988b Kickouts

Copyright 1991, 2006 Caterpillar Inc. All Rights Reserved.
Page 1 of 33
50W 2W0988 988B WHEEL LOADER Troubleshooting

Media Number SENR7334-01 Publication Date 1984/07/01 Update Date 2002/10/16
988B Kickouts
Serial Nos. 50W4638-Up
The 988B Kickouts are similar to the 980C and 992C systems in the ways that follow:
1. They use the position of magnets in relation to an electronic switch box to cause the kickout
action.
2. They use the same type of pilot control.
3. The bucket positioner "latches up" (the kickout keeps activated) to give easier control when the
bucket is loaded.
The 988B uses solid state (electronic, no moving parts) switches instead of reed switches. When the
magnets south pole is close, the solid state switch feels the magnetic field and connects or
disconnects the solenoid by way of a transistor.
NOTE: A yellow dot on the magnet identifies the south pole.
Service is not done on the solid state switches. There are easy tests to find if the switches are good or
bad. Be sure to do these tests instead of just making a replacement of parts.
(24) Lift Kickout (Serial Nos. 50W4638-Up)
The lift kickout uses a 9G117 Switch Assembly that is activated by a magnet on the lift arm. When
the magnet goes from position A to position B, the switch electronically connects pin 1 to connection
3 of the harness plug. This activates the 8N2572 Solenoid. Connection 3 will keep connected to pin 1
for about 1/2 second (if the magnet keeps close to the switch or if it does not), and then it will be
disconnected. The solenoid is activated again each time the magnet goes to position B after it has
first moved away.
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Copyright 1991, 2006 Caterpillar Inc. All Rights Reserved. Page 2 of 33
Figure 30. Lift Kickout Switch
Figure 31. Lift Kickout Circuit
Troubleshooting the Lift Kickout Circuit on the Machine
If the kickout does not work, do the tests that follow in order:
A. If the dome light does not work, check the kickout fuse (fuse #5 found in the left hand instrument
panel).
B. Check the distance between the magnet and the switch box. The distance must be .25 to .354 in.
(6.3 to 9.0 mm).
C. Move the lift arms so the magnet is not close to the switch box. With the power key switch turned
"ON", move another magnet close to the switch to see if this causes the solenoid to activate. If the
magnet causes the solenoid to activate, install a new magnet on the machine.
D. If the magnet did not make the solenoid activate, disconnect the switch harness from machine
harness. Make an electrical test of the pin and connections in the plug of the machine harness. With
the power key switch turned "ON", connections 2 and 3 must each have power (use the 5P7277
Voltage Tester connected to machine ground); pin 1 must not have power. Turn the power key
switch "OFF" and check for continuity to machine ground on pin 1 (use 8S4627 Circuit Tester). If
these pins and connections do not test correctly, look at the schematic Fig. 31 and find the causes.
E. If the machine harness test is correct but the kickout still does not work, connect a (jumper) wire
from the negative terminal (the P/W wire) of the solenoid to machine ground. With the power key
switch turned "ON", the solenoid must activate each time the wire is put to machine ground. If the
solenoid does not activate, check for +24 volts with the 5P7277 Tester at the positive (tan wire)
terminal of the solenoid while grounding the negative terminal of the solenoid. If voltage is present,
replace the solenoid. If voltage is not present, look at the schematic and find the causes.
F. If all of the other tests are correct, make a replacement of the 9G117 Switch Assembly.
If the lift kickout works the first time, but then the solenoid keeps activated and will not release, this
is an indication that +24 volts is not sent to pin 2 of the switch by the tan wire of the machine
harness. The switch works the first time from current through the solenoid. After the solenoid is
activated, there is not enough current for the switch to work so the solenoid keeps activated. Make
another check to be sure that the tan wire that goes to connection 2 of the harness plug does have
power when the switch plug is connected to it. To do this, push the point of the 5P7277 Tester
through the insulation of the tan wire. If the switch for sure gets +24 volts at pin 2, and the system
still latches up (the solenoid does not disconnect), make a replacement of the 9G117 Switch
Assembly.
Bench Test of 9G117 Switch Assembly
Connect the switch as in Figure 32. Move a 9P8819 Magnet over the 9G117 Switch Assembly at a
distance of .25 to .354 in. (6.3 to 9.0 mm). The solenoid must activate for about 0.5 seconds; it must
then deactivate (be not activated).
