uk538-3

K/LM8K/KICK/OUT
LOADMASTER 800/8000/9000 KICKOUT
Installation Instructions
Contents
Item #
Part Number
Description
Qty
1
S/AC/500-4-019
24V Relay (supplied as standard in kit)
or:
S/AC/500-4-067
12V Relay
2
S/CB/101-1-004
Cable
1
3
S/DC/500-10-456
Wiring ID Labels
3
3
1
1
2
Kickout systems - Original Equipment
Loader kickout systems operate in one of the following ways,
A.
A 'holding' solenoid holds the lift lever in the lift position. The kickout system disconnects power to the solenoid to
release the lift lever.
B.
A 'knock-out' solenoid pushes the lift lever back to the neutral position. The kickout system switches to +V to
operate the 'knock-out' solenoid.
C. Some machines (e.g. Volvo) have electronic control systems which use either a low current +V signal, or a 0V
signal to trigger the kickout mechanism.
Wiring the Loadmaster kickout system
The Loadmaster system can be wired to override any existing kickout mechanism. When the loader arm reaches
the reference position, both a 0V output (“KICKOUT SW 0V”) and a low current +V output* (“KICKOUT SW +V”)
are enabled via terminals on the junction box Link Cable.
*
The junction box has a link on the PCB to select either 24V or 12V output (“SW +V”). The factory default
setting is 24V. Ensure the link is at the 12V position and a 12V external relay is used on machines with a 12V
electrical system.
Depending on the particular machine, the appropriate output is connected either directly, or via an external relay
into the loader kickout system. In most cases the kickout can be connected by method A (fig. 1) or B (fig. 2) below
IMPORTANT! IF YOU ARE FOLLOWING METHOD A OR METHOD B FOR WIRING THE KICKOUT, (EXCLUDING THOSE
INSTRUCTIONS GIVEN FOR SPECIFIC MAKES AND MODELS), YOU MUST ENSURE THAT THE SOLENOID
CIRCUIT REMAINS ELECTRICALLY ISOLATED FROM THE LOADMASTER JUNCTION BOX CIRCUITRY, BY
USE OF AN INTERMEDIATE RELAY (24V RELAY SUPPLIED WITH THE INSTALLATION KIT).
FAILURE TO OBSERVE THIS PRECAUTION MAY ALLOW SEVERE ELECTRICAL INTERFERENCE, WHICH
CAN ADVERSELY AFFECT THE RELIABILITY OF THE LOADMASTER SYSTEM IN OPERATION.
1.
Take the covers off the lift lever to expose the kickout mechanism.
2.
Operate the kickout to determine if it operates by method A or method B as described above.
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K/LM8K/KICK/OUT
LOADMASTER 800/8000/9000 KICKOUT
Installation Instructions
Wiring method A
An external relay is powered from terminals on the junction box Link Cable. The CAT "F'" and "G" ranges and
Komatsu machines MUST USE an external relay which is included in the installation kit.
1.
Cut one of the wires feeding power to the solenoid and re-connect the cut ends to terminals 30 and 87a (Normally
Closed) on the external relay.
2.
Connect terminal 86 to “SW +V” and terminal 85 to “PER 0V” respectively on the junction box connecting lead.
When the Loadmaster sends a pulse, the external relay will operate and disconnect power to the kickout solenoid,
returning the lift lever to the neutral position.
Figure 1
Junction Box 'Link Cable'
Wiring method B
1.
Connect a power supply (not from the Loadmaster junction box) to terminal 30 on the relay. Connect into the +V
wire of the solenoid from terminal 87 (Normally Open) on the relay.
NOTE: Ensure that you are connecting to the +V wire on the solenoid and not to the 0V wire since this will result in
an electrical short when the kickout should operate. If necessary check beforehand using a voltmeter as
the lift lever is disengaged by the solenoid.
2.
Connect terminal 86 to “SW +V” and terminal 85 to “PER 0V” respectively on the junction box connecting lead.
When the Loadmaster sends a pulse to the junction box the external relay will connect power to the solenoid and
push the lift lever to the neutral position.
Figure 2
Junction Box 'Link Cable'
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K/LM8K/KICK/OUT
LOADMASTER 800/8000/9000 KICKOUT
Installation Instructions
The following instructions are for specific makes and models.
In most cases the Loadmaster junction box enables a LOW
CURRENT SIGNAL without requiring an external relay. DO
NOT WIRE DIRECTLY INTO A SOLENOID CIRCUIT. If your
machine is not described, please refer to 'Wiring method A'
(figure 1) or 'Wiring method B' (figure 2).
Volvo 'L' Models
All models: (fig. 3)
Locate the solenoid trip wire. It is the Yellow/Blue wire of the
third connector down from the top of the main circuit board
(fig. 3).
