CA150 SERVICE TRAINING

CA150 HYDRAULIC SYSTEM

 Poppet adjusting screw
Lock nut

Spring

Spring

Orifice

1
 By-pass nut (middle nut) was
unscrewed 3 full turns

Oil can circulate from one

side of the circuit to the other
when motors start working as
pumps

Circuit low pressure side

By-Pass function

Circuit high pressure

Figure 5
side

1
BY-PASS

Oil can flow from

one side of the
circuit to the other

Figure 6

1
 When pressure in the circuit
reaches the setting of the poppet,
It opens letting oil flow to the
pump control servo, de-stroking
the pump.

Circuit high pressure side

Figure 7

1
 Poppet is opened.
Oil can flow to the control
servo.
Pressure under servo relief
valve is charge pressure.
Servo relief opens and
pressure over it will be
charge pressure from that
point on, protecting the
pump servo.
Oil will go to reduce the
displacement of the pump

Figure 8

1
 Poppet is open, oil is flowing
through the orifice of the high
pressure spool.
Due to pressure drop through
the orifice, higher pressure before
the spool pushes the spool up
and opens the passage for the oil
Oil flowing through poppet to flow from the high pressure
side to the low pressure side

Circuit high pressure side

Figure 9

1
Oil is flowing the
orifice of the high
pressure spool.
Due to pressure
drop through this
orifice, pressure
before the orifice
pushes the high
pressure spool
against its spring
and opens a
passage for the
oil to flow to the
low pressure side

Figure 10
1
 Oil from charge pump moves
check valve up. Check valve
drags the high pressure spool
opening a passage for the oil to
to the low pressure side

Charge pump Oil

Circuit low pressure side

Figure 11

1
Check valve dragged Refill function
the high pressure spool
and opened a
passage for the charge
pump oil to go to
the low pressure side

1
 CA152 PROP. PUMP 380829

Neutral & B.U alarm switch

Servo Test Ports

Brake Valve Multi function valve

 CA152 PROP. PUMP 380829

Charge Relief valve

Neutral adjusting screw

Servo Test Port

 CA152 PROP PUMP 380829 Control valve

Check
Check valve
valve Check/orifice
 PUMP CONTROL VALVE 938251

Brake Valve

Neutral Switch

X7 To Brakes
L4 To tank
PUMP CONTROL VALVE 938251

Brake Valve Solenoid

PUMP CONTROL VALVE 938251

Brake valve spool

 PUMP CONTROL VALVE 938251

Out from Brake valve In from charge pump

From pump housing

To servo piston

To servo piston
Spool return spring
To control spool
 CA152 VIBRATION PUMP 373132

Hi-Amplitude solenoid

Pressure cut off valve

Max Displacement adjusting screw

 CA152 VIBRATION PUMP 373132
Low-Amplitude solenoid

Piston adjusting screw

Max. Displacement adjusting screw

Hi-Pressure relief valves

 CA152 VIBRATION PUMP 373132

Plug X2

Plug X1

Hi-Amplitude solenoid
Low-Amplitude solenoid

Pressure cut off valve

CA152 VIBRATION PUMP 373132

Orifice 1.8mm
ORIFICE
ORIFICE 1.8
1.8 mm
mm
ORIFICE
ORIFICE 1.8
1.8 mm
mm
VIBRATION
VIBRATION MOTOR
MOTOR 380077
380077
CA150 HYDRAULIC CHECK
CA150 ELECTRICAL SYSTEM
Battery charge Brake Engine temp+low oil pressure
CA150 Instrument Panel & Pedestal
Hyd. Filter restriction light
Hyd. Oil temperature light

Air cleaner restriction light

355263-Fuel gauge
 CA150 Wiring harnesses
904037-Fuse
801567-Hourmeter
904448-Starter relay 903640-Master Switch

384916

380281

Battery
 Knob
Knob
Mounting
Mounting Ring
Ring
Contact
Contact Block
Block
Contact
Contact Block
Block installed
installed on
on ring
ring
Knob
Knob locked
locked into
into mounting
mounting ring
ring
 Contact
Contact block
block (NO)
(NO)

Mounting
Mounting ring
ring
With
With one
one
Contact
Contact block
block Contact
Contact block
block (NC)
(NC)

Mounting
Mounting ring
ring
With
With three
three
Contact
Contact blocks
blocks
Contact Blocks

Normally Closed (NC) 1-2

Contacts are closed when block not
actuated. Red pin out.
Contacts are open when block is
actuated. Red pin in.

Normally Open (NO) 3-4

Contacts are open when block is
not actuated. Green pin out.
Contacts are closed when block is
actuated. Green pin in.
Knob to left: Two columns of contact blocks.
Contact blocks Right column-odd numbers
23-24 Left column-even numbers.
43-44 All contect blocks in the same column
actuated-CLOSED. are actuated at the same time.
Knob to right:
Contact blocks Contact block 13-14 is normally open
13-14 Contact blocks 21-22
33-34 41-42
are actuated-CLOSED. 61-62
81-82
101-102
are normally closed

Knob to left all contact

blocks on left are
actuated-OPEN.
Knob to right all contact blocks
on left are de-actuated
Closed.
Contect block on right
is actuated-Closed
Electric Wires 1999 & Up

Group 1 Lights
Wire color: White
Numbers:101-199
Group 2 Power wires
Wire color: Red
Numbers:201-299
Group 3 Engine functions
Wire color: Violet
Numbers:301-399
Group 5 Accessories(A/C, heater , etc)
Wire color: Green
Numbers:501-599
Group 6- Warning devices
Wire color: Yellow
Numbers:601-699
Group 7 Control circuits
Wire color: Blue
Numbers:701-799
Group 8 Monitoring circuits
Wire color: Brown
Numbers:801-899
Group 9 Ground wires
Color: Black
Numbers:901-999
CA150 electric wires Boxes on right side of pages are called Functions.

