errors.
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to navigate
through the errors if many.
• Lines 1 and 2 give a description of the error
• Line 3 gives the number of occurrences of that error.
Errors are logged even if the loader is turned off.
ERROR LOG
• Line 4 shows whether the fault is active or not at the ACCELERATOR PEDAL
current time. OUT OF RANGE
OCCURRENCE: 2
ACTIVE: TRUE
Figure 2.2.1.35: Diagnostic Center – Error log
POSSIBLE ERRORS LIST
• 0 - ELEV OVERTRAVEL / CHECK SENSOR LS-28

The error will occur when the elevator is near the frame and that the proximity sensor LS-28 is not sending any voltage
Symptoms: When this sensor is faulty, the elevator will not move up.
Adjust prox so that it detects just

when the bridge stop is leveled with
the bottom of the bridge.
Possible causes: Faulty proximity sensor

Wiring problem
Bridge module 1 problem
Incorrect adjustment of the sensor
Solutions:
Figure 2.2.1.36 Overtravel proximity switch
-Check in DIAGNOSTIC – INPUTS – LS-28 to make sure that the
sensor is working properly.

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• 1 - BRIDGE LEFT TRANSDUCER / OUT OF RANGE

• 2 - BRIDGE RIGHT TRANSDUCER / OUT OF RANGE
The bridge transducers are located under the bridge behind the bridge cargo stops pins. The error will occur when the
bridge transducer value is out of the valid range 130 to 800.
Possible causes: Faulty transducer

Incorrect position
Wiring problem
Network module problem
Solutions:
-Check the value at interface in DIAGNOSTIC
– INPUTS – RFT1 or RFT2.
-If the value is 0, check the voltage in the
transducer connector. There should be
Figure 2.2.1.37: Bridge rear cargo stops transducers
approximately 24V between pin A and C of the
transducer connector (under the bridge at the
back).
- If there is no voltage, make sure that the network module is powered (green light on the module, at the front of the
bridge). Correct the situation if required.
- If there is still no power at the connector, check the wiring.
-Check also the transducer with an ohmmeter to make sure it works properly. The resistance should be approximately
5 kOhms between pins A and C. Pin B is the signal and the resistance value should varie between 0 and 5 kOhms
when the sensor turns (between pins A and B, and pins C and B).
-It could be also an intermittent problem with the transducer even though it seems to work fine. If there is a dead zone
inside the sensor, it might trigger a fault. Replace the transducer.
-This error is reset only when the system is turned OFF.
- If the wiring is ok, check the network module. The two transducers (left and right) connectors on the network module
can be inverted to test if the input is faulty. In this case, RFT-1 and RFT-2 on the diagnostic center will be inverted.
• 3 - BRIDGE LEFT TRANSDUCER / UNADJUSTED, DO SETUP

• 4 - BRIDGE RIGHT TRANSDUCER / UNADJUSTED, DO SETUP
The error will occur when the bridge transducer value at interface (elevator interfaced with the bridge) is not close
enough to the original set point of the transducer at interface. The check is when done when the elevator is interfaced
with the bridge for approx 750ms and that elevator up command is active.
Symptoms: When this sensor is not adjusted, the elevator will move up slowly.
Possible causes: Faulty transducer

Incorrect adjustement.
Wiring problem
Solutions:
-Try to readjust the transducer set point in CONFIGURATION – BR TRANSDUCERS RESET. The transducer could be
simply unadjusted.

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-If the result of the setup is SETUP OK, try it again.

-If the result of the setup is ERROR, the system could not record valid values for set points. At interface, the transducer
value must be between 130 and 400. Check the value at interface in DIAGNOSTIC – INPUTS – RFT2.
-If the problem persists, check wiring.
-It could be also an intermittent problem with the transducer even though it seems to work fine. If there is a dead zone
insode the sensor, it might trigger a fault. Replace the transducer.
-If the wiring is ok, check the network module.
NOTE: DO NOT OVERTIGHT THE SENSOR SCREWS AS IT MAY CREATES PROBLEMS.
• 5 – BRIDGE AUTOLEVEL / RFT-6 ERROR DETECTED

The error will occur when the bridge autolevel sensor RFT-6 signal is not as expected. There are 2 signals out of the
sensor. The first signal is from 0.25V to 4.75V and the second signal is from 4.75V to 0.25V. The addition of the two
voltages must always be 5V. Both signals are required and if one of the cables is unplugged or wire broken, there will
be a fault detected.
Symptoms: When this sensor is faulty, the autolevel can not

be enabled.
Possible causes: Faulty sensor RFT-6

Cable unplugged
RFT-6
Wiring problem sensor
Solutions: 2 connectors
-In the F2-DIAGNOSTIC menu 2-INPUTS, Check the value of “RFT-6
AUTOLEVEL S1” and “RFT-6 AUTOLEVEL S2”. The values should be Figure 2.2.1.38: Bridge autolevel
between 200 and 4800 and S1 inversly proportional to S2 (e.g. S1=500,
S2=4500 (5000-500) OR S1=4000,S2=1000 (5000-4000)).
-If one of the values is 0, check the wiring of the sensor according to the electrical schematic because it is most probably
a broken wire.
-Add the values of “RFT-6 AUTOLEVEL S1” and “RFT-6 AUTOLEVEL S2”. The sum should be between 4800 and
5200. If not, replace the sensor RFT-6.
• 6 - MEMORY ERROR / CHANGE CONTROLLER

The error will occur when there is an internal memory error in the main controller. It is then recommended to change the
main controller (see procedure in this chapter).
• 7 - TEMPERATURE >85C / STOP OPERATION

The error will occur when the internal temperature of the main controller is above 85C. The loader must be stopped until
the error disappears. The main electrical box door should be opened to ventilate the enclosure. The error will be
cleared by itself when the temperature drops below 85C. Check for trace of burned wires/compomnents or fumes.

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• 8 - CAN 1 ERROR / CHECK WIRING

• 9 - CAN 2 ERROR / CHECK WIRING
The error will occur when the CAN port (network) of the main controller is not working properly.
Possible causes: CAN HIGH (wire 0181 or 0191) is connected to ground

CAN port damaged on the main controller
Solutions:
-Check the voltage on the CAN LOW and CAN HIGH lines. CAN LOW should be around 2VDC and CAN HIGH should
be around 2.5VDC. If one of those lines is at 0V or 24V, check the wiring.
-If one line was connected to 24V, there is a high probability that many CAN ports are damaged.
-If one line was connected to 0V or ground, there is normally no damage. Find the problem and the network should
come back to normal.
-CAN1 is related to wires 0180 (CAN low) and 0181 (CAN high).
-CAN2 is related to wires 0190 (CAN low) and 0191 (CAN high).
-Disconnect wires 0180, 0181, 0190 and 0191 from the main controller in the main controller box. Those wires can be
found on the terminal blocks. Turn OFF the power, and then back ON. If the error is still there, replace the main
controller.
• 10 - ACCELERATOR PEDAL / OUT OF RANGE

The error will occur when the accelerator pedal value is out of the valid range 0.25V to 4.75V. The normal operating
range for the pedal is 0.5V to 4.5V. The 5V source is provided from the switches module on the cargo console. The
pedal output is also connected to this module.
Possible causes: Faulty pedal.

Wiring problem
Cargo switches module problem (on the cargo console)
Solutions:
-Check the value of the pedal with a voltmeter in the console on pin 6 of the 6 pins connector at the back of the switches
module in the cargo console (wire 9616).
-If there is no voltage, check the 5V supply from the switches module pin 8 of the 9 pins connector (wire 9600)
-Check the wiring.
-Check also the voltage directly in the pedal connector.
-It is not possible to mesure the pedal output in ohms as it is an electronic pedal that needs 5V supply to output a
voltage.
-Make sure that the switches module SWM-1 in DIAGNOSTIC – NETWORK is working (value 1).

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• 12 - BRIDGE LIFT JOYSTICK / NO SIGNAL

• 13 - ELEV LIFT JOYSTICK / NO SIGNAL
• 14 - BRIDGE JOYSTICK / NO SIGNAL
• 15 - ELEV FRONT JOYSTICK / NO SIGNAL
• 16 - ELEV REAR JOYSTICK / NO SIGNAL
• 17 – AUX ELEV LIFT JOYSTICK / NO SIGNAL
• 18 – AUX BRIDGE JOYSTICK / NO SIGNAL
• 19 – AUX ELEV FRONT JOYSTICK / NO SIGNAL
• 20 – AUX ELEV REAR JOYSTICK / NO SIGNAL
• 21 – DRIVE JOYSTICK / NO SIGNAL
The error will occur when a joystick does not communicate with the main controller network requests.
Possible causes: Network problem

Wiring problem
Faulty joystick
Solutions:
-Check the light at the back of the joystick. It must be solid green for the joystick to work properly.
-If there is no light, there is a power problem. Check the wiring (wires 0180 and 0181).
-If there is a red light flashing or not, either there is a network problem or a faulty joystick.
-If the green light is flashing, it means that the joystick is working functional, but it does not receive signal from the main
controller. Most probably this is a network problem. Check the wiring
-Check the joystick troubleshooting section in this chapter.

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• 26 - REAR STOP PROX / CHECK PROX LS-18

The error will occur when the elevator rear stop proximity sensor does not detect the rear stop in the up position or down
position when it is supposed to be. It is located at the back of the elevator.
Symptoms: In this case, the elevator rear section will not allow any reverse movements.
Possible causes: No hydraulic power to the rear stop cylinder so the rear stop did not move as it was supposed to.
Incorrect adjustment, sensor too far from rear stop
Faulty proximity sensor LS-18
Wiring problem
Solutions:
-If the error is repetitive, check in DIAGNOSTIC – INPUTS –
LS-18 to make sure that the sensor is working properly.
-If not, check wiring.
Figure 2.2.1.40: Elevator rear stop proximity

switch (838 shown)
• 27- STAB UP PROX / SENSOR LS-1 (or 27-AXLE PROX DOWN

for 121)
• 28- STAB DOWN PROX / SENSOR LS-2 (or 28-AXLE PROX UP for 121)
There are two proximity sensors on the left-hand side loader’s stabilizer. Both sensors detect metal when the stabilizer
is up and none detects metal when the stabilizer is down. If this is not the way it is, those errors will show up.
Possible causes: Faulty proximity sensor

Faulty wiring
Stab failed to go down or up (mechanical or hydraulic problem)
Proximity sensor installed too far from stab
Solutions:
-If there is no light on the sensor, check, the wiring and inputs/outputs module power. If power is correct, replace the
sensor.
-If there is a light on the sensor when metal is in front of the sensor but it does not change state, the sensor is probably
faulty. Replace it.
-If everything seems normal under the platform, check on the diagnostic center in the menu F2-DIAGNOSTIC – INPUTS
to make sure that the proximity switch is functional. Make sure that the value shown on the diagnostic center (0 or 1)
corresponds to the light on the sensor.
-Check if proximity sensor is installed too far from stab.

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• 29 - CHASSIS 1 MODULE / ID 8 - NO SIGNAL

• 30 - BRIDGE 1 MODULE / ID 16 - NO SIGNAL
• 31 - BRIDGE 2 MODULE / ID 17 - NO SIGNAL
• 32 - ELEVATOR 1 MODULE / ID 20 - NO SIGNAL
• 36 - CHASSIS 3 MODULE / ID 10 - NO SIGNAL
• 37 - CONSOLE 1 MODULE / ID 91 - NO SIGNAL
• 38 - CARGO SWITCH MODULE / SM1 - NO SIGNAL
• 39 - DRIVER SWITCH MODULE / SM2 - NO SIGNAL
The error will occur when the main controller loses the Figure 2.2.1.42: Network devices
communication with a remote network device.
Possible causes: Network problem

No power at the remote device
Faulty remote device
Solutions:
-The first thing to check is if many devices do not communicate. If it is the case, most probably it will be a network or
power wiring problem. For example, if all the elevator modules are not responding, it is probably a wiring problem in the
elevator scissor cable, elevator connectors or in the main electrical box.
-Check the green light on the modules. If it is solid green, there is power but the network is not working. Check the
wiring of the network. It must be flashing green when it is operational.
-If there is no light, there is a power problem. Check the wiring.
-If there is a red light flashing or not, either there is a network problem or a faulty module.
• 40 – HYD LOW LEVEL / CHECK FLOAT FS-2

The error will occur when the oil level in the hydraulic tank is too low or when the
float is disconnected or not functional. It causes the engine to shutdown.
Possible causes: Faulty wiring

Faulty float switch
Solutions:
When the oil level is ok, the float switch is closed so there is voltage at the input of
the main controller.
-Verify the hydraulic oil level to make sure it is ok.
-In the diagnostic center menu F2-DIAGNOSTIC / 1-INPUTS, FS-2 shows the value
at the main controller input. Check if the value is a 1 (oil level ok) or 0 (oil level too
low).
Figure 2.2.1.43: Hydraulic
-If the value is 0, check the wiring. Disconnect the connector near the hydraulic level
low level float switch
float switch on top of the hydraulic tank right hand side. Make sure that you have
power on one of the wires in the connector (loader side).
-Check also the continuity between the two pins of the float switch connector. The contact is closed when the oil level is
ok. If not, disassemble the float switch and manually actuate the float. Turning the floating element upside down will
change the contact from “normally close” to “normally open” and inversely.