Figure 32. Bench Test of Lift Kickout Switch
(25) Bucket Positioner (Serial Nos. 50W4638-UP)
The bucket positioner uses a 9G116 Switch Assembly that is activated by a magnet that moves in
and out with the tilt cylinder rod. The bucket positioner system is different than the lift kickout in
that it "latches up" (the kickout keeps activated).
The 988B uses pilot valve operated hydraulic controls that need only a small force to operate the
implement. The tilt back detent needs greater force to move the lever out of the TILT BACK
position. In many applications the lever must be moved from HOLD to and from TILT BACK,
several times when the bucket is to be filled. The large force necessary to move the lever from the
detent would make the machine much harder to use. For this reason, when the kickout is first
activated with the bucket level, the kickout "latches up" (keeps activated) while the bucket is tilted
back farther during the procedure of getting a load. The detent is prevented from operation until the
bucket is dumped (tilted forward) past the level position. Then the circuit unlatches (disconnects)
and the detent is again ready to operate.
The "latch up" is done completely by the 9G116 Switch Assembly. When the bucket is tilted back,
the magnet moves from position A toward position B. The magnet has no effect at position B, but at
position C it causes the switch to electronically connect pin 2 to pin 3 of the harness plug. This
activates the 8N2572 Bucket Positioner Solenoid.
Figure 33. Bucket Positioner Switch
Figure 34. Bucket Positioner Circuit
The 9G116 Bucket Positioner Switch is not like the 9G117 Lift Kickout Switch in that it does not
disconnect after 0.5 seconds. It keeps connected until the bucket is dumped. When the bucket is
dumped, it moves the magnet back across the "ON" position (position C), which has no effect, and
then moves it across the "OFF" position (position B). When the magnet comes close to the "OFF"
position, the switch electronically disconnects pin 2 from pin 3. This stops the current flow in the
solenoid. The detent is ready to operate again.
Troubleshooting the Bucket Positioner Circuit on the Machine
IF THE BUCKET POSITIONER DOES NOT KICKOUT, do the tests that follow in order:
A. If the dome light does not work, check the fuse (fuse #5 found in the left hand instrument panel).
B. Check the distance between the magnet and the switch box (Fig. 33). The distance must be .25
to .354 in. (6.3 to 9.0 mm) and the magnet must go directly between the mounting bolts.
C. Move the magnet away from the switch box. With the main power switch turned ON, move
another magnet close to the ON position (position C) of the switch to see if this causes the solenoid
to activate. Move the magnet close to the OFF position (position B) of the switch to see if this causes
the solenoid to deactivate. If the magnet causes the solenoid to activate and deactivate, install a new
magnet on the machine.
D. If the magnet did not make the solenoid activate, disconnect the switch harness from the machine
harness. Make an electrical test of the pins and connection in the plug of the machine harness. With
the power switch turned ON, pin 2 and connection 1 must each have power (use the 5P7277 Voltage
Tester connected to machine ground); pin 3 must not have power. Turn the main power switch OFF
and check for continuity to machine ground on pin 3 (use the 8S4627 Circuit Tester). If these pins
and connections do not test correctly, look at the schematic (Figure 34) and find the causes.
E. If the machine harness test is correct but the kickout still does not work, connect a (jumper) wire
from the negative terminal (the P/B wire) of the solenoid to machine ground. With the main power
switch turned ON, the solenoid must activate each time the wire is put to machine ground. If the
solenoid does not activate, check for +24 volts with the 5P7277 Tester at the positive (tan wire)
terminal of the solenoid. If voltage is present, replace the solenoid. If voltage is not present, look at
the schematic (Figure 34) and find the causes.
F. If all of the other tests are correct, make a replacement of the 9G116 Switch Assembly.
IF THE BUCKET POSITIONER KICKS OUT THE FIRST TIME, LATCHES UP, AND WILL
NOT UNLATCH (the detent has kicked out and will not go back in for the next cycle), do the tests
that follow:
A. Check the distance between the magnet and the switch box; the distance must be .25 to .394 in.
(6.3 to 10.0 mm). Make sure that the magnet goes directly over the OFF position (position B).
B. With the system latched up, move a magnet close to the OFF position (position B) of the switch.
If the switch unlatches, install a new magnet on the machine.