Figure 3 : All Volvo 'L' models
L50 and L70 models only (fig. 4)
Connect into the Yellow/Blue wire using a 'Scotchlok'
connector. Connect this wire to the SW +V terminal on the
"Link Cable"
L90, L120, L150, L160, and L170 models only (fig. 5)
Connect into the Yellow/Blue wire using a 'Scotchlok'
connector. Connect this wire to the SW 0V terminal on the
"Link Cable"
Figure 4
Volvo D and E models
Either,
(i) Locate the solenoid trip wire. It is the GREY wire of the third
connector down from the top of the main circuit board (fig. 3).
Connect this wire to the SW 0V terminal on the "Link Cable"
(ii) Locate the Blue/White wire "9302" on the kickout switch and
cut it (figs 6,7). Connect one side to terminal 30 of the kickout
relay and the other side to terminal 87a of the kickout relay.
Connect relay terminal 86 to "SW+V" and terminal 85 to "PER
0V" on the "Link cable"
The relay connections are as illustrated on figure 1.
Figure 5
Blue/White
wire "9302"
Figure 6
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Figure 7
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K/LM8K/KICK/OUT
LOADMASTER 800/8000/9000 KICKOUT
Installation Instructions
Old type L160 Model only
Open the cover in the front left hand side of the cab to expose
the relay board.
Locate a Brown/White wire (fig.8) and cut it. Connect one side
to terminal 30 of the kickout relay and the other side to
terminal 87a of the kickout relay. Connect relay terminal 86 to
"SW+V" and terminal 85 to "PER 0V" on the "Link cable"
Connectors on relay board
The Loadmaster pulse will break the circuit through the
Brown/White wire.
Brown/White wire
The relay connections are as illustrated on figure 1.
Figure 8
CAT 980G and most G Series machines / CAT 980H
Use an external 24V relay Pt. No. S/AC/500-4-019
There is a large multi-pin connector underneath the righthand
armrest. The orange wire (pin 15) normally has 24v going to 0v
to as the kickout operates. This needs to be switched to 0v
using the 24v relay.
CAT 980G + MOST OTHER G SERIES
ORANGE WIRE FROM
GREY DEUTSCH
CONNECTOR
Connect relay terminal 86 to "SW+V" and terminal 85 to "PER
0V" on the "Link cable"
Cut the orange wire on the grey Deutsch connector and reconnect it via the relay (figure 9).
Figure 9
CAT 966F
Utilises the relay in the Loadmaster junction box.
Open the righthand door and locate the electrical connecting
block to the spool levers. The wires are mostly grey so use
your multimeter probe to determine the kickout solenoid wire.
It will have 24v going to 0v as the kickout operates.
Cut the wire and re-connect it from the solenoid to the SW 0V
terminal on the "Link cable" (figure 10).
Figure 10
CAT 980C
Utilises the relay in the Loadmaster junction box.
The kickout solenoid operates on the lift lever linkage. It has
screw terminals on the bottom end - a constant 24v on one
and 0v to the other terminal when the kickout operates.
Connect a wire from the 0v terminal of the solenoid to the "SW
0V" terminal on the "Link cable" (figure 11).
Figure 11
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K/LM8K/KICK/OUT
LOADMASTER 800/8000/9000 KICKOUT
Installation Instructions
CAT 970F, 980F, Komatsu WA320, WA470, Hitachi ZW310
Use an external 24V relay Pt. No. S/AC/500-4-019.
There are two pairs of red and black wires coming from the lift
control valve block, with identical rubber plugs. One pair is for
the bucket kickout solenoid, and one pair is for the lift kickout
solenoid.
(a) To find the lift kickout solenoid wires, unplug one of the plugs
and lift to check if the kickout works or not. Once the correct
plug is identified, cut the red wire. Re-connect the red wire
from the solenoid to terminal 87a of the relay.
(b) Connect relay terminal 86 to "SW+V" and terminal 85 to "PER
0V" on the "Link cable" (fig. 12).
(c) Re-connect the supply side of the red wire to terminal 30 of
the relay.
Figure 12
JCB 411
Use a suitable external 12V relay e.g HELLA 4RD 003 520-08
Lift the dashboard unit out (it is not fixed). Look through the
aperture to see the front of the lift lever block. On the front of
the hydraulic block is a square, grey 6-wire connector with 6
yellow wires through it. Use your multimeter probe to
determine the kickout solenoid wire. It will have 12v going to
0v as the kickout operates.
Cut the relevant wire and re-connect it from the solenoid to the
"SW 0V" terminal on the "Link cable".
Figure 13
CASE 621C, 721C, 821C, 921C
Open the door on the right hand side of the cab and locate the
6-pin plug with a wire numbered '54B' going to it. (On 'B' type
cabs you must lift out the air cleaner element to locate it).
CASE 621, 721, 821, 921
Cut the wire 54B. Connect one side to terminal 30 of the
kickout relay and the other side to terminal 87a of the kickout
relay.
Connect relay terminal 86 to "SW+V" and terminal 85 to "PER
0V" on the "Link cable" (fig. 14).
The Loadmaster pulse will break the circuit through the wire
54B.
The relay connections are as illustrated on figure 1.
Figure 14
NOTE: Please use the labels provided [3] to identify the individual
wire connections (power, kickout and fuse) into the vehicle
electrical system.
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