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-Check the wire junctions inside the float tube to make sure there is not an open circuit there.
• 41 – HYD LOW PRESSURE / CHECK SENSOR PS-6

The error will occur when the hydraulic pressure is too low and it causes
the engine to shutdown.
Possible causes: Hydraulic pump

Faulty wiring
Faulty pressure switch
Solutions:
-The first thing to check the pressure on the big block TP2. The pressure
must be minimum 200 PSI. If it is the case, the problem is electrical. If Figure 2.2.1.44: Hydraulic low
not, check your hydraulic circuit. pressure switch
-In the diagnostic center menu F2-DIAGNOSTIC / 1-INPUTS, PS-6
shows the value at the main controller input. Check if the value is a 1 (oil pressure ok) or 0 (oil pressure too low).
-If the value is 0, check the wiring. Disconnect the connector near the pressure switch on top of the big block. Make
sure that you have power on the connector pin B (loader side).
-Check also the continuity between the pins B and C of the pressure switch connector. The contact is closed when the
oil pressure is greater than 200 PSI. If not, replace the pressure switch.

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• 42 – FUEL SENDER LS-29 / OUT OF RANGE

The error will occur when the fuel sender signal is below or above operating limits. The sensor voltage range is 0.25 to
4.75V
Possible causes: Faulty sensor

Faulty wiring
Solutions:
-In the diagnostic center menu F2-DIAGNOSTIC / 1-INPUTS, LS-29 shows the value at the main controller input. Check
if the value is a 0 (no power or signal shorted to ground).
-If the value is 0, check the wiring. Disconnect the connector near the fuel level sender on top of the fuel tank. Make
sure that you have power on the connector (loader side).
-Make sure that the signal in the diagnostic center varies when you move the sensor.
• 44 – RR LEFT ELEV GUIDE / CHECK PROX LS-20

• 45 – RR RIGHT ELEV GUIDE / CHECK PROX LS-19
The error will occur when the elevator left or right side guide proximity
sensor does not detect the guide in the up position or down position when it
is supposed to be. It is located on the side of the platform near the front of
the elevator side guide.
Symptoms: The elevator will not lift (side guides interlock option)
Possible causes: No hydraulic power to the side guide cylinder so the
guide did not move as it was supposed to.
Figure 2.2.1.45: Side guide
Incorrect adjustment, sensor too far from side guide
proximity switch (838 shown)
Faulty proximity sensor
Wiring problem
Solutions:
-If the error is repetitive, check in DIAGNOSTIC – INPUTS – LS-XX to make sure that the sensor is working properly.
-If not, check wiring. If there is no diagnostic light on the proximity switch, there is no power so it might be the cable.

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• 46 – CARGO SWITCH MODULE / CHECK GASKET / VOLTAGE OUT OF RANGE

• 47 – DRIVER SWITCH MODULE / CHECK GASKET / VOLTAGE OUT OF RANGE
The error will occur when an anormal voltage at the inputs of the switch
module is detected. This may happen if a lot of water enter the module.
Symptoms: None
Possible causes: Water intrusion
Internal module problem
Solutions: Figure 2.2.1.38: Side guide
-Check module gasket. proximity switch (838 shown)

-Check for possible external water intrusion that would affect the
Figure 2.2.1.46: Cargo and Driver
module. Switch Modules
-If no water is seen, replace the module.
• 48 – BRIDGE SECURITY / RFT-7 SENSOR FAULT

The error will occur when a problem is detected with the bridge security
device sensor located at the front of the bridge between the scissor and the
chassis.
Symptoms: Bridge lift is slow

Possible causes: Wiring problem
Sensor screws too tight
Sensor faulty
Figure 2.2.1.47: Bridge Security
Device (121 shown)
Solutions:
-In the diagnostic center menu F2-DIAGNOSTIC / 1-INPUTS, RFT-7 shows
the value at the main controller input. Check if the value is a 0 (no power or signal shorted to ground) or 10000 (signal
shorted to positive).
-Value should be between 250 and 9750.
-Check that there is power at the sensor connector.
-Check wiring for possible wire break.

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• 49 – BRIDGE SECURITY / FAULT ENGAGED
The error will occur when a problematic situation with the bridge movement
is detected by the bridge security device sensor located at the front of the
bridge between the scissor and the chassis.
The system will stop the engine when there is a problem detected.
Different situations are covered:
1- The bridge is moving up or down and the bridge lift switches/joystick
are not activated.
2- The bridge is moving in the wrong direction than what is requested.
3- The elevator lifts the bridge while the bridge lift switches/joystick are Figure 2.2.1.48: Bridge Security
not activated. Device (121 shown)
Symptoms: Engine does not start

Engine stops 1-2 sec after starting
Possible causes: Bridge lift valve faulty
Elevator lift valve faulty
Wiring problem
Solutions:
- Check that there is no error #48 (sensor RFT-7) first and solve this before troubleshooting this error #49.
- Check for any problems related to the bridge or elevator movements.
- Check for stuck hydraulic valves or shorts in the wiring that would activate bridge or elevator lift valves.
• 50 – BRIDGE LIFT SWITCH / SHORT DETECTED
There are 2 redundant bridge lift switches. The error will occur when
one of the switch is active and that the other is not active for more
than 2 minutes.
This is a warning only. It does not block operation.
Possible causes: Faulty switch

Wiring problem
Solutions:
- Check voltage on all bridge lift switches to make sure that the
switches are working properly. It could be on the driver side or cargo
side.
- Check inputs in the diagnostic center to see if the PLC can read the
switches signals.

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• 54 – FR LEFT ELEV GUIDE / CHECK PROX LS-22

• 55 – FR RIGHT ELEV GUIDE / CHECK PROX LS-21
The error will occur when the elevator left or right side guide proximity
sensor does not detect the guide in the up position or down position when it
is supposed to be. It is located on the side of the platform near the front of
the elevator side guide.
Symptoms: The elevator will not lift (side guides interlock option)
Possible causes: No hydraulic power to the side guide cylinder so the
guide did not move as it was supposed to.
Figure 2.2.1.49: Side guide
Incorrect adjustment, sensor too far from side guide
proximity switch (838 shown)
Wiring problem
Solutions:
-If the error is repetitive, check in DIAGNOSTIC – INPUTS – LS-XX to make sure that the sensor is working properly.
-If not, check wiring. If there is no diagnostic light on the proximity switch, there is no power so it might be the cable.

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• 56 – ELEVATOR HEIGHT / CHECK SENSOR RFT-8

The error will occur when a problem is detected with the elevator
height sensor between the chassis and the front elevator scissor.
Symptoms: Elevator slow down near the chassis starts

too soon or too late.
Elevator does not stop above safety props
automatically or stops too high
Sensor faulty
Solutions:
-In the diagnostic center menu F2-DIAGNOSTIC / 1-INPUTS, RFT- Figure 2.2.1.50: Elevator Height
8 shows the value at the main controller input. Check if the value is a < 250 Sensor (121 shown)
(no power or signal shorted to ground) or > 9750 (signal shorted to
positive).
-Recalibrate the sensor in F3 menu ELEVATOR MIN and MAX HEIGHT ADJUST

NOTE: ALWAYS SET THE ZERO POINT AFTER MOVING THE SENSOR FROM THE DIAGNOSTIC CENTER.
• 57 – ELEVATOR HEIGHT / DO SETUP TO ADJUST

The error will occur when the calibration of the elevator height
sensor is too low.
Symptoms: Elevator slow down near the chassis starts too

late.
Elevator stops very close to safety props.
Sensor faulty
Solutions:
-Do setup in CONFIGURATION menu (45-ELEV MIN HEIGHT
ADJUST) Figure 2.2.1.51: Elevator Height Sensor
(121 shown)
-If the setup does not solve the problem, in the diagnostic center menu F2-
DIAGNOSTIC / 1-INPUTS, RFT-8 shows the value at the main controller input. Check if the value is a < 250 (no power
or signal shorted to ground) or > 9750 (signal shorted to positive).

NOTE: ALWAYS SET THE ZERO POINT AFTER MOVING THE SENSOR FROM THE DIAGNOSTIC CENTER.

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• 58 – PUMP PRESSURE PS-7 / NO PRESSURE / CHECK SENSOR

The error will occur when the PLC does not read pressure from the pump pressure sensor. The trigger points are
pressure below 100 psi (6.9 bar) when pump pressure is
active OR pump pressure below 700 (48 bar) psi when
pump control valve EP-10 value is above 300.
The PLC controls the pump pressure. The pressure

requested by the PLC is indicated in F5 menu SYSTEM
INFORMATION. If there is a problem with the pump
pressure sensor, the actual pump pressure may not match
the requested pump pressure. Typically, the pressure will
be lower than what is required.
Symptoms: Pump pressure is below requested

pressure
Possible causes:
Faulty pressure sensor
No pressure from pump
Pressure sensor wiring problem
Solutions:
Check pump pressure to make sure the pump delivers some pressure.
Check pressure sensor wiring
Replace pressure sensor
• 59 – AXLE SPEED SENSOR / NO SIGNAL (LS-07)

The error will occurs when there is no signal from the speed sensor and
that the proportional valve EP-61 value is above 300 (drive motor is
supposed to turn).
Symptoms: Drive is too slow
Possible causes:
Incorrect adjustment, sensor too far from Driveshaft
Wiring problem
Solutions:
-The sensor must read 4 pulses per shaft revolution. Make sure the
sensor is adjusted properly.
-If there is no power to the sensor, check wiring.
-If the sensor detects pulses but the speed displayed in INPUTS is 0 then check wiring from sensor to PLC.
-Replace sensor.

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• 60 – DRIVE/LIFT SENSOR / NO PRESSURE (PS-9)

If pressure sensor detects pressure below 100 psi (6.9 bar) and
that EP-61 proportional valve value is above 300, then this error
is triggered because when the proportional valve is opened,
there should be pressure inside the big block to feed the drive or
lift directional valves.
Symptoms: Cannot lift full weight on elevator.
Possible causes:
No pressure from pump
Wiring problem
Solutions:
Check pump pressure to make sure the pump delivers some pressure.
• 61 – SENSITIVE BUMPER / ACTIVATED
Possible causes:
Incorrect adjustment, sensor too close to target when
the bumper is not compressed
Wiring problem
Solutions:
There are 2 strings of proximity sensors connected in
series. The first string is for the longer center section
and it is connected to 1 input. The other bumpers are
connected together and connected to another input of
the bridge I/O modules.
-Check that you have signal from the 2 inputs in
DIAGNOSTIC – INPUTS to make sure that the sensor
is working properly. All sensors are normally closed so both inputs should show “1”.
-All proximity switch sensors behind the bumper should have their status light ON when the bumper is not pressed.

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• 62 – ALTERNATOR FAILURE / VOLTAGE < 24.5V

The system detects if the battery voltage is too low to detect potential alternator problem.
Possible causes:
-Faulty alternator
-Faulty battery
• 63 – ENGINE LOW OIL / LEVEL DETECTED

There is a float switch that will detect the low engine
oil level and shut down the engine.
Possible causes:
Incorrect adjustment, sensor too high
Faulty Sensor
Wiring problem
Solutions:
The sensor is normally closed and it is a simple
mechanical contact inside the float.
-Check that you have voltage feed wire and also on
the signal wire inside the float switch.
-Also check that the signal is coming back to the
main box.
-Check in DIAGNOSTIC – INPUTS – LS-XX to
make sure that the sensor read by the PLC. You
should read a “1” when there is oil.
• 64 – BRIDGE LIFT / PRESSURE (PS-10)(121-S ONLY)

This error is triggered, if pressure sensor detects current below 3 mA.
Symptoms: Pump pressure is limited. You may not be able to lift full weight on bridge.
Possible causes:
Wiring problem (4-20 mA loop is open)
Solutions:

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ERASE ALL ENTRIES:

• Back to the ERROR LOG menu, it is possible to erase the faults logged in the diagnostic center.
• When ERASE ALL ENTRIES is selected, it shows a
delete confirmation page.
• Press ( ok ) to confirm and clear all errors entries or press
( ESC ) to cancel.
• Only the non active errors will be deleted.
ERROR LOG
ALL ENTRIES WILL
BE ERASED
PRESS OK TO CONFIRM
Figure 2.2.1.55: Diagnostic Center – Erase all entries

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ENGINE CODES:
• When ENGINE CODES is selected, it shows the engine
faults one page per fault.
• Press ( ↑ ) or ( ↓ ) or (→) or (←) button to navigate through
the faults if many.
• SPN and FMI correspond to a fault. Check the engine
manual or Chap 5 for the description of the fault.
ENGINE CODES
ENGINE FAULT
SPN: 113
FMI : 2
OCCURRENCE: 3
INPUTS
Figure 2.2.1.56: Diagnostic Center – Engine codes

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I.C.5. Menu F5 – INFORMATION
• ENGINE
Displays engine information such as coolant
temperature, engine hours, engine speed, etc.
• SYSTEM STATUS
Displays system variables to help find out why
the loader does not respond to some or all
command, or does not want to start. All the
conditions and interlocks that blocks actions
are in this section.
• HISTORY INFORMATION
Historical data of the loader is in this section. ENGINE
SYSTEM STATUS
• VERSION HISTORY
Software part number and version. VERSION
Procedure:
• Press (F5) to select INFORMATION menu.
press (ok).
• Use ( ↑ ) or ( ↓ ) or (→) or (←) button to navigate
through the list.
• Press (esc) to go back to INFORMATION menu.
Figure 2.2.1.57: Diagnostic Center – Information

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I.C.6. Menu OPTIONS SETUP
This menu configures the software for the specific loader configuration/options as the same software version may be
common to loaders with different configurations.
Procedure:
• Turn OFF the ignition switch (power OFF).
• Press (F4), (F5) and (F6) at the same time to select OPTIONS SETUP
OPTIONS SETUP menu and hold the keys in. 01-838STD
• Turn ON the ignition switch (power ON) and wait until 07-ELEV JOYSTICK 0
the OPTIONS SETUP menu shows up (approximately 6 08-BRIDGE JOYSTICK 1
seconds). 09-DELUXE JOYSTICK 0
• Press ( ↑ ) or ( ↓ ) button to select the option.

