Maintenance — Electrical System

•Green steady on — Indicates power to the drive controller

•Red/green flashing — Indicates an error in the system

See “Drive Controller (Plus+1 Module)” on page172 for more information about the drive controller.

Control Module Error Codes

Malfunctioning drive function may indicate a control module error condition.

The following describes control module error codes. Error codes are indicated by flashing LEDs (3, Fig. 34) located near the electrical connectors at the bottom of the module.

The LED flash pattern for error messages starts with four medium-length flashes, which signal the start of the message, followed by a pause. After the pause, a number of long flashes may occur, indicating the first digit for the code. After another pause, a number of short flashes occur indicating the second digit for the code. After a final pause, the flash pattern then repeats.

More than one error code may be displayed, one after the other.

To illustrate, the flash pattern for error code “13” would be: Four medium flashes (message start), pause, one long flash (first digit of error code), pause, three short flashes (second digit of error code), pause. The flash pattern then repeats.

Machine Controller

The machine controller provides the following functions:

•Glow plug control

•Starter logic

•Sends forward/reverse signal to drive controller

See “Machine Controller” on page168 for more information about the machine controller.

Drive Controller

The drive controller provides computerized control of the drive system, and provides error-reporting functionality.

LED lights inside the cover indicate the following:

13Watchdog Ready Error

15Battery Voltage or Sensor Voltage Error

19Pump Current Forward Error

23Pump Current Reverse Error

27Motor Current Error

31Engine Speed RPM Error

35FNR Shortcut Error

39Inching Error

43Driving Pedal Error

47Mode Switch-2 Error

55Brake Pressure Defeat Error (or Parking Brake Error or Brake Light Error)

59Motor RPM and Direction Error

70General CAN Receive Error

Battery WARNING

Before servicing the battery or electrical system, disconnect the negative cable from the negative battery terminal. Alternately, if the machine is equipped with a battery disconnect switch, turn the the battery disconnect switch to the “OFF” position.

Refer to “Electrical System” on page15 for battery specifications. To access the battery, tilt the operator’s platform. See “Engine Maintenance” on page20.

The battery top must be kept clean. Clean it with an alkaline solution (ammonia or baking soda and water). After foaming has stopped, wipe the battery top with a damp towel. If the terminals and cable connection clamps are corroded or have a build-up, disconnect the cables and clean the terminals and clamps with the same alkaline solution. Thoroughly dry the battery using a clean towel.

Warning

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. ALWAYS charge the battery in a well-ventilated area.

Never lay a metal object on top of a battery, because a short circuit can result.

Battery acid is harmful to skin and fabrics. If acid spills, follow these first-aid tips:

1.Immediately remove any clothing on which acid spills.

2.If acid contacts skin, rinse the affected area with running water for 10 to 15 minutes.

3.If acid contacts eyes, flood eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

4.To neutralize acid spilled on the floor, use one of the following mixtures: a)0.5 kg (1 lbs.) of baking soda in 4 L (4 qts.) of water. b)0.5 L (0.5 qts.) of household ammonia in 4 L (4 qts.) of water.

Whenever the battery is removed, be sure to disconnect the negative (-) battery terminal connection first.

Using a Booster Battery (Jump-Starting)

IMPORTANT: Only complete these steps if the loader cannot be started using the ignition key switch.

If the loader does not start because of a “dead” (discharged) battery, start the loader using a battery jumper cable connected to the battery of another vehicle.

NOTE: The loader cannot be tow-started because no direct mechanical connection exists between the wheels and engine. Attempting to tow-start the machine may damage the drive train.

Warning

Do not jump-start a frozen battery, or it may explode. A discharged battery can freeze at -10°C (14°F).

NOTE: Check that the battery disconnect switch is not turned off before jump starting.

The booster battery must have a nominal voltage of 12Volts. The capacity (Amp-hour rating) of the currentsupplying battery must be approximately equal to that of the discharged battery.

Warning

Keep metal parts on your clothing and metal watchbands away from the positive (+) pole of the battery — risk of short circuit.

1.Turn the key switches of both machines to OFF. Be sure the machines are in neutral and NOT touching each other.

2.Check that battery jumper cables have a sufficient diameter.

3.Connect the positive jumper cable to the positive (+) terminal on the discharged battery.

4.Connect the negative jumper cable to the negative (-) terminal on the discharged battery.

NOTE: If the machine is equipped with the optional remote battery terminal, connect the cables to the terminal studs on the remote battery terminal. See “Remote Battery Terminal” on page43.

5.Connect the free end of the positive jumper cable to the positive (+) terminal on the booster battery.

6.Connect the free end of the negative jumper cable to a convenient ground on the machine carrying the booster battery.

7.Start the machine with the discharged battery. If the engine does not start immediately, stop cranking after 10 seconds and repeat starting procedure after approximately 30 seconds.

Warning

When the engine is running, components in the engine compartment rotate. Before removing the jumper cables, be sure that no loose clothing can become caught in the rotating components.

8.After the engine is running, remove the negative jumper cable connected the booster machine ground.

IMPORTANT: DO NOT allow the booster cable ends to touch when removing them. Arcs and direct short circuits can cause severe damage to the electrical system.

9.Disconnect the jumper cables from the machine with the discharged battery.

10.Remove the positive jumper cable from the booster battery.

11.Close the engine cover and confirm it is latched securely.

12.Allow the machine to run for at least 30 minutes to re-charge the battery.