C. If the magnet did not make the circuit unlatch, disconnect the switch harness from the machine
harness. With the main power switch turned ON, check for power on connection 1 in the plug of the
machine harness. If connection 1 does not have power, check the tan wire back to the solenoid and
find where the power is lost. If connection 1 has power, connect the machine harness to the switch
and go on to Step D.
D. With the system latched up (main power switch turned ON), disconnect the 9G116 Bucket
Positioner Switch harness. If the solenoid is de-energized (becomes not activated), make a
replacement of the 9G116 Switch Assembly. If the solenoid does not de-energize, go on to Step E.
E. Disconnect the P/B wire from the bucket positioner solenoid. If the solenoid de-energizes, check
for a short to ground in the P/B wire between the switch and the solenoid. If it does not de-energize,
make a replacement of the solenoid.
IF THE BUCKET POSITIONER KICKS OUT BUT WILL NOT LATCH UP, make a replacement
of the 9G116 Switch Assembly.
Bench Test of the 9G116 Bucket Positioner Switch Assembly
Connect the switch as in Fig. 35. Move a 9P8819 Magnet from position A to position B at a distance
of .25 to .394 in. (4.3 to 10.0 mm) from the switch box. There must be no effect when the magnet is
close to the OFF position (position B). When the magnet is close to the ON position (position C) the
solenoid must be activated and must keep activated as the magnet goes on to position D. Now move
the magnet from point D to point A. There must be no effect when the magnet is close to the ON (C)
position. When the magnet is close to the OFF (B) position, the solenoid must be de-energized
(become not activated).
Figure 35. Bench Test of Bucket Positioner Switch
Other Methods of Failure
1. Some problems may come only intermittently (come at intervals). These can be hard to find. Make
an identification of some condition that comes at the same time as a failure of the kickouts to operate
correctly, such as:
a. A failure with the machine in a right hand or left hand turn.
b. A failure only in cold or hot weather.
c. A failure that started after someone made repairs to the machine, etc.
Get all the information possible from the operator. Check for loose connection, including grounds, in
intermittent problems.
2. Fuses that blow (fail) with much frequency probably are caused by a grounded wire, between the
fuse and electronic switch box. Find which kickout switch box blows the fuse, then find the
grounded wire with the aid of the wiring schematic.
Troubleshooting Methods For Kickouts
1. Use the 8S4627 Circuit Tester and the 5P7277 Voltage Tester for testing circuits. Do not use a
VOM (volt-ohm-milliammeter).
2. Do not check the switch assemblies with a VOM, or by any other method except those shown
under "Bench Testing." There are no other simple tests to check the switches.
3. Do not use just the operators description of the problems. Operate the bucket controls to better
understand any problems. In relation to the bucket positioner, make an identification of specific
types of problems, for example:
a. Never kicks out.
b. Kicks out but will not latch up.
c. Kicks outs, latches up, but never unlatches.
4. If possible operate a different machine to see the characteristics of a system that works correctly,
before a repair of a bucket positioner.
Lift Kickout (Serial Nos. 50W1-50W4637)
The lift kickout uses a normally-open 1V9814 Reed Switch on the loader frame that is closed by a
magnet, installed on the right hand lift arm. The position of the magnet can be changed to adjust the
height of the kickout. When the reed switch closes, it closes the normally-open 9D8663 Relay which
activates a 1V8229 Solenoid. The solenoid pulls the detent to the disconnected position which lets
the lever go back to neutral. Diode D4 keeps the switch from arcing (flow of electricity across an
open switch). Diode D5 keeps the relay contacts from arcing. This circuit does not latch up (solenoid
is activated only when magnet is near the reed switch).
Figure 36. Lift Kickout Circuit
Figure 37. "Z" Relay
NOTE: 9D8661, 9D8662, and 9D8663 look like each other and have no Part No. on their body. One
can not be used in place of the other. The identification of the relays can be made as follows:
1. 9D8663 Relay has pins 1, 3, 4 and 5 but does not have a pin 2. 9D8661 and 9D8662 both have
pins 1, 2, 4 and 5 but do not have pin 3.
2. The identification of 9D8661 and 9D8662 can be made by the connection of an ohmmeter across
the coil (pins 4 & 5) of the relays. The resistance of relay 9D8661 must be 70 to 90 ohms. The
resistance of relay 9D8662 must be 140 to 180 ohms.
The adjustment of the magnet-to-switch distance is important. Approximately .25 in. (6.4 mm)