• Press (ok) to change the value (option installed or not or
selection through multiple choices).
• Change other options as needed.
• Turn OFF the ignition switch (power OFF) to exit.
Figure 2.2.1.58: Diagnostic Center – OPTIONS SETUP

Examples:
Option displayed: “01-838STD”

Pressing ok will change the loader type to “01-838WID”
Pressing ok again will change the loader type to “01-838COM” and so on.
Option displayed: “07-ELEV JOYSTICK 0”

Pressing ok will change the loader type to “07-ELEV JOYSTICK 1” (option active with a 1 at the end of the line)
Pressing ok again will change the loader type to “07-ELEV JOYSTICK 0” and so on. (option not active with a 0)

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I.C.6.a OPTIONS LIST
00- 838STD 96” wide with a 144” elevator and a 144” bridge
01- 838WID 125” wide with a 144” elevator and a 144” bridge
02- 838SUP 125” wide with a 189” elevator and a 225” bridge
03- 838COM 96” wide with a 144” elevator and a 225” bridge
04- 838UNI 125” wide with a 144” elevator and a 225” bridge
05- 929 929 model
06- 929S 929-S model
07- 121 121 model
08- 121S 121-S model
09- ELEV JOYSTICK Elevator lift joystick installed or not

10- BRIDGE JOYSTICK Bridge lift joystick installed or not
11- DELUXE JOYSTICK Deluxe joystick version installed or not
12- ELEV DUAL ROTATE Dual rotation point on the elevator.
13- JOYSTICK APPROACH Aircraft approach joystick installed or not
15- ENGINE C4.4 T3 Engine installed is a CATERPILLAR C4.4 TIER 3

ENGINE C4.4 T4 Engine installed is a CATERPILLAR C4.4i TIER 4i
DEUTZ 2012 EMR2 Engine installed is a DEUTZ 2012
DEUTZ 2012 EMR3 Engine installed is a DEUTZ 2012 TIER 3
FORD V10 6.8 Engine installed is a FORD V10
CUMMINS B3.3 T4i Engine installed is a CUMMINS B3.3 T4i
CUMMINS QSF3.8 T4 Engine installed is a CUMMINS QSF3.8 T4
30- BRIDGE SIDE SHIFT Bridge configuration is side shift (with MDWs)
36- POWERED TRAYS Option powered tray 96 inches (838 only)
40- LOW HYD LEVEL Option shutdown on low hydraulic level

41- LOW HYD PRESSURE Option shutdown on low hydraulic pressure
43- 60 IN. INTERLOCK Option elevator 60” interlock
45- ALTERNATE SLOW STOP Option to stop the elevator at a predefined higher height than the bottom position (929)
46- NO PARKING BRAKE Option parking brake not installed
47- BRIDGE REAR BARRIER Option bridge rear barrier installed
48- CONSOLE DRIVE INTERLOCK Option moveable console or powered console sliding tray installed to disable FWD when
console is not fully retracted.
50- OIL RECIRCULATE Option arctic kit (hydraulic oil recirculation)
51- LOW FUEL SHUTDWN Option shutdown on low fuel level
52- HAND PUMP Option hand pump (121 only)
53- BRIDGE AUTOLEVEL Option bridge autolevel installed to automatically adjust the bridge to the aircraft door
54- MARKER LIGHTS Option marker lights on elevator and engine compartment
55- DISABLE ERROR LAMP Option to desactivate the error lamp on the cargo console.

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56- SIDE GUIDES INTLK Elevator side guides interlock (standard)

57- SENSITIVE GUIDES Option elevator sensitive side guides interlock with reduced pressure
58- BRIDGE ALARM Option to have an alarm when the bridge moves up or down
59- AIRCRAFT DETECT Option to slow down and stop the loader at the aircraft door
60- BRIDGE SECURITY Monitoring of the bridge height to prevent unattended movement of the bridge (standard)
61- RHS TRAY INVERTER Valve to invert the right hand side tray for A380 docking
63- UNDER BRIDGE BEACON Option beacon at the front of the bridge to indicate a bridge movement
64- BRIDGE FAST SPEED ON when second bridge lift speed valve is installed.
65- ALL GUIDES DOWN Option to lower the elevator side guides and rear stop even when elevator is interfaced
with the bridge
66- AUX CONSOLE Option for an auxiliary console (121 only)
67- TRAY 145” Option bridge outer left hand side tray for extended bridge width (B777 door).
68- NO STAB ALARM Disable alarm when stabilizers move.
69- UNDER ELEV BEACON Option to have a beacon installed underneath the elevator
70- SENSITIVE BUMPER Option of sensing bumpers in front of the bridge to detect contact and stop the loader.
71- CHASSIS REAR HORN Option to have a kick horn installed at the rear of the chassis.
72- DRIVE REV INHIBIT BRG UP Option to inhibit the reverse when the bridge is above frame.
73- LOW ENGINE OIL SHUTDOWN Option to shutdown engine when engine oil level is low.
74- ALTERNATOR FAILURE LAMP Option to have a lamp indicating if battery voltage is too low.
75- LOW HYD OIL LEVEL LAMP Option to have a lamp indicating if hydraulic oil level is low.
76- PINNACLE TELEMATIC Pinnacle Telematic acquisition system compatibility
77- ENGINE WARM UP Option to wait 90s before engine demand if engine is < 20C (121 only)
78- NO RESTART ON FAULT Option to require some faults to be cleared by maintenance personnel before restarting
the unit after a shutdown
79- STRADDLE DETECT Option to have an beam sensor at the rear of the bridge to detect the presence on a
ULD and then inhibit platform down movement.
80- INWARD SIDE ROLLERS Option to turn side rollers inward during rotation
81- NO REAR WHEELS ALARM Option to disables the alarm on rear chassis down
82- ELEVATOR EXTENSION Option rear chassis extension with additional section of FTC, rollers and additional stabs
83- J1939 FILTER J1939 filter installed
NOTE: You will need the proper hardware for the options to work properly or else errors will be logged on the diagnostic center.

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Locations of Manifolds / Solenoid Valves & Coils
Figure 2.2.1.59: Manifold location on loaders
NOTE: Bridge And Elevator Manifolds Are All The Same As Shown Above But
Configured With Different Number Of Valves.

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II. Troubleshooting Strategy

Refer to chapter 2 section 2.2 for how to use the diagnostic center.
II.A. Electrical Switches and Controls (Inputs)

Three simple steps will help you find out problems fast. When you are facing a problem, follow this strategy:
- Operate the function with the diagnostic center
- Check the inputs related to the function
- Check the outputs functionality
The first step to find out the source of a problem is to identify what is not working. For example, the bridge up function is not
working from the cargo console. There are many elements between the joystick and the valve that do the action. To cut the
problem investigation by half, try first the function with the diagnostic center to discard the input portion from the system. Use the
OPERATION menu to activate BRIDGE UP function.
If the function works with the diagnostic center, it means that there is a problem with the input device or the wiring. Use the
diagnostic center, section F2-DIAGNOSTIC – INPUTS. It is very simple to confirm that the input works just looking at the joystick
bridge up line on the diagnostic center as it will show you the real-time value of the input. Activate the joystick bridge up and you
should see the value changing on the diagnostic center. If not, it is either a bad joystick or bad wiring.
In case the value of the joystick does not change on the diagnostic center when actuated, there is a diagnostic light under the
joystick to check its status. Refer to the joystick section in this chapter for joystick troubleshooting information.
If the inputs are found functional, the problem is on the outputs side. Activate the function (bridge up in this example) and check on
the diagnostic center in F2-DIAGNOSTIC – OUTPUTS DIGITAL OR ANALOG. Find the valves related to the problematic function
and check if they are activated or not. This will confirm that the PLC wants to activate the valves. It might not work but at least the
logic is checked here. At this point, if the valve is activated on the diagnostic center and that there is no voltage at the connector
(or light on the connector), there might be a problem with the output circuitry of the corresponding electronic module or wiring.
Replace if necessary.
Problem
Test function using the

diagnostic center to activate
this function.
FUNCTION
WORKS FINE
FUNCTION DOES
NOT WORK
Troubleshoot the input Troubleshoot the output

Check the ERROR LOG for
signals signals, hydraulic or other
any errors related to the
problems found in the ERROR
problem.
LOG section.

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II.A.1. Joysticks
The joysticks are “CAN Open joysticks” meaning that the position of the handle and the status of the switch, if any, are transmitted
over the network. This simplifies the wiring as there are only 6 wires to make it work.
The joysticks can be “daisy chained” together using the male and female connectors. Those two connectors are connected in
parallel inside the joystick. Two wires are for power ( red (+) and black(-) ) Two wires are for the CAN bus network.
Joystick from inside the Resistor

cargo console connectors
Male Female
connector connector
Figure 2.2.2.1: Joystick
All joysticks share the same wires. This means that two same joysticks can be connected on the network. What differentiates
them for the main controller is the resistor connected to the joystick. The resistor is a small square black box with two wires that
connect to the two pink connectors on the joystick. This gives a number to the joystick.
IDK-200
238769
001
Figure 2.2.2.2: Joystick resistor
On the electrical schematic you will find the joystick’s ID. The last digit of the identification IDK-200 is the ID, e.g. IDK-204 is ID 4.
Bridge lift and elevator lift joysticks DO NOT NEED resistors as the network ID is hardcoded inside the joystick.
A troubleshooting strategy to state whether or not a joystick is bad and need to be replaced is to try it at another place. Disconnect
all joysticks and connect the suspected bad one to the 4 pins connector coming from the console terminal block if it does not work,
change the ID resistor of the bad joystick with the resistor of a working joysticks. Reset the joystick and check if the problem
moves.
For troubleshooting, only connect one joystick at the time to see if this one works or not and do this for all joysticks. The joysticks
can be connected in any order as long as one connects to the main connector coming from the terminal blocks.

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JOYSTICK ID RESET PROCEDURE:
Changing the joystick resistor will not change the ID of the joystick as it is stored in memory. To install a new joystick or move it
from one location to the other on the panel requires a joystick RESET.
1. Power OFF.
2. Temporarily install a wire between the two resistor terminals on the joystick. (short-circuit)
Resistor
terminals
3. Power ON during 2-3 sec ONLY. (Power ON for more than 5 sec exits the reset sequence.)
4. Power OFF.
5. Power ON. At this point, the LED inside the joystick should be blinking RED. If not, go to step 1.
Remove rubber cap

to see the LED
6. Power OFF.
7. Install the new resistor.
8. Power ON. At this point, the LED inside the joystick should be GREEN.
NOT all joysticks can be exchanged. Only Bridge cargo, Elevator Front cargo and Elevator Rear cargo can
be exchanged. The Bridge lift and Elevator lift joystick do not have an external resistor.

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STATUS LIGHT
There is a status light under the joystick that indicates its status. The following table shows the different possibilities.
Figure 2.2.2.3: Joystick status light
If there is no light, it means that there is no power.
PREOPERATIONAL STATE means that the main controller is not sending signal.
OPERATIONAL STATE means that the main controller is sending pulses to the joystick. If a joystick is bad, it could still send
messages with position 0 but an error will be logged in the ERROR LOG menu to indicate a bad signal.
STOPPED STATE means that the main controller stopped sending pulses to the joystick and it is just waiting.
NOTE: If the light is YELLOW, the joystick must be returned to the manufacturer as it is in programming mode.

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II.B. Switches modules
The switches and light indicators on this module are connected to the CAN Bus network 2 and controlled by the main controller.
There is no wiring for those switches. It is only the power and the network wires.
The switches module is installed on the cargo console. It has 2 connectors. The 9-pin is for power, network and outputs. The 6-pin
is for inputs. (Switch is secured by means of C-clip brackets, make sure these are slightly tight just to put enough pressure on the
gasket loated at the perimeter of the switch. Since perimeter gasket is glued, a new gasket is needed everytime the switch module
is dismantled)
Figure 2.2.2.4: Switches module on the cargo console
Most of the console switches are connected to the inputs of this module so that the system can read the status of those switches.
II.B.1. Wiring
The back of the module looks like the following picture.
Figure 2.2.2.5: Switches module back view
The wire numbers correspond to the connector pins.

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For example, input 2 is wire number 9612 (96 is the ID of the module, 1 stands for Input and 2 means input 2). Another example,
output 4 is wire number 9604 (96 is the ID of the module, 0 stands for Output and 4 means for output 4).
Figure 2.2.2.6: Switches wiring
When an input pin is left unconnected, the voltage reads a few volts (around 4.5V except for input 6) because of the internal
resistors. The typical connection of a switch is the switch common connected to the input and the switch either pulls that wire to
ground or positive voltage. The status of all those switches is dispalayed on the diagnostic center in the section DIAGNOSTIC –
INPUTS.
VREF is a 5VDC power source.
CAN_L (#190) and CAN_H (#191) are the 2 wires for the network. THEY MUST NOT BE INVERTED or else it won’t work.
Hole where the

red light can be
Figure 2.2.2.7: Network 2 diagram seen
.
II.B.2. Status Light

There is a red status light at the back of the module. There are 3 states:
• No light: No power
• Red flashing light (1 Hz): This is the normal mode. This status indicates that the module is powered.
• Red flashing light (3 Hz): Internal problem, the module must to be replaced.