Wire 802 goes to

Component H2 on
Function #2

All electric connectors are labeled

And start by X.
Wire 804 is on connector X12
Pin 6

1
 CA 150 Ignition switch and main relay

Wire 30 receives power directly from the Master Switch Q1.

Ignition switch S1 receives power through wire 202.
Turning the Ignition switch to position 1 energizes the
Main relay K3. Terminal 87 connects to 30 and power
flows through wire 203 to wire 15.
Wire 15 feeds all fuses.

1
 To start the engine:
Power from F1.2(wire 213) to (1)
Power from neutral switch S4.1 (wire)307) to (6)
Power from Igniton switch S1(wire301) to (2)
Power out of (4) to the starter relay

To release the brakes:

Power from the eme/brake switch(wire 805) to (8)
Power out of (3) (wire804) to the brake
solenoid valve Y2
Note:Brakes only release
when F/R is in neutral

File: d:\Adobe\385083-1-Rev_-Ver1.dwg
 Wire 802 goes to battery
charge light.
Alternator (L) is ground
for the starter relay
and charge light.
If charge light does
not turn ON,
alternator will not
charge the battery

File: d:\Adobe\385083-1-Rev_-Ver1.dwg
CA150 Starter

Wire 303

From Master Switch

CA150 Alternator wires

Wires 801+310
Wire 226
CA150 Engine shut off solenoid

Wire 305
CA150 Engine temperature sensor 903632

Wire 808
CA150 Hydraulic filter restriction sensor

Wire 812
CA150 Hydraulic oil temperature sensor 903631

Wire 807
 When ground is closed through button on
F/R control (switch S6)(wire 701)
energizes the VBS and
power goes out of
(9)(wire 702) to the
Amplitude selector
switch S11

When button (switch S6)

is pushed again closing
ground de-energizes the
VBS

File: d:\Adobe\385083-3-Rev_-Ver0.dwg
 When engine is not running there is no
engine oil pressure and oil pressure sensor is closed,
energizing the hourmeter relay K5.
Terminal 30 close to 87 establishing
ground for the low oil pressure light.
After engine starts, oil pressure sensor
opens and de-energizes relay K5.
30 connects to 87a establishing ground
for the hourmeter

File: d:\Adobe\385083-4-Rev_-Ver0.dwg
CA150 Engine oil pressure sensor

Wire 808
 Interlock relay

Buzzer

CA150 With interlock

904704 Interlock Relay
CA150 Interlock When the brakes are released (S2 switch UP) and the
operator stands up closing the seat switch (S5), ground is
established for the interlock relay and buzzer, energizing
it . In 7 seconds power is shut off for the engine.

When the brakes are applied (S2 switch down), even if the operator stands up closing the
seat switch (S5) ground is not established because the contacts of the emergency switch (S2)
are open.
EMERGENCY SWITCH
If operator stands up the seat
Switch closes, closing ground
for the interlock relay
energizing it. 7 seconds later
engine will be shut off.

Ground for the seat switch

is open ( 31-32). Operator
can stand up and step down.
Interlock system will not
work.
Emergency Switch

(31-32)(NC) (11-12) (NC)

De-actuated De-actuated

KnobUP
Brakes released

(23-24) (NO)
De-actuated
Emergency Switch

(23-24) (NO) de-actuated (Open)

(31-32) + (11-12)
De-actuated (Closed)
Emergency Switch

(11-12) (NC)
(31-32) (NC) actuated
Actuated

KnobDOWN
Brakes applied

(13-14) (NO)
Actuated
Emergency Switch

(23-24) Actuated (Closed)

(31-32) + (11-12)
Actuated (Open)
CA150 Ignition Switch
CA150 Ignition Switch Inter-lock
relay

Emergency
switch
CA150 Ignition switch
 CA150 Ignition Switch CPL

(13-14) (NO)

3 position knob

Left- 0(
maintai
ned)
Center-1(maint
ained)
Right-2(spr
ingloaded)

(41-42) (NC)
(21-22) (NC)
CC150 Ignition switch-Left

(13-14) de-actuated
Open

(41-42)actuated
Open
(21-22)actuated
Open
Knobonl
eftpos
iti
on0
 CC150 Ignition switch-Center position

(13-14) De-actuated (Open)

(41-42)de-actuated
Closed
(21-22)de-actuated
Closed
Knobi
nce
nte
rpos
iti
on1
 CA 150 Ignition switch-Right position

(41-42)+(21-22) de-actuated (Closed

(13-14)actuated
Closed
Knobi
nrightposi
ti
on2(s
pri
ngl
oade
d)
Whenrel
ease
dr e
turnst
o1