distance between the magnet holder and the switch is correct. The pole of the magnet with
"S" (south) on it must be toward the switch. The 6D9705 Cover must be removed from the front of
the magnet to see the "S".
NOTE: A yellow dot is located on the south pole of the magnet (9P8819).
Figure 38. Magnet to Switch Adjustment
Figure 39. Lift Detent
If the kickout does not work and the distance between the switch and magnet is correct, put another
magnet near the switch with the main power switch on. The relay must make a "click" (sound made
when the relay closes or opens). A relay that "clicks" is still not necessarily a good one; the contacts
may be burned. Make a check for voltage and continuity as is necessary to find the problem.
(27) Bucket Positioner (50W1-50W4637)
The bucket positioner is similar to the lift kickout, except that it has a latching circuit (a switch
closes and activates a relay; the relay keeps activated even if the switch opens again). The switch is
activated by the south pole of the magnet.
NOTE: A yellow dot is located on the south pole of the magnet (9P8819).
The 988B uses pilot valve-operated hydraulic controls that need only a small force to operate the
implement. The tilt-back detent needs greater force to move the lever out of the tilt-back position. In
many applications the lever must be moved form "hold", to and from tilt-back, several times when
the bucket is to be filled. The large force necessary to move the lever from the detent would make
the machine much harder to use. For this reason, the bucket positioner is wired so that when the
kickout is first activated, with the bucket level, it latches (kickout keeps activated) even if the bucket
is tilted back farther during the procedure of getting a load. The detent is prevented from operation
until the bucket is dumped (tilted forward) past the level position. Then the circuit unlatches
(disconnects) and the detent again is ready to operate. Figure 40 shows how this is done.
Figure 40. Simplified Bucket Positioner Circuit
Sequence of Operation
1. The bucket kickout system is not engaged (the detent holds) until the bucket gets to the level
position. At this time, the magnet comes close to the "X" switch and closes it. This makes a ground
for the coil of the "X" relay, and the normally-open relay closes. When it closes, it makes a ground
for the "X" solenoid, which activates, and pulls the detent down away from the lever.
2. When the "X" relay closes, it also makes a ground for its own coil (thru wire A, thru diode D7,
thru the normally-closed contacts of "Y" relay, and thru wire B) so that it will keep closed, even
though the magnet moves on past "X" switch and opens it. This is the "latch-up" position.
3. When the operator dumps the bucket, the magnet moves past the "X" switch (which has no effect
since the "X" relay is already closed) and then comes to the "Y" switch. When the "Y" switch closes,
current flows in the coil of the normally-closed "Y" relay, and opens the contacts. Since the "Y"
relay contacts have the coil current for the "X" relay, this causes the "X" relay to open, and the "X"
solenoid is not activated. This lets the detent work again. The system is now ready for another cycle.
Figure 41. Position of Bucket Positioner Switches
The purpose of diode D7 is to prevent current flow in the reverse direction through the contacts of
"Y" relay. Without the diode, there would be reverse current flow when the "X" switch closes,
because current from the solenoid would flow through wires "C" and "B", through the "Y" relay, and
through wire "D" to ground through the "X" switch. The high current from the solenoid would
destroy the small "X" switch.
There are other diodes for the protection of switches and relay contacts from arcing. These diodes
are added to the schematic in Figure 42. Their purposes and locations are as follows:
Figure 42. Diode Protection of Bucket Positioner Circuit
Figure 43. "Y" Relay
Figure 44. "X" Relay
NOTE: 9D8661, 9D8662 and 9D8663 look like each other and have no Part No. on their body. One
A. 9D8663 Relay has pins 1, 3, 4 and 5 but does not have a pin 2 (see drawings). 9D8661 and
9D8662 both have pins 1, 2, 4 and 5 but do not have pin 3.
B. The identification of 9D8661 and 9D8662 can be made by the connection of an ohmmeter across
The tests for the magnet to switch distance and the linkage adjustment are the same as for the Lift
Kickout section.
Figure 45. Total Bucket Positioner Circuit
The total lift kickout and bucket positioner circuit (the 1V4858 Group) is shown in Figure 46.
Figure 46. 1V4858 Group, Combination of Lift Kickout and Bucket Positioner Circuit
Bucket positioner problems fall in three groups:
1. Obvious problems (problems easy to see): bad fuse, bucket positioner switch box knocked off