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II.C. CAN Bus Network Overview

There are two independent networks on the loader. Network 1 connects all the Inputs/Outputs modules and the diagnostic center.
Network 2 connects the switches module on the console.
CAN is the protocol use for the transmission of data between the modules. The principle is that each module sends messages to
each other to share their information. The Main Controller located in the main box is the brain where all the decisions are taken.
For example, when ELEVATOR UP fonction is active, valves connected to the main controller activate the rear platform lift. The
bridge I/O module (on which the bridge stop transducers are connected) transmits the position of the bridge stops to the main
controller where the decision will be taken to stop the elevator at the bridge interface. All the information is transmitted over the
two network wires.
The following figure represents Network 1.
Figure 2.2.2.8: Network 1 diagram
The wires for Network 1 are 0180 (CAN_L) and 0181 (CAN_H). The resistance value between those two wires is 60±10 ohms
because there are two 120 ohms resistors in parallel.
The wiring for an I/O module is either through the strain relief at its end or through the CAN in or CAN out connectors on top.

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Figure 2.2.2.9: Inputs/Outputs Module
There is a green light and a red light on all those modules to determine their status. The following table shows the different
possibilities.
Table 2.2.2.3: Inputs/Outputs Module diagnostic lights
There are also 3 rotary switches to set the network speed and network ID for each of the IO modules. The information is in the
electrical schematic.

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The following figure represents Network 2.
Figure 2.2.2.10: Network 2 diagram
The wires for Network 2 are 0190 (CAN_L) and 0191 (CAN_H). The resistance value between those two wires is 60±10 ohms
because there are two 120 ohms resistors in parallel.
Only the console switches module and the main controller are connected to this network.
NOTE: One network may be functional while the other may not.

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II.D. CAN Bus Network Troubleshooting Strategy
Check the status lights on the modules to find out if there is only one portion of the network that is not working. All green lights
must be flashing at 2 Hz. The goal is to isolate the problem with the different strategies.
You can disconnect parts of the network to isolate the problem. If the network is not functional, disconnect the 6 pins connectors at
the back of the main box. Reconnect them one by one or only one at the time and see if that part of the network is working looking
at the green flashing lights on the modules.
If you installed a new module, double check the switches settings with your electrical
schematic to make sure that the network speed and network ID are ok (S1, S2 and S3).
The rotary switches are very small and to make sure that the selected number is the right
one, turn the switch one position and then come back to the right setting. The new setting
only takes effect after a power OFF / ON cycle
To find out if it is a network wiring problem, do the following:
Turn the power OFF (turn OFF ignition key or push the E-Stop button)
Measure the resistance between CAN_L (wire#0190) and CAN_H (wire#0191) with an ohmmeter.
The resistance must be 60±10 ohms. If it is not the case, there is an open circuit on either of those wires.
Network
Network 1, wires 0180 and 0181 60±10 Ohms termination
Network 2, wires 0190 and 0191 60±10 Ohms resistors
Table 2.2.2.4: Resistance of CAN Networks Network Network
connectors terminals
1. Test at different locations the resistance between the two network wires to find out where
the wire break is (directly in the modules, on the terminal blocks, on the resistors in the
terminal blocks, in the connectors). For example, if the resistance is 60 ohms near the
main controller and 120 ohms on the switches module, the wire break is located between
the main box and the module. Test the resistance in the console on the connector coming
from the main box. If you read 60 ohms, it means that the wire break is between there
and the switches module… and so on.
2. If there is no wire break, it might be that wires CAN_L and CAN_H are inverted. In this
case, the resistance will be 60 ohms between the two lines but the network will not work.
Follow the two wires and make sure that they are not inverted somewhere.
Resistors Locations
Network 1:
-Resistor on the terminal block in the console
-Resistor on the front IO module on the elevator
Network 2:
-Resistor on the terminal block in the main box
-Resistor on the terminal block in the console

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II.E. Feedback Transducers
If there is a bridge stop transducer error in the ERROR LOG, the voltage read by the system is either out of range or misadjusted. Two
separate messages will appear in the ERROR LOG to distinguish the two problems.
The bridge stop real-time value can be monitored in the menu DIAGNOSTIC – INPUTS under RFT-1 (RIGHT) and RFT-2 (LEFT).
• Locate transducer on right side or left side depending of which transducer is faulty.
• Pull out both emergency stop buttons. Start loader.
• Lower elevator completely in the down position
• Select menu DIAGNOSTIC – INPUT. Find in the list RFT-1 and RFT-2.
• With ignition key ON, check the value of both transducer and make sure it is within the range of 130 to 800 while moving the pallet
stop with one hand from the down position to the up position (flush with the bridge).
• If the value is not within that range, replace the faulty transducer. Install elevator and bridge safety supports before replacement.
Up position Down position

flush with bridge
Figure 2.2.2.11: Cargo Stop Position
• Stop loader. Push emergency stop button for safety.

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

For Installing Right Side for Installing Left Side
Figure 2.2.2.12: Transducer Position to Install
• Rotate transducer counterclockwise to the approximate position shown below.

• Fasten, but do NOT tighten hardware with transducer in position shown above.
• Secure electrical connector to transducer.
• Reset bridge cargo stops settings (see next section)

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II.E.1. Bridge Rear Cargo Stops Calibration

Any time a new bridge stop transducer is installed on a loader or if there is an error on transducers, it is necessary to perform a
reset of bridge transducers. Bridge transducers set point at interface can be automatically set with the Diagnostic center.
Make sure there is no cargo on the decks and make sure all personnel are
clear of loader before using Diagnostic Center for any of the following
procedures.
Note: Loader must be in load mode with motor running. The Bridge and the Elevator
must be at frame (Bridge and Elevator completely down).
Lift the left hand side bridge stop with one hand to simulate the elevator at
interface with the bridge and make sure that the overtravel proximity
sensor located just behind the bridge left stop detects the bridge stop in
the interfaced position. If it is not the case, correct the situation before
starting the setup.
Adjust prox so that it detects
just when the bridge stop is
leveled with the bottom of the
bridge.
• Open main box and locate diagnostic center panel.

• Press ( ↑ ) or ( ↓ ) button to select ‘’BRIDGE TRANSDUCER
RESET’’ and then press (ok).
• Press ( ↑ ) button raise the elevator until it stops at interface
with the bridge. The elevator will rise the bridge a few inches.
• The diagnostic center will display STATUS: SETUP OK.
• If it displays STATUS: ERROR, one transducer might be bad.
Replace if necessary.
TRANSDUCERS ADJUST
MOVE ELEVATOR UP TO THE
NOTE: Elevator must be fully interfaced with BRIDGE
STATUS: NOT SETUP
bridge for correct adjustment. USE UP OR BOWN KWY TO ADJUST
• Press ( ↓ ) button lower the elevator until flush at frame position

(completely down).
NOTE: Elevator must be completely down to the frame for
correct adjustment of transducers.
• After making transducers setting, press (esc) button to go back

to CONFIGURATION menu.
NOTE: Parameter value will be automatically saved in system.
• Press (F1) to go to OPERATION menu to test new settings.

• Press (esc) to go back to MAIN menu.
Do NOT tighten one fastener completely

before tightening the other not to
damage the sensor. Do NOT overtight Figure 2.2.2.14 Bridge Transducers Reset
the scews as the required torque is very
low.

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II.F. Elevator Overtravel Protection – functionality validation (when installed)

There is a proximity switch installed on the bracket near the bridge left pallet stop. This proximity switch has a yellow light that can
be seen near its connector when the elevator is not at interface.
1) Validate that the proximity switch Yellow light is ON when the elevator is NOT at interface.
a. If this is not the case, check the wiring to verify that the proximity switch is powered. Refer to your electrical
schematic. If the proximity switch is faulty, order a replacement.
2) Validate that the proximity switch yellow light is OFF when the elevator is at interface with bridge.
a. If this is not the case probably the proximity switch is too far from the pallet stop and it does not detect it when the
elevator is at interface. The proximity switch should be at about 3/16” or 5mm from the pallet stop. Adjust it so
that it detects the pallet stop (the yellow light should be turned off when if detects metal).
b. THIS IS SERIOUS FAULT IF THE PROXIMITY SWITCH FAILS TO DETECT THE PALLET STOP WHEN THE
ELEVATOR IS AT INTERFACE AS THE PROTECTION WON’T BE ACTIVIATED IF A PROBLEM OCCURS.
TAKE THE NECESSARY ACTIONS TO CORRECT THE PROBLEM.
3) With diagnostic center, go to DIAGNOSTIC - INPUTS menu and validate that the Input LS-28 (the overtravel proximity
switch) is changing when the elevator is at interface with bridge (value will be 0) or not (value will be 1).
Adjust prox so that it detects just

when the bridge stop is leveled with
the bottom of the bridge (on the
edge).
Bridge cargo stop
Proximity sensor
Figure 2.2.2.15: Overtravel Protection Proximity Switch
NOTE: If an Overtravel error is in the ERROR LOG and you are not able to move the
elevator ‘’UP’’, you must lower the elevator at frame position to reset the error. If the
elevator won’t response, you must readjust the overtravel proximity switch LS-28 to
correct the problem.

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II.F.1 Straddle Interlock
There is an ultrasonic sensor installed on the front of the elevator facing toward the bridge. When you loose the detection of the
bridge with the ultrasonic sensor, a check is made on the bridge transducer to detect if something is on the bridge pallet stop. If it’s
the case, the elevator down, bridge lift and cargo transfer are blocked in order to avoid abnormal situation. To clear this status, you
need to raise the elevator at bridge interface in order to reactivate cargo transfer to clear the pallet stop.
Figure 2.2.2.16: Straddle Trigger Sensor
NOTE: If a straddle interlock engaged status is in the INFORMATION menu you are
not able to move the elevator ‘’DOWN’’, bridge “UP/DOWN” and carago transfer, you
must raise the elevator at interface with bridge position and clear the bridge pallet
stop to clear the status.

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II.G Troubleshooting Flowchart

II.G.1. Cargo System – MDWs one side
Test Individual Function using
Problem: MDW’s won’t operate in Diagnostic Center, main
one direction. control box.
Check Short/Open
Status
SHORT OPEN
IF NO DETECTED DETECTED
ERROR
Check resistance of Check continuity of
solenoid coil. solenoid coil.
Force output of proportional
valve and directional valve
using Diagnostic Center,
RESISTANCE
CONTINUITY
main control box.
OK
OK
Inspect cable from
electric module to
solenoid valve.
NOT OPERATE
OPERATE
RESISTANCE IS
Replace coil.
LOW
Check directional valve OFF Inspect module and

solenoid coil LED status. replace if defective.
Check joystick(s)
with Diagnostic
ON Remove and
Center,
main control box. inspect valve.
NOT
FUNCTIONAL
Check joystick(s) OK
status LED and Replace joystick(s)
network
Figure 2.2.2.20: Cargo Transfer System
NOTE: See electrical schematic for coil resistances.

NOTE: Refer to hydraulic schematic for coil numbers.

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Test Individual Function using

II.G.2. MDWs both sides Diagnostic Center, main
control box.
Problem: MDW’s won’t operate in
both directions.
Check Short/Open
Status
SHORT OPEN
IF NO DETECTED DETECTED
ERROR
solenoid coil. solenoid coil.
valve and directional valve
using Diagnostic Center,
RESISTANCE
CONTINUITY
main control box.
OK
OK
Inspect cable from
electric module to
solenoid valve.
NOT OPERATE
OPERATE
RESISTANCE IS NO
Replace coil.
LOW CONTINUITY
Check joystick(s) Test MDW’s in the other CORRESPONDING

with Diagnostic direction perpendicular to the CARGO TRANSFER
Center, one having the problem — at the OPERATES Check directional
main control box. Diagnostic Center. valve solenoid
coils LED status.
NOT
FUNCTIONAL ON OFF
CORRESPONDING
CARGO TRANSFER Inspect module and
Check joystick(s) DOES NOT OPERATES replace if defective.
status LED and
network
Check Remove and
OK proportional valve OFF Inspect module and inspect valve.
solenoid coils replace if defective.
Replace joystick(s) LED status.
ON Remove and
inspect valve.


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II.G.3. MDWs Slow

Problem: MDWs drastically slow or
slow with a load.
Does all MDW’s of one section
operate slow?
YES NO
Remove and inspect The valve might also not shift correctly in one
pressure compensator direction. Try to replace it.
cartridge. Replace as If the valve is ok, rebuild or replace worn or
needed. damaged hydraulic motor.

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II.G.4. Hydraulic Pump

Problem: Main hydraulic
Pump does not generate Check Short/Open Status on
pressure: Diagnostic Center in main
See performance control box.
charts for pressures.
IF NO SHORT OPEN
ERROR DETECTED ON DETECTED ON
PUMP ENABLE PUMP ENABLE
Use the manual override on

the pump enable valve Check resistance of Check continuity of
(SV-73) in the engine solenoid coil. solenoid coil.
compartment to increase the
pressure
RESISTANCE
CONTINUITY
PRESSURE IN NOT ADEQUATE
PRESSURE IS ADEQUATE
OK
OK
Inspect cable from
electric module to
solenoid valve.
RESISTANCE IS Replace coil. NO

LOW CONTINUITY
Job
complete
Shut unit down and inspect VALVE IS

pump enable solenoid Replace valve
valve (SV73) NOT OK
VALVE Follow pump Replace damaged

adjust pump.
IS OK procedure
Figure 2.2.2.23: Hydraulic Pump

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II.G.5. Excessive heat

Problem: Excessive heat Is towing bypass
in hydraulic fluid NO Close it.
closed?
(High temperature light in ON,
temperature > 185F or 85C)
YES
Leave ON/OFF switch ON for 10

mins. Trace heat back from return
filter to locate which manifold is
causing heat source.
HEAT SOURCE: HEAT SOURCE:
MANIFOLD FOR DRIVE / MANIFOLD FOR
ELEVATOR OR FOR CHASSIS, FOR BRIDGE
FRONT AXEL OR FOR ELEVATOR
HEAT SOURCE: (FRONT OR REAR)
Use drive circuit MANIFOLD FOR
pressure setting PUMP / ENGINE
Trace the heat from the
procedure.
manifold to the
Check pressure at component. Replace
pump manifold. component with internal
leakage.
PRESSURE
SYSTEM RELIEF IS
COMPENSATOR ON
TOO LOW
PUMP IS SET TOO HIGH
Adjust or replace Reduce setting by

relief valve. turning
counterclockwise
Figure 2.2.2.24: Hydraulic Pump

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II.G.6. Vehicle Drive Is drive/load mode switch Select drive mode

SW-21 (on drive panel) NO on drive panel.
Problem: Vehicle drive is in drive mode?
will not function, in
YES
forward or reverse.
Verify functioning of switch SWITCH AND

SV-21 in Diagnostic Center in
main control box. CONNECTORS
ARE BAD
SWITCH AND Troubleshoot switch

CONNECTORS SV-21 and replace
ARE GOOD module if needed.
Check Short/Open Status on

Diagnostic Center in main
control box.
IF NO SHORT OPEN
ERROR DETECTED DETECTED
Does elevator lift operate Check resistance of Check continuity of

correctly? solenoid coil SV67 solenoid coil SV67
or SV68. or SV68.
NO YES
RESISTANCE
CONTINUITY
Go to next section for
OK
OK
ELEVATOR LIFT AND DRIVE
TROUBLESHOOTING Inspect cable from
electric module to
solenoid valve.
Verify functioning of switch
SV-11 (FWR/REV switch) in
Diagnostic Center in main RESISTANCE IS Replace coil. NO
control box. LOW CONTINUITY
SWITCH AND
CONNECTORS
ARE GOOD SWITCH AND Troubleshoot switch
module SWM-2 and
CONNECTORS replace switch if needed.
Rebuild or replace forward ARE BAD
(SV67) and forward (SV68)
directional valve, as required.
Figure 2.2.2.25: Vehicle Drive
NOTE: Make sure that the elevator is at frame and that the operator console is
retracted (if equipped with a moveable console).

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II.G.7. Vehicle Drive
Problem: Vehicle drive

Check Shot/Open Status on
function in one direction Diagnostic Center in main
but not the other.
control box.
SHORT OPEN
DETECTED DETECTED

solenoid coil SV67 solenoid coil SV67
or SV68. or SV68.
RESISTANCE
CONTINUITY
OK
OK
IF NO Inspect cable from
ERROR electric module to
solenoid valve.
Verify functioning of switch
SV-11 (FWR/REV switch) in
Diagnostic Center in main RESISTANCE IS Replace coil. NO
control box. LOW CONTINUITY
SWITCH AND
CONNECTORS
ARE BAD Check pressure adjustment of
SWITCH AND drive FWR and REV are correctly
Troubleshoot CONNECTORS set. See hydraulic schematic for
switch module
ARE GOOD pressure adjustment details.
SWM-2 and
replace switch if
needed.
NOTE: Make sure that the elevator is at frame and that the operator console is
retracted (if equipped with a moveable console).

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II.G.8. Vehicule drive

Problem: Vehicle drive
will not function, neither in
forward or in reverse.
control box.
IF NO SHORT OPEN
ERROR DETECTED DETECTED
Does elevator lift operate Check resistance of Check continuity of

correctly? solenoid coil SV67 solenoid coil SV67
or SV68. or SV68.
NO
RESISTANCE
CONTINUITY
YES
Go to next Elevator Lift
OK
OK
and Drive Vehicle
troubleshooting section. Inspect cable from
electric module to
solenoid valve.

LOW CONTINUITY
Verify functioning of switch Troubleshoot switch

SV-11 (FWR/REV switch) in SWITCH AND module SWM-2 and
Diagnostic Center in main CONNECTORS replace module if
control box. ARE BAD needed.
Rebuild or replace forward

SWITCH AND (SV67) and forward (SV68)
CONNECTORS directional valve, as required.
ARE GOOD


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II.G.9. Elevator Lift Note: The drive/load Is drive/load mode switch Select load mode
SW-21 (on drive panel) NO on driver’s panel.
mode can be confirmed
Problem: Elevator on the diagnostic center is in load mode?
will not go up in the menu F5-
INFORMATION / YES
or down.
SYSTEM STATUS Verify functioning of switch SWITCH AND
ARE BAD
SWITCH AND
CONNECTORS Troubleshoot switch
ARE GOOD SV-21 and replace
switch if needed.
control box.
IF NO
ERROR SHORT OPEN
DETECTED DETECTED
Test elevator up/down Check resistance of Check continuity of
using the F1-OPERATION solenoid coil SV65 solenoid coil SV65
menu on the diagnostic or SV66. or SV66.
center.
ELEVATOR RESISTANCE
CONTINUITY
FUNCTIONS AT
DIAGNOSTC
OK
OK
CENTER
Inspect cable from
electric module to
Check solenoid valve.
joystick(s)/switch
with Diagnostic ELEVATOR
Center, DOES NOT RESISTANCE IS NO
Replace coil.
main control box. FUNCTIONS AT LOW CONTINUITY
DIAGNOSTC
NOT CENTER
FUNCTIONAL
Select drive mode on DRIVES valve and using Diagnostic OK
Check joystick(s) driver’s panel to drive Center, main control box and
status LED and loader. OK
check LED status on connector.
Network
JOYSTICK
DOES NOT NOT
IS BAD Rebuild or replace elevator
DRIVE OK
OK down (SV65) and/or up
Replace (SV66) directional valve, as
joystick(s)/switch Go to next section for Inspect and replace required.
ELEVATOR LIFT AND DRIVE main controller.
TROUBLESHOOTING
Figure 2.2.2.28: Elevator Lift


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II.G.10. Elevator Lift
Problem: Elevator Is drive/load mode switch Select load mode

goes down, but SW-21 (on drive panel) NO on driver’s panel.
won’t go up. is in load mode?
YES
Verify functioning of switch SWITCH AND

ARE BAD
SWITCH AND
CONNECTORS Troubleshoot switch
TRANSDUCER ARE GOOD SV-21 and replace
Go to next section for ERROR
switch if needed.
ELEVATOR LIFT DETECTED
TRANSDUCER ERROR
TROUBLESHOOTING Diagnostic Center in main
IF NO control box.
ERROR
SHORT OPEN
YES DETECTED DETECTED
Check on Diagnostic solenoid coil SV66. solenoid coil SV66.
Center if elevator at
bridge input is ‘’ON’’. RESISTANCE
CONTINUITY
NO
OK
OK
Inspect cable from
Test elevator up using electric module to
Diagnostic Center, main solenoid valve.
control box.
ELEVATOR ELEVATOR
DOES NOT FUNCTIONS AT LOW CONTINUITY
FUNCTIONS AT DIAGNOSTC
DIAGNOSTC CENTER
CENTER
Check joystick(s)
with Diagnostic
Verify if loader have
Center
an overtravel error on
Check joystick(s) status LED
the Diagnostic Center.
FUNCTIONAL and Network (see joystick
troubleshooting section)
YES NO Pressure is too low?
Check main pressure JOYSTICK
at big block IS BAD
Troubleshoot Rebuild or replace elevator
overtravel error. up (SV66) directional valve, Replace joystick(s)
as required.

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Problem: Elevator
goes up, but Check elevator at frame proximity switch
won’t go down. value on the diagnostic center and make
sure it is 0 (OFF).
PROX SWITCH IS
OFF

IF NO control box.
ERROR
SHORT OPEN
DETECTED DETECTED
solenoid coil SV65. solenoid coil SV65.
RESISTANCE
CONTINUITY
OK
OK
Inspect cable from
Test elevator down using electric module to
Diagnostic Center solenoid valve.

ELEVATOR ELEVATOR
DOES NOT FUNCTIONS AT LOW CONTINUITY
FUNCTIONS AT DIAGNOSTC
DIAGNOSTC CENTER
CENTER NOT
Check FUNCTIONAL
joystick/switch with
Rebuild or replace elevator Diagnostic Center
down (SV65) directional
valve, as required. Check joystick(s) status
LED, switch voltage and
Network status
JOYSTICK /SWITCH
Possibly the relief valve
IS BAD
adjustement for elevator
down, check elevator down Replace
pressure at the big block joystick(s)/switch
(Test port 4)


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II.G.11. Elevator Lift
Problem: elevator
goes up and
down slowly. Check for cargo stop NO TRANSDUCER
tranducer error on Diagnostic ERROR
TRANSDUCER Center in main control box. DETECTED
ERROR
DETECTED
Check value of
VALUE IS 1
Go to troubleshooting ELEVATOR AT
section TRANSDUCERS BRIDGE in INPUTS
ERRORS near RFT-1 line.
The cargo stop goes too low,
adjust so that it does not go too
low when elevator is not
ADJUSTMENT SEEMS
TO BE OK
interfaced to the bridge.
VALUE IS 0
The problem is
NO Is the tow bypass RESISTANCE IS hydraulic Check
valve opened? OK resistance of
solenoid coil EP-61.
NO JOYSTICK OR
Check elevator
VALUE IS 1000 WHEN
joystick value or RESISTANCE NO
FULLY PRESSED
elevator switch CONTINUITY
value on the TOO LOW
diagnostic center. Replace coil.
JOYSTICK/SWITCH
VALUE IS NOT 1000/1 Rebuild or replace
WHEN FULLY EP-61 valve, as
PRESSED required
Check
joystick/switch. See
corresponding
troubleshooting
section


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II.G.12. Elevator Lift and Vehicle Drive
Problem: Elevator lift

and drive slow speed
Check for any errors on the
diagnostic center in ERROR
LOG and solve those
problems first if any.
Select drive mode on

driver’s panel and move
loader FWR and REV.
LOADER DOES LOADER DRIVES OK

NOT DRIVE OK
Adjust elevator (up &

Check pressure at pump down) speeds at
manifold while elevator Diagnostic Center using
lift is operated from load chapter 2 procedure.
control panel.
PRESSURE PRESSURE SPEED OK

≤~2600 PSI (179 bar) (838) ~2600-3000 PSI (179-207 bar) (838)
≤~3300 PSI (228 bar) (929) ~3300-3700 PSI (228-255 bar) (929)
Job Complete.
Go to section Inspect and replace
hydraulic pump proportional valve
adjustment in (EP-61).
chapter 2. WON’T ADJUST
929’s UNITS
Reset proportional
Inspect and replace
valve threshold
proportional valve
using chapter 2
(EP-62).
procedure.
Adjust elevator (up &

down) speeds at
Diagnostic Center using
chapter 2 procedure.
Figure 2.2.2.32: Elevator Lift and Vehicle Drive


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II.G.13. Bridge Cargo Stops Transducers
Problem: Transducer
error (for elevator
at bridge). Check for tranducers errors
on Diagnostic Center in main
control box. ERROR :
TRANSDUCER
OUT OF RANGE
NO ERROR ERROR :
TRANSDUCER
UNADJUSTED
VALUE IS NOT VALUE IS

BETWEEN 130 Check transducer value BETWEEN 130
Check transducers values on the AND 800
AND 800 on diagnostic center
diagnostic center (RFT-1 and
when the stop is fully up
RFT-2). Values at
and fully down.
elevator/bridge interface must be
lower than when elevator is not VALUE = 0
touching the bridge stops. Check value The problem might be
intermittent, replace
the tranducer.
Transducer not
Do the calibration procedure connected or shorted to
TRANSDUCERS for the cargo stop transducers ground, check wiring or
WILL NOT using chapter 2 procedure. replace if needed
CALIBRATE
CORECTLY
LS-28 Transducer not

Check functionality of the VALUE > 900 connected or shorted to
ADJUSTED
overtravel proximity switch LS-28 positive, check wiring or
CORRECTLY
near the left bridge cargo stop. AND WORKING replace if needed
TRANSDUCERS
LS-28 IS NOT CALIBRATE CORECTLY
WORKING
CORRECTLY
Cycle elevator up and down

20 times NO TRANSDUCER
ERROR DETECTED
FOR RFT-1 OR RFT-2
Inspect and replace LS-28
Job complete.
Figure 2.2.2.33: Bridge Cargo Stops Transducers

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II.G.14. Elevator Rear Stop/Side Guides
Problem: Elevator
rear cargo stop
or side guide(s) Does the elevator
will not go down touches the bridge
(no 60’’/150cm cargo stops?
NO
Interlock option
installed).
YES
Check on Diagnostic Value =1 Inspect bridge rear cargo
Center “ELEVATOR stops to see if they are
NEAR BRIDGE” input stuck.
value.
Value = 0 YES NO
Lower elevator until Unjam cargo stops. Turn

platforms are no power off, then on, and
longer interfaced. retry.
Go to troubleshooting
section TRANSDUCERS
ERRORS

control box.
IF NO
ERROR SHORT OPEN
DETECTED DETECTED
Check pressure at the solenoid coils SV50, solenoid coils SV50,
manifold. SV51 or SV52. SV51 or SV52.
RESISTANCE
CONTINUITY
OK
OK
Inspect cable from

electric module to
solenoid valve.