(removed), too much distance between magnet and switch, detent spring too loose, wrong linkage
adjustment, wiring pulled off of front end.
2. "X" circuit problems: the kickout does not kickout (become "not" engaged).
3. "Y" circuit problems: the kickout works the first time, latches up, but will not unlatch (the detent
has kicked out and will not go back in for the next cycle).
First find what group the problem is in, then look at that part of the system.
Figure 47. Bucket Positioner and Lift Kickout Components
(28) Gauges
The right hand instrument panel has five electrical gauges.
1. Voltmeter (6N676)
2. Engine Coolant Temperature (6N674)
3. Torque Converter Temperature (6N675)
4. Engine Oil Pressure (6N673)
5. Engine Fuel Pressure (6N672)
The voltmeter needle (indicator) will come back to the left hand position when the power key switch
is turned off. The other gauges can stop in any position with the switch off.
To check for a temperature or pressure gauge problem, test the circuit as follows:
Remove the wire from the sender of the gauge that has a problem, with the power key switch turned
"ON"; make a note of the position of the needle. Then put the wire to ground on the machine frame
and make a note of the position of the needle.
If the gauge and its wiring are good, the gauge indication must be:
The senders have more failures than the gauges.
Figure 48. Engine Coolant Temperature Gauge
Figure 49. Converter Temperature Gauge
Figure 50. Engine Oil Pressure Gauge
Figure 51. Engine Fuel Pressure Gauge
Figure 52. Voltmeter
(29) Main Power Relay
Figure 53. Main Power Relay
The main power relay sends current to all the circuits, except for the engine stop circuit, starter
solenoid and motor, starter relay, and the power key switch. When the power key switch is placed in
either the "ON" or "START" position the main power relay will activate. After the engine is in
operation, the alternator will keep it activated.
The diode "C" in Diode Assembly #2 prevents +24V to reach the "R" terminal of the alternator. The
Diode "A" in Diode Assembly #2 is used to prevent operation of the circuit if the batteries are
reversed.
Figure 54. Main Power Relay Circuit
(30) Starter Circuit (Serial Nos. 50W3778-Up)
See WARNING at start of section INDIVIDUAL CIRCUIT DESCRIPTION.
Figure 56. Start Interlock Relay
Starting Sequence
1. The Battery Disconnect Switch (7N718) must be in the "ON" position. This sends current to the
Main Power Relay (7N5933) and the 8 amp Circuit Breaker (3R8920).
2. Put the key in the Power Key Switch (7G7892); turn it to the "ON" position. The normally-open
main power relay will now activate.
3. Turn the power key switch to the "START" position. The current thru the 8 amp circuit breaker
will activate the normally-open Starter Relay (9F3099). The normally-closed Start Interlock Relay
(9D8661) will remain closed until the engine is started, to complete the current flow.
4. The starter motor solenoid is now activated, and the starter motor gets current to turn the engine.
5. When the engine starts, current comes from the alternator. This current will activate the start
interlock relay. This opens the contacts and deactivates the starter relay. Now the starter motor
solenoid is deactivated and the starter motor does not turn.
NOTE: Current from the alternator will keep the main power relay energized during the engine shut
off sequence. This will provide power for the stop relay to operate until the engine stops.
6. When the power key switch is released from the "Start" position, diode "C" in Diode Assembly #3
prevents damage which can occur from arcing and the deactivation of the starter relay coil. The
diode "D" in Diode Assembly #3 prevents damage which can occur if the battery connections are
installed in the reverse order. This will not allow current to the switch, so the system can not be
switched "ON".
Figure 57. Starter Circuit (Serial Nos. 50W3778-Up)
(31) Starter Circuit (Serial Nos. 50W1-50W3777)
See WARNING at start of section INDIVIDUAL CIRCUIT DESCRIPTION.
Figure 58. Starter Circuit (Serial Nos. 50W1-50W3777)
Starting Sequence
1. The Battery Disconnect Switch must be in the "ON" position. This sends current to the Starter
Solenoid, Main Power Relay (7N5933), Starter Relay (9F3099), Glow Plug Relay (2V2658), thru a
15 amp Circuit Breaker to the Air Conditioner Relay (9D8663), Oil Pressure Switch (2N7744), Back
up Alarm Switch (2V7510), and Warning Horn Relay (9D8663).
2. Put the key in the Power Key Switch (1V6564) and turn it to the "ON" position. The normally-
open main power relay will activate. This will send current to the other circuits.
3. On cold weather starts, the glow plugs will be used. Switch the "Heat-Start" Switch to the "Heat"
position. This will only activate the glow plug relay.