LOW CONTINUITY
Figure 2.2.2.34: Elevator Rear Stop And Side Guides


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III. Control Modules

III.A. Replacing Inputs/Outputs Modules
When an inputs/ouputs module fails and need to be replace, simply remove all connectors and make sure to remember their
positions. Replace the module.
Figure 2.2.3.1: Inputs/Outputs Module
Open the cover as shown above and set the 3 rotary switches S1, S2 and S3 according to what was set in the module that was just
removed, or check your electrical schematic.
There is a green light and a red light on all those modules to determine their status. The following table shows the different
possibilities.
Table 2.2.3.1: Inputs/Outputs Module diagnostic lights

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III.B. Replacing Main Controller Module
When the main controller module is replaced, it must be programmed. This is normally done by TLD service. If you connect the
module and the green status LED is flashing at 5 Hz, it means that there is no software. Contact TLD service for programming.
- Simply unplug the module and remove the 4 screws holding it in place.
- Pull up the metal clip to remove the connector.
- Install the new module.
- Reinstall the connector by inserting the bottom part first, then align the metal clip and push it down.
- Turn the power ON.
- The green status light should blink at 2 Hz. If it stays steady ON, there is a problem with the programming as the software is not
running.
Figure 2.2.3.2: Main Controller Module
NOTE: The software is specific to each loader. Replacing the module with the one
from another loader is not garanteed to work. The software number and version for
the main controller program (P-) and diagnostic (D-) is indicated on the diagnostic
center startup page at power up.

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III.C. Programming of the Main Controller Module
To reprogram the main controller, you will need the programming cable TLD#054496 and if your computer is not equipped with a serial
port DB-9 connector, you will need also an USB to RS232 adapter. Not all converter works so we recommend that you buy the converter
TLD#7933209.
It is possible to reprogram the main controller using a software called “Downloader”. The program looks like the picture below.
Figure 2.2.3.5: Downloader program
1.1) Connect the PC to the connector shown on the picture below in the main box door.
Figure 2.2.3.6: Programming connector
Make sure that the lamp in the main box is ON as wire 0324 from the main controller is connected to that lamp. This tells to the main
controller that it can be programmed. You will get a communication error if wire 0324 is not powered.

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1.2) Click on the menu “Interface” and then “RS232”.
Figure 2.2.3.7: Downloader program RS232 setup
1.3) Select the COM port that you are using on your computer to download to the PLC and then click OK. You could have different COM
port than what is shown below. Contact your technical support to know that is the COM port you are using for your computer.
Figure 2.2.3.8: Downloader program COM port
The Bits per Second parameter is not really important as the software will look for the correct setting automatically.

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Depending on the operating system installed on your computer, the communication might not work. For example, if you use Chinese
Windows version, the following setting must be applied.
Go to Control Panel -> Regional and Language Option -> Advanced -> Language for Non-unicode programs -> English (United States) ->
Apply
Figure 2.2.3.9: Special configuration for Chinese Windows

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1.4) Click on menu “Options” and then “File Options”.
Figure 2.2.3.10: Downloader program Options
The check box must be as follow for uploading the program
WITHOUT THE PARAMETERS WITH THE PARAMETERS
All the files on the web site do not contain any parameters (elevator speed, valve thresholds, etc…). However, if a controller is replaced on
a unit and that this controller can still communicate with a PC, it is possible to retrieve the parameters and the program from the “old”
controller in order to program the new one and maintain original parameters.
If the program is loaded without the parameters, the loader must be setup according to chapter 2.1.

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FOLLOW THE PROCEDURE ON THIS PAGE ONLY IF YOU WANT TO UPLOAD THE SOFTWARE FROM THE MAIN CONTROLLER
TO YOUR COMPUTER. IF NOT SKIP THIS PAGE.
2.1) Click on the button Upload to transfer the program from the controller to your PC.
Figure 2.2.3.12: Downloader program Upload
2.2) Enter the file name and location of the file that will be saved on your computer.
Figure 2.2.3.13: Downloader program Upload
2.3) Click on “Save” and the program inside the controller will be transferred to your PC.

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THIS SECTION IS TO DOWNLOAD A FILE FROM YOUR COMPUTER TO THE CONTROLLER.
3.1) Click on menu “Options” and then “File Options”.
The check box must be as follow for downloading the program
WITHOUT THE PARAMETERS WITH THE PARAMETERS
All the files on the web site do not contain any parameters (elevator speed, valve thresholds, etc…). However, if a controller is replaced on
a unit and that this controller can still communicate with a PC, it is possible to retrieve the parameters and the program from the “old”
controller in order to program the new one and not change any parameters.

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3.2) Click on the button “Download” and a new window will be opened to select the file that you want to download (either a new version or
the program that you uploaded from another controller). The box “File of type” must be “H86 Files (*.H86)”. The files can be downloaded
from the TLD web site for each equipement.
Figure 2.2.3.16: Downloader program Download
3.3) Click on the button Run when the download is finished to start the program. At the same time, the green light on the controller will
start to flash to indicate that it is running.
Figure 2.2.3.17: Downloader program Download

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PROCEDURE IF THE CONTROLLER DIAGNOSTIC LIGHT IS YELLOW OR RED.
4.1) Select the menu as shown on the picture below.
Figure 2.2.3.18: Downloader program Reset
4.2) This will send a reset command to the controller. This screen will appear.
Figure 2.2.3.19: Downloader program Reset
Turn OFF the power to the controller for 5 seconds, and then turn it back ON. Click on OK to close the window. The diagnostic light on
the controller should be flashing green fast (5 Hz).
The operating system and application software must then be reloaded. Go back to the beginning of this section.

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IV. Pump Setup Procedure and Drive Circuit Pressure Setting

IV.A. Pump Setup Procedure, Big Block Loaders, 838/929
When the hydraulic pump has been removed and/or replaced — OR IF PUMP ADJUSTMENTS HAVE BEEN TAMPERED
WITH — perform the pump setup procedure, as follows. Make sure hydraulic tank is filled with platforms fully down using
hydraulic fluid which is adequate for typical ambient temperatures in the operating environment (ATF fluids prohibited).
Before starting loader for the first time, always make sure suction valve on hydraulic tank is fully open. Handle should be
aligned with (parallel to) suction hose to the main hydraulic pump on the engine. Hydraulic pump will be damaged if loader
is started when this valve is NOT open.
Figure 2.2.4.1: Open Suction Valve
• Attach 0 to 350 bar / 0 to 5000 psi pressure gauge to test port of chassis manifold. Check secondary pressures, as
described in the procedure, from this point
Figure 2.2.4.2: Location of Manifolds 838/929

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IV.A. Pump Setup Procedure, Big Block, continued
Pump are factory set. If you replace a new pump, usually no adjustement are are needed.
• Bleed air from pump.
• Disconnect electric lines to fuel shut-off solenoid (on engine) and pump enable (EP-10) on pump manifold). Engage
starter for 10 second intervals with 10 second rest periods — do this 6 times. System pressure at pump should be
between 17,2 and 41,4 bar / 250 and 600 psi during the last cranking. Turn the ignition (starter) switch off .
• Reconnect electric lines to fuel shut-off solenoid. Check hydraulic fluid level and refill, as required. Start engine. Check
system pressure (should be less than 41,4 bar / 600 psi).
NOTE: For newer loaders featuring adjustable differential on pump – **REFER TO
CHAP 2 SECTION 1 item IV.B for pump adjustment screws location on different
models. If system pressure is more than 41,4 bar / 600 psi at this point, loosen jam
nut on adjustable differential. Turn clockwise until system pressure is 31 to 34,5 bar /
450 to 500 psi at idle. Tighten jam nut and paint exposed threads to mark correct
setting.
• Stop Engine. Remove bleeder vent on pump and let air escape, until bubbles stop, then replace screw plug.
• Reconnect pump enable (EP-10). Start engine, idle for 1 minute. Turn pressure screw on pump clockwise until system
pressure reaches 103,5 bar / 1500 psi.
Figure 2.2.4.3: Pump Enable Solenoid (EP-10)

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IV.A. Pump Setup Procedure, Big Block, continued
• Let loader idle for a few more minutes, checking for leaks around the pump and manifold.
Next step is the pressure adjustments, **REFER TO CHAP 2 SECTION 1 item IV.B for pump adjustment screws
physical location.
• Turn pump pressure cutoff screw** (on pump) clockwise until system pressure (pump test port reading) read 214 bar /
4100 psi.
• Loosen jam nut on system relief valve (bottom of pump manifold). Turn relief screw clockwise until it no longer turns.
Turn adjustment screw* on relief valve counterclockwise (bottom of pump manifold), until system pressure drop to 327
bar / 4750 psi. Tighten jam nut and paint exposed threads to mark setting
• Turn pump pressure cutoff screw* clockwise until system pressure = 317 bar / 4500 psi. Tighten jam nut and paint
exposed threads to mark setting
• Loosen jam nut on secondary pressure reducing valve (big block manifold). Turn pressure reducing valve adjustment
screw* counterclockwise until secondary pressure (read pressure at chassis or bridge manifold test port) = 210 bar /
3000 psi. Tighten jam nut and paint exposed threads to mark setting.
• Proceed to the next section of this procedure: Setting Drive Pressures (next page).

June 2009 Page 90
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IV.B. Drive Circuit Pressure Setting, Big Block Loaders

When one or both motors have been removed and/or replaced on the front drive axle, set drive circuit pressure as
follows.
Figure 2.2.4.4: Big Block Manifold
• Attach pressure gauge (0 to 70 bar / 0 to 1000 psi) to charge pressure test port (stamped C.P.) on the rear of the Big
Block manifold (see figure below).
Front of
Loader
Front of
Loader
Charge Pressure Large Pressure

(C.P.) Test port Reducing Valve
Figure 2.2.4.5: Test Port and Large Pressure Reducing Valve
• Loosen jam nut on large pressure reducing valve (see figure above).
• Make sure both red emergency stop buttons are pulled out and start engine. Put loader in load mode (stabilizers down).
With the help of an assistant, go to the main electric box and select on the diagnostic center F1 - OPERATION and
then LOW DEMAND function.

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IV.B. Drive Circuit Pressure Setting, Big Block, continued

• Turn adjusting screw on pressure reducing valve until gauge reads 13.8 bar / 200 psi. Tighten jam nut and paint
exposed threads to mark correct setting.
• Remove pressure gauge from Big Block manifold.
IV.C. More on Pump Setup, Big Block Loaders

• With engine running and unit in load mode (stabilizers down), transfer a load of approximately 7 tons / 15,000 lbs onto
the 838 elevator, 15 ton/33000 lbs onto the 929 elevator, or 22 ton/ 44000 lbs onto the 929-S elevator or 30 ton/ 66000
lbs onto the 121 elevator
• Loosen jam nut on torque screw** (horsepower limiter) on the pump. Have a helper operate the elevator lift up, while
turning torque screw clockwise until engine just starts to bog down. Several trials might be needed to find proper HP
limiter adjustment. New pumps are factory adjusted and should not require adjustments.
NOTE: This can be done at ground level (instead of using load panel on operator’s
console) by using the F1-OPERATION menu on the Diagnostic Center. (Use function
Elevator lift slow or fast, then use the up/down arrow keys to raise or lower the
elevator).
• Back out torque screw (on pump) slightly (counterclockwise) from the point where engine just begins to bog while lifting
a load on the elevator. Tighten jam nut and paint exposed threads to mark correct setting.
**REFER TO CHAP 2 SECTION 1 item IV.B for pump adjustment screws location on different models.
• Lower elevator and remove/transfer test loads from platform. Turn ignition (starter) switch off.
• Remove all gauges and cap test ports securely.
• Check oil level in hydraulic tank with platforms fully down and refill, as required.
• Adjust speed for engine RPM, LOW RPM and HIGH RPM, as described in section 2 of this chapter. Adjust speed for
bridge lift and/or elevator lift speed, as required. Set conveyor speeds for bridge and elevator, as described in Chapter
2, using Diagnostic Center.
Braking/decelerating distance
If needed Adjust braking/decelerating valves as per recommendation - see chapter 2 section VII. Several trials might
be needed to properly adjust deceleration distances. Do not readjust unless valves are to replace old ones

June 2009 Page 92
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V. Parking Brake Pressure Release Setup
• The front axle is equipped with a parking brake. 27.6 bar (400 psi) pressure is required to unlock it. To
setup this pressure, refer to the following procedure:
• Lower the stabilizers to make sure the parking brake is engaged.
• Attach pressure gauge (0 to 70 bar / 0 to 1000 psi) to test port TP6 near the front right of the Big Block
manifold (see figure below).
• The parking brake must be engaged to read the pressure on TP6 (Connector LED OFF).
• Adjust pressure reducing to 27.6 bar (400 psi) taking great care to never go over 30 bar (435 psi) which
could damage the axle.
• Tighten jam nut and paint exposed threads to mark correct setting.
Parking Brake Pressure

Reducing Valve
Test Port TP6

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VI. Auto-Level Option Troubleshooting
The bridge auto-level option adjusts the bridge height automatically to follow aircraft door heigh changes.
The enable switch is located on the switch module on the cargo console as shown on the picture below.
Auto-Level Enable
Auto-Level Disable
Figure 2.2.5.1: Auto-Level buttons
When it is possible to activate the auto-level (condition is bridge not at frame), the switch lower LED will be ON. To
enable the function, press the upper button.
There are operations not allowed for security. The bridge is not allowed to move more than 2 in (5 cm) “by itself”.
Also, if the wheel is turning too fast, it will call an error. When a problem occurs, the lower LED of the switch
flashes.
Troubleshooting:
The first thing to look if the autolevel is not working is the INPUTS menu of section F2-DIAGNOSTIC to check the
functionality of the rotary sensor mounted on the auto-level wheel.
Autolevel sensor value 'RFT-6 AUTOLEVEL S1' is in the range 250 to 4750.
Autolevel sensor value 'RFT-6 AUTOLEVEL S2' is in the range 4750 to 250 (inverted signal).
If the sensor is not within this range, replace the sensor.

June 2009 Page 94
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Spring clip
Magnet
Sensor
Figure 2.2.5.2: Auto-Level Sensor (838 shown)
Pulling on the spring clip
If you pull on the spring clip to test the auto-level, turn it very slowly (as there is a filter function to slow down the
signal received) to avoid bouncing up and down as the bridge platform moves due to cargo movements.

June 2009 Page 95
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V.A Autolevel Test Setup Procedure
Start engine and put loader in LOAD mode. Raise bridge to a height to allow some movement and to use
1 a forklift at the front to “manipulate” the clip and cable by +/- 1 cm or 0.25”.
Bring loader and forklift “nose-to-nose” with fork directly over auto-level box, clip cable to fork, and turn
2 ON auto-level system. Check for green LED on auto-level switch on the console.
3 Check that bridge flat-top chains or PDUs move in forward and reverse directions.
Lift fork by 0.5” (12mm) and stop (in order to pull the cable up). The auto-level system should adjust
bridge height. Repeat this, up and down, nine times. Note that movement of the cable does NOT cause
4 instant movement of bridge height. Note that the distance between the fork and the bridge should stay
constant (±0.25", 6mm) after every adjustment.
Now lift the fork by 6 inches (15 cm) to make sure auto-level system goes into safety shutdown mode.
5 Test bridge flat-top chains or PDUs to make sure they do NOT move in forward. Check for flashing LED
on auto-level switch on the console.
6 Reenable the auto-level by pushing on the autolevel switch up position.
Now lower fork by 6 inches (15 cm) to make sure auto-level system goes into safety shutdown mode.
7 Test bridge flat-top chains or PDUs to make sure they do NOT move in forward. Check for flashing LED
on auto-level switch on the console.
8 Reenable the auto-level by pushing on the autolevel switch up position.
Lift fork very, very slowly 2 inches (5 cm). This way, the safety shutdown is triggered because of the
timedown, but not because of the distance. Again, make sure auto-level system goes into safety
9 shutdown mode. Test bridge flat-top chains or PDUs to make sure they do NOT move in forward. Check
for flashing red LED on auto-level placard on the console.
If everything checks out, auto-level system is in correct operating condition. Turn system OFF, lower
10 bridge, turn engine off. End of procedure.

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VII. Deceleration settings (see section VI.B. for valve location):
To maintain correct operation of dynamic braking (hydrostatic pressure required to stop the loader when foot is
lifted from accelerator pedal, but NOT using brake pedal/service brakes). NOTE: In general, TLD policy is to
recommend NOT tampering with factory adjustment of counterbalance valves which control dynamic braking.
However, factory seal MAY be broken, and if this is the case, this procedure explains the correct adjustment.
NOTE: If dynamic braking is too aggressive, it could be a safety hazard when driving in the
standing position. If dynamic braking is not aggressive enough, it may lead to premature
wearing of the service brake shoes and/or aircraft damage.
Description: Check to see if factory seal has been broken on counterbalance valves controlling dynamic braking. If
seal is unbroken, no adjustment is necessary – procedure is complete. If factory has been broken and
adjustment is necessary, check stopping distance for dynamic braking, both forward and reverse. Adjust
counterbalance valve(s) as required.
1. On a clear, dry stretch of pavement where it will be possible to drive
loader full speed for at least 20 m (65 ft), set a marker or flag at the
halfway point.
2. With stabilizers up and both emergency stop buttons pulled out, start
engine and drive loader for approximately 5 – 10 minutes to “warm up”
drive circuit / hydraulic fluid. IF you have an 838 unit, make sure it is
set to low speed (turtle mode)
3. Now go to one end of the “driving track” and step on the accelerator to
bring the loader up to full speed in the forward drive mode, before
reaching the “halfway flag.”
4. When front wheels (or drive console) pass by this halfway point, lift
foot from accelerator pedal.
NOTE: DO NOT PRESS BRAKE PEDAL.
5. After unit comes to a full stop under dynamic braking, put stabilizers down to secure this position and measure
the stopping distance from halfway marker to front wheels. Stopping distance should be 4.5m to 6m (15ft to 20ft)
for an 838 loader in low speed and 6m to 9m (20ft to 30ft) for a 929**. There is one CB valve for FWD movement
and another one for the REV movement (located on each side of the big block manifold),If not, adjustment
procedure, starting with step #6 below. Try to set speed to the middle of this interval, as much as possible playing
with the Counterbalance valve adjustment, see section Pump Setup Procedure for valve location.
6. With stabilizers down, operate bridge lift up until it is possible to install safety supports. Stop engine and push
emergency stop button for safety.
7. Locate counterbalance valves for dynamic braking. Look on Big Block manifold. The manifold is inscribed with
markings to show “forward” and “reverse.” see section Pump Setup Procedure for valve location.
8. If stopping distance is TOO SHORT (dynamic braking too aggressive), turn C/B valve CLOCKWISE. If stopping
distance is TOO FAR (dynamic braking is not aggressive enough), turn C/B valve COUNTERCLOCKWISE. Retest
braking distance and readjust, if necessary, until dynamic braking is within recommended distances in step #5.
9. Repeat steps #3 through #5 for REVERSE drive mode – and also adjust steps #6 through #8, if necessary.
10. If everything checks out, procedure is complete. Make sure join nut are secured on C/B valve.
** refers to Chap 5 for more information

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X. Fastening Torque Values

X.A. Imperial fasteners Value in Foot-pounds without Lube
Diameter and thread per

Grade 5 Grade 8
inch
1/4-20 8 12
1/4-28 10 14
5/16-18 17 24
5/16-24 19 27
3/8-16 30 45
3/8-24 35 50
7/16-14 50 70
7/16-20 55 80
1/2-13 75 110
1/2-20 85 120
9/16-12 110 150
9/16-18 120 170
5/8-11 150 210
5/8-18 170 240
3/4-10 260 380
3/4-16 300 420
7/8-9 430 600
7/8-14 470 670
1.0-8 640 910
1.0-14 720 1020
1-1/8~7 790 1290
1-1/8~2 890 1440
1-1/4~7 1120 1820
1-1/4~12 1240 2010
1-1/2~6 1950 3160
1-1/2~12 2200 3560

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X.B. Metric fasteners Value in Foot-pounds without lube.
X.C. Hydraulic Fittings and Cartridges Value in Foot-pounds.
CAVITY PLUG INSTALLATION TORQUES
TLD ASSEMBLY TORQUES

DESCRIPTION VENDOR CAVITY SIZE
P/N IN LBS FT LBS Nm
032595 CAVITY PLUG, 4-WAY 2-POS HYDRAFORCE 10-4 300 ± 12 25 ± 1 34 ± 1.5

033154 CAVITY PLUG, ALL PORTS BLOCKED SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
037328 CAVITY PLUG, 3-WAY 2-POS PARKER 10-3 300 ± 12 25 ± 1 34 ± 1.5
039876 CAVITY PLUG SUN T-3A 570 ± 30 47.5 ± 2.5 62.5 ± 2.5
038492 CAVITY PLUG, PORT 3 BLOCKED SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
041555 CAVITY PLUG, ALL OPENED SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
032596 CAVITY PLUG, 4-WAY 2-POS HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
034148 CAVITY PLUG, ALL PORTS BLOCKED SUN T-16A 1860 ± 60 155 ± 5 207.5 ± 7.5
034149 CAVITY PLUG, PORT 3 BLOCKED SUN T-17A 1860 ± 60 155 ± 5 207.5 ± 7.5
037055 CAVITY PLUG, PORT 1 AND 4 BLOCKED HYDRAFORCE 10-4 300 ± 12 25 ± 1 34 ± 1.5
037351 CAVITY PLUG VICKERS 16-3 1020 ± 60 85 ± 5 115 ± 6
CAVITY PLUG, PORT 1 TO PORT 3 OPENED,
040052 PORT 2 BLOCKED SUN T-19A 4350 ± 150 362.5 ± 12.5 482.5 ± 17.5
CAVITY PLUG, PORT 1 TO PORT 2 OPENED,
040321 PORT 3 AND 4 BLOCKED SUN T-23A 1860 ± 60 155 ± 5 207.5 ± 7.5

June 2009 Page 99
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JIC FITTING THREAD ASSEMBLY TORQUES
SWIVEL NUT OR
SAE PORT ASSEMBLY TORQUES TUBE CONNECTION
FITTING SIZE HOSE CONNECTION
THREAD SIZE
IN LBS FT LBS Nm T.F.F.T.** T.F.F.T.**
-2 5/16-24 37 2 3 ± 0.2 4 ± 0.25 - -

-3 3/8-24 68 3 5.5 ± 0.25 7.5 ± 0.3 - -
-4 7/16-20 140 ± 10 11.5 ± 0.8 15 ± 1 2 2
-5 1/2-20 180 ± 15 15 ± 1 20 ± 1.3 2 2
-6 9/16-18 250 ± 15 21 ± 1 28 ± 1.3 1 1/2 1 1/4
-8 3/4-16 550 ± 25 46 ± 2 62 ± 3 1 1/2 1
-10 7/8-14 650 ± 50 54 ± 4 73 ± 5 1 1/2 1
-12 1 1/16-12 1000 ± 50 83 ± 4 113 ± 5 1 1/4 1
-14 1 3/16-12 1260 ± 60 105 ± 5 143 ± 7 1 1
-16 1 5/16-12 1450 ± 50 120 ± 4 163 ± 5 1 1
-20 1 5/8-12 2000 ± 100 170 ± 8 231 ± 11 1 1
-24 1 7/8-12 2400 ± 150 200 ± 12 272 ± 16 1 1
-32 2 1/2-12 3200 ± 200 270 ± 16 367 ± 22 1 1
ADJUSTABLE SAE STRAIGHT THREAD ASSEMBLY TORQUES

ASSEMBLY TORQUES
FITTING SIZE SAE PORT THREAD SIZE
IN LBS FT LBS Nm
-2 5/16-24 63 ± 3 5.2 ± 0.3 7 ± 0.5

-3 3/8-24 105 ± 5 8.8 ± 0.4 12 ± 0.6
-4 7/16-20 190 ± 9 16 ± 0.8 21 ± 1
-5 1/2-20 263 ± 13 22 ± 1 30 ± 1.5
-6 9/16-18 368 ± 18 30 ± 1.5 42 ± 2
-8 3/4-16 650 ± 32 54 ± 2.7 74 ± 3
-10 7/8-14 1070 ± 54 89 ± 4.5 121 ± 6
-12 1 1/16-12 1700 ± 85 140 ± 7 192 ± 10
-14 1 3/16-12 2200 ± 110 184 ± 9 250 ± 12
-16 1 5/16-12 2500 ± 125 210 ± 10 285 ± 14
-20 1 5/8-12 3150 ± 160 263 ± 16 357 ± 18
-24 1 7/8-12 3840 ± 190 320 ± 19 436 ± 22
-32 2 1/2-12 4725 ± 235 395 ± 21 535 ± 27

June 2009 Page 100
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SAE STRAIGHT THREAD ASSEMBLY TORQUES

ASSEMBLY TORQUES
FITTING SIZE SAE PORT THREAD SIZE
IN LBS FT LBS Nm
-2 5/16-24 90 ± 4 7.5 ± 0.4 10 ± 0.5

-3 3/8-24 160 ± 8 13.5 ± 0.7 18 ± 0.9
-4 7/16-20 275 ± 13 22.75 ± 1 31 ± 1.5
-5 1/2-20 295 ± 15 24.5 ± 1.2 33 ± 1.7
-6 9/16-18 365 ± 18 31 ± 1.5 41 ± 2
-8 3/4-16 650 ± 32 54 ± 2.7 74 ± 3.5
-10 7/8-14 1070 ± 54 89 ± 4.5 121 ± 6
-12 1 1/16-12 1700 ± 85 140 ± 7 192 ± 10
-14 1 3/16-12 2200 ± 110 184 ± 9 250 ± 12
-16 1 5/16-12 2500 ± 125 210 ± 10 285 ± 14
-20 1 5/8-12 3150 ± 160 263 ± 16 357 ± 18
-24 1 7/8-12 3840 ± 190 320 ± 19 436 ± 22
-32 2 1/2-12 4725 ± 235 395 ± 21 535 ± 27
TAPERED PIPE THREAD ASSEMBLY TURN