4. Turn the "Heat-Start" Switch to the "Start" position. This will now activate the glow plug relay
and the starter relay.
5. When the engine starts, current from the alternator will keep the main power relay activated.
When the "Heat-Start" Switch is released the glow plug relay and starter relay will deactivate.
Figure 61. Glow Plug Relay
Figure 62. Warning Horn Relay & A/C Relay
(32) Alternator
The alternator sends current to the main power relay when the engine is in operation. The alternator
also sends current to activate the alternator relay. When activated, the alternator relay sends current
to the service meter and warning horn relay.
Figure 63. Alternator
(33) Engine Stop Circuit (Serial Nos. 50W3778-Up)
During engine operation the power key switch (7G7892) is in the "ON" position. When turned to the
"OFF" position this activates the Stop Solenoid Relay (9D8663). This normally-open relay will
close and send current to the Stop Solenoid (9G111). This moves the linkage on the governor, to the
"Fuel-Off" position.
Figure 64. Engine Stop Circuit (Serial Nos. 50W3778-Up)
Figure 65. Engine Stop Relay
(34) Engine Stop Circuit (Serial Nos. 50W1-50W3777)
During engine operation current is supplied to the stop solenoid switch. Pushing the stop solenoid
switch activates the stop solenoid. This moves the linkage on the governor, to the "Fuel Off"
position.
Figure 66. Engine Stop Circuit (Serial Nos. 50W1-50W3777)
(35) Start Aid Circuit (Ether Aid Circuit)
By pushing the Start Aid Switch (3D9718), current is sent to the Ether Aid Solenoid (6N7674) and
on to the Deactivating Temperature Switch (6N5899). The deactivating temperature switch is a
normally-closed switch. If the temperature is over 100F (38C), the switch is activated and opens.
The ether aid solenoid then can not be activated by the start aid switch. Until the engine temperature
returns to under 80F (27C), the switch will not deactivate.
Diode "A", in Diode Assembly #3 prevents damage that can occur when the ether aid solenoid is
deactivated.
Figure 67. Start Aid Circuit
(36) Head Lamps
The current for the head lamps is sent from a 9M9085 Automatic-resetting (automatically closes
again) Circuit Breaker.
Figure 68. Head Lamps
(37) Front & Rear Flood Lights
Figure 69. Front & Rear Flood Lights
(38) Auxiliary Flood Lights
The auxiliary lights, which are attachments, are installed on the top of the cab.
Figure 70. Auxiliary Flood Lights
(39) Panel and Tail Lights
The gauge lights are each at ground through the body of the gauge. The body of the gauge is at
ground through the black wire.
Figure 71. Panel & Tail Lights
(40) Stop Lights
Figure 72. Stop Lights
(41) Dome Light
The current for the dome light comes from the left hand instrument panel.
Figure 73. Dome Light
(42) Windshield Wiper & Washer
The 9D202 Windshield Wiper Motor has a switch inside that automatically causes the return of the
wipers to the "park" (stopped) position when the on-off switch is turned off. The motor also has a
high and low speed. Three power wires from the on-off switch are necessary. One wire is necessary
for each of the speeds. The other wire, which must have current when the switch is on or off, sends
current to the park position of the motor so that the wipers go to the park position when the on-off
switch is turned off. The (1V7362) Wiper On-Off Switch gets current from the 60 amp circuit
breaker installed on the engine panel.
Figure 74. Windshield Wiper & Washer
(43) Heater (Floor-Mounted)
The fan for the floor heater is controlled by a 7N5329 Switch with its own indicator bulb. This bulb
must be Part No. 5D19.
Figure 75. Heater (Floor-Mounted)
(44) Air Conditioner (Serial Nos. 50W3778-Up)
The air conditioner, which is an attachment, is installed on the roof of the cab. It gets current from
the same harness that is a supply for the dome light. There is a 30 amp circuit breaker in the air
conditioner unit. The different positions of the blower switch give three fan speeds. The 6P3236
Switch is also a supply of current to the thermostat and when the thermostat switch is closed, to the
air conditioner compressor clutch. The thermostat switch opens and closes to keep the correct
temperature.
The supply of current for the air conditioner, through the harness, comes from the Main Power
Relay. The relay is closed when the Main Power Switch is in the "ON" position.
Figure 76. Air Conditioner
(45) Air Conditioner Relay (Serial Nos. 50W1-50W3777)
In this series current is sent to the air conditioner from the Fuel Pressure Switch 2N7744. The engine
must be in operation for the air conditioner relay (9D8663) to activate. When the relay is activated
the air conditioner can operate.
Figure 78. A/C Relay
Copyright 1991, 2006 Caterpillar Inc.

All Rights Reserved.

988b Kickouts

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50W 2W0988 988B WHEEL LOADER Troubleshooting

2. They use the same type of pilot control.

NOTE: A yellow dot on the magnet identifies the south pole.

(24) Lift Kickout (Serial Nos. 50W4638-Up)

Figure 30. Lift Kickout Switch

Figure 31. Lift Kickout Circuit

Troubleshooting the Lift Kickout Circuit on the Machine

Bench Test of 9G117 Switch Assembly

Figure 32. Bench Test of Lift Kickout Switch

(25) Bucket Positioner (Serial Nos. 50W4638-UP)

Figure 33. Bucket Positioner Switch

Figure 34. Bucket Positioner Circuit

Troubleshooting the Bucket Positioner Circuit on the Machine

Bench Test of the 9G116 Bucket Positioner Switch Assembly

Figure 35. Bench Test of Bucket Positioner Switch

Other Methods of Failure

a. A failure with the machine in a right hand or left hand turn.

b. A failure only in cold or hot weather.

Troubleshooting Methods For Kickouts

a. Never kicks out.

b. Kicks out but will not latch up.

c. Kicks outs, latches up, but never unlatches.

Lift Kickout (Serial Nos. 50W1-50W4637)

Figure 36. Lift Kickout Circuit

Figure 37. "Z" Relay

Figure 38. Magnet to Switch Adjustment

Figure 39. Lift Detent

(27) Bucket Positioner (50W1-50W4637)

Figure 40. Simplified Bucket Positioner Circuit

Figure 41. Position of Bucket Positioner Switches

Figure 42. Diode Protection of Bucket Positioner Circuit

Figure 43. "Y" Relay

Figure 44. "X" Relay

Figure 45. Total Bucket Positioner Circuit

Bucket positioner problems fall in three groups:

Figure 47. Bucket Positioner and Lift Kickout Components

The right hand instrument panel has five electrical gauges.

2. Engine Coolant Temperature (6N674)

3. Torque Converter Temperature (6N675)

4. Engine Oil Pressure (6N673)

5. Engine Fuel Pressure (6N672)

The senders have more failures than the gauges.

Figure 48. Engine Coolant Temperature Gauge

Figure 49. Converter Temperature Gauge

Figure 50. Engine Oil Pressure Gauge

Figure 51. Engine Fuel Pressure Gauge

Figure 52. Voltmeter

(29) Main Power Relay

Figure 53. Main Power Relay

Figure 54. Main Power Relay Circuit

(30) Starter Circuit (Serial Nos. 50W3778-Up)

See WARNING at start of section INDIVIDUAL CIRCUIT DESCRIPTION.

Figure 56. Start Interlock Relay

Figure 57. Starter Circuit (Serial Nos. 50W3778-Up)

(31) Starter Circuit (Serial Nos. 50W1-50W3777)

See WARNING at start of section INDIVIDUAL CIRCUIT DESCRIPTION.

Figure 58. Starter Circuit (Serial Nos. 50W1-50W3777)

Figure 61. Glow Plug Relay

Figure 62. Warning Horn Relay & A/C Relay

Figure 63. Alternator

(33) Engine Stop Circuit (Serial Nos. 50W3778-Up)

Figure 64. Engine Stop Circuit (Serial Nos. 50W3778-Up)