TURNS
FROM
FITTING
NPTF BSPT FINGER
SIZE
TIGHT
T.F.F.T.**
-2 1/8-27 1/8-28 2-3

-3 1/4-18 1/4-19 2-3
-4 3/8-18 3/8-19 2-3
-5 1/2-14 1/2-14 2-3
-6 3/4-14 3/4-14 2-3
-8 1-11,5 1-11 1,5 - 2,5
-10 1 1/4-11,5 1 1/4-11 1,5 - 2,5
-12 1 1/2-11,5 1 1/2-11 1,5 - 2,5
-14 2-11,5 2-11 1,5 - 2,5

June 2009 Page 101
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SAE AND METRIC 4 BOLTS FLANGE CODE 61 AND CODE 62 ASSEMBLY TORQUES
FLANGE KIT FLANGE BOLTS ASSEMBLY TORQUES

DASH SIZE FLANGE CODE INCH BOLT SIZE
TLD P/N SIZE IN LBS FT LBS Nm
140826 -8 1/2'' CODE 61 5/16-18 204 ± 24 17 ± 2 24 ± 2.5

-12 3/4'' CODE 61 3/8-16 300 ± 54 25 ± 4.5 34 ± 6
041213 -16 1'' CODE 61 3/8-16 372 ± 54 31 ± 4.5 42 ± 6
139960 -20 1 1/4'' CODE 61 7/16-14 492 ± 60 41 ± 5 56 ± 7
140767 -24 1 1/2'' CODE 61 1/2-13 624 ± 72 52 ± 6 70 ± 8
140540 / 031073 -32 2'' 1/2-13 720 72 60 6 82 8

CODE 61 ± ± ±
-40 2 1/2'' CODE 61 1/2-13 1020 ± 108 85 ± 9 115 ± 12
035822 -48 3'' CODE 61 5/8-11 1728 ± 180 144 ± 15 195 ± 20
-56 3 1/2'' CODE 61 5/8-11 1500 ± 96 125 ± 8 170 ± 11
-64 4'' CODE 61 5/8-11 1500 ± 96 125 ± 8 170 ± 11
-80 5'' CODE 61 5/8-11 1500 ± 96 125 ± 8 170 ± 11
-8 13 MM CODE 61 M8X1,25 216 ± 21.6 18 ± 1.8 25 ± 2.5

-12 19 MM CODE 61 M10X1,5 432 ± 42 36 ± 3.5 49 ± 5
-16 25 MM CODE 61 M10X1,5 432 ± 42 36 ± 3.5 49 ± 5
-20 32 MM CODE 61 M10X1,5 750 ± 72 62.5 ± 6 85 ± 8
-24 38 MM CODE 61 M12X1,75 750 ± 72 62.5 ± 6 85 ± 8
-32 51 MM CODE 61 M12X1,75 1200 ± 84 100 ± 7 135 ± 10
-40 64 MM CODE 61 M12X1,75 840 ± 84 70 ± 7 95 ± 10
-8 1/2'' CODE 62 5/16-18 204 ± 24 17 ± 2 24 ± 2.5

140827 -12 3/4'' CODE 62 3/8-16 360 ± 54 30 ± 4.5 41 ± 6
139967 -16 1'' CODE 62 7/16-14 552 ± 54 46 ± 4.5 63 ± 6
035719 / 038553 -20 1 1/4'' 1/2-13 828 72 69 6 94 8

CODE 62 ± ± ±
035720 / 038555 -24 1 1/2'' CODE 62 5/8-11 1500 ± 96 125 ± 8 170 ± 11
-32 2'' CODE 62 3/4-10 2496 ± 240 208 ± 20 283 ± 27
-8 13 MM CODE 62 M8X1,25 216 ± 21.6 18 ± 1.8 25 ± 2.5

-12 19 MM CODE 62 M10X1,5 432 ± 42 36 ± 3.5 49 ± 5
-16 25 MM CODE 62 M12X1,75 750 ± 72 62.5 ± 6 85 ± 8
035920 -20 32 MM CODE 62 M14X2,0 1200 ± 84 100 ± 7 135 ± 10
-24 38 MM CODE 62 M16X2,0 1860 180 155 ± 15 210 ± 20
-32 51 MM CODE 62 M20X2,5 3756 ± 348 313 ± 29 425 ± 40

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CARTRIDGE INSTALLATION TORQUES

TLD CAVITY ASSEMBLY TORQUES
DESCRIPTION VENDOR
P/N SIZE IN LBS FT LBS Nm
022418 CHECK VALVE SUN T-16A 1860 ± 60 155 ± 5 207.5 ± 7.5

030080 PROPORTIONNAL FLOW CONTROL VICKERS 16-3 1020 ± 60 85 ± 5 115 ± 6
030089 FLOW DIVIDER HYDRAFORCE 10-4 300 ± 12 25 ± 1 34 ± 1.5
030113 RELIEF VALVE SUN T-3A 570 ± 30 47.5 ± 2.5 62.5 ± 2.5
030515 PROPORTIONNAL FLOW CONTROL VALVE HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
030519 PRESSURE COMPENSATOR HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
030652 COUNTER BALANCE SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
030685 PO CHECK VALVE SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
031514 CHECK VALVE, PILOT CLOSED SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
031516 MANUAL VALVE, PULL TO OPEN HYDRAFORCE 10-2 300 ± 12 25 ± 1 34 ± 1.5
032298 PRESSURE COMPENSATED FLOW CONTROL VICKERS 10-2 444 ± 24 37 ± 2 50 ± 2.5
032316 VALVE, 4-WAYS, 2-POSITION PARKER 10-4 450 ± 30 37.5 ± 2.5 50 ± 3
032532 PRESSURE REDUCER HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
032533 CHECK VALVE HYDRAFORCE 10-2 450 ± 30 37.5 ± 2.5 50 ± 3
032534 COUNTER BALANCE SUN T-23A 1860 ± 60 155 ± 5 207.5 ± 7.5
032535 3-WAYS 2POSITION DELTA 6-3 144 ± 6 12 ± 0.5 16 ± 1
032610 VALVE, 4-WAYS, 2-POSITION HYDRAFORCE 10-4 300 ± 12 25 ± 1 34 ± 1.5
033019 PRESSURE REDUCER SUN T-17A 1860 ± 60 155 ± 5 207.5 ± 7.5
033066 CHECK VALVE SUN T-16A 1860 ± 60 155 ± 5 207.5 ± 7.5
033074 PILOT-TO-OPEN CHECK VALVE HYDRAFORCE 8-3 240 ± 12 20 ± 1 27 ± 1.5
033547 VALVE 2-WAYS 2-POSITION NORMALY OPENED HYDRAFORCE 10-2 300 ± 12 25 ± 1 34 ± 1.5
035696 POPPET VALVE, 2-WAYS, NORMALY OPENED HYDRAFORCE 8-2 240 ± 12 20 ± 1 27 ± 1.5
036425 PRESSURE REDUCING / RELIEVING VALVE SUN T-19A 4350 ± 150 362.5 ± 12.5 482.5 ± 17.5
037242 PRESSURE REDUCING / RELIEVING VALVE HYDRAFORCE 10-3 300 ± 25 ± 1 34 ± 1.5
037257 MANUAL VALVE, TOW BYPASS PARKER 10-3 480 ± 60 40 ± 5 54 ± 7
038223 COUNTER BALANCE SUN T-2A 566.4 ± 30 47.2 ± 2.5 62.5 ± 2.5
038413 PILOT-TO-CLOSE LOGIC SUN T-17A 1860 ± 60 155 ± 5 207.5 ± 7.5
038425 PILOT-TO-CLOSE CHECK VALVE SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
038443 NEEDLE VALVE HYDRAFORCE 10-2 300 ± 12 25 ± 1 34 ± 1.5
038444 RV50-22 RELIEF VALVE HYDRAFORCE 10-2 300 ± 12 25 ± 1 34 ± 1.5
038491 NC VALVE, 2-WAYS BI-DIRECTIONNAL HYDRAFORCE 10-2 300 ± 12 25 ± 1 34 ± 1.5
038587 PRESSURE REDUCING/RELIEVING PO VALVE HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
038953 SIDE TO NOSE CHECK VALVE SUN T-162A 330 ± 30 27.5 ± 2.5 37 ± 2.5
038992 PRESSURE REDUCING/RELIEVING VALVE SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
041023 RELIEF VALVE PARKER 10-2 300 ± 12 25 ± 1 34 ± 1.5

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CARTRIDGE INSTALLATION TORQUES (Continued)
TLD CAVITY
DESCRIPTION VENDOR ASSEMBLY TORQUES
P/N SIZE
041154 COUNTERBALANCE VALVE SUN T-11A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
041191 FLOW REGULATOR ADJUSTABLE STERLING 10-2 444 ± 24 37 ± 2 50 ± 2.5
041192 VALVE, 4-WAYS 2-POSITION PARKER 10-4 300 ± 12 25 ± 1 34 ± 1.5
041349 PROPORTIONNAL FLOW CONTROL VALVE HYDRAFORCE 10-3 300 ± 12 25 ± 1 34 ± 1.5
041351 PROPORTIONNAL FLOW CONTROL VALVE VICKERS 16-3 1020 ± 60 85 ± 5 115 ± 6
041385 COUNTERBALANCE VALVE SUN T-2A 570 ± 30 47.5 ± 2.5 62.5 ± 2.5
041404 VALVE, 6-WAYS 2-POSITION HYDRAFORCE 10-6 312 ± 12 26 ± 1 35 ± 1.5
041507 VALVE, 2-WAYS 2-POSITION, NORMALY CLOSED SUN T-13A 390 ± 30 32.5 ± 2.5 47.5 ± 2.5
041516 TOW BY-PASS VALVE, SCREW TYPE PARKER 10-3 300 ± 12 25 ± 1 34 ± 1.5

June 2009 Page 104
TXL-838/929/121
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Chapter 2: Service and Troubleshooting

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Chapter 2: Service and Troubleshooting

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TXL-838/929/121

Chapter 2: Service and Troubleshooting

Chapter 2 / Section 2: Troubleshooting ...................................................................................................... 3

Service and Troubleshooting Chapter 2

II.G.7. Vehicle Drive ................................................................................................................................................................... 69

Service and Troubleshooting Chapter 2

Chapter 2 / Section 2: Troubleshooting

ELEVATOR 1 (I/O) modules

Diagnostic Center Display.

Service and Troubleshooting Chapter 2

Network termination resistor:

Figure 2.2.1.3: Network diagram

Service and Troubleshooting Chapter 2

Figure 2.2.1.4: Network diagram

Service and Troubleshooting Chapter 2

I.A. What the Diagnostic Center Can Do

Service and Troubleshooting Chapter 2

I.B. Diagnostic center overview

The Diagnostic Center is divided into 5 sections which are

F2 – DIAGNOSTIC: This menu is used to test all loader

F4 – ERROR LOG: This menu identifies and records the

F5 – INFORMATION: This menu gives information

Figure 2.2.1.5: Diagnostic Center

Navigation through menus:

Press ( ↑ ) or ( ↓ ) button to move up or down one line.

Press (→) or (←) button to see next or previous page.

Press (ok) to select parameter or function.

Service and Troubleshooting Chapter 2

I.C. Menus quick reference

MOVE ↑, ←, ↓, → ANALOG OUTPUTS OUTPUTS NETWORK

MOVE ↑, ←, ↓, → MOVE ↑, ←, ↓, → MOVE ↑, ←, ↓, →

Service and Troubleshooting Chapter 2

I.C. Menus quick reference (continued)

USE ARROWS TO Line 1 Line 2

Figure 2.2.1.7: Quick reference menu

Service and Troubleshooting Chapter 2

Diagnostic center menus

Service and Troubleshooting Chapter 2

I.C.2. Menu F2 – DIAGNOSTIC

Service and Troubleshooting Chapter 2

FUNCTION OUTPUTS ANALOG

Example for reading the display on this page:

NOTE: There is no feedback loop for EP-1, EP- OUTPUTS

• Line 4 shows proportional valve value EP-61 for

NOTE: There is a feedback loop for EP-61 and

Figure 2.2.1.10: Diagnostic Center – Outputs analog

Service and Troubleshooting Chapter 2

FUNCTION OUTPUTS DIGITAL

Figure 2.2.1.11: Diagnostic Center – Outputs digital

Service and Troubleshooting Chapter 2

Figure 2.2.1.12: Diagnostic Center – Network

Service and Troubleshooting Chapter 2

I.C.3. Menu F3 – CONFIGURATION

A well-tunned loader does NOT need frequent adjustment. A loader

Figure 2.2.1.13: Diagnostic Center in Main Electrical Box

NOTE: Loader ignition switch (starter) must

F1 – OPERATION: This menu is used to operate the F1 – OPERATION

Figure 2.2.1.14: Diagnostic Center – Configuration

Service and Troubleshooting Chapter 2

• 00-ENGINE IDLE RPM

Proportional valves thresholds 838 / 929 / 121:

Cargo transfer speeds 838 / 929 / 121: