Tm12554.pdf 401l69

130G Excavator Diagnostic

OPERATION AND TEST MANUAL (T3/S3a) models 130G (PIN: 1FF130GX__D040001 - ) TM12554 10SEP15 (ENGLISH)

For complete service information also see: 130G Excavator Repair (PIN: 1FF130GX_ _D040001-)

TM12557

JDLink (MTG) Technical Manual

TM114519

PowerTech E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel System With CTM502 Denso HPCR PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier CTM104 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine) JDLINK/ZXLINK Machine Monitoring System

CTM10006

John Deere Construction and Forestry


(g) by Belgreen v2.1

Table of contents FOREWORD TECHNICAL INFORMATION FORM Section 9000 - GENERAL INFORMATION Group 01 - Safety Section 9001 - DIAGNOSTICS Group 10 - Main Controller (MCZ) Diagnostic Trouble Codes Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes Group 30 - Monitor Controller (DSZ) Diagnostic Trouble Codes Group 40 - Air Conditioner Controller (ACF) Diagnostic Trouble Codes Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10 - Operational Checkout Procedure Section 9010 - ENGINE Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9015 - ELECTRICAL SYSTEM Group 05 - System Information Group 10 - System Diagrams Group 15 - Sub-System Diagnostics Group 16 - Monitor Operation Group 20 - References Section 9020 - POWER TRAIN Group 05 - Theory of Operation Group 15 - Diagnostic Information Section 9025 - HYDRAULIC SYSTEM Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 25 - Tests Section 9031 - HEATING AND AIR CONDITIONING Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 25 - Tests Section 9900 - DEALER FABRICATED TOOLS Group 99 - Dealer Fabricated Tools

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Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.



GENERAL INFORMATION


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Section 9000 page 1




Section 9000 - GENERAL INFORMATION Table of contents Group 01 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Only If Qualified ...................................................................................................................... 2 Wear Protective Equipment .................................................................................................................. 3 Avoid Unauthorized Machine Modifications .......................................................................................... 3 Control Pattern Selector—If Equipped .................................................................................................. 3 Add Cab Guarding for Special Uses ...................................................................................................... 4 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 5 Avoid High-Pressure Oils ...................................................................................................................... 5 Work In Ventilated Area ........................................................................................................................ 6 Prevent Fires ........................................................................................................................................ 6 Prevent Battery Explosions ................................................................................................................... 7 Handle Chemical Products Safely ......................................................................................................... 8 Dispose of Waste Properly .................................................................................................................... 8 Prepare for Emergencies ...................................................................................................................... 9 Clean Debris from Machine .................................................................................................................. 9 Use Steps and Handholds Correctly ..................................................................................................... 9 Start Only From Operator′s Seat ......................................................................................................... 10 Use and Maintain Seat Belt ................................................................................................................ 10 Prevent Unintended Machine Movement ............................................................................................ 11 Avoid Work Site Hazards .................................................................................................................... 12 Keep Riders Off Machine .................................................................................................................... 13 Avoid Backover Accidents .................................................................................................................. 13 Inspect and Maintain ROPS ................................................................................................................. 13 Avoid Machine Tip Over ...................................................................................................................... 14 Use Special Care When Lifting Objects ............................................................................................... 15 Add and Operate Attachments Safely ................................................................................................ 15 Park and Prepare for Service Safely ................................................................................................... 15 Service Cooling System Safely ........................................................................................................... 16 Remove Paint Before Welding or Heating ........................................................................................... 17 Make Welding Repairs Safely ............................................................................................................. 18 Drive Metal Pins Safely ....................................................................................................................... 18



Section 9000 - GENERAL INFORMATION

Group 01: Safety

Group 01 - Safety Recognize Safety Information

Safety alert Symbols

Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards. On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Safety Messages <- Go to Section TOC

Section 9000 page 1



Group 01: Safety

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life. If you do not understand any part of this manual and need assistance, your John Deere dealer.

Operate Only If Qualified Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site.


Section 9000 page 2



Group 01: Safety

Wear Protective Equipment

Protective Clothing Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use for hearing protection.

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

Control Pattern Selector—If Equipped This machine may be equipped with a control pattern selector valve. Ensure all bystanders are clear of machine and area is <- Go to Section TOC

Section 9000 page 3



Group 01: Safety

large enough to operate machine functions. the machine response to each control movement.

Add Cab Guarding for Special Uses Special work situations or machine attachments could create an environment with falling or flying objects. Working near an overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or working in a waste management application, for example, could require added guarding to protect the operator. Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection recommendations of the manufacturer of any specialized attachment or equipment. your authorized John Deere dealer for information on protective guarding.

Inspect Machine

Inspect Machine Inspect machine carefully each day by walking around it before starting. Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

Stay Clear of Moving Parts

Stay Clear of Moving Parts Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting, or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.


Section 9000 page 4



Group 01: Safety

Avoid High-Pressure Fluids

High Pressure Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Avoid High-Pressure Oils

Avoid High Pressure Oils


Section 9000 page 5



Group 01: Safety

Avoid High-Pressure Oils This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury. Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system. If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene could result. a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

Work In Ventilated Area

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Prevent Fires

Handle Fuel Safely <- Go to Section TOC

Section 9000 page 6



Group 01: Safety

Clean Machine Regularly

Carry A Fire Extinguisher Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment. Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). <- Go to Section TOC

Section 9000 page 7



Group 01: Safety

Handle Chemical Products Safely

Material Safety Data Sheet Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. (See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Dispose of Waste Properly

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John <- Go to Section TOC

Section 9000 page 8



Group 01: Safety

Deere dealer.

Prepare for Emergencies

First Aid Kit Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Clean Debris from Machine

Clean Debris From Machine Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and free of debris. Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

Use Steps and Handholds Correctly


Section 9000 page 9



Group 01: Safety

Use Handholds And Steps Prevent falls by facing the machine when you get on and off. Maintain 3-point with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

Start Only From Operator′s Seat

Operate Only From Operators Seat Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

Use and Maintain Seat Belt

Use and Maintain Seat Belt Use seat belt when operating machine . to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or <- Go to Section TOC

Section 9000 page 10



Group 01: Safety

does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.

Prevent Unintended Machine Movement

Unintended Machine Movement Be careful not to accidentally actuate control levers when coworkers are present. Pull pilot shutoff lever to locked (UP) position during work interruptions. Pull pilot shutoff lever to locked (UP) position and stop engine before allowing anyone to approach machine. Always lower work equipment to the ground and pull pilot shutoff lever to locked (UP) position before standing up or leaving the operator′s seat. Stop engine before exiting.





Group 01: Safety

Avoid Work Site Hazards

Work Site Hazards

Work Site Hazards

Work Site Hazards Avoid with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before digging. Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or arm with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and uned loads. Avoid swinging or raising booms, attachments, or loads over or near bystanders. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to machine. When working close to an excavation, position travel motors away from the hole. <- Go to Section TOC




Group 01: Safety

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc). At high speeds, hitting obstacles (rocks, uneven concrete, or manholes) can cause a sudden stop. Always wear seat belt.

Keep Riders Off Machine

Keep Riders Off Machine Only allow operator on machine. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair the ability to operate machine safely.

Avoid Backover Accidents

Avoid Backover Accidents Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.

Inspect and Maintain ROPS A damaged rollover protective structure (ROPS) should be replaced, not reused.





Group 01: Safety

The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. To maintain the ROPS: Replace missing hardware using correct grade hardware. Check hardware torque. Check isolation mounts for damage, looseness, or wear; replace them if necessary. Check ROPS for cracks or physical damage.

Avoid Machine Tip Over

Use Seat Belt

Unloading Machine

Do Not Jump Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.





Group 01: Safety

Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.

Use Special Care When Lifting Objects

Use Special Care When Lifting Objects Never use this machine to lift people. Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave the seat when there is a raised load. Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over. Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.

Add and Operate Attachments Safely Always compatibility of attachments by ing your authorized dealer. Adding unapproved attachments could affect machine stability or reliability and could create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

Park and Prepare for Service Safely





Group 01: Safety

Do Not Operate Tag

Machine Properly Warn others of service work. Always park and prepare machine for service or repair properly. Park machine on a level surface and lower equipment to the ground. Place pilot shutoff lever in locked (UP) position. Stop engine and remove key. Attach a “Do Not Operate” tag in an obvious place in the operator′s station. Securely machine or attachment before working under it. Do not machine with any hydraulically actuated equipment. Do not machine with cinder blocks or wooden pieces that may crumble or crush. Do not machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

Service Cooling System Safely





Group 01: Safety

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns. Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.




DIAGNOSTICS


Make Welding Repairs Safely

Heating Near Pressurized Fluid Lines

IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables.

Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

Drive Metal Pins Safely

Hardened Metal Parts Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.






Section 9001 - DIAGNOSTICS Table of contents Group 10 - Main Controller (MCZ) Diagnostic Trouble Codes ........................................................... 1 Main Controller (MCZ) Diagnostic Trouble Codes ................................................................................. 1 Controller Area Network (CAN 0) Diagnostics ....................................................................................... 2 Controller Area Network (CAN 1) Diagnostic Procedure ..................................................................... 13 Interface Controller Area Network (N-CAN) Diagnostics ..................................................................... 26 Engine Controller Area Network (Engine CAN) Diagnostics ................................................................ 33 Abnormal EEPROM Diagnostic Procedure ........................................................................................... 37 Abnormal RAM Diagnostic Procedure ................................................................................................. 37 Abnormal A/D Converter Diagnostic Procedure .................................................................................. 38 Abnormal Sensor Voltage Diagnostic Procedure ................................................................................ 38 011006.02 - Engine Controller Communication Error ......................................................................... 39 011007.02 - (CAN 0) Data Converter Communication Error 1 ............................................................ 39 011008.02 - (CAN 1) Data Converter Communication Error 2 ............................................................ 39 011009.02 - (CAN 0) Monitor Controller Communication Error 1 ........................................................ 39 011010.02 - (CAN 1) Monitor Controller Communication Error 2 ........................................................ 39 Abnormal Engine Speed Diagnostic Procedure ................................................................................... 40 Engine Control Dial Sensor Circuit High Input Diagnostic Procedure .................................................. 41 Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure ................................................... 43 Pump 1 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure ........................................ 45 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure ........................................ 47 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure ........................................ 50 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure ........................................ 52 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure ................................. 55 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure .................................. 57 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure ................................. 60 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure .................................. 62 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ................................................ 65 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ................................................. 67 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ........................................... 70 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ............................................ 72 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ............................................... 75 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ................................................ 77 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ................................................ 80 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ................................................. 82 Front Attachment Pilot Pressure Sensor Circuit High Input High Diagnostic Procedure ...................... 85 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ............................... 87 Pump 2 Flow Rate Limit Solenoid Valve Abnormal Diagnostic Procedure ........................... 90 Pump 2 Flow Rate Limit Solenoid Valve High Current Diagnostic Procedure ...................... 93 Pump 2 Flow Rate Limit Solenoid Valve Low Current Diagnostic Procedure ....................... 96 Torque Control Solenoid Valve Abnormal Diagnostic Procedure ........................................ 99 Torque Control Solenoid Valve High Current Diagnostic Procedure ................................. 102 Torque Control Solenoid Valve Low Current Diagnostic Procedure .................................. 105 4-Spool Solenoid Valve Unit (SF) Abnormal Diagnostic Procedure ................................... 108 4-Spool Solenoid Valve Unit (SF) High Input Diagnostic Procedure .................................. 111 4-Spool Solenoid Valve Unit (SF) Low Input Diagnostic Procedure ................................... 114 4-Spool Solenoid Valve Unit (SC) Abnormal Diagnostic Procedure ................................... 117 4-Spool Solenoid Valve Unit (SC) High Input Diagnostic Procedure .................................. 120 4-Spool Solenoid Valve Unit (SC) Low Input Diagnostic Procedure ................................... 123 4-Spool Solenoid Valve Unit (SG) Abnormal Diagnostic Procedure ................................... 126 4-Spool Solenoid Valve Unit (SG) High Input Diagnostic Procedure .................................. 129 <- Go to Global Table of contents




4-Spool Solenoid Valve Unit (SG) Low Input Diagnostic Procedure ................................... 132 011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal ................................................... 134 011408.03 - 2-Spool Solenoid Valve Unit (SJ) High Input .................................................. 134 011408.04 - 2-Spool Solenoid Valve Unit (SJ) Low Input ................................................... 134 011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal ................................................. 134 011409.03 - 2-Spool Solenoid Valve Unit (SZ) High Input ................................................ 134 011409.04 - 2-Spool Solenoid Valve Unit (SZ) Low Input ................................................. 134 4-Spool Solenoid Valve Unit (SD) Abnormal Diagnostic Procedure ................................... 135 4-Spool Solenoid Valve Unit (SG) High Input Diagnostic Procedure .................................. 138 4-Spool Solenoid Valve Unit (SG) Low Input Diagnostic Procedure ................................... 141 011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal ............ 143 011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve High Current ....... 143 011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Low Current ........ 143 011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal ............ 143 011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve High Current ....... 143 011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Low Current ........ 143 011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal .................................. 143 011436.03 - Breaker Relief Proportional Solenoid Valve High Current ............................. 143 011436.04 - Breaker Relief Proportional Solenoid Valve Low Current .............................. 143 2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure ............................ 144 Selector Valve Solenoid Valve Disconnected or Not Present Diagnostic Procedure ......................... 147 Idle Stop Relay Circuit Malfunction Diagnostic Procedure ................................................................ 149 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure ................... 151 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure .................... 153 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure .................................................................................................................................. 155 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure .................................................................................................................................. 157 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure .................................................................................................................................. 159 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure .................................................................................................................................. 161 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure .......................................................... 163 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure ...................................................... 165 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Diagnostic Procedure ................................................................................................................................................... 168 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) High Current Diagnostic Procedure .................................................................................................................................. 171 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Low Current Diagnostic Procedure .................................................................................................................................. 173 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Diagnostic Procedure ................................................................................................................................................... 175 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) High Current Diagnostic Procedure .................................................................................................................................. 178 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Low Current Diagnostic Procedure .................................................................................................................................. 180 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure .................................... 182 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure ..................................... 184 020010.02 - Exhaust Filter Alarm ..................................................................................................... 185 Electric Control Lever Alarm Diagnostic Procedure .......................................................................... 186 020062.02 - Hydraulic Oil Temperature Alarm ................................................................................. 186 Attachment Pedal or Blade and Outrigger Control Lever Alarm Diagnostic Procedure ..................... 187 Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes ................................................ 188 <- Go to Global Table of contents




Engine Control Unit (ECU) Diagnostic Trouble Codes ....................................................................... 188 Coolant Level Low—Moderately Severe Level Diagnostic Procedure ................................................ 189 Coolant Level Low—Most Severe Level Diagnostic Procedure .......................................................... 191 Battery Voltage Low Diagnostic Procedure ....................................................................................... 192 Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure ..................................................... 193 Variable Speed Fan Solenoid Short Circuit Diagnostic Procedure ..................................................... 195 Reversing Fan Switch Active Too Long Diagnostic Procedure .......................................................... 196 Requested Speed/Speed Limit Diagnostic Procedure ....................................................................... 198 Hydraulic Temperature Diagnostic Procedure .................................................................................. 199 Fan Speed High—Moderately Severe Level Diagnostic Procedure .................................................... 200 Fan Speed Low—Most Severe Level Diagnostic Procedure ............................................................... 202 001639.18 - Fan Speed Low—Moderately Severe Level ................................................................... 203 003701.14 - Exhaust Filter Cleaning Not Required ........................................................................... 203 Reversing Fan Solenoid Open Circuit Diagnostic Procedure ............................................................. 204 Reversing Fan Solenoid Short Circuit Diagnostic Procedure ............................................................. 206 Group 30 - Monitor Controller (DSZ) Diagnostic Trouble Codes .................................................. 207 Monitor Controller (DSZ) Diagnostic Trouble Codes ......................................................................... 207 013002.02 - ECU Communication Error ............................................................................................ 207 013003.02 - Main Controller (MCZ) Communication Error 1 ............................................................. 207 013004.02 - Main Controller (MCZ) Communication Error 2 ............................................................. 207 013005.02 - Monitor Controller (DSZ) Communication Error 1 ......................................................... 207 013006.02 - Monitor Controller (DSZ) Communication Error 2 ......................................................... 207 013007.02 - Machine Controller (BCZ) Communication Error ........................................................... 207 Monitor Internal Temperature Sensor Diagnostic Procedure ............................................................ 207 Alternator Alarm Diagnostic Procedure ............................................................................................ 208 013310.03 - Shorted Circuit in Coolant Temperature Sensor ........................................................... 208 Fuel Level Sensor Open Circuit Diagnostic Procedure ...................................................................... 209 Fuel Level Sensor Shorted Circuit Diagnostic Procedure .................................................................. 211 013334.02 - Radiator Coolant Error .................................................................................................. 212 Flash Memory Read/Write Error Diagnostic Procedure ..................................................................... 212 External RAM Read/Write Error Diagnostic Procedure ...................................................................... 213 Abnormal EEPROM Diagnostics Procedure ....................................................................................... 213 Communication Terminal:Communication Error Diagnostic Procedure ............................................ 214 Abnormal Internal RAM Diagnostic Procedure .................................................................................. 215 014021.02 - Communication Terminal Security Error ....................................................................... 215 014022.02 - SIM Card Error .............................................................................................................. 215 014023.02 - Security Error ............................................................................................................... 215 020100.02 - Overheat Alarm ............................................................................................................ 215 020101.02 - Engine Warning Alarm .................................................................................................. 215 020102.02 - Engine Oil Pressure Alarm ............................................................................................ 216 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure ............................................................. 217 020106.02 - Air Cleaner Restriction Alarm ....................................................................................... 218 020107.02 - Water Separator Alarm ................................................................................................. 218 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure ................................................................. 219 020110.02 - Fuel Filter Restriction Alarm ......................................................................................... 220 020113.02 - System Error Alarm ...................................................................................................... 220 020114.02 - Overheat Alarm ............................................................................................................ 220 020133.02 - Crane Function Alarm ................................................................................................... 220 020142.02 - Intake Air Temperature Alarm ...................................................................................... 220 020145.02 - Boost Temperature Increase Alarm .............................................................................. 220 020146.02 - Fuel Temperature Increase Alarm ................................................................................ 220 020149.02 - EGR Gas Temperature Alarm ........................................................................................ 220 Group 40 - Air Conditioner Controller (ACF) Diagnostic Trouble Codes ..................................... 221 <- Go to Global Table of contents




Air Conditioner Controller (ACF) Diagnostic Trouble Codes .............................................................. 221 Open Circuit in Air Recirculation Sensor Diagnostic Procedure ........................................................ 222 Short-Circuited Air Recirculation Sensor Diagnostic Procedure ........................................................ 224 Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure ......................................... 226 Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure .......................................... 228 Short-Circuited Solar Radiation Sensor Diagnostic Procedure .......................................................... 230 Open Circuit In Air Conditioner Freeze Control Switch Diagnostic Procedure ................................... 232 Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure ................................... 234 Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure ......... 236 Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure ............................... 238 Communication Error Diagnostic Procedure ..................................................................................... 240 CAN Bus Off Error Diagnostic Procedure ........................................................................................... 241



Section 9001 - DIAGNOSTICS

Group 10: Main Controller (MCZ) Diagnostic Trouble Codes

Group 10 - Main Controller (MCZ) Diagnostic Trouble Codes Main Controller (MCZ) Diagnostic Trouble Codes For additional information on the main controller circuit, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) Main controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) See MPDr Application . (Group 9015-20.)


Section 9001 page 1




Controller Area Network 0 (CAN 0) Circuit Diagnostics There are three CAN networks on this machine. This diagnostic procedure is for the CAN 0 network. For more diagnostic information on other CAN networks, see appropriate CAN circuit diagnostics. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification

100-Pin Connector (X3)

Torque

10 N·m 89 lb·in

Controller Area Network (CAN 0) Diagnostics ( 1 ) CAN 0 Connector Check

Action: Check harness connections to the following controllers for damage, corrosion, or debris. Main contoller (MCZ) (A3) and monitor controller (DSZ) (A4). See Cab Harness (W1) Component Location . (Group 9015-10.) Engine control unit (ECU) (A1). See Machine Harness (W2) Component Location . (Group 9015-10.) Modular telematics gateway (MTG) (A6000). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to MCZ and DSZ Continuity Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) MCZ and DSZ Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 31-pin connector A (X31). Disconnect monitor controller 28-pin connector A (X20). Check for continuity between: Pin 28 of cab harness-to-main controller 31-pin connector A (X31). and pin 24 of monitor controller 28-pin connector A (X20). Pin 29 of cab harness-to-main controller 31-pin connector A (X31). and pin 23 of monitor controller 28-pin connector A (X20). Is continuity indicated?


Section 9001 page 2




Result: YES:Go to MCZ and ECU Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 3 ) MCZ and ECU Continuity Check

Action: Key switch in OFF position. Disconnect engine control unit (ECU)-to-engine harness connector 2 (X15). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin B1 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pin 28 of cab harness-to-main controller 31pin connector A (X31). Pin A1 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pin 29 of cab harness-to-main controller 31pin connector A (X31). Is continuity indicated?

Result: YES:Go to MCZ and Service ADVISOR™ Diagnostic Connector Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 4 ) MCZ and Service ADVISOR™ Diagnostic Connector Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin C of Service ADVISOR™ diagnostic connector (X1) and pin 28 of cab harness-to-main controller 31-pin connector A (X31). Pin D of Service ADVISOR™ diagnostic connector (X1) and pin 29 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?

Result: YES:Go to MCZ and Modular Telematics Gateway (MTG) Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 5 ) MCZ and Modular Telematics Gateway (MTG) Continuity Check

Action: Key switch in OFF position. Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). Disconnect cab harness-to-main controller 31-pin connector A (X31). <- Go to Section TOC

Section 9001 page 3




Check for continuity between: Pin H1 of modular telematics gateway (MTG) control unit 48-pin connector (X6014) and pin 29 of cab harness-to-main controller 31-pin connector A (X31). Pin H2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014) and pin 28 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?

Result: YES:Go to MCZ and CAN 0 Termination Resistor (R12) Continuity Check NO:Open circuit, repair or replace harness. See appropriate harness. ( 6 ) MCZ and CAN 0 Termination Resistor (R12) Continuity Check

Action: Key switch OFF. Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin B of CAN 0 termination resistor (R12) and pin 29 of cab harness-to-main controller 31-pin connector A (X31). Pin A of CAN 0 termination resistor (R12) and pin 28 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?

Result: YES:Go to MCZ Short to Ground Check. NO:Open circuit in CAN between main controller MCZ and CAN 0 termination resistor (R12).Repair or replace harnesses. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) ( 7 ) MCZ Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 of cab harness-to-main controller 24pin connector E (X35). Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 of cab harness-to-main controller 24pin connector E (X35). Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 of cab harness-to-main controller 26-pin connector F (X36). Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?


Section 9001 page 4




Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to DSZ Short to Ground Check. ( 8 ) DSZ Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 24 of monitor controller 28-pin connector A (X20) and pin 22 of monitor controller 28-pin connector A (X20). Pin 23 of monitor controller 28-pin connector A (X20) and pin 22 of monitor controller 28-pin connector A (X20). Pin 24 of monitor controller 28-pin connector A (X20) and pins 35 and 36 of monitor controller 36-pin connector B (X21). Pin 23 of monitor controller 28-pin connector A (X20) and pins 35 and 36 of monitor controller 36-pin connector B (X21). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to ECU Short to Ground Check. ( 9 ) ECU Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 2 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pins 21, 27, 43, and 44 of engine control unit (ECU)-to-engine harness connector 2 (X15). Pin 3 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pins 21, 27, 43, and 44 of ECU engine control unit (ECU)-to-engine harness connector 2 (X15). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Service ADVISOR™ Diagnostic Connector Short to Ground Check. ( 10 ) Service ADVISOR™ Diagnostic Connector Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). <- Go to Section TOC

Section 9001 page 5




Check for continuity between: Pin C and pin A of Service ADVISOR™ diagnostic connector (X1). Pin D and pin A of Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Modular Telematics Gateway (MTG) Short to Ground Check. ( 11 ) MTG Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin H1 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Pin H2 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to MCZ Short to Power Check ( 12 ) MCZ Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 2, 5, and 6 of cab harness-to-main controller 24-pin connector E (X35). Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 2, 5, and 6 of cab harness-to-main controller 24-pin connector E (X35). Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 3, 4, and 10 of cab harness-to-main controller 26-pin connector F (X36). Pin 3 of cab harness-to-main controller 30-pin connector D (X34) and pins 3, 4, and 10 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to DSZ Short to Power Check. <- Go to Section TOC

Section 9001 page 6




( 13 ) DSZ Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 24 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of monitor controller 28-pin connector A (X20). Pin 23 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of monitor controller 28-pin connector A (X20). Pin 24 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21). Pin 23 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to ECU Short to Power Check. ( 14 ) ECU Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin 2 and pins 7, 13, 14, 23, and 24 of engine control unit-to-engine harness connector 2 (X15). Pin 3 and pins 7, 13, 14, 23, and 24 of engine control unit-to-engine harness connector 2 (X15). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to MTG Short to Power Check. ( 15 ) MTG Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin H1 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Pin H2 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?


Section 9001 page 7




Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to Service ADVISOR™ Diagnostic Connector Short to Power Check. ( 16 ) Service ADVISOR™ Diagnostic Connector Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin C and pin B of Service ADVISOR™ diagnostic connector (X1). Pin D and pin B of Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to MCZ CAN High and Low Side Continuity Check ( 17 ) MCZ CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin 2 and pin 3 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to DSZ CAN High and Low Side Continuity Check. ( 18 ) DSZ CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin 23 and pin 24 of monitor controller 28-pin connector A (X20). Is continuity indicated?


Section 9001 page 8




Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to ECU CAN High and Low Side Continuity Check. ( 19 ) ECU CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin 2 and pin 3 on engine control unit (ECU)-to-engine harness connector 2 (X15). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to MTG CAN High and Low Side Continuity Check. ( 20 ) MTG CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin H1 and pin H2 on modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check. ( 21 ) Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin C and pin D on Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to CAN 0 Termination Resistor (R12) High and Low Side Continuity Check <- Go to Section TOC

Section 9001 page 9




( 22 ) CAN 0 Termination Resistor (R12) High and Low Side Continuity Check

Action: Key switch OFF. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU) ,and modular telematics gateway (MTG). Check for continuity between R12 connector pins A and B. Is continuity indicated?

Result: YES:CAN wires short circuit.Repair or replace harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Go to MCZ CAN Resistance Check. ( 23 ) MCZ CAN Resistance Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check resistance between pin 2 and pin 3 on cab harness-to-main controller 30-pin connector D (X34). Is resistance between 50—70 ohms?

Result: YES:Go to Code Check. NO:Go to DSZ CAN Resistance Check. ( 24 ) Code Check

Action: Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Turn key switch to ON position. Clear all codes and check for DTCs. Are CAN communication codes still present?

Result: YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Go to DSZ CAN Resistance Check. ( 25 ) DSZ CAN Resistance Check

Action: Key switch in OFF position. <- Go to Section TOC





Disconnect monitor controller 28-pin connector A (X20). Check resistance between pin 23 and pin 24 on monitor controller 28-pin connector A (X20). Is resistance between 110—130 ohms?

Result: YES:Go to Code Check. NO:Go to ECU CAN Resistance Check. ( 26 ) Code Check


Result: YES:Monitor controller (DSZ) malfunction.Replace (DSZ), see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Go to ECU CAN Resistance Check. ( 27 ) ECU CAN Resistance Check

Action: Key switch in OFF position. Disconnect engine control unit (ECU)-to-engine harness connector 2 (X15). Check resistance between pin 2 and pin 3 on engine control unit (ECU)-to-engine harness connector 2 (X15). Is resistance between 110—130 ohms?

Result: YES:Go to Code Check. NO:Go to Service ADVISOR ™ Resistance Check. ( 28 ) Code Check







Result: YES:Engine control unit (ECU) malfunction.Replace (ECU), see Engine Control Unit (ECU) Remove and Install . (Group 9015-20.) NO:Go to Service ADVISOR™ Resistance Check. ( 29 ) Service ADVISOR™ Resistance Check

Action: Key switch in OFF position. Check resistance between pin C and pin D on Service ADVISOR™ diagnostic connector (X1). Is resistance between 110—130 ohms?

Result: YES:Clear codes and check for DTCs. NO:Checks complete.






Controller Area Network 1 (CAN 1) Circuit Diagnostics There are four CAN networks on this machine. This diagnostic procedure is for the CAN 1 network. For more diagnostic information on other CAN networks, see appropriate CAN circuit diagnostics. Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Controller Area Network (CAN 1) Diagnostic Procedure ( 1 ) CAN 1 Connector Check

Action: Check harness connections to the following controllers for damage, corrosion, or debris. Main contoller (MCZ) (A3) and monitor controller (DCZ) (A4). See Cab Harness (W1) Component Location . (Group 9015-10.) Machine controller (BCZ) (A11), data converter (A5), and radio (A6). See Cab Harness (W1) Component Location . (Group 9015-10.) Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to MCZ and Data Converter Continuity Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) MCZ and Data Converter Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect data converter (A5). Check for continuity between: Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 5 on data converter (A5). Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on data converter (A5). Is continuity indicated?






Result: YES:Go to MCZ and DSZ Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 3 ) MCZ and DSZ Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect monitor controller 28-pin connector A (X20). Check for continuity between: Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 26 on monitor controller 28-pin connector A (X20). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 25 on monitor controller 28-pin connector A (X20). Is continuity indicated?

Result: YES:Go to MCZ and BCZ Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 4 ) MCZ and BCZ Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect machine controller 20-pin connector B (X11). Check for continuity between: Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 1 on machine controller 20-pin connector B (X11). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on machine controller 20-pin connector B (X11). Is continuity indicated?

Result: YES:Go to MCZ and Radio Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 5 ) MCZ and Radio Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). <- Go to Section TOC





Disconnect radio connector (A6). Check for continuity between: Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 4 on radio connector (A6). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 12 on radio connector (A6). Is continuity indicated?

Result: YES:Go to MCZ and ACF Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 6 ) MCZ and ACF Continuity Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect air conditioner controller (A7). Check for continuity between: Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pin 10 on air conditioner controller (A7). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pin 11 on air conditioner controller (A7). Is continuity indicated?

Result: YES:Go to MCZ Short to Ground Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 7 ) MCZ Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 on cab harness-to-main controller 24pin connector E (X35). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 on cab harness-to-main controller 24pin connector E (X35). Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 on cab harness-to-main controller 26-pin connector F (X36). Pin 5 on cab harness-to-main controller 30-pin connector D (X34) and pins 4, 5, and 6 on cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?






Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Data Converter Short to Ground Check. ( 8 ) Data Converter Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 5 on data converter (A5) and pins 14 and 15 on data converter (A5) connector. Pin 11 on data converter (A5) and pins 14 and 15 on data converter (A5) connector. Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to DSZ Short to Ground Check. ( 9 ) DSZ Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 25 on monitor controller 28-pin connector A (X20) and pin 22 on monitor controller 28-pin connector A (X20). Pin 26 on monitor controller 28-pin connector A (X20) and pin 22 on monitor controller 28-pin connector A (X20). Pin 25 on monitor controller 28-pin connector A (X20) and pins 35 and 36 on monitor controller 36-pin connector B (X21). Pin 26 on monitor controller 28-pin connector A (X20) and pins 35 and 36 on monitor controller 36-pin connector B (X21). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to BCZ Short to Ground Check. ( 10 ) BCZ Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: <- Go to Section TOC





Pin 1 on machine controller 20-pin connector B (X11) and pin 8 on machine controller 8-pin connector A (X10). Pin 11 on machine controller 20-pin connector B (X11) and pin 8 on machine controller 8-pin connector A (X10). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Radio Short to Ground Check. ( 11 ) Radio Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 4 and pin 15 on radio connector (A6). Pin 12 and pin 15 on radio connector (A6). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to ACF Short to Ground Check. ( 12 ) ACF Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 10 on air conditioner controller connector (A7) and pins 4 and 9 on connector (A7). Pin 11 on air conditioner controller connector (A7) and pins 4 and 9 on connector (A7). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to MCZ Short to Power Check. ( 13 ) MCZ Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, <- Go to Section TOC





and air conditioner controller (ACF). Check for continuity between: Pin 4 of cab harness-to-main controller 30-pin connector D (X34) and pins 5 and 6 of cab harness-to-main controller 24pin connector E (X35). Pin 5 of cab harness-to-main controller 30-pin connector D (X34) and pins 5 and 6 of cab harness-to-main controller 24pin connector E (X35). Pin 4 of cab harness-to-main controller 30-pin connector D (X34) and pins 1, 2, 3, and 4 of cab harness-to-main controller 26-pin connector F (X36). Pin 5 of cab harness-to-main controller 30-pin connector D (X34) and pins 1, 2, 3, and 4 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to Data Converter Short to Power Check. ( 14 ) Data Converter Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 5 on data converter (A5) and pins 1, 2, and 7 on data converter (A5) connector. Pin 11 on data converter (A5) and pins 1, 2, and 7 on data converter (A5) connector. Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to DSZ Short to Power Check. ( 15 ) DSZ Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 25 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of connector A (X20). Pin 26 of monitor controller 28-pin connector A (X20) and pins 16 and 17 of connector A (X20). Pin 25 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21). Pin 26 of monitor controller 28-pin connector A (X20) and pins 17 and 18 of monitor controller 36-pin connector B (X21). Is continuity indicated?






Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to BCZ Short to Power Check. ( 16 ) BCZ Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 1 and pin 19 on machine controller 20-pin connector B (X11). Pin 11 and pin 19 on machine controller 20-pin connector B (X11). Pin 1 on machine controller 20-pin connector B (X11) and pin 4 on machine controller 8-pin connector A (X10). Pin 11 on machine controller 20-pin connector B (X11) and pin 4 on machine controller 8-pin connector A (X10). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to Radio Short to Power Check. ( 17 ) Radio Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 4 on radio connector (A6) and pins 8 and 16 on connector (A6). Pin 12 on radio connector (A6) and pins 8 and 16 on connector (A6). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to ACF Short to Power Check. ( 18 ) ACF Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: <- Go to Section TOC





Pin 10 and pin 7 on air conditioner controller connector (A7). Pin 11 and pin 7 on air conditioner controller connector (A7). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to MCZ CAN High and Low Side Continuity Check. ( 19 ) MCZ CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between pin 4 and pin 5 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to Data Converter CAN High and Low Side Continuity Check. ( 20 ) Data Converter CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between pin 5 and pin 11 on data converter (A5). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to DSZ CAN High and Low Side Continuity Check. ( 21 ) DSZ CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between pin 25 and pin 26 of monitor controller 28-pin connector A (X20). Is continuity indicated?






Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to BCZ CAN High and Low Side Continuity Check. ( 22 ) BCZ CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between pin 1 and pin 11 on machine controller 20-pin connector B (X11). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to Radio CAN High and Low Side Continuity Check. ( 23 ) Radio CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between pin 5 and pin 11 on radio connector (A6). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to ACF CAN High and Low Side Continuity Check. ( 24 ) ACF CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between pin 10 and pin 11 on air conditioner controller connector (A7). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to MCZ CAN Resistance Check. <- Go to Section TOC





( 25 ) MCZ CAN Resistance Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check resistance between pin 4 and pin 5 on cab harness-to-main controller 30-pin connector D (X34). Is resistance between 50—70 ohms?

Result: YES:Go to Code Check. NO:Go to Data Converter CAN Resistance Check. ( 26 ) Code Check

Action: Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Turn key switch to ON position. Clear all codes and check for DTCs. Are CAN communication codes still present?

Result: YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Go to Data Converter CAN Resistance Check. ( 27 ) Data Converter CAN Resistance Check

Action: Key switch in OFF position. Disconnect data converter (A5). Check resistance between pin 5 and pin 11 on data converter (A5). Is resistance between 50—70 ohms?

Result: YES:Go to Code Check. NO:Go to DSZ CAN Resistance Check. ( 28 ) Code Check

Action: Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Turn key switch to ON position. <- Go to Section TOC





Clear all codes and check for DTCs. Are CAN communication codes still present?

Result: YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.) NO:Go to DSZ CAN Resistance Check. ( 29 ) DSZ CAN Resistance Check

Action: Key switch in OFF position. Disconnect monitor controller 28-pin connector A (X20). Check resistance between pin 25 and pin 26 on monitor controller 28-pin connector A (X20). Is resistance between 110—130 Ω?

Result: YES:Go to Code Check. NO:Go to BCZ CAN Resistance Check. ( 30 ) Code Check


Result: YES:Monitor controller (DSZ) malfunction.Replace DSZ, see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Go to BCZ CAN Resistance Check. ( 31 ) BCZ CAN Resistance Check

Action: Key switch in OFF position. Disconnect machine controller 20-pin connector B (X11). Check resistance between pin 1 and pin 11 on machine controller 20-pin connector B (X11). Is resistance between 110—130 Ω?

Result: YES:Go to Code Check. <- Go to Section TOC





NO:Go to Radio CAN Resistance Check. ( 32 ) Code Check


Result: YES:Machine controller (BCZ) malfunction.Replace BCZ, see Machine controller (BCZ) Remove and Install . (Group 9015-20.) NO:Go to Radio CAN Resistance Check.. ( 33 ) Radio CAN Resistance Check

Action: Key switch in OFF position. Disconnect radio connector (A6). Check resistance between pin 4 and pin 12 on radio connector (A6). Is resistance between 50—70 Ω?

Result: YES:Go to Code Check. NO:Go to ACF CAN Resistance Check. ( 34 ) Code Check


Result: YES:Radio malfunction.Replace radio. NO:Go to ACF CAN Resistance Check. ( 35 ) ACF CAN Resistance Check






Disconnect air conditioner controller (A7). Check resistance between pin 10 and pin 11 on air conditioner controller (A7). Is resistance between 50—70 Ω?

Result: YES:Clear codes and check for DTCs. NO:Checks complete.






Interface Controller Area Network (N-CAN) Diagnostics There are four CAN networks on this machine. This diagnostic procedure is for the N-CAN network. For more diagnostic information on other CAN networks, see appropriate CAN circuit diagnostics. Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Interface Controller Area Network (N-CAN) Diagnostics ( 1 ) N-CAN Connector Check

Action: Check harness connections to the following controllers for damage, corrosion, or debris. Data converter (A5). See Cab Harness (W1) Component Location . (Group 9015-10.) Modular telematics gateway (MTG) (A6000). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Data Converter and Service ADVISOR™ Diagnostic Connector Continuity Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Data Converter and Service ADVISOR™ Diagnostic Connector Continuity Check

Action: Key switch in OFF position. Disconnect data converter (A5). Check for continuity between: Pin 6 on data converter (A5) and pin J of Service ADVISOR™ diagnostic connector (X1). Pin 12 on data converter (A5) and pin H of Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Go to Data Converter to Interface CAN Resistor 1 (R10) Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 3 ) Data Converter to Interface CAN Resistor 1 (R10) Continuity Check






Action: Key switch in OFF position. Disconnect data converter (A5). Check for continuity between: Pin 6 on data converter (A5) and pin B of interface CAN resistor 1 (R10). Pin 12 on data converter (A5) and pin A of interface CAN resistor 1 (R10). Is continuity indicated?

Result: YES:Go to Data Converter to Modular Telematics Gateway (MTG) Connector Continuity Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 4 ) Data Converter to Modular Telematics Gateway (MTG) Connector Continuity Check

Action: Key switch in OFF position. Disconnect data converter (A5). Check for continuity between: Pin 6 on data converter 17-pin connector () and pin G1 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Pin 12 on data converter 17-pin connector () and pin G2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?

Result: YES:Go to Data Converter Short to Ground Check. NO:Open circuit, repair or replace harness. See appropriate harness. ( 5 ) Data Converter Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 6 on data converter 17-pin connector () and pins 14 and 15 on connector (). Pin 12 on data converter 17-pin connector () and pins 14 and 15 on connector (). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness.






NO:Go to Service ADVISOR™ Diagnostic Connector Short to Ground Check. ( 6 ) Service ADVISOR™ Diagnostic Connector Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin H and pin A on Service ADVISOR™ diagnostic connector (X1). Pin J and pin A on Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Interface CAN Resistor 1 (R10) Short to Ground Check. ( 7 ) Interface CAN Resistor 1 (R10) Short to Ground Check

Action: Key switch in OFF position. Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). Check for continuity between interface CAN resistor 1 (R10) pin A and ground. Check for continuity between interface CAN resistor 1 (R10) pin B and ground. Is there continuity between CAN circuit and ground circuit?

Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to MTG Short to Ground Check. ( 8 ) MTG Short to Ground Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin G1 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Pin G2 and pin F3 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?






Result: YES:Short to ground, repair or replace harness. See appropriate harness. NO:Go to Data Converter Short to Power Check. ( 9 ) Data Converter Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and air conditioner controller (ACF). Check for continuity between: Pin 6 on data converter 17-pin connector () and pins 1, 2, and 7 on connector (). Pin 12 on data converter 17-pin connector () and pins 1, 2, and 7 on connector (). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to DSZ Short to Power Check. ( 10 ) Service ADVISOR™ Diagnostic Connector Short to Power

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin H and pin B of Service ADVISOR™ diagnostic connector (X1). Pin J and pin B of Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to MTG Short to Power Check. ( 11 ) MTG Short to Power Check

Action: Key switch in OFF position. Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics gateway (MTG). Check for continuity between: Pin G1 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). Pin G2 and pins L1, M1, and M2 of modular telematics gateway (MTG) control unit 48-pin connector (X6014). <- Go to Section TOC





Is continuity indicated?

Result: YES:Short to power, repair or replace harness. See appropriate harness. NO:Go to Service ADVISOR™ Diagnostic Connector Short to Power Check. ( 12 ) Data Converter CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Check for continuity between pin 6 and pin 12 on data converter 17-pin connector (). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check. ( 13 ) Service ADVISOR™ Diagnostic Connector CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Check for continuity between pin H and pin J on Service ADVISOR™ diagnostic connector (X1). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to MTG CAN High and Low Side Continuity Check. ( 14 ) MTG CAN High and Low Side Continuity Check

Action: Key switch in OFF position. Disconnect data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Check for continuity between pin G1 and pin G2 on modular telematics gateway (MTG) control unit 48-pin connector (X6014). Is continuity indicated?

Result: YES:Open circuit, repair or replace harness. See appropriate harness. NO:Go to Data Converter Resistance Check. <- Go to Section TOC





( 15 ) Data Converter Resistance Check

Action: Key switch in OFF position. Disconnect data converter 17-pin connector (). Check resistance between pin 6 and pin 12 on data converter 17-pin connector (). Is resistance between 50—70 ohms?

Result: YES:Go to Code Check. NO:Go to Service ADVISOR™ Diagnostic Connector Resistance Check. ( 16 ) Code Check

Action: Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Turn key switch to ON position. Clear all codes and check for DTCs. Are CAN communication codes still present?

Result: YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.) NO:Go to Service ADVISOR™ Diagnostic Connector Resistance Check. ( 17 ) Service ADVISOR™ Diagnostic Connector Resistance Check

Action: Key switch in OFF position. Check resistance between pin H and pin J on Service ADVISOR™ diagnostic connector (X1). Is resistance between 50—70 ohms?

Result: YES:Go to Code Check. NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.) ( 18 ) Code Check

Action: Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Turn key switch to ON position. Clear all codes and check for DTCs. <- Go to Section TOC





Are CAN communication codes still present?

Result: YES:Check CAN bus terminator. See Electrical Component Checks . (9015-20.) NO:Go to MTG Resistance Check ( 19 ) MTG Resistance Check

Action: Key switch in OFF position. Check resistance between pin G1 and pin G2 on modular telematics gateway 48-pin connector (X6014). Is resistance between 50—70 ohms?

Result: YES:Go to DTC Check. NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.) ( 20 ) DTC Check

Action: Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1 (R10). Turn key switch to ON position. Clear all codes and check for DTCs. Are CAN communication codes still present?

Result: YES:MTG malfunction. NO:Checks complete.






Engine Controller Area Network (Engine CAN) Diagnostics There are four CAN networks on this machine. This diagnostic procedure is for the Engine CAN network. For more diagnostic information on other CAN networks, see the appropriate CAN circuit diagnostics. Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Engine Controller Area Network (Engine CAN) Diagnostics ( 1 ) Engine CAN Connector Check

Action: Check harness connections to the following controllers for damage, corrosion, or debris. Engine control unit (ECU) (A1) and variable geometry turbocharger (VGT) (A2). See Machine Harness (W2) Component Location . (Group 9015-10.) Service ADVISOR ™ diagnostic connector (X1). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to VGT and ECU Continuity Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) VGT and ECU Continuity Check

Action: Key switch OFF. Check for continuity between variable geometry turbocharger (VGT) pin 15 and engine control unit (ECU) pin 110 (X15). Check for continuity between variable geometry turbocharger (VGT) pin 16 and engine control unit (ECU) pin 88 (X15). Is there continuity between the connectors?

Result: YES:Go to Continuity Check VGT to Engine CAN Termination Resistor (R8). NO:Open circuit in CAN between VGT and ECU connector (X15).Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) ( 3 ) Continuity Check VGT to Engine CAN Termination Resistor (R8)






Action: Key switch OFF. Check for continuity between variable geometry turbocharger (VGT) pin 15 and engine CAN termination resistor (R8) pin A. Check for continuity between variable geometry turbocharger (VGT) pin 16 and engine CAN termination resistor (R8) pin B. Is there continuity between the connectors?

Result: YES:Go to VGT Short to Ground Check. NO:Open circuit in CAN between VGT and engine CAN termination resistor. Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) ( 4 ) VGT Short to Ground Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT) connector. Check for continuity between VGT pin 15 and VGT pin 14. Check for continuity between VGT pin 16 and VGT pin 14. Is there continuity between the CAN circuit and ground circuit?

Result: YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Engine CAN termination resistor (R8) Short to Ground Check. ( 5 ) Engine CAN termination resistor (R8) Short to Ground Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT) connector. Check for continuity between engine CAN termination resistor (R8) pin A and ground. Check for continuity between engine CAN termination resistor (R8) pin B and ground. Is there continuity between CAN circuit and ground circuit?

Result: YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Engine Control Unit (ECU) Short to Ground Check. ( 6 ) Engine Control Unit (ECU) Short to Ground Check






Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT) connector and engine control unit (ECU). Check for continuity between ECU pin 110 and pins 61, 62, 63, 64, 65, 66, 97, 119, and 137. Check for continuity between ECU pin 88 and pins 61, 62, 63, 64, 65, 66, 97, 119, and 137. Is there continuity between CAN circuit and ground circuit?

Result: YES:CAN circuit short to ground.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to VGT Short to Power Check. ( 7 ) Variable Geometry Turbocharger (VGT) Short to Power Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT) connector. Check for continuity between VGT pin 15 and VGT pin 13. Check for continuity between VGT pin 16 and VGT pin 13. Is there continuity between the CAN circuit and power circuit?

Result: YES:CAN circuit short to power.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Go to Engine Control Unit (ECU) Short to Power Check. ( 8 ) Go to Engine Control Unit (ECU) Short to Power Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT) connector and engine control unit (ECU). Check for continuity between ECU pin 110 and pins 67, 89, 111, 133, and 134. Check for continuity between ECU pin 88 and pins 67, 89, 111, 133, and 134. Is there continuity between CAN circuit and power circuit?

Result: YES:CAN circuit short to power.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Variable Geometry Turbocharger (VGT) CAN High and Low Side Continuity Check. ( 9 ) Variable Geometry Turbocharger (VGT) CAN High and Low Side Continuity Check <- Go to Section TOC





Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor (R8). Check for continuity between VGT pin 15 and 16. Is there continuity between CAN circuit?

Result: YES:CAN wires short circuit.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Engine Control Unit (ECU) Resistance Check. ( 10 ) Engine Control Unit (ECU) High and Low Side Continuity Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor (R8). Check for continuity between ECU pin 88 and 110. Is there continuity between CAN circuit?

Result: YES:ECU wires short circuit.Repair or replace harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Engine Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Variable Geometry Turbocharger (VGT) Resistance Check. ( 11 ) Variable Geometry Turbocharger (VGT) Resistance Check

Action: Key switch OFF. Disconnect variable geometry turbocharger (VGT). Check for continuity between VGT pin 15 and 16. Is resistance between 50—70Ω?

Result: YES:Go to Engine Control Unit (ECU) Resistance Check. NO:Check CAN bus terminator. See Electrical Component Checks . (9015-20.) ( 12 ) Engine Control Unit (ECU) Resistance Check

Action: Key switch OFF.






Disconnect engine control unit (ECU) connector (X15). Check for continuity between ECU pins 88 and 110. Is resistance between 110—130Ω?

Result: YES:Checks complete. NO:ECU malfunction. Repair or replace. See Engine Control Unit (ECU) Remove and Install . (9015-20.) 011000.02- Abnormal EEPROM 360

Abnormal EEPROM Diagnostic Procedure ( 1 ) Code Check

Action: Clear and check again for diagnostic trouble codes. Is DTC 011000.02—Abnormal EEPROM still present?

Result: YES:Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) YES:Code is still present, but machine is still operable. Go to Machine Function Check. NO:Main controller (MCZ) is OK. ( 2 ) Machine Function Check

Action: Is operation of machine normal? See Operational Checkout . (Group 9005-05.)

Result: YES:Machine may be operated, but it is recommended that the main controller (MCZ) be replaced. NO:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) 011001.02- Abnormal RAM 360

Abnormal RAM Diagnostic Procedure ( 1 ) Code Check

Action: Clear and check again for diagnostic trouble codes. Is DTC 011001.02—Abnormal RAM still present?

Result: YES:Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) <- Go to Section TOC





YES:Code is still present, but machine is still operable. Go to Machine Function Check. NO:Main controller (MCZ) is OK. ( 2 ) Machine Function Check


Result: YES:Machine may be operated, but it is recommended that the main controller (MCZ) be replaced. NO:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) 011002.02- Abnormal A/D Converter 360

Abnormal A/D Converter Diagnostic Procedure ( 1 ) Code Check

Action: Clear and check again for diagnostic trouble codes. Is DTC 011002.02—Abnormal A/D Converter still present?

Result: YES:Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) YES:Code is still present, but machine is still operable. Go to Machine Function Check. NO:Main controller (MCZ) is OK. ( 2 ) Machine Function Check


Result: YES:Machine may be operated but it is recommended that the main controller (MCZ) be replaced. NO:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) 011003.03- Abnormal Sensor Voltage 360

Individual sensor or component Diagnostic Trouble Code (DTC) may also be present within this code. Engine speed dial may not function correctly when this code is present.

Abnormal Sensor Voltage Diagnostic Procedure ( 1 ) Sensor Check

Action: Key switch: Off <- Go to Section TOC





If other sensor DTCs are present, diagnose all other DTCs before continuing. Clear and check again for DTCs. Is DTC 011003.03— Abnormal Sensor Voltage still present?

Result: YES:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Sensor malfunction. Replace appropriate sensor. 011006.02- Engine Controller Communication Error 360

Engine Controller Communication Error For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) 011007.02- (CAN 0) Data Converter Communication Error 1 360

(CAN 0) Data Converter Communication Error 1 For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) 011008.02- (CAN 1) Data Converter Communication Error 2 360

(CAN 1) Data Converter Communication Error 2 For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) 011009.02- (CAN 0) Monitor Controller Communication Error 1 360

(CAN 0) Monitor Controller Communication Error 1 For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) 011010.02- (CAN 1) Monitor Controller Communication Error 2 360

(CAN 1) Monitor Controller Communication Error 2 For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.)






011100.02- Abnormal Engine Speed 360

Engine speed detected 4000 rpm or above.

Abnormal Engine Speed Diagnostic Procedure →NOTE: The main controller (MCZ) receives engine speed via the CAN 0 network from the engine control unit (ECU). ( 1 ) Engine Speed Check

Action: engine speed with Service ADVISOR ™ or MPDr. See MPDr Connection Procedure . (Group 9015-20.) See Service ADVISOR™ Connection Procedure . (Group 9015-20.) For information on engine speeds, see Engine Speed Control System Operation . (Group 9010-05.) Is engine speed within specification?

Result: YES:CAN 0 communication malfunction. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) NO: engine speed using optical tachometer on crankshaft belt pulley.






011101.03- Engine Control Dial Sensor Circuit High Input 360

Engine control dial (R15) signal voltage is high (above 4.78 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Engine Control Dial Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Cab harness-to-switch connector 3 (X29) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Voltage Check NO:Repair or replace connector. See appropriate harness. ( 2 ) Voltage Check

Action: Key switch in OFF position. Disconnect cab harness-to-switch connector 3 (X29). Turn key switch to ON position. Check voltage between pins 4 and 6 of cab harness-to-switch connector 3 (X29). Is approximately 5 volts indicated?

Result: YES:Go to Signal Voltage Check. NO:Repair or replace harness. See appropriate harness. ( 3 ) Signal Voltage Check

Action: Key switch in OFF position. Disconnect cab harness-to-main controller 30-pin connector D (X34). <- Go to Section TOC





Turn key switch to ON position. Check between pin 16 of cab harness-to-main controller 30-pin connector D (X34) and machine ground for voltage. Is voltage above 4.78 V indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Go to Harness Check. ( 4 ) Harness Check

Action: Key switch in OFF position. Disconnect cab harness-to-switch connector 3 (X29). Disconnect main controller connectors (X31— X36). Check for continuity between pin 16 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?

Result: YES:Circuit is short to power. Repair or replace harness. See appropriate harness. NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.)






011101.04- Engine Control Dial Sensor Circuit Low Input 360

Engine control dial (R15) signal voltage is low (below 0.22 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Cab harness-to-switch connector 3 (X29) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Component Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Voltage Check

Action: Key switch in OFF position. Disconnect cab harness-to-switch connector 3 (X29). Turn key switch to ON position. Check voltage between pins 4 and 6 of cab harness-to-switch connector 3 (X29). Is approximately 5 volts indicated?

Result: YES:Go to Open Circuit Check. NO:Repair or replace harness. See appropriate harness. ( 3 ) Open Circuit Check

Action: Key switch in OFF position. Disconnect cab harness-to-switch connector 3 (X29). <- Go to Section TOC





Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 4 of cab harness-to-switch connector 3 (X29) and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 5 of cab harness-to-switch connector 3 (X29) and pin 16 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?

Result: YES:Go to Short Circuit Check. NO:Repair or replace harness. See appropriate harness. ( 4 ) Short Circuit Check

Action: Key switch in OFF position. Disconnect cab harness-to-switch connector 3 (X29). Check for continuity between: Pin 4 of cab harness-to-switch connector 3 (X29) and machine ground. Pin 5 of cab harness-to-switch connector 3 (X29) and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.)






011200.03- Pump 1 Delivery Pressure Sensor Circuit High Input 360

Pump 1 delivery pressure sensor (B35) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 1 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Pump 1 delivery pressure sensor (B35) and pump harness splice connector (X97). See Pump Harness (W8) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Component Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Component Check

Action: →NOTE: Return connectors to appropriate sensors after check is completed.

Disconnect pump 1 delivery pressure sensor (B35). Disconnect pump 2 delivery pressure sensor (B37). Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011200.03—Pump 1 Delivery Pressure Sensor Circuit High Input. Is code active? <- Go to Section TOC





Result: YES:Go to Voltage Check. NO:Pump 1 delivery pressure sensor (B35) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect pump 1 delivery pressure sensor (B35). Turn key switch to ON position. Check between pin 2 of pump 1 delivery pressure sensor (B35) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect pump 1 delivery pressure sensor (B35). Disconnect main controller connectors (X31—X36). Check for continuity between pin 14 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011200.04- Pump 1 Delivery Pressure Sensor Circuit Low Input 360

Pump 1 delivery pressure sensor (B35) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 1 delivery pressure sensor (B35). Disconnect pump 2 delivery pressure sensor (B37). Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect pump 1 delivery pressure sensor (B35). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 1 delivery pressure sensor (B35) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Pump 1 delivery pressure sensor (B35) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 3 of pump 1 delivery pressure sensor (B35) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of pump 1 delivery pressure sensor (B35) connector and pin 14 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?


Action: Key switch in OFF position. Pump 1 delivery pressure sensor (B35) disconnected. Check for continuity between:






Pin 2 of pump 1 delivery pressure sensor (B35) connector and machine ground. Pin 3 of pump 1 delivery pressure sensor (B35) connector and machine ground. Is continuity indicated?







011202.03- Pump 2 Delivery Pressure Sensor Circuit High Input 360

Pump 2 delivery pressure sensor (B37) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 2 delivery pressure sensor (B37). Disconnect pump 1 delivery pressure sensor (B35). Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011202.03—Pump 2 Delivery Pressure Sensor Circuit High Input. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect pump 2 delivery pressure sensor (B37). Turn key switch to ON position. Check between pin 2 of pump 2 delivery pressure sensor (B37) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect pump 2 delivery pressure sensor (B37). Disconnect main controller connectors (X31—X36). Check for continuity between pin 15 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011202.04- Pump 2 Delivery Pressure Sensor Circuit Low Input 360

Pump 2 delivery pressure sensor (B37) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 delivery pressure sensor open or short to ground.

Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 2 delivery pressure sensor (B37). Disconnect pump 1 delivery pressure sensor (B35). Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input. <- Go to Section TOC





Is code active?


Action: Key switch in OFF position. Disconnect pump 2 delivery pressure sensor (B37). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor (B37) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Pump 2 delivery pressure sensor (B37) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 3 of pump 2 delivery pressure sensor (B37) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of pump 2 delivery pressure sensor (B37) connector and pin 15 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?


Action: Key switch in OFF position. Pump 2 delivery pressure sensor (B37) disconnected. <- Go to Section TOC





Check for continuity between: Pin 2 of pump 2 delivery pressure sensor (B37) connector and machine ground. Pin 3 of pump 2 delivery pressure sensor (B37) connector and machine ground. Is continuity indicated?







011206.03- Pump 1 Flow Control Pressure Sensor Circuit High Input 360

Pump 1 control pressure sensor (B36) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Pump 1 control pressure sensor (B36) and pump harness splice connector (X97). See Pump Harness (W8) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and pump harness-to-machine harness connector (X40). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Disconnect pump 1 control pressure sensor (B36). Disconnect pump 2 control pressure sensor (B38). Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011206.03—Pump 1 Flow Control Pressure Sensor Circuit High Input. Is code active? <- Go to Section TOC





Result: YES:Go to Voltage Check. NO:Pump 1 control pressure sensor (B36) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect pump 1 control pressure sensor (B36). Turn key switch to ON position. Check between pin 2 of pump 1 control pressure sensor (B36) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect pump 1 control pressure sensor (B36). Disconnect main controller connectors (X31—X36). Check for continuity between pin 8 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011206.04- Pump 1 Flow Control Pressure Sensor Circuit Low Input 360

Pump 1 control pressure sensor (B36) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 1 control pressure sensor (B36). Disconnect pump 2 control pressure sensor (B38). Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011206.04—Pump 1 Flow Control Pressure Sensor Circuit Low Input. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect pump 1 control pressure sensor (B36). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 1 control pressure sensor (B36) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Pump 1 control pressure sensor (B36) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of pump 1 control pressure sensor (B36) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of pump 1 control pressure sensor (B36) connector and pin 8 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?


Action: Key switch in OFF position. Pump 1 control pressure sensor (B36) disconnected. Check for continuity between:






Pin 1 of pump 1 control pressure sensor (B36) connector and machine ground. Pin 2 of pump 1 control pressure sensor (B36) connector and machine ground. Is continuity indicated?







011208.03- Pump 2 Flow Control Pressure Sensor Circuit High Input 360

Pump 2 control pressure sensor (B38) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 2 control pressure sensor (B38). Disconnect pump 1 control pressure sensor (B36). Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.03—Pump 2 Flow Control Pressure Sensor Circuit High Input. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect pump 2 control pressure sensor (B38). Turn key switch to ON position. Check between pin 2 of pump 2 control pressure sensor (B38) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect pump 2 control pressure sensor (B38). Disconnect main controller connectors (X31—X36). Check for continuity between pin 17 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011208.04- Pump 2 Flow Control Pressure Sensor Circuit Low Input 360

Pump 2 control pressure sensor (B38) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check




Disconnect pump 2 control pressure sensor (B38). Disconnect pump 1 control pressure sensor (B36). Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.04—Pump 2 Flow Control Pressure Sensor Circuit Low Input. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect pump 2 control pressure sensor (B38). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor (B38) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Pump 2 control pressure sensor (B38) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of pump 2 control pressure sensor (B38) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of pump 2 control pressure sensor (B38) connector and pin 13 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?


Action: Key switch in OFF position. Pump 2 control pressure sensor (B38) disconnected. Check for continuity between:






Pin 1 of pump 2 control pressure sensor (B38) connector and machine ground. Pin 2 of pump 2 control pressure sensor (B38) connector and machine ground. Is continuity indicated?







011301.03- Swing Pilot Pressure Sensor Circuit High Input 360

Swing pressure sensor (B33) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Disconnect swing pressure sensor (B33). Disconnect travel pressure sensor (B34). Connect swing pressure sensor (B33) connector to travel pressure sensor (B34). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011301.03—Swing Pilot Pressure Sensor Circuit High Input. Is code active?






Result: YES:Go to Voltage Check. NO:Swing pressure sensor (B33) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect swing pressure sensor (B33). Turn key switch to ON position. Check between pin 2 of swing pressure sensor (B33) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect swing pressure sensor (B33). Disconnect main controller connectors (X31—X36). Check for continuity between pin 15 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011301.04- Swing Pilot Pressure Sensor Circuit Low Input 360

Swing pressure sensor (B33) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Disconnect swing pressure sensor (B33). Disconnect travel pressure sensor (B34). Connect swing pressure sensor (B33) connector to travel pressure sensor (B34). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011301.04—Swing Pilot Pressure Sensor Circuit Low Input. Is code active?






Result: YES:Go to Voltage Check. NO:Swing pressure sensor (B33) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect swing pressure sensor (B33). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of swing pressure sensor (B33) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Swing pressure sensor (B33) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of swing pressure sensor (B33) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of swing pressure sensor (B33) connector and pin 15 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?


Action: Key switch in OFF position. Swing pressure sensor (B33) disconnected. Check for continuity between: Pin 1 of swing pressure sensor (B33) connector and machine ground. Pin 2 of swing pressure sensor (B33) connector and machine ground. <- Go to Section TOC












011302.03- Boom Up Pilot Pressure Sensor Circuit High Input 360

Boom up pressure sensor (B30) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Boom up pressure sensor (B30) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch boom up pressure sensor (B30) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011302.03—Boom Up Pilot Pressure Sensor Circuit High Input. Is code active?

Result: YES:Go to Voltage Check. NO:Boom up pressure sensor (B30) malfunction. Replace sensor.






( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect boom up pressure sensor (B30). Turn key switch to ON position. Check between pin 2 of boom up pressure sensor (B30) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect boom up pressure sensor (B30). Disconnect main controller connectors (X31—X36). Check for continuity between pin 6 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011302.04- Boom Up Pilot Pressure Sensor Circuit Low Input 360

Boom up pressure sensor (B30) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Boom up pressure sensor (B30) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch boom up pressure sensor (B30) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011302.04—Boom Up Pilot Pressure Sensor Circuit Low Input. Is code active?

Result: YES:Go to Voltage Check. NO:Boom up pressure sensor (B30) malfunction. Replace sensor.






( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect boom up pressure sensor (B30). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of boom up pressure sensor (B30) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Boom up pressure sensor (B30) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of boom up pressure sensor (B30) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of boom up pressure sensor (B30) connector and pin 6 of cab harness-to-main controller 24-pin connector D (X34). Is continuity indicated?


Action: Key switch in OFF position. Boom up pressure sensor (B30) disconnected. Check for continuity between: Pin 1 of boom up pressure sensor (B30) connector and machine ground. Pin 2 of boom up pressure sensor (B30) connector and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. <- Go to Section TOC





NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.)






011303.03- Arm In Pilot Pressure Sensor Circuit High Input 360

Arm in pressure sensor (B31) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch arm in pressure sensor (B31) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011303.03—Arm In Pilot Pressure Sensor Circuit High Input. Is code active?

Result: YES:Go to Voltage Check. NO:Arm in pressure sensor (B31) malfunction. Replace sensor.






( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect arm in pressure sensor (B31). Turn key switch to ON position. Check between pin 2 of arm in pressure sensor (B31) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect arm in pressure sensor (B31). Disconnect main controller connectors (X31—X36). Check for continuity between pin 7 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011303.04- Arm In Pilot Pressure Sensor Circuit Low Input 360

Arm in pressure sensor (B31) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch arm in pressure sensor (B31) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011303.04—Arm In Pilot Pressure Sensor Circuit Low Input. Is code active?

Result: YES:Go to Voltage Check. NO:Arm in pressure sensor (B31) malfunction. Replace sensor.






( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect arm in pressure sensor (B31). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of arm in pressure sensor (B31) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Arm in pressure sensor (B31) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector E (X36). Check for continuity between: Pin 1 of arm in pressure sensor (B31) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of arm in pressure sensor (B31) connector and pin 7 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?


Action: Key switch in OFF position. Arm in pressure sensor (B31) disconnected. Check for continuity between: Pin 1 of arm in pressure sensor (B31) connector and machine ground. Pin 2 of arm in pressure sensor (B31) connector and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. <- Go to Section TOC





NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.)






011304.03- Travel Pilot Pressure Sensor Circuit High Input 360

Travel pressure sensor (B33) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Disconnect travel pressure sensor (B34). Disconnect swing pressure sensor (B33). Connect travel pressure sensor (B34) connector to swing pressure sensor (B33). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011304.03—Travel Pilot Pressure Sensor Circuit High Input. Is code active?






Result: YES:Go to Voltage Check. NO:Travel pressure sensor (B34) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect travel pressure sensor (B34). Turn key switch to ON position. Check between pin 2 of travel pressure sensor (B34) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect travel pressure sensor (B34). Disconnect main controller connectors (X31—X36). Check for continuity between pin 9 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011304.04- Travel Pilot Pressure Sensor Circuit Low Input 360

Travel pressure sensor (B34) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Disconnect travel pressure sensor (B34). Disconnect swing pressure sensor (B33). Connect travel pressure sensor (B34) connector to swing pressure sensor (B33). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011304.04—Travel Pilot Pressure Sensor Circuit Low Input. Is code active?






Result: YES:Go to Voltage Check. NO:Travel pressure sensor (B34) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect travel pressure sensor (B34). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of travel pressure sensor (B34) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Travel pressure sensor (B34) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of travel pressure sensor (B34) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of travel pressure sensor (B34) connector and pin 9 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?


Action: Key switch in OFF position. Travel pressure sensor (B34) disconnected. Check for continuity between: Pin 1 of travel pressure sensor (B34) connector and machine ground. Pin 2 of travel pressure sensor (B34) connector and machine ground. <- Go to Section TOC












011307.03- Front Attachment Pilot Pressure Sensor Circuit High Input 360

Front attachment pressure sensor (B32) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Front Attachment Pilot Pressure Sensor Circuit High Input High Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011307.03—Front Attachment Pilot Pressure Sensor Circuit High Input. Is code active?

Result: YES:Go to Voltage Check. NO:Front attachment pressure sensor (B32) malfunction. Replace sensor. <- Go to Section TOC





( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect front attachment pressure sensor (B32). Turn key switch to ON position. Check between pin 2 of front attachment pressure sensor (B32) connector and machine ground for voltage. Is voltage indicated?


Action: Key switch in OFF position. Disconnect front attachment pressure sensor (B31). Disconnect main controller connectors (X31—X36). Check for continuity between pin 14 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors. Is continuity indicated between any circuits?







011307.04- Front Attachment Pilot Pressure Sensor Circuit Low Input 360

Front attachment pressure sensor (B32) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011307.04—Front Attachment Pilot Pressure Sensor Circuit Low Input. Is code active?

Result: YES:Go to Voltage Check. NO:Front attachment pressure sensor (B32) malfunction. Replace sensor. <- Go to Section TOC





( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect front attachment pressure sensor (B32). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of front attachment pressure sensor (B32) connector. Is approximately 5 V indicated?


Action: Key switch in OFF position. Front attachment pressure sensor (B32) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of front attachment pressure sensor (B32) connector and pin 25 of cab harness-to-main controller 26-pin connector F (X36). Pin 2 of front attachment pressure sensor (B32) connector and pin 14 of cab harness-to-main controller 30-pin connector D (X34). Is continuity indicated?


Action: Key switch in OFF position. Front attachment pressure sensor (B32) disconnected. Check for continuity between: Pin 1 of front attachment pressure sensor (B32) connector and machine ground. Pin 2 of front attachment pressure sensor (B32) connector and machine ground. Is continuity indicated?












011400.02- Pump 2 Flow Rate Limit Solenoid Valve Abnormal 360

Pump 2 flow rate limit solenoid (marked SB) (Y20) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: →NOTE: Return connectors to appropriate solenoids after check is completed.

Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.02—Pump 2 Flow Rate Limit Solenoid Abnormal. Is code active? <- Go to Section TOC





Result: YES:Go to Continuity Check. NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (Y20). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to pin 7 cab of harness-to-main controller 31-pin connector A (X31). Pin 2 of pump 2 flow rate limit solenoid (Y20) connector to pin 6 cab of harness-to-main controller 31-pin connector A (X31). Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Go to Short Circuit Check. ( 4 ) Short Circuit Check

Action: Key switch in OFF position. Pump 2 flow rate limit solenoid (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to machine ground. Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?

Result: YES:Go to Harness Check. NO:Short to ground. Repair or replace harness. See appropriate harness. ( 5 ) Harness Check

Action: Key switch in OFF position. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector. <- Go to Section TOC





Is continuity indicated between any pins?

Result: YES:Short to power. Repair or replace harness. See appropriate harness. NO:Go to Solenoid Check. ( 6 ) Solenoid Check

Action: Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is pump 2 flow rate limit solenoid (Y20) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid.






011400.03- Pump 2 Flow Rate Limit Solenoid Valve High Current 360

Pump 2 flow rate limit solenoid (marked SB) (Y20) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve High Current Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.03—Pump 2 Flow Rate Limit Solenoid Valve High Current. Is code active? <- Go to Section TOC








Action: Key switch in OFF position. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector. Is continuity indicated between any pins?


Action: Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is pump 2 flow rate limit solenoid (Y20) within specification?












011400.04- Pump 2 Flow Rate Limit Solenoid Valve Low Current 360

Pump 2 flow rate limit solenoid (marked SB) (Y20) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Pump 2 Flow Rate Limit Solenoid Valve Low Current Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.04—Pump 2 Flow Rate Limit Solenoid Valve Low Current. Is code active? <- Go to Section TOC








Action: Key switch in OFF position. Pump 2 flow rate limit solenoid (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of pump 2 flow rate limit solenoid (Y20) connector to machine ground. Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?

Result: YES:Go to Solenoid Check. NO:Short to ground. Repair or replace harness. See appropriate harness. ( 5 ) Solenoid Check

Action: Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) <- Go to Section TOC





Is pump 2 flow rate limit solenoid (Y20) within specification?







011401.02- Torque Control Solenoid Valve Abnormal 360

Torque control solenoid (marked ST) (Y21) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Torque Control Solenoid Valve Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Key switch in OFF position. Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.02—Torque Control Solenoid Valve Abnormal . Is code active? <- Go to Section TOC





Result: YES:Go to Continuity Check. NO:Torque control solenoid (Y21) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of torque control solenoid (Y21) connector to pin 3 cab of harness-to-main controller 31-pin connector A (X31). Pin 2 of torque control solenoid (Y21) connector to pin 2 cab of harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Torque control solenoid (Y21) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of torque control solenoid (Y21) connector to machine ground. Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector. Is continuity indicated between any pins? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is torque control solenoid (Y21) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Torque control solenoid (Y21) malfunction. Replace solenoid.






011401.03- Torque Control Solenoid Valve High Current 360

Torque control solenoid (marked ST) (Y21) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Torque Control Solenoid Valve High Current Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.03—Torque Control Solenoid Valve High Current. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of torque control solenoid (Y21) connector to pin 3 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of torque control solenoid (Y21) connector to pin 2 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?




Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is torque control solenoid (Y21) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group <- Go to Section TOC





9015-20.) NO:Torque control solenoid (Y21) malfunction. Replace solenoid.






011401.04- Torque Control Solenoid Valve Low Current 360

Torque control solenoid (marked ST) (Y21) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Torque Control Solenoid Valve Low Current Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.04—Torque Control Solenoid Valve Low Current. Is code active? <- Go to Section TOC






Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of torque control solenoid (Y21) connector to pin 3 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of torque control solenoid (Y21) connector to pin 2 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Torque control solenoid (Y21) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of torque control solenoid (Y21) connector to machine ground. Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is torque control solenoid (Y21) within specification? <- Go to Section TOC





Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Torque control solenoid (Y21) malfunction. Replace solenoid.






011402.02- 4-Spool Solenoid Valve Unit (SF) Abnormal 360

Dig regenerative solenoid (marked SF) (Y22) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SF) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Key switch in OFF position. Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.02—3-Spool Solenoid Valve Unit (SF) Abnormal . Is code active?






Result: YES:Go to Continuity Check. NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect dig regenerative solenoid (Y22). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of dig regenerative solenoid (Y22) connector to pin 15 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of dig regenerative solenoid (Y22) connector to pin 14 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Dig regenerative solenoid (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of dig regenerative solenoid (Y22) connector to machine ground. Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?








Action: Key switch in OFF position. Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is dig regenerative solenoid (Y22) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.






011402.03- 4-Spool Solenoid Valve Unit (SF) High Input 360

Dig regenerative solenoid (marked SF) (Y22) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SF) High Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.03—3-Spool Solenoid Valve Unit (SF) High Input. Is code active?











Action: Key switch in OFF position. Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is dig regenerative solenoid (Y22) within specification?






9015-20.) NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.






011402.04- 4-Spool Solenoid Valve Unit (SF) Low Input 360

Dig regenerative solenoid (marked SF) (Y22) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SF) Low Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.04—3-Spool Solenoid Valve Unit (SF) Low Input. Is code active?









Action: Key switch in OFF position. Dig regenerative solenoid (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of dig regenerative solenoid (Y22) connector to machine ground. Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is dig regenerative solenoid (Y22) within specification? <- Go to Section TOC





Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Dig regenerative solenoid (Y22) malfunction. Replace solenoid.






011403.02- 4-Spool Solenoid Valve Unit (SC) Abnormal 360

Arm regenerative solenoid (marked SC) (Y23) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SC) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Key switch in OFF position. Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.02—3-Spool Solenoid Valve Unit (SC) Abnormal . Is code active?






Result: YES:Go to Continuity Check. NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect arm regenerative solenoid (Y23). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of arm regenerative solenoid (Y23) connector to pin 11 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of arm regenerative solenoid (Y23) connector to pin 10 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Arm regenerative solenoid (Y23) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of arm regenerative solenoid (Y23) connector to machine ground. Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?








Action: Key switch in OFF position. Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm regenerative solenoid (Y23) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.






011403.03- 4-Spool Solenoid Valve Unit (SC) High Input 360

Arm regenerative solenoid (marked SC) (Y23) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SC) High Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.03—3-Spool Solenoid Valve Unit (SC) High Input. Is code active?











Action: Key switch in OFF position. Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm regenerative solenoid (Y23) within specification?






9015-20.) NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.






011403.04- 4-Spool Solenoid Valve Unit (SC) Low Input 360

Arm regenerative solenoid (marked SC) (Y23) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SC) Low Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.04—3-Spool Solenoid Valve Unit (SC) Low Input. Is code active?









Action: Key switch in OFF position. Arm regenerative solenoid (Y23) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of arm regenerative solenoid (Y23) connector to machine ground. Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm regenerative solenoid (Y23) within specification? <- Go to Section TOC





Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Arm regenerative solenoid (Y23) malfunction. Replace solenoid.






011407.02- 4-Spool Solenoid Valve Unit (SG) Abnormal 360

Power dig solenoid (marked SG) (Y24) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SG) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Key switch in OFF position. Disconnect power dig solenoid (marked SG) (Y24). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.02—3-Spool Solenoid Valve Unit (SG) Abnormal . Is code active?






Result: YES:Go to Continuity Check. NO:Power dig solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect power dig solenoid (Y24). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of power dig solenoid (Y24) connector to pin 12 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of power dig solenoid (Y24) connector to pin 13 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Power dig solenoid (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of power dig solenoid (Y24) connector to machine ground. Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?








Action: Key switch in OFF position. Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is power dig solenoid (Y24) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Power dig solenoid (Y24) malfunction. Replace solenoid.






011407.03- 4-Spool Solenoid Valve Unit (SG) High Input 360

Power dig solenoid (marked SG) (Y24) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SG) High Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect power dig solenoid (marked SG) (Y24). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.03—3-Spool Solenoid Valve Unit (SG) High Input. Is code active?











Action: Key switch in OFF position. Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is power dig solenoid (Y24) within specification?






9015-20.) NO:Power dig solenoid (Y24) malfunction. Replace solenoid.






011407.04- 4-Spool Solenoid Valve Unit (SG) Low Input 360

Power dig solenoid (marked SG) (Y24) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SG) Low Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect power dig solenoid (marked SG) (Y24). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.04—3-Spool Solenoid Valve Unit (SG) Low Input. Is code active?









Action: Key switch in OFF position. Power dig solenoid (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of power dig solenoid (Y24) connector to machine ground. Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is power dig solenoid (Y24) within specification? <- Go to Section TOC





Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Power dig solenoid (Y24) malfunction. Replace solenoid. 011408.02- 2-Spool Solenoid Valve Unit (SJ) Abnormal 360

Not applicable to this machine. 011408.03- 2-Spool Solenoid Valve Unit (SJ) High Input 360

Not applicable to this machine. 011408.04- 2-Spool Solenoid Valve Unit (SJ) Low Input 360

Not applicable to this machine. 011409.02- 2-Spool Solenoid Valve Unit (SZ) Abnormal 360

Not applicable to this machine. 011409.03- 2-Spool Solenoid Valve Unit (SZ) High Input 360

Not applicable to this machine. 011409.04- 2-Spool Solenoid Valve Unit (SZ) Low Input 360

Not applicable to this machine.






011428.02- 4-Spool Solenoid Valve Unit (SD) Abnormal 360

Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SD) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Arm 2 flow control solenoid (Y27) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?



Key switch in OFF position. Disconnect arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.02—4-Spool Solenoid Valve Unit (SD) Abnormal . Is code active?






Result: YES:Go to Continuity Check. NO:Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect arm 2 flow control solenoid (Y27). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of arm 2 flow control solenoid (Y27) connector to pin 8 cab of harness-to-main controller 31-pin connector A (X31). Pin 2 of arm 2 flow control solenoid (Y27) connector to pin 9 cab of harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. Arm 2 flow control solenoid (Y27) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of arm 2 flow control solenoid (Y27) connector to machine ground. Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?








Action: Key switch in OFF position. Disconnect arm 2 flow control solenoid (Y27). Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm 2 flow control solenoid (Y27) within specification?

Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid.






011428.03- 4-Spool Solenoid Valve Unit (SD) High Input 360

Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SG) High Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.03—4-Spool Solenoid Valve Unit (SG) High Input. Is code active?











Action: Key switch in OFF position. Disconnect arm 2 flow control solenoid (Y27). Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm 2 flow control solenoid (Y27) within specification?






9015-20.) NO:Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid.






011428.04- 4-Spool Solenoid Valve Unit (SD) Low Input 185

Arm 2 flow control solenoid (marked SD) (Y27) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

4-Spool Solenoid Valve Unit (SG) Low Input Diagnostic Procedure ( 1 ) Connector Check




Key switch in OFF position. Disconnect arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.04—4-Spool Solenoid Valve Unit (SD) Low Input. Is code active?









Action: Key switch in OFF position. Arm 2 flow control solenoid (Y27) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of arm 2 flow control solenoid (Y27) connector to machine ground. Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?


Action: Key switch in OFF position. Disconnect arm 2 flow control solenoid (Y27). Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.) Is arm 2 flow control solenoid (Y27) within specification? <- Go to Section TOC





Result: YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid. 011434.02- Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal 360

Not applicable to this machine. 011434.03- Attachment Relief 1 (Upper) Proportional Solenoid Valve High Current 360

Not applicable to this machine. 011434.04- Attachment Relief 1 (Upper) Proportional Solenoid Valve Low Current 360

Not applicable to this machine. 011435.02- Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal 360

Not applicable to this machine. 011435.03- Attachment Relief 2 (Lower) Proportional Solenoid Valve High Current 360

Not applicable to this machine. 011435.04- Attachment Relief 2 (Lower) Proportional Solenoid Valve Low Current 360

Not applicable to this machine. 011436.02- Breaker Relief Proportional Solenoid Valve Abnormal 360

Not applicable to this machine. 011436.03- Breaker Relief Proportional Solenoid Valve High Current 360

Not applicable to this machine. 011436.04- Breaker Relief Proportional Solenoid Valve Low Current 360







011457.02- 2-Speed Activation Solenoid Disconnected or Not Present 360

→NOTE: The 2-speed activation solenoid is part of the combined pump flow kit. If the machine does not have this kit installed, the solenoid will not be present. Switch machine to dig mode or to an attachment mode that is not set up for combined pump flow, then clear the DTC. Operate machine and the DTC does not reappear. If the machine has this solenoid, continue with 2-speed activation solenoid diagnostic procedure.

2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure ( 1 ) Fuse Check

Action: Ignition OFF. Remove fuse F5 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram . (Group 9015-10.) Check fuse F5 for continuity. Is continuity indicated?

Result: YES:Go to Solenoid Check. NO:Replace fuse. ( 2 ) Solenoid Check

Action: Ignition OFF. Disconnect harness from 2-speed activation solenoid. See 2-Speed Harness (W32) Component Location . (Group 9015-10.) Test solenoid. See Proportional Solenoid Test . (Group 9015-20.) Is 2-speed activation solenoid within specification?

Result: YES:Go to 2-Speed Harness Continuity Check. NO:Solenoid malfunction. Replace solenoid. ( 3 ) 2-Speed Harness Continuity Check

Action: Ignition OFF. Disconnect attachment harness-to-2-speed harness connector (X87). See Attachment Harness (W17) Component Location . (Group 9015-10.) Check continuity between 2-speed activation solenoid valve (Y43) connector pin 1 and attachment harness-to-2-speed harness connector (X87) pin 4. <- Go to Section TOC





Check continuity between 2-speed activation solenoid valve (Y43) pin 2 and attachment harness-to-2-speed harness connector (X87) pin 5. See 2-Speed Harness (W32) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Go to Attachment Harness Continuity Check. NO:Open circuit in 2-speed harness. Repair or replace harness. ( 4 ) Attachment Harness Continuity Check

Action: Disconnect attachment connector (X46). See Machine Harness (W2) Component Location . (Group 9015-10.) Check for continuity between attachment harness-to-2-speed harness connector (X87) pin 4 and attachment connector (X46) pin 10. Check continuity between attachment harness-to-2-speed harness connector (X87) pin 5 and attachment connector (X46) pin 11. See Attachment Harness (W17) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Go to Machine Harness Continuity Check. NO:Open circuit in attachment harness. Repair or replace harness. ( 5 ) Machine Harness Continuity Check

Action: Disconnect cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.) Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A12 and attachment connector (X46) pin 10. Check continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and attachment connector (X46) pin 11. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Go to Cab Harness Continuity Check. NO:Open circuit in machine harness. Repair or replace harness. ( 6 ) Cab Harness Continuity Check

Action: Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group 9015-10.) Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A12 and cab harness-to-main controller 17-pin connector (X33) pin 3.






Check continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and fuse F5. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Open circuit in cab harness. Repair or replace cab harness.






011458.02- Selector Valve Solenoid Valve Disconnected or Not Present 360

→NOTE: The selector valve solenoid valve is part of the auxiliary high flow line kit. If the machine does not have this kit installed, the solenoid will not be present. Switch machine to dig mode, then clear the DTC. Operate machine and the DTC does not reappear. If the machine has this solenoid, continue with selector valve solenoid valve diagnostic procedure.

Selector Valve Solenoid Valve Disconnected or Not Present Diagnostic Procedure ( 1 ) Fuse Check


Result: YES:Go to Solenoid Check. NO:Replace fuse. ( 2 ) Solenoid Check

Action: Disconnect connector from selector valve solenoid valve (Y40). See Attachment Harness (W17) Component Location . (Group 9015-10.) Test solenoid valve. See Proportional Solenoid Test . (Group 9015-20.) Is selector valve solenoid valve within specification?

Result: YES:Go to Attachment Harness (W17) Continuity Check. NO:Solenoid malfunction. Replace selector valve solenoid valve. ( 3 ) Attachment Harness (W17) Continuity Check

Action: Disconnect attachment connector (X46). See Machine Harness (W2) Component Location . (Group 9015-10.) Check for continuity between attachment connector (X46) pin 9 and selector valve solenoid valve (Y40) connector pin 2. Check for continuity between attachment connector (X46) pin 11 and selector valve solenoid valve (Y40) connector pin 1. See Attachment Harness (W17) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits? <- Go to Section TOC





Result: YES:Go to Machine Harness (W2) Continuity Check. NO:Open circuit in attachment harness. Repair or replace harness. ( 4 ) Machine Harness (W2) Continuity Check

Action: Disconnect cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.) Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A4 and attachment connector (X46) pin 9. Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and attachment connector (X46) pin 11. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Go to Cab Harness (W1) Continuity Check. NO:Open circuit in machine harness. Repair or replace harness. ( 5 ) Cab Harness (W1) Continuity Check

Action: Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group 9015-10.) Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin A4 and cab harness-to-main controller 17-pin connector C (X33) pin 3. Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and fuse F5. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) Is continuity indicated in both circuits?

Result: YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Open circuit in cab harness. Repair or replace harness.






011459.02- Idle Stop Relay Circuit Malfunction 360

Idle Stop Relay Circuit Malfunction Diagnostic Procedure ( 1 ) Fuse Check


Result: YES:Go to Voltage Check. NO:Replace fuse. ( 2 ) Voltage Check

Action: Install fuse F18 in fuse box F50. Ignition ON. Disconnect connector from idle stop relay (K11). Check for 24 volts at idle stop relay (K11) connector pin 1. Are there 24 volts present?

Result: YES:Go to Relay Check. NO:Open circuit in cab harness (W1) between idle stop relay (K11) and fuse F18. Repair or replace harness. ( 3 ) Relay Check

Action: Ignition OFF. Test idle stop relay. See Relay Test . (Group 9015-20.) Is relay within specification?

Result: YES:Go to Cab Harness (W1) Continuity Check. NO:Replace idle stop relay. ( 4 ) Cab Harness (W1) Continuity Check






Action: Disconnect cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1) Component Location . (Group 9015-10.) Check for continuity between idle stop relay (K11) connector pin 2 and cab harness-to-main controller 17-pin connector C (X33) pin 5. Check for continuity between idle stop relay (K11) connector pin 3 and cab harness-to-main controller 17-pin connector C (X33) pin 5. Check for continuity between idle stop relay (K11) connector pin 5 and ground. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) Is continuity indicated in all circuits?

Result: YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group 9015-20.) NO:Open circuit in cab harness. Repair or replace harness.






015011.03- Hydraulic Oil Temperature Sensor Circuit High Input (Pilot) 360

Secondary hydraulic oil temperature sensor (B68) voltage is high (above 4.35 V).

Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Secondary hydraulic oil temperature sensor (B68). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect secondary hydraulic oil temperature sensor (B68). Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group 9015-20.) Is secondary hydraulic oil temperature sensor within specification?

Result: YES:Go to Voltage Check. NO:Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Secondary hydraulic oil temperature sensor (B68) disconnected. Turn key switch to ON position. Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for more than 4.25 V. Is correct voltage indicated? <- Go to Section TOC





Result: YES:Go to Harness Check. NO:Repair or replace harness. See appropriate harness. ( 4 ) Harness Check

Action: Key switch in OFF position. Secondary hydraulic oil temperature sensor (B68) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of secondary hydraulic oil temperature sensor (B68) and pin 7 of cab harness-to-main controller 17-pin connector C (X33). Pin 2 of secondary hydraulic oil temperature sensor (B68) and pins 16 and 17 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?

Result: YES:Checks complete. NO:Repair or replace harness. See appropriate harness.






015011.04- Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot) 360

Secondary hydraulic oil temperature sensor low (below 0.23 V).

Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Secondary hydraulic oil temperature sensor (B68). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect secondary hydraulic oil temperature sensor (B68). Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group 9015-20.) Is secondary hydraulic oil temperature sensor within specification?

Result: YES:Go to Voltage Check. NO:Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Secondary hydraulic oil temperature sensor (B68) disconnected. Turn key switch to ON position. Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for less than 0.1 V. Is correct voltage indicated? <- Go to Section TOC





Result: YES:Checks complete. NO:Go to Harness Check. ( 4 ) Harness Check

Action: Key switch in OFF position. Secondary hydraulic oil temperature sensor (B68) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of secondary hydraulic oil temperature sensor (B68) and pin 7 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?

Result: YES:Checks complete. NO:Repair or replace harness. See appropriate harness.






015016.03- Right Analog Stroke Sensor Circuit High Input 360

Auxiliary function lever (AFL) proportional control switch (S29) voltage is high (above 4.5 V).

Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). Auxiliary function lever (AFL) connector 1 (X574). Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Voltage Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Voltage Check

Action: Key switch in the OFF position. Disconnect AFL connector (marked R_GRIP) (X536). Turn key switch to ON position. Check between pin 3 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 0.0 V. Is correct voltage indicated?


Action: Key switch in the OFF position. AFL connector (marked R_GRIP) (X536) disconnected. Disconnect main controller connectors (X31—X36). Check for continuity between pin 3 of AFL connector (marked R_GRIP) (X536) to all pins on all option controller connectors. Is continuity indicated between any circuits? <- Go to Section TOC





Result: YES:Auxiliary function lever (AFL) proportional control switch (S29) malfunction. Replace switch. NO:Checks complete.






015016.04- Right Analog Stroke Sensor Circuit Low Input 360

Auxiliary function lever (AFL) proportional control switch (S29) voltage is low (below 0.1 V).

Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in the OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). Auxiliary function lever (AFL) connector 1 (X574). Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Voltage Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Voltage Check

Action: Key switch in the OFF position. Disconnect AFL connector (marked R_GRIP) (X536). Turn key switch to ON position. Check between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 5 V. Is correct voltage indicated?


Action: Key switch in the OFF position. AFL connector (marked R_GRIP) (X536) disconnected. Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of AFL connector (marked R_GRIP) (X536) and pins 25 and 26 of cab harness-to-main controller 26-pin connector F (X36). <- Go to Section TOC





Pin 2 of AFL connector (marked R_GRIP) (X536) and pins 16 and 17 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?


Action: Key switch in the OFF position. AFL connector (marked R_GRIP) (X536) disconnected. Check for continuity between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Checks complete.






011810.03- Electric Lever Operating Pressure Sensor 1 High Voltage 360

Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is high (above 4.5 V).

Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 24-pin connector B (X32). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) AFL solenoid pressure sensor (marked PS1) (B85). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Component Check. NO:Repair or replace connectors. See appropriate harness. ( 2 ) Component Check

Action: Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011810.03—Electric Lever Operating Pressure Sensor 1 High Voltage. Is code active? Return connectors to appropriate sensors after check is complete.

Result: YES:Go to Voltage Check. NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Turn key switch to ON position. <- Go to Section TOC





Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground for approximately 0.0 V. Is correct voltage indicated?


Action: Key switch in OFF position. Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Disconnect main controller connectors (X31—X36). Check for continuity between pin 2 of cab harness-to-main controller 24-pin connector B (X32) to all pins on all main controller connectors. Is continuity indicated between any circuits?

Result: YES:Circuit is short to power. Repair or replace harness. See appropriate harness. NO:Checks complete.






011810.04- Electric Lever Operating Pressure Sensor 1 Low Voltage 360

Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is low (below 0.1 V).

Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 24-pin connector B (X32). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) AFL solenoid pressure sensor (marked PS1) (B85). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011810.04—Electric Lever Operating Pressure Sensor 1 Low Voltage. Is code active? Return connectors to appropriate sensors after check is complete.

Result: YES:Go to Voltage Check. NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor. ( 3 ) Voltage Check

Action: Key switch in OFF position. Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Turn key switch to ON position. <- Go to Section TOC





Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground for approximately 0.0 V. Is correct voltage indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check

Action: Key switch in OFF position. AFL solenoid pressure sensor (marked PS1) (B85) disconnected. Disconnect cab harness-to-main controller 24-pin connector B (X32). Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and pin 2 of cab harness-to-main controller 24-pin connector B (X32). Is continuity indicated?


Action: Key switch in OFF position. AFL solenoid pressure sensor (marked PS1) (B85) disconnected. Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Checks complete.






011812.02- OPT Electric Lever 1 Neutral Abnormal 360

Secondary pilot shutoff solenoid (marked PiC) (Y66) signal voltage 0.1 V or less.

OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Optional connector (X26). Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Secondary pilot shutoff solenoid (marked PiC) (Y66). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Continuity Check. NO:Repair or replace connectors. See appropriate harness. ( 2 ) Continuity Check

Action: Key switch in OFF position. Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66). Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between: Pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) connector to pin 6 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?

Result: YES:Go to Solenoid Check. NO:Repair or replace harness. See appropriate harness. ( 3 ) Solenoid Check

Action: Key switch in OFF position. Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.)






Is secondary pilot shutoff solenoid (marked PiC) (Y66) within specification?

Result: YES:Checks complete. NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.






011813.02- OPT Electric Lever 1 Abnormal Operation 360

Secondary pilot shutoff solenoid (marked PiC) (Y66) current above 920 mA and below 70 mA with slow or no operation.

OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Optional connector (X26). Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Secondary pilot shutoff solenoid (marked PiC) (Y66). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66). Switch connectors of secondary pilot shutoff solenoid (marked PiC) (Y66) with another solenoid. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011813.02—OPT Electric Lever 1 Abnormal Operation. Is code active? Return connectors to appropriate solenoids after check is complete.

Result: YES:Go to Continuity Check. NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid. ( 3 ) Continuity Check

Action: Key switch in OFF position. Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. <- Go to Section TOC





Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) connector to pin 6 of cab harness-tomain controller 17-pin connector C (X33). Is continuity indicated?


Action: Key switch in OFF position. Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) to machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. NO:Go to Harness Check. ( 5 ) Harness Check

Action: Key switch in OFF position. Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector. Is continuity indicated between any pins?


Action: Key switch in OFF position. Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.) Is secondary pilot shutoff solenoid (marked PiC) (Y66) within specification? <- Go to Section TOC





Result: YES:Checks complete. NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.






011816.02- OPT Solenoid 1 Abnormal 360

Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA and below 70 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.02—OPT Solenoid 1 Abnormal. Is code active? Return connectors to appropriate solenoids after check is complete.

Result: YES:Go to Continuity Check. NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. ( 3 ) Continuity Check






Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. AFL solenoid A (marked 1A) (Y61) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground. Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?









AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?

Result: YES:Checks complete. NO:AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.






011816.03- OPT Solenoid 1 Current High 360

Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) High Current Diagnostic Procedure ( 1 ) Connector Check



Action: Key switch in OFF position. Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.03—OPT Solenoid 1 Current High. Is code active? Return connectors to appropriate solenoids after check is complete.











Action: Key switch in OFF position. AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?







011816.04- OPT Solenoid 1 Current Low 360

Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current below 56 mA.

Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Low Current Diagnostic Procedure ( 1 ) Connector Check



Action: Key switch in OFF position. Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.04—OPT Solenoid 1 Current Low. Is code active? Return connectors to appropriate solenoids after check is complete.









Action: Key switch in OFF position. AFL solenoid A (marked 1A) (Y61) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground. Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. NO:Go to Solenoid Check. ( 5 ) Solenoid Check

Action: Key switch in OFF position. AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?







011817.02- OPT Solenoid 2 Abnormal 360

Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA and below 70 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 31-pin connector A (X31). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) connector 1 (X574). See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location . (Group 9015-10.) Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.02—OPT Solenoid 2 Abnormal. Is code active? Return connectors to appropriate solenoids after check is complete.

Result: YES:Go to Continuity Check. NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. ( 3 ) Continuity Check






Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between: Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31). Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main controller 31-pin connector A (X31). Is continuity indicated?


Action: Key switch in OFF position. AFL solenoid B (marked 1B) (Y62) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground. Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?









AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?

Result: YES:Checks complete. NO:AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.






011817.03- OPT Solenoid 2 Current High 360

Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) High Current Diagnostic Procedure ( 1 ) Connector Check



Action: Key switch in OFF position. Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.03—OPT Solenoid 2 Current High. Is code active? Return connectors to appropriate solenoids after check is complete.











Action: Key switch in OFF position. AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?







011817.04- OPT Solenoid 2 Current Low 360

Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current below 56 mA.

Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Low Current Diagnostic Procedure ( 1 ) Connector Check



Action: Key switch in OFF position. Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.04—OPT Solenoid 2 Current Low. Is code active? Return connectors to appropriate solenoids after check is complete.









Action: Key switch in OFF position. AFL solenoid B (marked 1B) (Y62) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between: Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground. Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. NO:Go to Solenoid Check. ( 5 ) Solenoid Check

Action: Key switch in OFF position. AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?







011901.03- Hydraulic Oil Temperature Sensor Circuit High Input 360

Hydraulic oil temperature sensor (B40) voltage is high (above 4.35 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Hydraulic oil temperature sensor (B40) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness to-main controller 17-pin connector C (X33) and cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect hydraulic oil temperature sensor (B40). Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.) Is hydraulic oil temperature sensor (B40) within specification?

Result: YES:Go to Open Circuit Check. NO:Hydraulic oil temperature sensor (B40) malfunction. Replace sensor. ( 3 ) Open Circuit Check






Hydraulic oil temperature sensor (B40) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between: Pin 1 of hydraulic oil temperature sensor (B40) connector and pin 1 of cab harness-to-main controller 17-pin connector C (X33). Pin 2 of hydraulic oil temperature sensor (B40) connector and pin 16 of cab harness-to-main controller 26-pin connector F (X36). Is continuity indicated?

Result: YES:Repair or replace harness. See appropriate harness. NO:Go to Voltage Check. ( 4 ) Voltage Check

Action: Key switch in OFF position. Hydraulic oil temperature sensor (B40) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Turn key switch to ON position. Check pin 1 of hydraulic oil temperature sensor (B40) connector for voltage. Is voltage indicated?

Result: YES:Short circuit to power. Repair or replace harness. See appropriate harness. NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.)






011901.04- Hydraulic Oil Temperature Sensor Circuit Low Input 360

Hydraulic oil temperature sensor (B40) voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb·in

Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Hydraulic oil temperature sensor (B40) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location . (Group 9015-10.) Machine harness splice connector (X98) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness to-main controller 17-pin connector C (X33) and cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Key switch in OFF position. Disconnect hydraulic oil temperature sensor (B40). Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.) Is hydraulic oil temperature sensor (B40) within specification?

Result: YES:Go to Voltage Check. NO:Hydraulic oil temperature sensor (B40) malfunction. Replace sensor. ( 3 ) Voltage Check






Hydraulic oil temperature sensor (B40) disconnected. Turn key switch to ON position. Check between pin 1 and pin 2 on hydraulic oil temperature sensor (B40) connector for voltage. Is voltage indicated?

Result: YES:Go to Short Circuit Check. NO:Open circuit. Repair or replace harness. See appropriate harness. ( 4 ) Short Circuit Check

Action: Key switch in OFF position. Hydraulic oil temperature sensor (B40) disconnected. Check for continuity between pin 1 of hydraulic oil temperature sensor (B40) and machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group 9015-20.) 020010.02- Exhaust Filter Alarm 360







020011.02- Electric Lever Alarm 360

Electric control lever system is abnormal. →NOTE: There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble codes associated with auxiliary diagnostics before continuing with procedure.

Electric Control Lever Alarm Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537). Auxiliary function lever (AFL) connector 1 (X574). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?

Result: YES:Signal error. NO:Repair or replace harness. See appropriate harness. 020062.02- Hydraulic Oil Temperature Alarm 360

Hydraulic Oil Temperature Alarm Diagnose the diagnostic trouble codes (DTC) of main controller (MCZ) diagnostic trouble codes. See 011901.03 — Hydraulic Oil Temperature Sensor Circuit High and see 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low . (Group 9001-10.)





Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

020303.02- Electric Lever Pilot Cut Alarm 360

Electric control lever abnormal signal in neutral position. →NOTE: There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble codes before continuing with procedure.

Attachment Pedal or Blade and Outrigger Control Lever Alarm Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris: See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-main controller 17-pin connector C (X33). Cab harness-to-main controller 26-pin connector F (X36). See Auxiliary Function Lever (AFL) Harness (W75) Component Location . (Group 9015-10.) Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537). Auxiliary function lever (AFL) connector 1 (X574). Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577). Are connectors in good condition and free of corrosion and debris?

Result: YES:Pilot signal error. NO:Repair or replace harness. See appropriate harness.






Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes For additional information on the engine control unit circuit, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) See MPDr Application . (Group 9015-20.)






000111.07- Coolant Level Low—Moderately Severe Level 346

Loss of coolant detected by engine coolant loss level sensor (S5001) in the surge tank.

Coolant Level Low—Moderately Severe Level Diagnostic Procedure Alarm Level: Coolant Level Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Coolant Level Check

Action: Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.) Is coolant level low?

Result: YES:Add coolant to surge tank and check cooling system for leaks. NO:Go to Connector Check. ( 2 ) Connector Check

Action: Check harness connection to engine coolant loss level sensor (S5001) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Component Check. NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) ( 3 ) Component Check

Action: Disconnect engine coolant loss level sensor (S5001). Does monitor indicate low coolant level?

Result: YES:Engine coolant loss level sensor (S5001) malfunction. Replace sensor. NO:Go to Short to Ground Check ( 4 ) Short to Ground Check

Action: Engine coolant loss level sensor (S5001) disconnected. Check wire Y01 YEL for on engine coolant loss level sensor (S5001) connector pin 1 for continuity to ground. Is continuity to ground indicated?






Result: YES:Checks complete. NO:Repair or replace harness as necessary.






000111.17- Coolant Level Low—Most Severe Level 346

Loss of coolant detected by engine coolant service level sensor (S5002) in the surge tank.

Coolant Level Low—Most Severe Level Diagnostic Procedure Alarm Level: Coolant Level Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Coolant Level Check

Action: Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.) Is coolant level low?

Result: YES:Add coolant to surge tank and check cooling system for leaks. NO:Go to Connector Check. ( 2 ) Connector Check

Action: Check harness connection to engine coolant service level sensor (S5002) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Disconnect engine coolant service level sensor (S5002). Does sensor indicate low coolant level?

Result: YES:Engine coolant service level sensor (S5002) malfunction. Replace sensor. NO:Go to Short to Ground Check. ( 4 ) Short to Ground Check

Action: Engine coolant service level sensor (S5002) disconnected. Check wire Y02 YEL on engine coolant service level sensor (S5002) connector pin 1 for continuity to ground. Is continuity to ground indicated?






Result: YES:Checks complete. NO:Repair or replace harness as necessary. 000158.01- Battery Voltage Low 346

Low battery voltage detected by engine control unit (ECU).

Battery Voltage Low Diagnostic Procedure ( 1 ) Voltage Check

Action: Ignition OFF. Test battery voltage. See Electrical Component Checks . (Group 9015-20.) Is battery voltage within specification?

Result: YES:Checks complete. NO:Go to Battery Charge. ( 2 ) Battery Charge

Action: Charge battery. See Using Battery Charger . (Operator’s Manual.) Test battery voltage. See Electrical Component Checks . (Group 9015-20.) Is battery voltage within specification?

Result: YES:Checks complete. NO:Replace batteries. See Battery Remove and Install . (Group 9015-20.)






000647.05- Variable Speed Fan Solenoid Open Circuit 346

Variable speed fan solenoid (Y5005) open circuit.

Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection to variable speed fan solenoid (Y5005) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.) Does variable speed fan solenoid (Y5005) test OK?

Result: YES:Go to Open Circuit Check. NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid. ( 3 ) Open Circuit Check

Action: Variable speed fan solenoid (Y5005) disconnected. Disconnect ECU-to-engine interface harness connector 3 (X16). Check wire J01 TAN for continuity between variable speed fan solenoid (Y5005) pin 2 and ECU-to-engine interface harness connector 3 (X16) pin 15. Disconnect engine interface harness ground (W43). Check wire G01G BLK for continuity between variable speed fan solenoid (Y5005) pin 1 and engine interface harness ground connector (W43). Is continuity indicated?

Result: YES:Checks complete. NO:Repair or replace harness as necessary. <- Go to Section TOC










000647.06- Variable Speed Fan Solenoid Short Circuit 346

Variable speed fan solenoid (Y5005) short circuit.

Variable Speed Fan Solenoid Short Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection to variable speed fan solenoid (Y5005) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.) Does variable speed fan solenoid (Y5005) test OK?

Result: YES:Go to Short to Ground Check. NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid. ( 3 ) Short to Ground Check

Action: Variable speed fan solenoid (Y5005) disconnected. Disconnect ECU-to-engine interface harness connector 3 (X16). Check wire J01 TAN between variable speed fan solenoid connector pin 2 (Y5005) and machine ground. Is continuity indicated?

Result: YES:Circuit is shorted to ground. Repair or replace harness as necessary. NO:Checks complete.






000647.16- Reversing Fan Switch Active Too Long 346

Reversing fan switch (S15) stuck on.

Reversing Fan Switch Active Too Long Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Function Check

Action: Is operator holding reversing fan switch (S15) too long? Is reversing fan switch (S15) stuck ON?

Result: YES:Advise operator of reversing fan function or clean reversing fan switch (S15). See Reversing Fan Switch—If Equipped . (Operator’s Manual.) NO:Go to Component Check. ( 2 ) Component Check

Action: Disconnect reversing fan switch (S15). See Reversing Fan Switch Harness (W23) Component Location and see Cab Harness (W1) Component Location . (Group 9015-10.) Place reversing fan switch (S15) in OFF position. Check reversing fan switch (S15) for continuity between pins 6 and 9. See Reversing Fan Switch Harness (W23) Wiring Diagram . (Group 9015-10.) Check for continuity between pins 8 and 9. Is continuity indicated?

Result: YES:Reversing fan switch (S15) malfunction. Replace switch. NO:Go to Short to Power Check. ( 3 ) Short to Power Check

Action: Reversing fan switch (S15) disconnected. Turn key switch to ON position. Is power indicated at pin 9 of reversing fan switch connector (S15)?

Result: YES:Circuit is shorted to power. Repair or replace harness as necessary. NO:Checks complete. <- Go to Section TOC










000898.09- Requested Speed/Speed Limit 346

Speed request CAN message is missing from ECU.

Requested Speed/Speed Limit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection at flex load controller (FLC) (A15) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to CAN Circuit Check. NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) ( 2 ) CAN Circuit Check

Action: Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) Does CAN circuit test good?

Result: YES:Checks complete. NO:Repair CAN circuit.






001638.09- Hydraulic Temperature 346

Hydraulic temperature CAN message is missing from ECU. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Hydraulic Temperature Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Code Check

Action: Check for the following diagnostic trouble codes. Is diagnostic trouble codes 011901.03 present? Is diagnostic trouble codes 011901.04 present?

Result: YES:See code 011901.03— Hydraulic Oil Temperature Sensor Circuit High Input . (Group 9001-20.) YES:See code 011901.04— Hydraulic Oil Temperature Sensor Circuit Low Input . (Group 9001-20.) NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check

Action: Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) Does CAN circuit test good?

Result: YES:Checks complete. NO:Repair CAN circuit.






001639.00- Fan Speed High—Most Severe Level 346

ECU detects higher fan speed than desired.

Fan Speed High—Moderately Severe Level Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection at fan speed sensor (B53) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Code Check. NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) ( 2 ) Code Check

Action: Check for active ECU diagnostic trouble codes. Is ECU diagnostic trouble codes 000647.05 present? Is ECU diagnostic trouble codes 000647.06 present?

Result: YES:See ECU code 000647.05— Variable Speed Fan Solenoid Open Circuit . (Group 9001-20.) YES:See ECU code 000647.06— Variable Speed Fan Solenoid Short Circuit . (Group 9001-20.) NO:Go to Solenoid Check. ( 3 ) Solenoid Check

Action: Test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.) Does variable speed fan solenoid (Y5005) test OK?

Result: YES:Go to Harness Check. NO:Variable speed fan solenoid (Y5005) malfunction. Replace solenoid. ( 4 ) Harness Check

Action: Disconnect fan speed sensor (B53) and ECU-to-engine interface harness connector 3 (X16).






Check wire R05 BLK for continuity between fan speed sensor (B53) pin B and ECU-to-engine interface harness connector 3 (X16) pin 33. Check wire M04 PUR for continuity between fan speed sensor (B53) pin C and ECU-to-engine interface harness connector 3 (X16) pin 18. Is continuity indicated?

Result: YES:Go to Fan Speed Check. NO:Repair or replace harness as necessary. ( 5 ) Fan Speed Check

Action: Check fan speed. See Fan Speed Test . (Group 9025-25.) Is fan speed within specification?

Result: YES:Checks complete. NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.)






001639.01- Fan Speed Low—Most Severe Level 346

ECU detects zero fan speed.

Fan Speed Low—Most Severe Level Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection at fan speed sensor (B53) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Voltage Check. NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.) ( 2 ) Voltage Check

Action: Disconnect fan speed sensor (B53). Turn key switch to ON position. Check wire P02 RED of fan speed sensor connector (B53) pin A for voltage. Is voltage greater than 5.0 V?

Result: YES:Repair or replace harness as necessary. NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check

Action: Fan speed sensor (B53) disconnected. Disconnect ECU-to-engine interface harness connector 3 (X16). Check wire R05 BLK for continuity between fan speed sensor (B53) pin B and ECU-to-engine interface harness connector 3 (X16) pin 33. Check wire M04 PUR for continuity between fan speed sensor (B53) pin C and ECU-to-engine interface harness connector 3 (X16) pin 18. Is continuity indicated?

Result: YES:Go to Fan Speed Check. <- Go to Section TOC





NO:Repair or replace harness as necessary. ( 4 ) Fan Speed Check

Action: Check fan speed. See Fan Speed Test . (Group 9025-25.) Is fan speed within specification?

Result: YES:Fan speed sensor (B53) malfunction. Replace sensor. NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.) 001639.18- Fan Speed Low—Moderately Severe Level 346

For diagnostic procedure, see 001639.01—Fan Speed Low—Most Severe Level . (Group 9001-20.) 003701.14- Exhaust Filter Cleaning Not Required 346

Operator requested a parked exhaust filter cleaning, but an exhaust filter cleaning was not required.






005484.05- Reversing Fan Solenoid Open Circuit 346

Reversing fan solenoid (Y9) open circuit.

Reversing Fan Solenoid Open Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection to reversing fan solenoid (Y9) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.) Does reversing fan solenoid (Y9) test OK?

Result: YES:Go to Open Circuit Check. NO:Reversing fan solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Open Circuit Check

Action: Reversing fan solenoid (Y9) disconnected. Disconnect ECU-to-engine interface harness connector 3 (X16). Check wire J02 TAN for continuity between reversing fan solenoid (Y9) pin 2 and ECU-to-engine interface harness connector 3 (X16) pin 48. Disconnect engine interface harness ground (W43). Check wire G01C BLK for continuity between reversing fan solenoid (Y9) pin 1 and engine interface harness ground connector (W43). Is continuity indicated?

Result: YES:Checks complete. NO:Repair or replace harness as necessary. <- Go to Section TOC









Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes

005484.06- Reversing Fan Solenoid Short Circuit 346

Reversing fan solenoid (Y9) short circuit.

Reversing Fan Solenoid Short Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) ( 1 ) Connector Check

Action: Check harness connection to reversing fan solenoid (Y9) and engine control unit (ECU)-to-engine interface harness connector 3 (X16). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.) Does reversing fan solenoid (Y9) test OK?

Result: YES:Go to Short to Ground Check. NO:Reversing fan solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Short to Ground Check

Action: Reversing fan solenoid (Y9) disconnected. Disconnect ECU-to-engine interface harness connector 3 (X16). Check wire J01 TAN between reversing fan solenoid connector (Y9) pin 2 and machine ground. Is continuity indicated?

Result: YES:Repair or replace harness as necessary. NO:Checks complete.






Group 30 - Monitor Controller (DSZ) Diagnostic Trouble Codes Monitor Controller (DSZ) Diagnostic Trouble Codes For additional information on the monitor controller circuit, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) Monitor controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) See MPDr Application . (Group 9015-20.) 013002.02- ECU Communication Error 395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) 013003.02- Main Controller (MCZ) Communication Error 1 395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) 013004.02- Main Controller (MCZ) Communication Error 2 395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) 013005.02- Monitor Controller (DSZ) Communication Error 1 395

Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) 013006.02- Monitor Controller (DSZ) Communication Error 2 395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) 013007.02- Machine Controller (BCZ) Communication Error 395

Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) 013303.02- Abnormal Monitor Internal Temperature Sensor 395

The monitor screen becomes dark.

Monitor Internal Temperature Sensor Diagnostic Procedure ( 1 ) Temperature Check

Action: Check temperature in or around monitor controller. Is temperature above 85°C (185°F)?

Result: YES:Go to Screen Check. NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) ( 2 ) Screen Check






Action: Cool monitor controller and observe monitor screen. Does monitor screen return to normal as monitor cooled?

Result: YES:Monitor controller is OK. NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) 013304.02- Alternator Alarm 395

Alternator output above 33.5 volts.

Alternator Alarm Diagnostic Procedure ( 1 ) Alternator Output Check

Action: Measure alternator output. See Alternator Test . (Group 9015-20.) Is voltage below 33.5 volts?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Alternator malfunction.Repair or replace alternator. 013310.03- Shorted Circuit in Coolant Temperature Sensor 395







013311.03- Fuel Level Sensor Open Circuit 395

Fuel level sensor (B18) open circuit. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Fuel Level Sensor Open Circuit Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Fuel level sensor connector (B18) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin connector A (X20). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Resistance Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Resistance Check

Action: Key switch in OFF position. Disconnect fuel level sensor connector (B18). Check resistance between pins 1 and 2 on fuel level sensor connector (B18). Is sensor within specifications? Fuel Level Sensor Specifications Fuel Level Sensor Specifications Float Position

Resistance (ohms)

Upper Limit (full)

6-10

3/4

26

1/2

33-43

1/4

53

Alarm Level

82-88

Lower Limit (empty)

90-100






Result: YES:Go to Continuity Check. NO:Fuel level sensor malfunction. Replace sensor. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18). Check for continuity between: Pin 1 on fuel level sensor connector (B18) and pin 23 on machine harness splice connector (X98). Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20). Is continuity indicated?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Repair or replace harness. See appropriate harness.






013311.04- Fuel Level Sensor Shorted Circuit 395

Fuel level sensor (B18) shorted to ground. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Fuel Level Sensor Shorted Circuit Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Fuel level sensor connector (B18) and machine harness splice connector (X98). See Machine Harness (W2) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin connector A (X20). See Cab Harness (W1) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Resistance Check. NO:Repair or replace connector. See appropriate harness. ( 2 ) Resistance Check

Action: Key switch in OFF position. Disconnect fuel level sensor connector (B18). Check resistance between pins 1 and 2 on fuel level sensor connector (B18). Is sensor within specifications? Fuel Level Sensor Specifications Fuel Level Sensor Specifications Float Position

Resistance (ohms)

Upper Limit (full)

6-10

3/4

26

1/2

33-43

1/4

53

Alarm Level

82-88

Lower Limit (empty)

90-100






Result: YES:Go to Continuity Check. NO:Fuel level sensor malfunction. Replace sensor. ( 3 ) Continuity Check

Action: Key switch in OFF position. Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18). Check for continuity between: Pin 1 on fuel level sensor connector (B18) and pin 23 on machine harness splice connector (X98). Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20). Is continuity indicated?

Result: YES:Go to Short Circuit Check.Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Repair or replace harness. See appropriate harness. ( 4 ) Short Circuit Check

Action: Key switch in OFF position. Disconnect monitor controller 28-pin connector A (X20). Check for continuity between pin 18 on monitor controller 28-pin connector A (X20) and machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. NO:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) 013334.02- Radiator Coolant Error 186

Diagnose the diagnostic trouble codes (DTC) in the engine control unit (ECU), then clear codes and re-check DTCs. See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.) See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) 014001.02- Flash Memory Read/Write Error 395

Flash Memory Read/Write Error Diagnostic Procedure Flash Memory Read/Write Error in monitor controller. ( 1 ) Diagnostic Trouble Code Check






Action: Clear codes and check for code again. Is diagnostic trouble code (DTC) 014001.02—Flash Memory Read/Write Error still present?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Monitor controller is OK. 014002.02- External RAM Read/Write Error 395

External RAM Read/Write Error Diagnostic Procedure External RAM Read/Write Error in monitor controller. ( 1 ) Diagnostic Trouble Code Check

Action: Clear codes and check for code again. Is diagnostic trouble code (DTC) 014002.02—External RAM Read/Write Error still present?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Monitor controller is OK. 014003.02- Abnormal EEPROM 395

Abnormal EEPROM Diagnostics Procedure Abnormal EEPROM in monitor controller. ( 1 ) Diagnostic Trouble Code Check

Action: Clear codes and check for code again. Is diagnostic trouble code (DTC) 014003.02—Abnormal EEPROM still present?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Monitor controller is OK.






014006.02- Communication Terminal:Communication Error 395

Communication Terminal:Communication Error Diagnostic Procedure ( 1 ) Fuse Check

Action: Key switch in OFF position. Remove fuses (F6000—F6002). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Check fuses (F6000—F6002) for continuity. Is continuity indicated?

Result: YES:Go to Power Check. NO:Replace defective fuse(s). ( 2 ) Power Check

Action: Key switch in OFF position. Disconnect satellite (SAT) module control unit 48-pin connector (X6015). See Satellite (SAT) Harness (W6003) Component Location . (Group 9015-10.) Turn key switch to ON position. Check for voltage between pins M1 and M2 on satellite (SAT) module control unit 48-pin connector (X6015). Is voltage between 22—25 volts?


Action: Key switch in OFF position. Disconnect satellite (SAT) module control unit 48-pin connector (X6015). Disconnect modular telematics gateway (MTG) connector (X6014). Check continuity between: Pin A1 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A2 on modular telematics gateway (MTG) connector (X6014). Pin A2 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A1 on modular telematics gateway (MTG) connector (X6014). Is continuity indicated?






Result: YES:Go to Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) NO:Repair or replace harness. See appropriate harness. 014008.02- Abnormal Internal RAM 395

Abnormal Internal RAM Diagnostic Procedure Abnormal Internal RAM in monitor controller. ( 1 ) Diagnostic Trouble Code Check

Action: Clear codes and check for code again. Is diagnostic trouble code (DTC) 014008.02—Abnormal Internal RAM still present?

Result: YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) NO:Monitor controller is OK. 014021.02- Communication Terminal Security Error 395

Security malfunction of mobile communication equipment. For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.) 014022.02- SIM Card Error 395

For more information on JDLink ™ and ZXLink ™ , see TM114519. 014023.02- Security Error 395

Communication error with the main controller (MCZ). For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.) 020100.02- Overheat Alarm 395

Not applicable to this machine. 020101.02- Engine Warning Alarm 395

Diagnose the Diagnostic Trouble Codes (DTC) in the Engine Control Unit (ECU). See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.) <- Go to Section TOC





020102.02- Engine Oil Pressure Alarm 395

Diagnose the Diagnostic Trouble Codes (DTC) in the Engine Control Unit (ECU). See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)






020105.02- Hydraulic Oil Filter Restriction Alarm 395

IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure ( 1 ) Filter Check

Action: Replace hydraulic oil filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.) Is DTC 020105.02 still present?

Result: YES:Go to Hydraulic Oil Filter Restriction Switch Check. NO:Checks complete. ( 2 ) Hydraulic Oil Filter Restriction Switch Check

Action: Key switch in OFF position. Disconnect hydraulic oil filter restriction switch (B27). See Machine Harness (W2) Component Location . (Group 9015-10.) Check for continuity between terminals of hydraulic oil filter restriction switch. Is continuity indicated?

Result: YES:Hydraulic oil filter restriction switch malfunction. Replace switch. NO:Go to Circuit Check. ( 3 ) Circuit Check

Action: Key switch in OFF position. Disconnect monitor controller 36-pin connector B (X21) and hydraulic oil filter restriction switch (B27). Check for continuity between pin 13 on monitor controller 36-pin connector B (X21) and machine ground. Is continuity indicated?

Result: YES:Short to ground. Repair or replace harness. See appropriate harness. <- Go to Section TOC





NO:Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.) 020106.02- Air Cleaner Restriction Alarm 395

Not applicable to this machine. 020107.02- Water Separator Alarm 395







020109.02- Pilot Control Shut-Off Lever Alarm 395

Pilot Control Shut-Off Lever Alarm Diagnostic Procedure ( 1 ) Connector Check

Action: Key switch in OFF position. Check the following connectors for damage, corrosion, or debris. Cab harness-to-pilot shutoff switch harness connector (X65). See Pilot Shutoff Switch Harness (W11) Component Location . (Group 9015-10.) Cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.) Check cab harness-to-pilot shutoff switch harness connector (X65) for corrosion, loose fit, bent/pressed out pins or crimp malfunctions. Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Code Check. NO:Repair or replace connector(s) or pin(s) as needed. ( 2 ) Code Check

Action: Clear codes and check for code again. Is diagnostic trouble code (DTC) 020109.02—Pilot Control Shut-Off Lever Alarm?

Result: YES:Go to Pilot Shutoff Switch 1 (S3) Check. NO:Monitor controller is OK. ( 3 ) Pilot Shutoff Switch 1 (S3) Check

Action: Pilot control shutoff lever in locked (UP) position. Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff switch harness connector (X65). Is continuity indicated?

Result: YES:Short in pilot shutoff switch harness (W11). Repair or replace harness. NO:Go to Pilot Shutoff Switch 2 (S4) Check. ( 4 ) Pilot Shutoff Switch 2 (S4) Check

Action: Pilot control shutoff lever in unlocked (DOWN) position. <- Go to Section TOC




Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff switch harness connector (X65). Is continuity indicated?

Result: YES:Short in pilot shutoff switch harness (W11). Repair or replace harness. NO:Checks complete. 020110.02- Fuel Filter Restriction Alarm 395

Diagnose diagnostic trouble code (DTC) 000094.17 of the engine control unit (ECU). See 4.5 (4045) and 6.8 L (6068) Engine . (CTM 502.) 020113.02- System Error Alarm 395

Faulty controller area network (CAN) circuit. For more information: See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.) See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.) See Interface Controller Area Network (N-CAN) Diagnostics . (Group 9001-10.) See Engine Controller Area Network (Engine CAN) Diagnostics . (Group 9001-10.) 020114.02- Overheat Alarm 395

Not applicable to this machine. 020133.02- Crane Function Alarm 395

Not applicable to this machine. 020142.02- Intake Air Temperature Alarm 395

Not applicable to this machine. 020145.02- Boost Temperature Increase Alarm 395

Not applicable to this machine. 020146.02- Fuel Temperature Increase Alarm 395

Not applicable to this machine. 020149.02- EGR Gas Temperature Alarm 395







Group 40 - Air Conditioner Controller (ACF) Diagnostic Trouble Codes Air Conditioner Controller (ACF) Diagnostic Trouble Codes Air conditioner controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) See MPDr Application . (Group 9015-20.)






11- Open Circuit in Air Recirculation Sensor 188

Open Circuit in Air Recirculation Sensor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air recirculation sensor (B55) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air recirculation sensor (B55) connectors. Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air recirculation sensor (B55) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is there continuity on the appropriate pins?

Result: YES:Go to Voltage Check. NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Air recirculation sensor (B55) disconnected. Turn key switch to ON position. Check air recirculation sensor (B55) circuit voltage to ground. Is voltage greater than 4.95 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Sensor Check. ( 4 ) Sensor Check






Action: Turn key switch to OFF position. Air recirculation sensor (B55) disconnected. Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.) Is air recirculation sensor within specification?

Result: YES:Checks complete. NO:Air recirculation sensor malfunction. Replace sensor.






12- Short-Circuited Air Recirculation Sensor 188

Short-Circuited Air Recirculation Sensor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air recirculation sensor (B55) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air recirculation sensor (B55) connectors. Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air recirculation sensor (B55) connectors for continuity to machine ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is continuity to ground indicated?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Voltage Check. ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Air recirculation sensor (B55) disconnected. Turn key switch to ON position. Check air recirculation sensor (B55) circuit voltage to ground. Is voltage less than 0.3 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Sensor Check. ( 4 ) Sensor Check






Action: Turn key switch to OFF position. Air recirculation sensor (B55) disconnected. Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.) Is air recirculation sensor within specification?

Result: YES:Checks complete. NO:Air recirculation sensor malfunction. Replace sensor.






13- Open Circuit in Ambient Air Temperature Sensor 188


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check the following connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Ambient air temperature sensor (B22). See Machine Harness (W2) Component Location . (Group 9015-10.) Machine harness-to-cab harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Machine Harness (W2) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and ambient air temperature sensor (B22). Check wires between air conditioner controller (A7) and ambient air temperature sensor (B22) connectors for continuity. Is there continuity on the appropriate pins?

Result: YES:Go to Voltage Check. NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Ambient air temperature sensor (B22) disconnected. <- Go to Section TOC





Turn key switch to ON position. Check ambient air temperature sensor (B22) circuit voltage to ground. Is voltage greater than 4.88 V?

Result: YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. NO:Go to Sensor Check. ( 4 ) Sensor Check

Action: Turn key switch to OFF position. Ambient air temperature sensor (B22) disconnected. Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.) Is ambient air temperature sensor within specification?

Result: YES:Checks complete. NO:Ambient air temperature sensor malfunction. Replace sensor.






14- Short-Circuited Ambient Air Temperature Sensor 188


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check the following connectors for damage, corrosion, or debris. Ambient air temperature sensor (B22). See Machine Harness (W2) Component Location . (Group 9015-10.) Machine harness-to-cab harness 100-pin connector (X3). See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Machine Harness (W2) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and ambient air temperature sensor (B22) connectors. Check wires between air conditioner controller (A7) and ambient air temperature sensor (B22) connectors for continuity to machine ground. Is continuity to ground indicated?

Result: YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. NO:Go to Voltage Check. ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Ambient air temperature sensor (B22) disconnected. <- Go to Section TOC





Turn key switch to ON position. Check ambient air temperature sensor (B22) circuit voltage to ground. Is voltage less than 0.096 V?

Result: YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. NO:Go to Sensor Check. ( 4 ) Sensor Check

Action: Turn key switch to OFF position. Disconnect ambient air temperature sensor (B22) connector. Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.) Is ambient air temperature sensor within specification?

Result: YES:Checks complete. NO:Ambient air temperature sensor malfunction. Replace sensor.






18- Short-Circuited Solar Radiation Sensor 188

Short-Circuited Solar Radiation Sensor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check the following connectors for damage, corrosion, or debris. Solar sensor (B21). See Monitor Harness (W3) Component Location . (Group 9015-10.) Monitor harness-to-cab harness (X17). See Cab Harness (W1) Component Location . (Group 9015-10.) Cab harness-to-air conditioner 10-pin connector (X52) and air conditioner controller (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Monitor Harness (W3) Wiring Diagram , see Cab Harness (W1) Wiring Diagram , or see Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and solar sensor (B21) connectors. Check wires between air conditioner controller (A7) and solar sensor (B21) connectors for continuity. Is continuity indicated on appropriate pins?

Result: YES:Go to Voltage Check. NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Solar sensor (B21) disconnected. Turn key switch to ON position. Check solar sensor (B21) circuit voltage to ground. Is voltage greater than 5.04 V?

Result: YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram. NO:Solar sensor malfunction. Replace sensor. <- Go to Section TOC










21- Open Circuit in Air Conditioner Freeze Control Switch 188

Open Circuit In Air Conditioner Freeze Control Switch Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors. Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is there continuity on the appropriate pins?

Result: YES:Go to Voltage Check. NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Air conditioner freeze control switch (B41) disconnected. Turn key switch to ON position. Check air conditioner freeze control switch (B41) circuit voltage to ground. Is voltage greater than 4.79 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Switch Check. ( 4 ) Switch Check <- Go to Section TOC





Action: Turn key switch to OFF position. Air conditioner freeze control switch (B41) disconnected. Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.) Is air conditioner freeze control switch within specification?

Result: YES:Checks complete. NO:Air conditioner freeze control switch malfunction. Replace switch.






22- Short-Circuited Air Conditioner Freeze Control Switch 188

Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors. Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner freeze control switch (B41) connectors for continuity to machine ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is continuity to ground indicated?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Voltage Check. ( 3 ) Voltage Check

Action: Turn key switch to OFF position. Air conditioner freeze control switch (B41) disconnected. Turn key switch to ON position. Check air conditioner freeze control switch (B41) circuit voltage to ground. Is voltage less than 0.096 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Go to Switch Check.






( 4 ) Switch Check

Action: Turn key switch to OFF position. Air conditioner freeze control switch (B41) disconnected. Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.) Is air conditioner freeze control switch within specification?

Result: YES:Checks complete. NO:Air conditioner freeze control switch malfunction. Replace switch.






43- Abnormal Air Conditioner and Heater Blower Port Change Servomotor 188

Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air conditioner and heater blower port change servomotor (M10) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air conditioner and heater blower port change servomotor (M10). Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner and heater blower port change servomotor (M10) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is there continuity on the appropriate pins?

Result: YES:Go to Open Circuit Check. NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 3 ) Open Circuit Check

Action: Turn key switch to OFF position. Air conditioner and heater blower port change servomotor (M10) disconnected. Turn key switch to ON position. Turn temperature control/mode switch and blower speed switch to ON position. Check air conditioner and heater blower port change servomotor (M10) circuit voltage to ground. Is voltage greater than 5 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)






NO:Go to Short Circuit Check. ( 4 ) Short Circuit Check

Action: Turn key switch to OFF position. Air conditioner and heater blower port change servomotor (M10) disconnected. Turn key switch to ON position. Turn temperature control/mode switch and blower speed switch to ON position. Check air conditioner and heater blower port change servomotor (M10) circuit voltage to ground. Is voltage present?

Result: YES:Air conditioner and heater blower port change servomotor malfunction. Replace servomotor. NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)






44- Abnormal Air Conditioner and Heater Mixer Servomotor 188

Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check air conditioner controller (A7) and air conditioner and heater mixer servomotor (M11) connectors for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?


Action: Turn key switch to OFF position. Disconnect air conditioner controller (A7) and air conditioner and heater mixer servomotor (M11). Check heater and air conditioner harness (W41) wires between air conditioner controller (A7) and air conditioner and heater mixer servomotor (M11) connectors for continuity. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is there continuity on the appropriate pins?

Result: YES:Go to Open Circuit Check. NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 3 ) Open Circuit Check

Action: Turn key switch to OFF position. Air conditioner and heater mixer servomotor (M11) disconnected. Turn key switch to ON position. Turn temperature control/mode switch and blower speed switch to ON position. Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground. Is voltage greater than 4.8V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)






NO:Go to Short Circuit Check. ( 4 ) Short Circuit Check

Action: Turn key switch to OFF position. Air conditioner and heater mixer servomotor (M11) disconnected. Turn key switch to ON position. Turn temperature control/mode switch and blower speed switch to ON position. Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground. Is voltage less than 0.2 V?

Result: YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) NO:Air conditioner and heater mixer servomotor (M11) malfunction. Replace servomotor.






91- Communication Error 188

Communication Error Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check harness connection to monitor controller (A4) and air conditioner controller (A7) for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location and see Monitor Harness (W3) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect monitor controller (A4) and air conditioner controller (A7) connectors. Check heater and air conditioner harness (W41) wires between monitor controller (A4) and air conditioner controller (A7) connectors for continuity. Is there continuity on the appropriate pins?

Result: YES:Air conditioner controller (A7) malfunction. Replace controller. NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.




OPERATIONAL CHECKOUT PROCEDURE


92- CAN Bus Off Error 188

CAN Bus Off Error Diagnostic Procedure ( 1 ) Connector Check

Action: Turn key switch to OFF position. Check harness connection to monitor controller (A4) and air conditioner controller (A7) for damage, corrosion, or debris. See Heater and Air Conditioner Harness (W41) Component Location and see Monitor Harness (W3) Component Location . (Group 9015-10.) Are connectors in good condition and free of corrosion and debris?

Result: YES:Go to Harness Check. NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.) ( 2 ) Harness Check

Action: Turn key switch to OFF position. Disconnect monitor controller (A4) and air conditioner controller (A7) connectors. Check heater and air conditioner harness (W41) wires between monitor controller (A4) and air conditioner controller (A7) connectors for continuity. Is there continuity on the appropriate pins?

Result: YES:Air conditioner controller (A7) malfunction. Replace controller. NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.






Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Table of contents Group 10 - Operational Checkout Procedure ....................................................................................... 1 Operational Checks—Key Switch On, Engine On Checks ...................................................................... 1



Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Group 10 - Operational Checkout Procedure Operational Checkout This procedure is used to check operation of machine. It is designed so you can do a walk around inspection, check machine operation, and perform specific checks from the operator′s seat. If there is a problem with machine, diagnostic information in this checkout will help pinpoint the probable cause. This information may allow you to perform a simple adjustment to correct the problem. Use the table of contents to help find adjustment procedures. A location will be required which is level and has adequate space to complete checks. No tools or equipment are needed to perform checkout. Complete necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring) prior to doing checkout. The machine must be at operating temperature for many of the checks. See Hydraulic Oil Warm-up Procedure . (Group 9025-25.) Read each check completely before performing. If no problem is found, you will be instructed to go to the next check. If a problem is indicated, you will be referred to a procedure for adjustment, repair, or replacement. The monitor can be used to perform diagnostic and operational checks. The monitor can display engine speed, pressures, and diagnostic trouble codes (DTCs).

Diagnostic Trouble Code Check ( 1 ) Display and Clear Trouble Codes

Action: Always check for diagnostic trouble codes and correct them before performing operational checkout. Diagnostic trouble codes can be displayed by using one of the following methods: Monitor Service ADVISOR ™ MPDr sss: Are diagnostic trouble codes present?

Result: YES:Correct all diagnostic trouble codes before proceeding. See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . See Reading Diagnostic Trouble Codes With Monitor Display . See MPDr Application . (Group 9015-20.) NO:Proceed with operational checkout.

Operational Checks—Key Switch Off, Engine Off Checks ( 1 ) Horn Circuit Check

Action:


Section 9005 page 1




Horn Circuit LEGEND: 1

Horn Button

Key switch in OFF position. Press horn button (1) on top of left pilot control lever. sss: Does horn sound?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check horn 10 A fuse (F19) (marked HORN). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check horn wiring harness. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram . (Group 9015-10.) ( 2 ) Hour Meter and Fuel Gauge Checks <- Go to Section TOC

Section 9005 page 2




Action:

Switch


Section 9005 page 3




Hour Meter and Fuel Gauge Screen LEGEND: 1 2 6

Hour Meter Home Button Fuel Gauge

Press and hold home button (2) until default screen appears. sss: Does hour meter (1) display machine hours? sss: Does fuel gauge (6) display correct fuel level?


Measurement

Specification


Torque

10 N·m 89 lb.-in.


Section 9005 page 4




Result: YES:Go to next check. NO:Check power on 5 A fuse (F17) (marked POWER ON). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring. See Cab Harness (W1) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)

Operational Checks—Key Switch On, Engine Off Checks ( 1 ) Monitor Start Up Check

Action: LEGEND: 1 System Starting Screen 2 Default Screen

System Starting Screen

Default Screen

→NOTE: The exhaust filter auto cleaning disabled indicator will display on the monitor when the key switch is in ON position. Once the engine is started, the indicator will disappear unless exhaust filter auto cleaning has been disabled by the operator through the monitor.

When the key switch is turned to the ON position, the system starting screen (1) displays for about 2 seconds and then the default screen (2) is displayed. Turn key switch to ON position. sss: Does monitor display system starting screen? sss: <- Go to Section TOC

Section 9005 page 5




Does default screen with hour meter appear after system starting screen disappears?

Result: YES:Go to next check. NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.) ( 2 ) Monitor, Gauges, and Battery Relay Checks

Action:

Default Screen


Section 9005 page 6




Engine Preheat Indicator LEGEND: 1 2 3 4 5 6 7 8

Work Mode Indicator Exhaust Filter Auto Cleaning Disabled Indicator Power Mode Indicator Hour Meter Engine Coolant Temperature Gauge Fuel Gauge Travel Mode Indicator Engine Preheat Indicator

IMPORTANT: This machine is equipped with glow plugs. Glow plugs are automatically controlled by the engine controller when the key is turned ON. Do not start the engine until the engine preheat indicator (8) disappears on the monitor. Indicator will not appear if ambient air temperature is above 0°C (32°F).



Section 9005 page 7




→NOTE: If engine coolant temperature is below 30°C (86°F) engine temperature gauge needle may not move.

Turn key switch to ON. sss: Does battery relay click? sss: Does engine coolant temperature gauge (5) display correct engine coolant temperature? sss: Does fuel gauge (6) display correct fuel level? sss: Does hour meter (4) display machine hours? sss: Does work mode indicator (1) display correct work mode (dig or attachment)? sss: Does travel mode indicator (7) display correct travel mode? sss: Does power mode indicator (3) display correct power mode?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Monitor does not turn ON. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring. See Cab Harness (W1) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Check key switch. See Electrical Component Checks . (Group 9015-20.) Check battery relay. See Electrical Component Checks . (Group 9015-20.) Check wiring. See Machine Harness (W2) Wiring Diagram and see Cab Harness (W1) Wiring Diagram . (Group 9015-10.) NO:Neither engine coolant temperature gauge nor fuel gauge moves. Check gauge sensor and wiring. See Machine Harness (W2) Wiring Diagram and see Cab Harness (W1) Wiring Diagram . (Group 9015-10.) NO:Other than normal indicator lights remain on. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes With Monitor Display or see Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) <- Go to Section TOC

Section 9005 page 8




( 3 ) Rear Camera Check

Action: LEGEND: 5

Default Screen

LEGEND: 1

Main Menu Screen

Default Screen

Main Menu Screen LEGEND: 2 3 4

Monitor Dial Back Button Home Button

Switch


Section 9005 page 9




CAUTION:

To avoid possible injury or death to operator or others. The rear view camera image is designed to supplement other safety practices and is not intended to be the sole method of collision avoidance. Always be alert and aware of the surroundings when operating this machine.

Turn key switch to ON position. When the default screen (5) is displayed, press monitor dial (2) on the switch . sss: Does main menu (1) display? Rotate monitor dial to highlight settings menu. Press monitor dial. sss: Does settings menu display? At settings menu, rotate monitor dial to highlight rear view camera monitor. Press monitor dial to display rear view camera monitor menu. sss: Does rear view camera monitor menu display? Press monitor dial to turn camera ON (enable). Press home button (4). LEGEND: 6

Rear View Image

Rear View Image sss: Does rear view image (6) display on default screen?

Repeat above steps. At rear view camera monitor menu, press monitor dial to turn camera OFF (disable). <- Go to Section TOC





Press home button. sss: Does default screen appear without rear view image?

Result: YES:Go to next check. NO:Menus do not display. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications . (Group 9015-10.) NO: See Rear Camera Harness (W19) Component Location and see Rear Camera Harness (W19) Wiring Diagram . (Group 9015-10.) ( 4 ) Travel Lever and Pedal Neutral Checks

Action:

Travel Lever and Pedal LEGEND: 1 2

Forward Rearward

Push both travel levers and pedals forward (1), then release. Pull both travel levers and pedals rearward (2), then release. <- Go to Section TOC





sss: Do levers and pedals require equal effort to operate in forward and reverse? sss: Do levers and pedals return to neutral at the same time when released?

Result: YES:Go to next check. NO:Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Disassemble and Assemble . (Group 3360.) ( 5 ) Light Circuit Checks

Action:

Switch LEGEND: 3

Work Light Switch

Turn work light switch (3) to 1st position. sss: Is monitor back light and base machine work light on? sss: <- Go to Section TOC





Does switch illuminate? Turn light switch to 2nd position. sss: Does base machine work light stay on and switch stay illuminated? sss: Does boom work light come on and monitor back light change to night mode?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check work and drive lights 20 A fuse (F1) (marked LAMP) and controller 5 A fuses (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring harness. See System Functional Schematic . (Group 9015-10.) See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) ( 6 ) Windshield Wiper Control Check

Action:






Switch LEGEND: 4

Windshield Wiper and Washer Switch

→NOTE: Front window must be fully closed and latched for windshield wiper to operate.

Turn windshield wiper and washer switch (4) to 1st INT position. sss: Does wiper operate intermittently (8 second interval)? Turn windshield wiper and washer switch to 2nd INT position. sss: Does wiper operate intermittently, but faster than when in first position (5 second interval)? Turn windshield wiper and washer switch to 3rd INT position. sss: Does wiper operate intermittently, but faster than when in second position (3 second interval)? <- Go to Section TOC





Turn windshield wiper and washer switch to ON position. sss: Does wiper operate continuously? Turn windshield wiper and washer switch to OFF position. sss: Does wiper arm stop and retract to left side of windshield?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.) See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) ( 7 ) Windshield Washer Control Check

Action:






Switch LEGEND: 4


IMPORTANT: Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually operated with no fluid in the washer fluid tank. →NOTE: While wiper is being operated in INT mode, when windshield wiper and washer switch is pressed, wiper mode is changed to continuous mode.

Press windshield wiper and washer switch (4). sss: Is washer fluid supplied to windshield? Press and hold windshield wiper and washer switch for 3 seconds. sss: Does wiper start and continue operating until switch is released?






Release windshield wiper and washer switch. sss: Does wiper stop and retract to left side of windshield?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check washer fluid level. See Check Windshield Washer Fluid Level . (Operator’s Manual.) NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) NO:Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) ( 8 ) Windshield Wiper Circuit Check

Action:

Front Window Release Handle LEGEND: 1 2


Lock Pin Lock Release Bar





CAUTION:

Prevent possible injury from window closing. Upper front window comes down very forcefully. Close window only when sitting on operator′s seat. Guide window down slowly.

CAUTION:

Prevent possible injury from window closing. Always lock the pin in cab frame boss hole. →NOTE: The wiper cannot operate with the upper front window open. The washer can operate with the upper front window open. When closing window, check that window upper left corner makes good with the cab.

Slide lock pin (1) inward, then down into notch. Pull lock release bar (2) toward operator’s seat. While holding lower handle on window, pull window up and back as far as it can go. Slide lock pin into cab frame boss hole and rotate downward into the locked position.

Switch <- Go to Section TOC




LEGEND: 4



Turn windshield wiper and washer switch (4) to ON position. sss: Does wiper circuit click? sss: Does wiper remain stationary in park position?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiper wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) ( 9 ) Windshield Washer Circuit Check

Action: IMPORTANT: Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually operated with no fluid in the washer fluid tank.






Switch LEGEND: 4


Press windshield wiper and washer switch (4) and hold for 3 seconds. sss: Is washer fluid supplied to windshield?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Check washer fluid level. See Check Windshield Washer Fluid Level . (Operator′s Manual.) NO:Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications . (Group 9015-10.) <- Go to Section TOC





NO:Check wiring harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) NO:Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)

Operational Checks—Key Switch On, Engine On Checks ( 1 ) Monitor and Gauge Circuit Checks

Action: LEGEND: 1 Power Mode Indicator 2 Hour Meter 3 Engine Coolant Temperature Gauge 4 Fuel Gauge 5 Alarm Indicator

Operating Screen

IMPORTANT: Engine damage could occur if the alarm indicator (5) or engine oil pressure alarm indicator comes on after engine starts. Turn off machine immediately.


Start engine. sss: Do all alarm indicator displays remain off after engine starts? sss: Does alarm indicator remain off after engine starts? sss: Does engine coolant temperature gauge (3) display correct engine coolant temperature? sss: Does fuel gauge (4) display correct fuel level?






Result: YES:Go to next check. NO:Engine oil pressure alarm displayed. Immediately stop engine and check engine oil level. See Check Engine Oil Level . (Operator’s Manual.) OK: See Check Engine Oil Pressure . (CTM104.) NO:Alternator alarm indicator displayed. Check alternator drive belt. OK:Check alternator. See Alternator Test . (Group 9015-20.) NO:Other alarm indicators display on monitor. See Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) ( 2 ) Pilot Shutoff Circuit Check

Action: LEGEND: 1

Engine Speed Dial

Engine Speed Dial

Locked

CAUTION:

Avoid possible injury. Machine may move during this check. Make sure area is clear and large enough to operate all machine functions.

Turn engine speed dial (1) to L (slow idle) position. Place pilot shutoff lever in locked (UP) position. Slowly actuate dig and travel functions. <- Go to Section TOC





sss: Do dig and travel functions operate?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Check wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Switch Harness (W11) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) See Pilot Control Valve Operation . (Group 9025-05.) NO:Continue check.

Action:

Unlocked Place pilot shutoff lever in unlocked (DOWN) position. Slowly actuate dig and travel functions. sss: Do dig and travel functions operate?


Measurement

Specification


Torque

10 N·m 89 lb.-in.






Result: YES:Go to next check. NO: See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Switch Harness (W11) Wiring Diagram . (Group 9015-10.) See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) See Pilot Control Valve Operation . (Group 9025-05.) ( 3 ) Fan Reversing System - If Equipped

Action:

Fan Reversing Switch

Switch LEGEND: 1 2 3 9

Engine Speed Dial Auto-Idle Switch Blower Speed Switch Fan Reversing Switch

Place pilot shutoff lever in unlocked (DOWN) position. <- Go to Section TOC





Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press blower speed switch (3) OFF. Press reversing cooling fan switch to MANUAL position. sss: Does fan speed slow down? sss: After approximately 20 seconds, does the fan speed increase and rotate in reverse direction for approximately 30 seconds? sss: Does the fan speed slow for approximately 20 seconds? Does fan direction return to normal? sss: Does fan speed increase?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO: See Reversing Fan Switch Harness (W23) Wiring Diagram . See Reversing Fan Switch Harness (W23) Component Location . See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) ( 4 ) Engine Speed Dial Check

Action:







Engine Speed Dial Auto-Idle Switch Travel Mode Switch Power Mode Button

Turn auto-idle switch (2) to A/I OFF position. Place pilot shutoff lever in locked (UP) position. Turn engine speed dial (1) clockwise. sss: Does engine speed increase? Turn engine speed dial counterclockwise. sss: Does engine speed decrease?

Result: YES:Go to next check. NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.) <- Go to Section TOC





OK:Check engine speed dial on monitor display. See Service Menu . (Group 9015-16.) See Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) Check wiring harness. See System Functional Schematic . (Group 9015-10.) ( 5 ) ECO (Economy) Mode and PWR (Power) Mode Checks

Action:


Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button

Press power mode button (4) until PWR (power) mode is displayed on monitor. Turn auto-idle switch (2) to A/I OFF position. Turn engine speed dial (1) to H (fast idle) position. Press power mode button until ECO (economy) mode is displayed on monitor. sss: Does engine speed decrease? Press power mode button until PWR (power) mode is displayed on monitor. sss: <- Go to Section TOC





Does engine speed increase?

Result: YES:Go to next check. NO: See Engine Speed Control System Operation (Group 9010-05.) for additional information on engine speed and power mode. ( 6 ) H/P (High Power) Mode Check

Action:



Press power mode button (4) until PWR (power) mode is displayed on monitor. Turn auto-idle switch (2) to A/I OFF position. Turn engine speed dial (1) to H (fast idle) position. Press power mode button until H/P (high power) mode is displayed on monitor. Actuate arm in function over relief. <- Go to Section TOC





sss: Does engine speed increase as function goes over relief?

Result: YES:Go to next check. NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.) See Service Menu . (Group 9015-16.) See Engine Speed Control System Operation . (Group 9010-05.) NO:Check main controller (MCZ) pressure sensors. See Pressure Sensor Test . (Group 9015-20.) NO: See System Functional Schematic . (Group 9015-10.) NO: See H/P (High Power) Function Does Not Operate, PWR (Power) Mode Is Normal . (Group 9025-15.) ( 7 ) Auto-Idle Circuit Check

Action:



Turn engine speed dial (1) to H (fast idle) position. <- Go to Section TOC





Press power mode button (4) until H/P (high power) mode is displayed on monitor. Turn auto-idle switch (2) to A/I off position. Place pilot shutoff lever in unlocked (DOWN) position. Turn auto-idle switch to A/I on position. sss: Does engine speed decrease after 4—6 seconds? Slowly actuate dig function. sss: Does engine speed return to fast idle?

Result: YES:Go to next check. NO:Check solenoid 20 A fuse (F4) (marked SOLENOID). See Fuse and Relay Specifications . (Group 9015-10.) See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) See System Functional Schematic . (Group 9015-10.) ( 8 ) Travel Alarm Check

Action: LEGEND: A B C

Pilot Shutoff Lever Travel Levers Travel Pedals

Travel Alarm

CAUTION:

Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to operate machine.

Place pilot shutoff lever (A) in unlocked (DOWN) position. Push travel pedals or levers forward. sss: Does travel alarm sound?






Push travel pedals or pull levers rearward. sss: Does travel alarm sound?

Result: YES:Go to next check. NO:Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring. See Travel Alarm Harness (W26) Wiring Diagram . (Group 9015-10.) See Travel Alarm Harness (W26) Component Location . (Group 9015-10.) ( 9 ) Travel Alarm Cancel Switch Circuit Check

Action: LEGEND: 1 Reversing Fan Switch 2 Seat Heater Switch 3 Travel Alarm Cancel Switch

Left Console

CAUTION:

Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to operate machine.

→NOTE: Travel alarm must operate for this check.

Place pilot shutoff lever in unlocked (DOWN) position. Push travel pedals or levers and allow travel alarm to operate for a minimum of 12 seconds. sss: <- Go to Section TOC





Does travel alarm sound? While continuing travel, push travel alarm cancel switch (3). sss: Does travel alarm stop sounding?

Result: YES:Go to next check. NO:Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring. See Travel Alarm Harness (W26) Wiring Diagram . (Group 9015-10.) See Travel Alarm Harness (W26) Component Location . (Group 9015-10.) ( 10 ) Hydraulic Oil Tank Pressurization Check

Action: LEGEND: 1 Hydraulic Oil Tank Pressure Release Button 2 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Cover

IMPORTANT: The pressurized oil tank creates pressure at the inlet to the hydraulic pumps. If tank cover does not seal, hydraulic pumps could cavitate and be damaged.

Raise boom to full height, then lower boom to ground. Slowly depress pressure release button (1) on hydraulic oil tank cover. sss: Is air heard escaping from the pressure release button on hydraulic oil tank cover?

Result: YES:Go to next check. NO:Replace hydraulic oil tank cover. ( 11 ) Control Lever Pattern Check-Excavator Pattern






Action:

Control Lever Pattern Check - Excavator Pattern LEGEND: 1 2 3 4 5 6 7 8

Arm Out Arm In Swing Left Swing Right Boom Down Boom Up Bucket Load Bucket Dump

CAUTION:

Prevent possible injury from unexpected machine movement. Clear all persons from the area before operating machine.

Turn engine speed dial to L (slow idle) position. Place pilot shutoff lever in unlocked (DOWN) position. Slowly move hydraulic levers to all positions. sss: Do bucket, boom, arm, and swing move according to pattern?

Result: YES:Go to next check. NO: See Control Lever Pattern Operation . (Operator′s Manual.) NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern . (Group 9025-15.) ( 12 ) Control Lever Pattern Check- Backhoe Pattern <- Go to Section TOC





Action:

Control Lever Pattern Check - Backhoe Pattern LEGEND: 1 2 3 4 5 6 7 8

Arm Out Arm In Swing Left Swing Right Boom Down Boom Up Bucket Load Bucket Dump

CAUTION:


Turn engine speed dial to L (slow idle) position. Place pilot shutoff lever in unlocked (DOWN) position. Slowly move hydraulic levers to all positions. sss: Do bucket, boom, arm, and swing move according to pattern?

Result: YES:Go to next check. NO: See Control Lever Pattern Operation . (Operator′s Manual.) NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern . (Group 9025-15.) ( 13 ) Swing Dynamic Braking Check <- Go to Section TOC





Action:

Swing Dynamic Braking








CAUTION:

Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket. Machine must be on level ground.

Position upperstructure with boom to the front. Move arm to the extended position, bucket to the retracted position, and bucket-to-arm pivot pin at same level as boom-toframe pivot pin. Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Fully actuate swing function. Swing clockwise 90 degrees and then release lever. sss: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever? Position upperstructure with boom to the front. Fully actuate swing function. Swing counterclockwise 90 degrees and then release lever. sss: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever?

Result: YES:Go to next check. NO: Perform Swing Motor Leakage Test . (Group 9025-25.) Perform Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) NO:Check swing valve spool and spring. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 14 ) Swing Park Brake and Circuit Drift Checks

Action:

Machine Position Fill the bucket with dirt. Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine <- Go to Section TOC





approximately 300 mm (1 ft) with the boom and then put a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin. Position upperstructure with cab over travel motors, perpendicular to tracks. Turn engine speed dial to L (slow idle) position. Wait approximately 5 minutes with all functions in neutral. →NOTE: Function does not need to be fully actuated to disengage the swing park brake.

Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10 seconds. sss: Does upperstructure hold position when swing park brake is engaged? sss: Does upperstructure move only slightly when swing park brake is disengaged? Swing upperstructure 180 degrees counterclockwise and repeat procedure. Turn engine speed dial to L (slow idle) position. Wait approximately 5 minutes with all functions in neutral. Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10 seconds. sss: Does upperstructure hold position when swing park brake is engaged? sss: Does upperstructure move only slightly when swing park brake is disengaged?

Result: YES:Go to next check. NO:Upperstructure moves when all functions are in neutral and park brake is engaged. Check for pilot oil pressure to swing park brake. See Upperstructure Drift With Swing Valve In Neutral . (Group 9025-15.) NO:Upperstructure movement is excessive when park brake is disengaged. Perform Swing Motor Leakage Test . (Group 9025-25.) NO:Check swing spool in the control valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 15 ) Swing Power Check

Action:






Machine Position



Fill the bucket with dirt. Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine approximately 300 mm (1 ft) with the boom and then put a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-to-frame pivot pin.






Swing upperstructure clockwise so it is 90 degrees to the slope. Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until H/P (high power) mode is displayed on monitor. Actuate the swing function to swing uphill. sss: Does upperstructure swing uphill? Swing upperstructure 180 degrees counterclockwise and repeat procedure. Turn engine speed dial to H (fast idle) position. Power mode button in H/P (high power) mode. Actuate the swing function to swing uphill. sss: Does upperstructure swing uphill?

Result: YES:Go to next check. NO: See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) NO:Check swing motor leakage. Perform Swing Motor Leakage Test . (Group 9025-25.) NO:Check swing spool in control valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 16 ) Dig Function Drift Check (loaded bucket)

Action:

Machine Position—Loaded Bucket Fill bucket with material to specification. <- Go to Section TOC





Item

Measurement

Specification

Loaded Bucket

Weight (approximate)

750 kg 1650 lb.

Position bucket at maximum reach with bucket pivot pin at same height as boom pivot pin. Retract arm cylinder, then extend about 50 mm (2 in.). Extend bucket cylinder, then retract about 50 mm (2 in.). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Measure distance from bottom of bucket to ground. Compare measurements to specifications.

Item

Measurement

Specification

Drift

10 mm

Dig Function Drift Specifications (loaded bucket) Boom Cylinder

0.39 in. Arm Cylinder

Drift

20 mm 0.79 in.

Bucket Cylinder

Drift

Bottom of Bucket-to-Ground

Drift

15 mm 0.59 in. 110 mm 4.33 in.

Item

Measurement

Specification

Drift

5 mm

Blade Drift Specifications (if equipped) Blade Cylinder

0.20 in. Bottom of Blade-to-Ground

Drift

20 mm 0.79 in.

sss: Is cylinder drift within specification?

Result: YES:Go to next check. NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.) ( 17 ) Dig Function Drift Check (empty bucket)

Action:






Machine Position—Empty Bucket LEGEND: 1

Arm Tip Position Above Ground

Empty bucket of material. Extend arm cylinder, then retract about 50 mm (2 in.). Extend bucket cylinder, then retract about 50 mm (2 in.). Lower boom until arm tip is 1 m (40 in.) above ground (1). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Measure distance from arm tip to ground. Compare measurements to specifications.

Item

Measurement

Specification

Dig Function Drift Specifications (empty bucket) Boom Cylinder

Drift

5 mm 0.20 in.

Arm Cylinder

Drift

Bucket Cylinder

Drift

15 mm 0.59 in. 10 mm 0.39 in.

Arm Tip-to-Ground

Drift

100 mm 3.94 in.

Item

Measurement

Specification

Drift

5 mm

Blade Drift Specifications (if equipped) Blade Cylinder

0.20 in. Bottom of Blade-to-Ground

Drift

20 mm 0.79 in.

sss: <- Go to Section TOC





Is cylinder drift within specification?

Result: YES:Go to next check. NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.) ( 18 ) Swing Priority Circuit Check

Action:

CAUTION:

Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket. Machine must be on level ground.

Swing Priority Check








IMPORTANT: Avoid possible machine damage. Position machine as shown. Operate swing and arm in slowly a few times before attempting to perform check to ensure bucket does not machine or ground.

Position machine as shown. Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Operate swing function and record time required for three complete revolutions.

Item

Measurement

Specification

Swing Function

Time—Three Revolutions

12.50—14.50 sec.

Position machine as shown, arm extended, bucket curled, and upperstructure 90 degrees to tracks. <- Go to Section TOC





Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Raise boom high enough so bucket does not the machine or ground during arm in and swing combined operation. Operate swing function and slowly actuate arm in function when upperstructure is in line with tracks. Record time required for three complete revolutions. →NOTE: Swing speed should not slow when actuating arm in. sss: Does swing speed remain unchanged when actuating arm in?

Result: YES:Go to next check. NO:Check arm 1 flow rate pilot valve. See Pilot Signal Manifold Operation . (Group 9025-05.) See Arm 1 Flow Rate Control Valve Circuit Operation . (Group 9025-05.) ( 19 ) Control Valve Lift Check Test

Action:

Control Valve Lift LEGEND: 1

Engine Speed Dial

Engine Speed Dial Turn engine speed dial (1) to L (slow idle) position. Position machine as shown. <- Go to Section TOC





Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder). sss: Do functions move in opposite direction as pilot control levers are first moved, then change direction as levers are moved farther?

Result: YES: See Load Falls When Control Valve Is Actuated To Raise Load With Engine Running At Slow Idle . (Group 9025-15.) NO:Go to next check. ( 20 ) Boom Up, Arm In, and Bucket Combined Function Operation Check

Action:



Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press power mode button (4) until PWR (power) mode is displayed on monitor. <- Go to Section TOC





Actuate boom up function, arm in function, and then bucket function in combination. sss: Does boom continue to move at approximately the same speed after bucket function is actuated?

Result: YES:Go to next check. NO:If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 21 ) Boom Regenerative Valve Operation Check

Action:



Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Raise boom and extend the arm to full extension. <- Go to Section TOC





Actuate the boom down, then arm in and boom up functions in combined operation. sss: Does the boom move smoothly through the complete cycle down and up and not hesitate when it goes past the vertical position?

Result: YES:Go to next check. NO:Check boom up pressure sensor (B30). See Pressure Sensor Test . (Group 9015-20.) NO:Check boom regenerative valve. See Boom Regenerative Valve Circuit Operation . (Group 9025-05.) See Control Valve (5Spool) Disassemble and Assemble . (Group 3360.) ( 22 ) Arm Regenerative Valve Operation Check

Action:



Turn engine speed dial (1) to H (fast idle) position. <- Go to Section TOC





Press power mode button (4) until PWR (power) mode is displayed on monitor. Extend the arm to full extension and then lower boom so bucket is on the ground. Actuate the boom up and arm in functions in combined operation. sss: Does the arm move smoothly through the complete cycle and not hesitate when it goes through the vertical position?

Result: YES:Go to next check. NO:Check arm in pressure sensor (B31). See Pressure Sensor Test . (Group 9015-20.) Check arm regenerative solenoid valve. See Arm Regenerative Valve Circuit Operation . (Group 9025-05.) OK:Check arm regenerative valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 23 ) Bucket Regenerative Valve Operation Check

Action:

Switch LEGEND: 1 2 3 4 <- Go to Section TOC

Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button Section 9005 page 48




Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Actuate boom up, arm out and bucket dump functions. Actuate boom down function, arm in function, and then bucket curl function. sss: Does the bucket move smoothly through the complete cycle and not hesitate when it goes to the curl position?

Result: YES:Go to next check. NO:Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation . (Group 9025-05.) ( 24 ) Travel Speed Selection Check

Action:

Switch LEGEND: 1 2 3 4 <- Go to Section TOC

Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button Section 9005 page 49




Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to slow speed (turtle) mode. Actuate travel function to full speed. Turn travel speed switch to fast speed (rabbit) mode. sss: Does machine travel speed increase? Actuate a dig function and then return to neutral. sss: Does machine travel speed decrease and then increase as dig function is actuated and then released? Turn travel speed switch to slow speed (turtle) mode. sss: Does machine travel speed decrease?

Result: YES:Go to next check. NO:Check travel pressure sensor (B34) and travel speed switch (S11). See Pressure Sensor Test . (Group 9015-20.) See Travel Motor Speed Circuit Operation . (Group 9025-05.) ( 25 ) Travel System Tracking Check

Action:

CAUTION:


Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)






Machine Position LEGEND: 9

Bucket Height

Fully extend arm cylinder and bucket cylinder. Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.








Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Turn travel speed switch (3) to fast speed (rabbit) mode. Press power mode button (4) until PWR (power) mode is displayed on monitor.

Tracking Check LEGEND: 5 6 7 8

Distance of Mistrack Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.) Test Line (distance): 20 m (66 ft.) Track Print

Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.). →NOTE: When machine mistracks right, hydraulic pump 1 circuit oil flow may be less than specification. When machine mistracks left, hydraulic pump 2 circuit oil flow may be less than specification. <- Go to Section TOC





Observe direction of mistrack. Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8). Measure and record greatest distance of mistrack (5) between inside edge of track print and test line. Repeat procedure in reverse travel. sss: Does machine mistrack less than 150 mm (5.91 in.)?

Result: YES:Go to next check. NO:Check track sag. See Check and Adjust Track Sag. (Operator’s Manual.) NO: Perform Travel Motor Leakage Test or perform Pump Flow Test . (Group 9025-25.) ( 26 ) Travel System Tracking Checks While Operating a Dig Function

Action:

Switch LEGEND: 1 2 3 <- Go to Section TOC

Engine Speed Dial Auto-Idle Switch Travel Speed Switch Section 9005 page 53



4


Power Mode Button →NOTE: Machine will slow down during this test.

Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to fast speed (rabbit) mode. Operate machine at full speed forward on a flat and level surface. After machine is moving, actuate arm out from neutral to full actuation and extend the arm. sss: Does machine mistrack excessively when the arm is extended?

Result: YES: See Combined Travel And Dig Functions Slow Or No Power . (Group 9025-15.) NO:Go to next check. ( 27 ) Travel System Maneuverability Check

Action:








Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to fast speed (rabbit) mode. Drive machine at full speed forward down a slope. Turn in each direction. sss: Does each track slow down in response to pedal or lever movement in order to turn? Repeat the procedure in reverse travel. Turn travel speed switch to fast speed (rabbit) mode. Drive machine at full speed in reverse down a slope. Turn in each direction. sss: Does each track slow down in response to pedal or lever movement in order to turn?

Result: YES:Go to next check. NO: See Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline . (Group 9025-15.) ( 28 ) Cycle Times Check

Action:

CAUTION:

Prevent possible injury from unexpected machine movement. Clear all persons from the area before operating machine. →NOTE: Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-up Procedure . (Group 9025-25.) →NOTE: Cycle times are calculated using 2.52 m arm and 0.5 m 3 bucket. Different weight and attachments will affect cycle times.






Switch LEGEND: 1 2 3 4 5

Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button Monitor Dial

Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Rotate monitor dial (5) to highlight and select Dig mode from Work Mode menu. See Main Menu—Work Mode . (Operator’s Manual.)






Boom

Arm, Bucket, Swing Move machine to position shown for each test. Record cycle time for each function.

Item

Measurement Specification

Boom Raise (cylinder extend)

Cycle Time

2.8—3.4 sec.

Boom Lower (cylinder retract)

Cycle Time

2.1—2.7 sec.

Arm In (cylinder extend)

Cycle Time

2.9—3.5 sec.

Arm Out (cylinder retract)

Cycle Time

2.5—3.1 sec.

Bucket Load (cylinder extend)

Cycle Time

3.2—3.8 sec.

Bucket Dump (cylinder retract)

Cycle Time

2.1—2.7 sec.

Blade Raise (cylinder retract)

Cycle Time

2.0—2.6 sec.

Blade Lower (cylinder extend)

Cycle Time

1.8—2.4 sec.

Swing Left or Right, 3 Revolutions

Cycle Time

12.5—14.5 sec.

Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in FAST position)

Cycle Time

11.8—14.2 sec.

Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in SLOW position)

Cycle Time

18.6—24.4 sec.

Track Raised for 3 Revolutions (check in forward and reverse with travel mode switch in FAST position)

Cycle Time

23.4—27.4 sec.

Track Raised for 3 Revolutions (check in forward and reverse with travel mode switch in SLOW position)

Cycle Time

23.4—27.4 sec.

sss: Does machine perform within specifications?

Result: YES:Go to next check. NO: See All Hydraulic Functions Slow or see Some Dig Functions Slow (Not All) . (Group 9025-15.) ( 29 ) Heater and Air Conditioning Circuit Check

Action:






Switch LEGEND: 5 6

Temperature Control/Mode Switch Blower Speed Switch

Start engine and warm to normal operating temperature. Turn temperature control/mode switch (5) clockwise to maximum heat position. sss: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position. sss: Does air conditioner compressor clutch solenoid “click”? sss: Does cool air come from the vents?







Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Go to next check. NO:Heater does not operate. Check air conditioner and heater 20 A fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.) NO:Check wiring harness. See System Functional Schematic . See Cab Harness (W1) Wiring Diagram . See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) NO:Check system operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.) ( 30 ) Heater and Air Conditioner Controls Check (Automatic Temperature Control)

Action:

Switch






Monitor-Air Conditioner and Heater Display LEGEND: 5 6 7 8 9 10

Temperature Control/Mode Switch Blower Speed Switch Fan Speed AUTO Display Vent Position Temperature Setting

Key ON, press blower speed switch (6). Start engine and warm to normal operating temperature. Press blower speed switch. sss: Does air conditioner compressor clutch solenoid “click”? sss: Does AUTO display (8), display on monitor? sss: Does monitor display vent position (9), fan speed (7), and temperature setting (10)? Turn temperature control/mode switch (5) clockwise to maximum heat position. <- Go to Section TOC





sss: Does vent position change? sss: Does temperature setting increase? sss: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position. sss: Does vent position change? sss: Does temperature setting decrease? sss: Does cool air come from the vents? Press blower speed switch. sss: Does air conditioner compressor clutch solenoid “click”? (air conditioner and heater are ON in manual mode.) sss: Does AUTO display go OFF? Turn temperature control/mode switch clockwise to maximum heat position. sss: Does vent position change? sss: Does temperature setting increase? sss: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position. sss: Does vent position change? sss: Does temperature setting decrease? sss:




ENGINE


Does cool air come from the vents? Press temperature control/mode switch. sss: Does vent position change? Repeat for all four vent positions. sss: Does vent position change each time switch is pressed? Press blower speed switch. sss: Are air conditioner and heater OFF? (press blower speed switch to start air conditioner and heater).


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Checks complete. NO:Heater fan does not blow air. Check air conditioner and heater 20 A fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.) Check wiring harness. See System Functional Schematic . See Cab Harness (W1) Wiring Diagram . See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Check system operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)






Section 9010 - ENGINE Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Engine Identification ............................................................................................................................. 1 John Deere Engine ................................................................................................................................ 2 Engine Fuel System Component Location ............................................................................................ 4 Engine Cooling System Component Location ....................................................................................... 6 Cold Weather Starting Aid .................................................................................................................... 7 Engine Speed Control System Operation .............................................................................................. 8 Group 15 - Diagnostic Information ...................................................................................................... 12 John Deere Engine .............................................................................................................................. 12 Group 20 - Adjustments ........................................................................................................................ 13 John Deere Engine .............................................................................................................................. 13 Group 25 - Tests ..................................................................................................................................... 14 John Deere Engine .............................................................................................................................. 14 Radiator Temperature Differential Check ........................................................................................... 15 Engine Power Test Using Turbocharger Boost Pressure ..................................................................... 18



Section 9010 - ENGINE

Group 05: Theory of Operation

Group 05 - Theory of Operation Engine Identification Choosing the Correct ing Manuals John Deere excavators are available in different machine configurations based on the various markets into which they are sold. Different ing manuals exist for different machine configurations. Product identification numbers (PINs) are listed on the front covers of excavator manuals. These numbers are used to identify the correct ing manual for your machine. Product Serial Number Identification

PIN Plate (17 character) LEGEND: 1 2

PIN Plate 17 Character PIN

The PIN plate (1) is located on front, right corner of the cab. Each machine has a 17 character PIN (2) shown on this plate. The last 6 characters of the PIN represent the machine′s product serial number.

Engine Model Number Identification


Section 9010 page 1




Engine Serial Number Plate LEGEND: 3 Engine Serial Number Plate 4 9 Character Engine Model Number

Engine Serial Number Plate Location—4045HT067 The engine serial number plate (3) is located on the right side of the engine. Each engine has a 9 character engine model number (4) shown on this plate.

Engine Emissions Level Identification The 9 character engine model number corresponds to a specific engine emissions level. Engine Model Number Classification Engine Model Number

Engine Emissions Level

4045HT067

Tier 3/Stage IIIA

For machines with a 17 character PIN, where the 11 th character is D, this character also corresponds to a specific engine emissions level. PIN Classification 17 Character PIN (11

th

Engine Emissions Level

character)

xxxxxxxxxx D xxxxxx

Tier 3/Stage IIIA

John Deere Engine


Section 9010 page 2




→NOTE: For proper engine identification, see Engine Identification . (Group 9010-05.)

For additional information on John Deere PowerTech ™ engines and components for engine model 4045HT067, see the following component technical manuals (CTMs). See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.) See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.)


Section 9010 page 3




Engine Fuel System Component Location

Engine Fuel System Component Location LEGEND: 1 Primary Fuel Filter and Water Separator 2 Final Fuel Filter and Water Separator 3 Auxiliary Fuel Filter and Water Separator (if equipped) 4 Auxiliary Fuel Filter and Water Separator-to-Primary Fuel Filter and Water Separator Hose 5 Final Fuel Filter-to-High Pressure Fuel Pump Hose 6 Fuel Tank-to-Auxiliary Fuel Filter and Water Separator Hose (supply hose) 7 High Pressure Fuel Pump-to-Fuel Cooler Hose 8 Fuel Cooler-to-Fuel Tank Hose (return hose) 9 Fuel Cooler 10 Fuel Tank 11 Fuel Tank Drain Hose 12 Fuel Transfer Pump-to-Final Fuel Filter and Water Separator Hose 13 Primary Fuel Filter and Water Separator-to-Fuel Transfer Pump Hose <- Go to Section TOC

Section 9010 page 4



14 15


Fuel Transfer Pump High Pressure Fuel Pump


Section 9010 page 5




Engine Cooling System Component Location

Engine Cooling System Component Location LEGEND: 1 2 3 4 5 6 7 8 9 10 11


Radiator Radiator-to-Coolant Pump Hose Radiator-to-Thermostat Housing Hose Surge Tank Surge Tank Overflow Hose Surge Tank-to-Radiator Hose Surge Tank-to-Thermostat Housing Hose Surge Tank-to-Coolant Pump Hose Coolant Pump-to-Heater Hose Engine-to-Heater Hose Coolant Pump

Section 9010 page 6




Cold Weather Starting Aid

Auto-Ether Injection System LEGEND: 2 Y19

Ether Canister Ether Start Aid Solenoid

The cold start aid system used on this machine is auto-ether injection. Ether injection helps to start the engine in cold weather by injecting a specific amount of ether into the intake manifold. When the ignition is ON and the engine control unit (ECU) detects the fuel temperature is below a specified temperature, the ether start aid solenoid (Y19) energizes, and ether flows from the canister (2) to the intake manifold and mixes with intake air. When the ether/air mixture reaches the combustion chamber, it mixes with diesel fuel. Ether ignites at a lower temperature than diesel fuel, therefore, inside the combustion chamber the ether ignites first, heating the diesel fuel and aiding combustion. The cold start aid system is disabled under the following conditions: Coolant temperature is above 40°C. Coolant temperature and fuel temperature are both invalid. For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)


Section 9010 page 7




Engine Speed Control System Operation Specifications SPECIFICATIONS Engine Speeds Slow Idle

750—850 rpm

Fast Idle—PWR Mode

1850—1950 rpm

Fast Idle—ECO Mode (no load)

1700—1800 rpm

Fast Idle—H/P Travel Mode (travel over relief)

1950—2050 rpm

Fast Idle—Relief Operation (boom up over relief) 2050—2130 rpm Auto-Idle

1150—1250 rpm

Auto Warm-Up

1. 1300—1500 rpmHydraulic oil 0°C or lower (32°F or lower)Engine coolant - Not applicable 2. 1350—1450 rpmHydraulic oil 0°C or more (32°F or more)andEngine coolant 0—25°C (32—77°F) 3. 1150—1250 rpmHydraulic oil 0°C or more (32°F or more)andEngine coolant 25—50°C (77—122°F) 4. 1050—1150 rpmFuel 0°C or less (32°F or less)Engine coolant - Not applicableHydraulic oil - Not applicable

Idle Speed-Up

850—950 rpm

Switch LEGEND: 1 Engine Speed Dial 2 Auto-Idle Switch 3 Travel Speed Switch 4 Power Mode Button The engine speed is controlled by the following items: Engine Speed Dial (1) <- Go to Section TOC

Section 9010 page 8




Power Mode Button (4) H/P (high power) Mode PWR (power) Mode ECO (economy) Mode Work Mode Control Travel HP Mode Control Auto-Idle Switch (2) Auto Warm-Up Control Idle Speed-Up Control Engine Speed Dial The purpose of the engine speed dial is to control the engine speed via operator input. The main controller uses these input signals from the engine speed dial, travel pressure sensor (B34), and the attachment pressure sensor (B60) to determine appropriate engine speed. The main controller then sends a signal via controller area network (CAN) to the engine control unit (ECU), and the ECU then sets engine rpm. H/P (high power) Mode The purpose of the H/P mode is to increase engine speed using certain hydraulic functions. The main controller sends a signal to the ECU via CAN to raise engine rpm when the following conditions are met: Power mode button in H/P mode. Work mode switch in dig mode. Engine speed is 1500 rpm or higher. Arm in, boom up, or a combination of both functions actuated. Pump delivery pressure high. PWR (power) Mode The function of PWR mode is to control the engine speed from slow idle to fast idle in response to the position of the engine speed dial. ECO (economy) Mode (no load) The purpose of ECO mode is to lower engine speed to reduce fuel consumption and noise level. The main controller receives input signals from the engine speed dial, power mode button, and the pump delivery pressure sensors, then sends a signal via CAN to the ECU to reduce engine rpm when the following conditions are met: Engine speed above 1800 rpm. Power mode button in ECO mode. Pump control pressure low or pump delivery pressure high. Engine speed will increase up to 100 rpm over the engine speed dial setting for increased pump flow when the following conditions are met: Engine speed above 1800 rpm. Power mode button in ECO mode. Pump control pressure high. Average pump delivery pressure low. Travel HP (high power) Mode Control The purpose of travel HP mode is to increase engine speed for faster travel. The main controller uses these input signals from the travel pressure sensor, engine speed dial, travel speed switch and delivery pressure sensors to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to increase engine speed when the following conditions are met: Engine speed dial in the fast idle speed position. Travel function is operated. <- Go to Section TOC

Section 9010 page 9



Group 15: Diagnostic Information

Front attachment not operated. Delivery pressure of either pump is high. Auto-Idle Control The purpose of auto-idle control is to lower engine speed to reduce fuel consumption and noise levels while engine is running and no hydraulic function actuated. The main controller uses these input signals from the travel pressure sensor, front attachment pressure sensor, engine speed dial, and power mode button to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to lower engine rpm. Auto-idle is activated when the following conditions are met: Auto-idle control switch in the auto-idle position. No functions activated for approximately 4 seconds. Engine speed is greater than 1200 rpm. Auto-idle control is deactivated when the following conditions are met: Auto-idle control switch turned to OFF. A hydraulic function is actuated. Power mode button is pressed from ECO to PWR, PWR to H/P, or H/P to ECO. Engine speed dial is turned to change engine speed. When auto-idle is deactivated, the engine rpm increases to the setting of the engine speed dial. Auto Warm-Up Control The purpose of auto warm-up control is to increase engine coolant, hydraulic oil, and fuel temperatures to proper operating temperatures. This is achieved by increasing engine speed. The temperature values read by the main controller determine the appropriate target engine speed for auto warm-up. The main controller then sends a signal via CAN to the ECU to adjust engine rpm according to the following conditions. 1. Only when hydraulic oil temperature is below 0°C (32°F), the main controller sends a signal to the ECU to run the engine between 1300—1500 rpm until the hydraulic oil temperature raises above 0°C (32°F). Engine coolant temperature is not considered for auto warm-up by the main controller when hydraulic oil temperature is below 0°C. 2. When hydraulic oil temperature is above 0°C (32°F) and engine coolant temperature is 0—25°C (32—77°F), the main controller sends a signal to the ECU to run the engine between 1350—1450 rpm until the engine coolant temperature raises above 25°C (77°F). 3. When hydraulic oil temperature is above 0°C (32°F) and engine coolant temperature is 25—50°C (77—122°F), the main controller sends a signal to the ECU to run the engine between 1150—1250 rpm until the engine coolant temperature raises above 50°C (122°F). 4. When fuel temperature is 0°C (32°F) or below, the main controller sends a signal to the ECU to run the engine at 1050—1150 rpm until fuel temperature rises above 2°C (36°F). After 12 minutes or when the hydraulic oil temperature is above 2°C (36°F), the warm-up circuit is deactivated and engine runs at slow idle speed. 5. Only after the engine coolant temperature is raised above 50°C (122°F), the warm-up circuit is deactivated and engine runs at -selected idle speed. Idle Speed-Up Control The purpose of the idle speed-up control is to increase the engine rpm when a travel or dig function is actuated at slow idle. The main controller uses these input signals from the travel pressure sensor, front attachment pressure sensor, and engine speed dial to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to increase the engine rpm. Idle speed-up is activated when the following conditions are met: Engine speed below 900 rpm. Travel or dig function actuated. <- Go to Section TOC









Group 20: Adjustments

Group 15 - Diagnostic Information John Deere Engine →NOTE: For proper engine identification, see Engine Identification . (Group 9010-05.)






Group 25: Tests

Group 20 - Adjustments John Deere Engine →NOTE: For proper engine identification, see Engine Identification . (Group 9010-05.)






Group 25: Tests

Group 25 - Tests John Deere Engine →NOTE: For proper engine identification, see Engine Identification . (Group 9010-05.)






Group 25: Tests

Radiator Temperature Differential Check Specifications SPECIFICATIONS Radiator Temperature Differential Check Engine Speed Dial Position

Fast Idle

Work Mode Switch Position

Dig Mode

Power Mode Button Position

H/P (high power)

Auto-Idle Switch Position

OFF

Top to Bottom of Radiator Temperature Differential (typical)

4—7°C 7.2—12.6°F

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07253 Non- Temperature Measuring Gun

→NOTE: Test will be more accurate at higher ambient temperatures.

LEGEND: 1 2

Top Test Position Bottom Test Position

Radiator Test Positions

[1] - Check the following items before performing this test. Correct coolant is in engine and at the proper level. Radiator and any screens are clean of any dirt or debris. Fan blades are not damaged and fan is installed correctly. Proportional fan speed solenoid is functioning properly. All shields, guards, shrouds, baffles, and hoods are in place and properly fastened. Any foam or seals are in place and in good condition. [2] -





Group 25: Tests

→NOTE: Engine must be at or above 93°C (200°F) and readings must be taken when engine is under full load. Allow heat to transfer throughout engine components.

Warm engine to 93°C (200°F) to allow thermostats to open fully. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [3] - Run machine at specifications. Item

Measurement

Specification

Engine Speed Dial

Position

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

H/P (high power)

Auto-Idle Switch

Position

OFF

Radiator Temperature Differential Check

[4] IMPORTANT: To avoid hydraulic system damage, do not hold hydraulic functions over relief for more than 30 second intervals.

Hold arm-in function, at relief, to keep a full load on engine. Temperature readings must be taken with full load on engine. [5] →NOTE: Coolant enters radiator through upper radiator hose, travels through the radiator, then exits radiator through lower radiator hose. See Engine Cooling System Component Location . (Group 9010-05.)

Use JT07253 Non- Temperature Measuring Gun to measure the temperature differential between the top test position (1) and bottom test position (2) of radiator. Repeat test three times. Non- Temperature Measuring Gun JT07253 Measure Temperature [6] - Average readings and compare to specification. Item

Measurement

Specification

Top to Bottom of Radiator

Temperature Differential (typical)

4—7°C 7.2—12.6°F

[7] →NOTE: A higher temperature differential than specification indicates low coolant flow. A lower temperature differential than specification indicates low air flow.





Group 25: Tests

For diagnosing problems, see John Deere Engine . (Group 9010-15.)





Group 25: Tests

Engine Power Test Using Turbocharger Boost Pressure Specifications SPECIFICATIONS Power Mode Button Position

H/P (high power)

Turbocharger Boost Pressure

105 kPa 1.05 bar 15.2 psi

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07248 Turbo Boost Test Kit

Other Material OTHER MATERIAL 242 Loctite Thread Lock and Sealer (medium strength)

This procedure should only be used as a guide to determine engine condition. →NOTE: Boost specifications are based on use of No. 2 fuel. If using No. 1 fuel, reduce boost specifications by 7%.

[1] LEGEND: 1 3 4

Adapter Hose Pressure Gauge

Turbo Boost Test Hook-Up Remove plug from intake manifold and install adapter (1). Install hose (3) and pressure gauge (4) from JT07248 Turbo Boost Test Kit. Turbo Boost Test Kit JT07248 To measure turbocharger boost pressure. [2] - Warm engine and hydraulic oil to normal operating temperature. Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) <- Go to Section TOC




Group 25: Tests

[3] - Turn engine speed dial to fast idle. [4] - Press power mode button to H/P (high power) position. Item

Measurement

Specification

Power Mode Button

Position

H/P (high power)

[5] - Slowly actuate arm in function over relief and hold until engine rpm stabilizes at highest reading. Repeat this step at least six times. Record the highest pressure reading. [6] →NOTE: If using the JT07248 Turbo Boost Kit, a check valve at the pressure gauge inlet traps the highest reading for boost pressure and does not decrease as the pressure decreases.

Compare highest reading to specifications.

Item

Measurement

Specification

Pressure

105 kPa

Turbocharger Boost Test Turbocharger Boost

1.05 bar 15.2 psi

→NOTE: Pressure gauge accuracy is very critical for this test. Do not make adjustments to injection pump fuel delivery on the machine to raise or lower boost pressure.

→NOTE: New engine may not develop specified boost pressure. Check after 50 hours of operation.

[7] - If turbocharger boost pressure is low, check the following: Wrong fuel. Restricted air filter elements. Restricted fuel filter elements. Restricted muffler, remove muffler and rerun test. Exhaust manifold leaks. For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.) Check charge air cooler piping and fittings for leaks. Faulty fuel injection pump. Faulty MAP sensor. Replace MAP sensor. Low compression pressure. For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.) Cam lobe wear (valve clearance). For more information on PowerTech ™ , and PowerTech ™ Plus, PowerTech ™ E, see PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.) Faulty fuel injectors. Carbon build-up in turbocharger. Turbocharger compressor or turbine wheel rubbing housing. <- Go to Section TOC



ELECTRICAL SYSTEM


[8] - Remove gauge and fittings. [9] - Apply PM37418 Thread Lock and Sealer (medium strength) to plug. Tighten plug.






Section 9015 - ELECTRICAL SYSTEM Table of contents Group 05 - System Information ............................................................................................................. 1 Electrical Diagram Information ............................................................................................................. 1 Group 10 - System Diagrams ............................................................................................................... 11 Explanation of Wire Markings ............................................................................................................. 11 Fuse and Relay Specifications ............................................................................................................ 12 System Functional Schematic, Component Location, and Wiring Diagram Master Legend ................ 21 System Functional Schematic ............................................................................................................. 29 Cab Harness (W1) Component Location ............................................................................................. 68 Cab Harness (W1) Wiring Diagram ..................................................................................................... 75 Machine Harness (W2) Component Location ...................................................................................... 95 Machine Harness (W2) Wiring Diagram .............................................................................................. 99 Monitor Harness (W3) Component Location ..................................................................................... 104 Monitor Harness (W3) Wiring Diagram ............................................................................................. 105 Engine Harness (W4) Component Location ...................................................................................... 107 Engine Harness (W4) Wiring Diagram .............................................................................................. 111 Engine Interface Harness (W5) Component Location ....................................................................... 116 Engine Interface Harness (W5) Wiring Diagram ............................................................................... 118 Pump Harness (W8) Component Location ........................................................................................ 121 Pump Harness (W8) Wiring Diagram ................................................................................................ 124 Service ADVISOR™ Remote (SAR) Harness (W10) Component Location .......................................... 125 Service ADVISOR™ Remote (SAR) Harness (W10) Wiring Diagram .................................................. 126 Pilot Shutoff Switch Harness (W11) Component Location ................................................................. 127 Pilot Shutoff Switch Harness (W11) Wiring Diagram ......................................................................... 128 Auxiliary Fuse Box Harness (W13) Component Location .................................................................. 129 Auxiliary Fuse Box Harness (W13) Wiring Diagram .......................................................................... 130 Heated Air Seat Harness (W14) Component Location ...................................................................... 132 Heated Air Seat Harness (W14) Wiring Diagram .............................................................................. 134 Multi-Function Pilot Control Lever Harness (W15) Component Location ........................................... 135 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram ................................................... 137 Travel Alarm Cancel Switch Harness (W16) Component Location .................................................... 138 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram ............................................................ 139 Attachment Harness (W17) Component Location ............................................................................. 140 Attachment Harness (W17) Wiring Diagram ..................................................................................... 142 Rear Camera Harness (W19) Component Location .......................................................................... 144 Rear Camera Harness (W19) Wiring Diagram .................................................................................. 145 Pilot Shutoff Valve Harness (W21) Component Location .................................................................. 146 Pilot Shutoff Valve Harness (W21) Wiring Diagram .......................................................................... 147 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location ............................................ 147 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram .................................................... 148 Reversing Fan Switch Harness (W23) Component Location ............................................................. 148 Reversing Fan Switch Harness (W23) Wiring Diagram ..................................................................... 149 Seat Heater Switch Harness (W24) Component Location ................................................................. 149 Seat Heater Switch Harness (W24) Wiring Diagram ......................................................................... 150 Travel Alarm Harness (W26) Component Location ........................................................................... 151 Travel Alarm Harness (W26) Wiring Diagram ................................................................................... 152 Starter Harness (W27) Component Location .................................................................................... 153 Starter Harness (W27) Wiring Diagram ............................................................................................ 154 Starter Switch Harness (W29) Component Location ......................................................................... 155 Starter Switch Harness (W29) Wiring Diagram ................................................................................. 156 2-Speed Harness (W32) Component Location .................................................................................. 156 <- Go to Global Table of contents




2-Speed Harness (W32) Wiring Diagram .......................................................................................... 157 Fuel Injector Harness (W38) Component Location ............................................................................ 158 Fuel Injector Harness (W38) Wiring Diagram .................................................................................... 159 Heater and Air Conditioner Harness (W41) Component Location ..................................................... 161 Heater and Air Conditioner Harness (W41) Wiring Diagram ............................................................. 162 Auxiliary Solenoid Harness (W61) Component Location ................................................................... 164 Auxiliary Solenoid Harness (W61) Wiring Diagram ........................................................................... 166 Auxiliary Function Lever (AFL) Harness (W75) Component Location ................................................ 168 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram ........................................................ 170 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location ................................. 172 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram ......................................... 174 Modular Telematics Gateway (MTG) Harness (W6002) Component Location ................................... 175 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ........................................... 176 Satellite (SAT) Harness (W6003) Component Location ..................................................................... 176 Satellite (SAT) Harness (W6003) Wiring Diagram ............................................................................. 177 Group 15 - Sub-System Diagnostics ................................................................................................. 178 Controller Area Network (CAN) Theory of Operation ........................................................................ 178 Starting and Charging Circuit Theory of Operation ........................................................................... 184 Monitor Controller (DSZ) Circuit Theory of Operation ....................................................................... 189 Engine Control Unit (ECU) Circuit Theory of Operation ..................................................................... 197 Main Controller (MCZ) Circuit Theory of Operation ........................................................................... 214 Machine Controller (BCZ) Circuit Theory of Operation ...................................................................... 232 Windshield Wiper and Washer Circuit Theory of Operation .............................................................. 234 Lighting Circuit Theory of Operation ................................................................................................. 237 Travel Alarm Circuit Theory of Operation ......................................................................................... 240 Pilot Shutoff Circuit Theory of Operation .......................................................................................... 243 Attachment Control Circuit Theory of Operation .............................................................................. 246 Group 16 - Monitor Operation ............................................................................................................ 256 Service Menu .................................................................................................................................... 256 Troubleshooting ................................................................................................................................ 256 Monitoring ........................................................................................................................................ 258 Controller Version ............................................................................................................................. 261 Issued Warning Record ..................................................................................................................... 261 Operation ......................................................................................................................................... 262 Machine Setting ................................................................................................................................ 263 Monitor Setting ................................................................................................................................. 266 Group 20 - References ......................................................................................................................... 268 Reading Diagnostic Trouble Codes with Monitor Display .................................................................. 268 Service ADVISOR™ Diagnostic Application ....................................................................................... 268 Service ADVISOR™ Connection Procedure ....................................................................................... 269 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................ 271 MPDr Application .............................................................................................................................. 273 MPDr Connection Procedure ............................................................................................................. 274 Fuse Test .......................................................................................................................................... 276 Relay Test ......................................................................................................................................... 283 Pressure Sensor Test ........................................................................................................................ 284 Solenoid Test .................................................................................................................................... 285 Proportional Solenoid Test ................................................................................................................ 286 Temperature Sensor Test ................................................................................................................. 287 Alternator Test .................................................................................................................................. 288 Component Checks ........................................................................................................................... 290 Battery Remove and Install .............................................................................................................. 297 Rear Cover Remove and Install ........................................................................................................ 299 <- Go to Global Table of contents




Main Controller (MCZ) Remove and Install ....................................................................................... 301 Machine Controller (BCZ) Remove and Install .................................................................................. 304 Engine Control Unit (ECU) Remove and Install ................................................................................. 306 Data Converter Remove and Install .................................................................................................. 306 Monitor Controller (DSZ) Remove and Install ................................................................................... 308 Air Conditioner Controller (ACF) Remove and Install ........................................................................ 310 Key Switch Remove and Install ......................................................................................................... 310 Right Switch Console Remove and Install ......................................................................................... 312 Left Switch Console Remove and Install ........................................................................................... 314 Travel Alarm Remove and Install ...................................................................................................... 315 Disconnect Tab Retainer Connectors ................................................................................................ 315 Disconnecting Spring Wire Clip Connectors ...................................................................................... 316 Replace DEUTSCH™ Connectors ...................................................................................................... 318 Replace DEUTSCH™ Rectangular or Triangular Connectors ............................................................. 320 Install DEUTSCH™ ............................................................................................................... 322 Replace WEATHER PACK™ Connector .............................................................................................. 324 Install WEATHER PACK™ ..................................................................................................... 326 Replace (Pull Type) Metri-Pack™ Connectors ................................................................................... 328 Replace (Push Type) Metri-Pack™ Connectors ................................................................................. 329 Replace CINCH™ Connectors ........................................................................................................... 330 Install CINCH™ .................................................................................................................... 332 Repair 32 and 48 Way CINCH™ Connectors ..................................................................................... 334 Remove Connector Body from Blade Terminals ............................................................................... 338



Section 9015 - ELECTRICAL SYSTEM

Group 05: System Information

Group 05 - System Information Electrical Diagram Information →NOTE: All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in the OFF position.

Explanation of Wire Markings System Functional Schematic Diagram


Section 9015 page 1




System Functional Schematic Example LEGEND: 1 2 3 4 5 <- Go to Section TOC

Continuity Chart Power Wires Routing Location Information Wire Identification Ground Wires Section 9015 page 2



7 8 9 10 11 12 13 F60 F61 G1 G2 K19 S1 W5 W6


Section Number Component Name Component Identification Number Component Schematic Symbol Connector Identification Number Connector Connector Pin Information Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Battery Relay Key Switch Battery To Frame Ground Engine To Frame Ground

The System Functional Schematic is made up of equal sections to simplify searching the schematic. Each section of the System Functional Schematic is assigned a number (7). The System Functional Schematic is formatted with power supply wires (2) shown near the top of the drawing and ground wires (5) near the bottom. The schematic may contain some harness or connector information. When connector information is shown, it will be displayed as a double chevron (12) with a component identification number (11) corresponding to the connector identification number. Connector pin information (13) will be displayed in a text size smaller than that of the connector identification number. Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component Location). Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The section and component identification number are given in the first line of information and any pin information for the component is given in parenthesis in the second line. In this example, power is going TO section 23, component B14 on pin C4. Wiring Diagram


Section 9015 page 3




Wiring Diagram Example LEGEND: 1 2 3 4 5 <- Go to Section TOC

Wire Number Wire End #1 Termination Location Wire Color Wire End #2 Termination Location Wiring Diagram Wire Legend Section 9015 page 4



6 7 8 9 10 11 12 13 14


Component Identification Number Connector End View Wire Number Connector Pin Number Connector Pin Number Wire Number Wire Color Wire Termination Location Wire Harness

Each harness on the machine is drawn showing components, connectors, and wires. Harnesses are identified by a “W” component identification number and description (W6 ENGINE HARNESS, Etc.). A component or connector identification number (6) identifies each component on the harness. Each harness branch (14) is terminated by an end view of the connector (7). The connector end view show pin (9) and wire number (8) information which corresponds to the component or connector wire table. The wire table displays the component or connector pin number (10), the wire number (11), the wire color (12), and the location where the wire terminates (13). A wire legend (5) is provided for each harness. All wires in the harness are listed in the wire legend. The wire legend contains a wire number (1), End #1 (2), wire color (3), and End #2 (4) information for each wire. The wire number and color are unique to each harness and may not match other wire numbers and colors on other harnesses. The component identification numbers or wire numbers listed in the End #1 and End #2 columns indicate where the wire terminates within the harness. Wiring Diagram


Section 9015 page 5




Wiring Diagram Example LEGEND: 1 2 3 4 5 <- Go to Section TOC

Component Identification Number Connector Connector End View Wire Harness Wire Number Section 9015 page 6



6 7 8 9 10


Wire Splice Wire End #1 Termination Location Wire Number Wire Color Wire End #2 Termination Location

Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and branches. A component identification or connector number (1) identifies each component. The harness branch (4) is terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5) is indicated. An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to differentiate the side of the harness that the wires come from. A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire. Component Location Diagram The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram. Connector End View Diagram The Connector End View Diagram is a pictorial end view of the component connectors showing the number of pins in the connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram. Electrical Schematic Symbols


Section 9015 page 7




Electrical Schematic Symbols


Section 9015 page 8



LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 <- Go to Section TOC


Battery Wire Splice Fuse Circuit Breaker Power Outlet Alternator Air Conditioner Compressor Compressor Liquid Pump Antenna Diode Zener Diode Capacitor Magnet Flasher Buzzer Horn Alarm Clock Internal Ground Single Point Ground External Ground Sensor Sensor with Normally Open Switch Speed Sensor Rotary Sensor Single Element Bulb Dual Element Bulb Solenoid Operated Hydraulic Valve With Suppression Diode Solenoid Normally Open Solenoid Normally Closed Starter Motor Starter Motor DC Motor DC Stepping Motor Wiper Motor Blower Motor Servo Motor Speedometer Tachometer Temperature Gauge Liquid Level Gauge Gauge Hourmeter Resistor Variable Resistor Manually Adjusted Variable Resistor Multi-Pin Connector Single Pin Connector Connector 4 Pin Relay 5 Pin Relay 5 Pin Relay With Internal Suppression Diode 5 Pin Relay With Internal Suppression Resistor Key Switch Temperature Switch Normally Open Temperature Switch Normally Closed Pressure Switch Normally Open Pressure Switch Normally Closed Liquid Level Switch Normally Open Liquid Level Switch Normally Closed Momentary Switch Normally Open Momentary Switch Normally Closed Toggle Switch Normally Open Toggle Switch Normally Closed 2 Way Toggle Switch Normally Open Section 9015 page 9



67 68 69 70 71 72 73 74 75 76 77 78 79


Group 10: System Diagrams

2 Way Toggle Switch Normally Closed Manual Switch Operation Push Switch Operation Pull Switch Operation Turn Switch Operation Toggle Switch Operation Pedal Switch Operation Key Switch Operation Detent Switch Operation Temperature Sensor Solar Sensor Pressure Sensor Liquid Level Sensor





Group 10 - System Diagrams Explanation of Wire Markings Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on some connector drawings simply as reference numbers, useful in tracing wires through the harness. Some wires are solid wire colors. These would be identified by one color name such as RED or BLK or GRN. Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a wire identified as RED/WHT would be a primarily RED wire, with a WHT stripe. A wire identified as WHT/RED would be a primarily WHT wire with a RED stripe. Following is a listing of wire color abbreviations used on drawings. BLK—Black BLU—Blue BRN—Brown CABLE—Bare Wire DK GRN—Dark Green GRN—Green GRY—Grey LT BLU—Light Blue LT GRN—Light Green ORG—Orange PNK—Pink PUR—Purple RED—Red SK BLU—Sky Blue TAN—Tan VLT—Violet WHT—White YEL—Yellow






Fuse and Relay Specifications Fuse and Relay Specifications (S.N. —040754)

Relay and Fuse Block Component Location LEGEND: 1 2 3

Relay Block Fuse Block 1 Fuse Block 2

Fuse Block 1






Fuse Block 1 LEGEND: F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20

Work and Boom Lights 20 A Fuse (marked LAMP) Windshield Wiper and Washer 10 A Fuse (marked WIPER) Air Conditioner and Heater 20 A Fuse (marked HEATER) Solenoid 20 A Fuse (marked SOLENOID) Travel Alarm 5 A Fuse (marked OPT. 1 ALT) 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Start Position Signal 5 A Fuse (marked START) Engine Control Unit (ECU) 30 A Fuse (marked ECU) Radio Backup 10 A Fuse (marked BACK UP) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Not Used Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Monitor 5 A Fuse (marked MONITOR) Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) Start Aid 20 A Fuse (marked START AID) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Horn 10 A Fuse (marked HORN) Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Fuse Block 2







Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) IMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) Not Used Not Used Not Used Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) Not Used Not Used Not Used Not Used Not Used Not Used

Additional fuses located near the engine control unit (ECU): F6000— JDLink ™ Unswitched Power 7.5 A Fuse F6001— JDLink ™ Ground 7.5 A Fuse F6002— JDLink ™ Switched Power 7.5 A Fuse Additional fuses located in the engine compartment: F63—Glow Plug 50 A Fuse Additional fuses located under cover behind radiator door:






F45—Starter In-line 30 A Fuse F60—Alternator 65 A Fuse F61—Battery 45 A Fuse Relay Block

Relay Block LEGEND: K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14

Load Dump Relay Pilot Shutoff Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay (not used)

Additional relays located in the engine compartment: K16—Glow Plug Relay Additional relays are located by the air conditioning unit: K15—Air Conditioner Blower Motor Relay K17—Max Hi Relay K18—Air Conditioner Compressor Clutch Relay Additional relays located under cover behind cooling package door: K19—Battery Relay K34—Starter Relay <- Go to Section TOC





K35—Starter Protection Relay Additional relays located behind cab seat: K20—Seat Heater Relay K30—Right Solenoid Relay B K31—Right Solenoid Relay A K32—Left Solenoid Relay B K33—Left Solenoid Relay A

Fuse and Relay Specifications (S.N. 040755— )

Relay and Fuse Block Component Location LEGEND: 1 2 3

Relay Block Fuse Block 1 Fuse Block 2

Fuse Block 1






Fuse Block 1 LEGEND: F1 Work and Boom Lights 20 A Fuse (marked LAMP) F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER) F3 Air Conditioner and Heater 20 A Fuse (marked HEATER) F4 Solenoid 20 A Fuse (marked SOLENOID) F5 Optional and Attachment Connector 20 A Fuse (marked OPT. 1 ALT) F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) F7 Start Position Signal 5 A Fuse (marked START) F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) F9 Radio Backup 10 A Fuse (marked BACK UP) F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM) F12 Radio and Dome 5 A Fuse (marked RADIO) F13 Lighter 10 A Fuse (marked LIGHTER) F14 Monitor 5 A Fuse (marked MONITOR) F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) F16 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) F17 Power On 5 A Fuse (marked POWER ON) F18 Idle Stop 5 A Fuse (marked IDLE STOP) F19 Horn 10 A Fuse (marked HORN) F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Fuse Block 2







Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) IMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) Not Used Not Used Not Used Not Used Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG) Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used) Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used) Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used) Not Used Not Used

Additional fuses located near the engine control unit (ECU): F6000— JDLink ™ Unswitched Power 7.5 A Fuse F6001— JDLink ™ Ground 7.5 A Fuse F6002— JDLink ™ Switched Power 7.5 A Fuse Additional fuses located in the engine compartment: F5002—Fuel Transfer Pump 15 A Fuse Additional fuses located under cover behind radiator door:






F45—Starter In-line 30 A Fuse F60—Alternator 65 A Fuse F61—Battery 45 A Fuse Relay Block

Relay Block LEGEND: K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13

Load Dump Relay Pilot Shutoff Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay

Additional relays located in the engine compartment: K16—Glow Plug Relay Additional relays are located by the air conditioning unit: K15—Air Conditioner Blower Motor Relay K17—Max Hi Relay K18—Air Conditioner Compressor Clutch Relay Additional relays located under cover behind cooling package door: K19—Battery Relay K34—Starter Relay K35—Starter Protection Relay <- Go to Section TOC





Additional relays located behind cab seat: K20—Seat Heater Relay K30—Right Solenoid Relay B K31—Right Solenoid Relay A K32—Left Solenoid Relay B K33—Left Solenoid Relay A






System Functional Schematic, Component Location, and Wiring Diagram Master Legend A1—Engine Control Unit (ECU) ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 ) A2—Variable Geometry Turbocharger (VGT) ( W5 ) A3—Main Controller (MCZ) ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) A4—Monitor Controller (DSZ) ( SE4 , SE5 , SE6 ) ( W1 ) ( W3 ) A5—Data Converter ( SE20 ) ( W1 ) A6—Radio ( SE18 ) ( W1 ) A7—Air Conditioner Controller (ACF) ( SE23 ) ( W41 ) A8—12-Volt Power Converter ( SE17 ) ( W1 ) A10—Monitor ( SE6 ) ( W3 ) A11—Machine Controller (BCZ) ( SE19 ) ( W1 ) A12—Rear Camera ( SE6 ) ( W19 ) A6000—Modular Telematics Gateway (MTG) Controller ( SE21 ) ( W5 ) A6001—GPS/Cellular Antenna ( SE21 ) B16—Air Filter Restriction Switch ( SE14 ) ( W5 ) A6002—Satellite (SAT) Module Control Unit ( SE21 ) ( W6003 ) B18—Fuel Level Sensor ( SE4 ) ( W2 ) B20—Air Conditioner High/Low Pressure Switch ( SE22 ) ( W2 ) B21—Solar Sensor ( SE24 ) ( W3 ) B22—Ambient Air Temperature Sensor ( SE23 ) ( W2 ) B23—High Note Horn ( SE22 ) ( W2 ) B24—Low Note Horn ( SE22 ) ( W2 ) B25—Right Speaker ( SE18 ) ( W1 ) B26—Left Speaker ( SE18 ) ( W1 ) B27—Hydraulic Oil Filter Restriction Switch (if equipped) ( SE4 ) ( W2 ) B30—Boom Up Pressure Sensor ( SE7 ) ( W2 ) B31—Arm In Pressure Sensor ( SE8 ) ( W2 ) B32—Front Attachment Pressure Sensor ( SE8 ) ( W2 ) B33—Swing Pressure Sensor ( SE8 ) ( W2 ) B34—Travel Pressure Sensor ( SE8 ) ( W2 ) B35—Pump 1 Delivery Pressure Sensor ( SE8 ) ( W8 ) B36—Pump 1 Control Pressure Sensor ( SE8 ) ( W8 ) B37—Pump 2 Delivery Pressure Sensor ( SE9 ) ( W8 ) B38—Pump 2 Control Pressure Sensor ( SE9 ) ( W8 ) B40—Hydraulic Oil Temperature Sensor ( SE9 ) ( W2 ) B41—Air Conditioner Freeze Control Switch ( SE24 ) ( W41 ) B53—Fan Speed Sensor ( SE13 , SE15 ) ( W5 ) B55—Air Recirculation Sensor ( SE24 ) ( W41 ) B60—Attachment Pressure Sensor ( SE9 ) ( W17 ) B61—Arm Out Pressure Sensor ( SE9 ) ( W17 ) B68—Secondary Hydraulic Oil Temperature Sensor ( SE30 ) ( W76 ) B80—Seat Temperature Switch 1 ( SE26 ) ( W17 ) B81—Seat Temperature Switch 2 ( SE26 ) B82—Ambient Air Temperature Sensor 2 ( SE10 ) ( W5 ) B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) ( SE30 ) ( W76 ) B5100—Fuel Rail Pressure Sensor ( SE13 ) ( W4 ) B5101—Engine Oil Pressure Sensor ( SE11 ) ( W4 ) B5107—Inlet Fuel Pressure Sensor ( SE14 ) ( W4 ) B5206—Manifold Air Temperature (MAT) Sensor ( SE11 ) ( W4 ) B5208—Engine Coolant Temperature Sensor ( SE11 ) ( W4 ) B5209—Fuel Temperature Sensor ( SE10 ) ( W4 ) B5300—Turbocharger Speed Sensor ( SE15 ) ( W4 ) B5301—Crankshaft Position Sensor ( SE11 ) ( W4 ) B5302—Camshaft Position Sensor ( SE11 ) ( W4 ) B5500—Intake Air Sensor ( SE12 ) ( W4 ) B5600—Water-in-Fuel Sensor ( SE10 ) ( W5 ) E1—Work Light ( SE17 ) ( W2 ) E2—Boom Light ( SE17 ) ( W2 ) <- Go to Section TOC





E3—Cab Dome Light ( SE19 ) E5—Switch Back Light 1 ( SE6 ) E6—Switch Back Light 2 ( SE5 ) E7—Switch Back Light 3 ( SE6 ) E8—Switch Back Light 4 ( SE6 ) E9—Key Switch Light ( SE20 ) E10—Switch Back Light 5 ( SE20 ) F1—Work and Boom Lights 20 A Fuse (marked LAMP) ( SE17 ) ( W1 ) F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) ( SE16 ) ( W1 ) F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) ( SE22 ) ( W1 ) F4—Solenoid 20 A Fuse (marked SOLENOID) ( SE3 ) ( W1 ) F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT) ( SE9 ) ( W1 ) F6—12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) ( SE17 ) ( W1 ) F7—Start Position Signal 5 A Fuse (marked START) ( W1 ) F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU) ( SE14 ) ( W1 ) F9—Radio Backup 10 A Fuse (marked BACK UP) ( SE4 ) ( W1 ) F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) ( SE7 ) ( W1 ) F11—Not Used ( W1 ) F12—Radio and Dome 5 A Fuse (marked RADIO) ( SE18 ) ( W1 ) F13—Lighter 10 A Fuse (marked LIGHTER) ( SE18 ) ( W1 ) F14—Monitor 5 A Fuse (marked MONITOR) ( SE4 ) ( W1 ) F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) ( SE18 ) ( W1 ) F17—Power On 5 A Fuse (marked POWER ON) ( SE4 ) ( W1 ) F18—Idle Stop 5 A Fuse (marked IDLE STOP) ( SE1 ) ( W1 ) F19—Horn 10 A Fuse (marked HORN) ( SE22 ) ( W1 ) F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) ( SE17 ) ( W1 ) F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) ( SE26 ) ( W13 ) F22—Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) ( SE25 ) ( W13 ) F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) ( SE25 ) ( W13 ) F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) ( SE25 ) ( W13 ) F25—IMMOBI 5 A Fuse (marked IMOBI) ( SE25 ) ( W13 ) F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) ( SE25 ) ( W13 ) F27—Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX_3) ( SE25 ) ( W13 ) F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) ( SE26 ) ( W13 ) F32—Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) ( SE25 ) ( W13 ) F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) ( SE25 ) ( W13 ) F34—Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX_2) ( SE25 ) ( W13 ) F45—Starter In-line 30 A Fuse ( SE2 ) ( W27 ) F50—Fuse Box ( W1 ) F51—Auxiliary Fuse Box ( W13 ) F60—Alternator 65 A Fuse ( SE1 ) ( W2 ) F61—Battery 45 A Fuse ( SE1 ) ( W2 ) F62—Wiper Motor Assembly Circuit Breaker ( SE16 ) F6000— JDLink ™ Unswitched Power 7.5 A Fuse ( SE21 ) ( W5 ) F6001—JDLink™ Ground 7.5 A Fuse ( SE21 ) ( W5 ) F6002—JDLink™ Switched Power 7.5 A Fuse ( SE21 ) ( W5 ) G1—Battery ( SE1 ) ( W2 ) G2—Battery ( SE1 ) ( W2 ) G3—Alternator ( SE3 ) ( W2 ) G5—12-Volt Power Outlet ( SE17 ) ( W1 ) H2—Security Alarm ( SE4 ) ( W1 ) H3—Monitor Warning Alarm ( SE4 ) ( W3 ) H4—Travel Alarm ( SE9 ) ( W26 ) K1—Load Dump Relay ( SE3 ) ( W1 ) K2—Pilot Shutoff Solenoid Relay ( SE3 ) ( W1 ) K3—Security Alarm Relay ( SE4 ) ( W1 ) K4—Starter Cut Relay ( SE2 ) ( W1 ) K5—Security Relay ( SE2 ) ( W1 ) K6—Windshield Wiper Relay ( SE16 ) ( W1 ) K7—Work Light Relay ( SE17 ) ( W1 ) K8—Boom Light Relay ( SE17 ) ( W1 ) <- Go to Section TOC





K9—Windshield Washer Relay ( SE16 ) ( W1 ) K10—Horn Relay ( SE22 ) ( W1 ) K11—Idle Stop Relay ( SE1 ) ( W1 ) K12—Accessory Cut Relay ( SE1 ) ( W1 ) K13—Key Cut Relay ( SE1 ) ( W1 ) K15—Air Conditioner Blower Motor Relay ( SE23 ) ( W41 ) K17—Max Hi Relay ( SE23 ) ( W41 ) K18—Air Conditioner Compressor Clutch Relay ( SE22 ) ( W41 ) K19—Battery Relay ( SE1 ) ( W2 ) K20—Seat Heater Relay ( SE26 ) K30—Right Solenoid Relay B ( SE27 ) ( W15 ) K31—Right Solenoid Relay A ( SE27 ) ( W15 ) K31—Right Solenoid Relay (marked RSW1) ( SE28 ) ( W75 ) K32—Left Solenoid Relay B ( SE27 ) ( W15 ) K32—Left Solenoid Relay B (marked LSW1) ( SE28 ) ( W75 ) K33—Left Solenoid Relay A ( SE27 ) ( W15 ) K33—Left Solenoid Relay A (marked LSW3) ( SE29 ) ( W75 ) K34—Starter Relay ( SE2 ) ( W2 ) ( W27 ) K35—Starter Protection Relay ( SE2 ) ( W27 M1—Starter Motor ( SE2 ) ( W2 ) ( W5 ) ( W27 ) M5—Windshield Wiper Motor ( SE16 ) M6—Windshield Washer Motor ( SE16 ) ( W2 ) M7—Air Conditioner and Heater Blower Motor ( SE23 ) ( W41 ) M9—Air Conditioner and Heater Internal and External Servo Motor ( SE24 ) ( W41 ) M10—Air Conditioner and Heater Blower Port Change Servo Motor ( SE24 ) ( W41 ) M11—Air Conditioner and Heater Mixer Servo Motor ( SE24 ) ( W41 ) M12—Seat Air Compressor Motor ( SE26 ) ( W14 ) M13—High Pressure Fuel Pump ( SE11 ) ( W4 ) R9—Lighter ( SE18 ) ( W1 ) R10—Interface CAN Resistor 1 ( SE20 ) ( W1 ) R11—Interface CAN Resistor 2 (later models) ( SE21 ) ( W5 ) R12—CAN 0 Termination Resistor ( SE11 ) ( W2 ) R13—Alternator Resistor ( SE3 ) ( W2 ) R15—Engine Speed Dial ( SE7 ) ( W1 ) R16—Blower Motor Transistor ( SE23 ) ( W41 ) R17—Blower Motor Resistor ( SE23 ) ( W41 ) R18—Seat Heater ( SE26 ) ( W14 ) S1—Key Switch ( SE1 ) ( W29 ) S2—Cab Dome Light Switch ( SE19 ) S3—Pilot Shutoff Switch 1 ( SE3 ) ( W17 ) S4—Pilot Shutoff Switch 2 ( SE3 ) ( W17 ) S5—Horn Switch ( SE22 ) ( W1 ), ( W75 ) S7—Power Dig Switch ( SE10 , SE28 ) ( W1 ) or ( W75 ) S8—Auto-Idle Switch ( SE7 ) ( W1 ) S9—Windshield Wiper and Washer Switch ( SE20 ) ( W1 ) S10—Work Light Switch ( SE6 ) ( W1 ) S11—Travel Speed Switch ( SE7 ) ( W1 ) S12—Power Mode Button ( SE7 ) ( W1 ) S13—Travel Alarm Cancel Switch ( SE9 ) ( W16 ) S14—Door Switch ( SE20 ) ( W1 ) S15—Reversing Fan Switch ( SE13 ) ( W23 ) S18— Service ADVISOR ™ Remote (SAR) Switch ( SE11 ) ( W1 ) S20—Seat Belt Switch ( SE6 ) ( W1 ) S21—Blower Motor Speed Switch ( SE5 ) ( W1 ) S22—Temperature Control/Mode Switch ( SE5 ) ( W1 ) S23—Radio Volume and Power Switch ( SE6 ) ( W1 ) S24—Radio Tuning Switch ( SE5 ) ( W1 ) S25—Monitor Dial ( SE5 ) ( W1 ) S26—Back Button ( SE5 ) ( W1 ) S27—Home Button ( SE5 ) ( W1 ) S28—Window Switch ( SE16 ) <- Go to Section TOC





S29—Auxiliary Function Lever (AFL) Proportional Control Switch ( SE28 ) ( W75 ) S30—Right Pilot Control Lever Switch B (marked B) ( SE27 ) ( W15 ) S31—Right Pilot Control Lever Switch A (marked C) ( SE27 ) ( W15 ) S31—Right Pilot Control Lever Switch ( SE28 ) ( W75 ) S32—Left Pilot Control Lever Switch B (marked B) ( SE27 ) ( W15 ) or ( W75 ) S33—Left Pilot Control Lever Switch A (marked C) ( SE27 ) ( W15 ) or ( W75 ) S34—Right Enable Switch ( SE27 ) ( W15 ), ( W22 ) S34—Right Enable Switch (marked ON/OFF) ( SE28 ) ( W75 ) S35—Left Enable Switch ( SE27 ) ( W15 ), ( W22 ) S35—Left Enable Switch (marked ON/OFF) ( SE28 ) ( W75 ) S40—Hydraulic Oil Temperature Switch (if equipped) ( SE4 ) ( W2 ) S50—0 Key ( SE5 ) ( W1 ) S51—1 Key ( SE5 ) ( W1 ) S52—2 Key ( SE5 ) ( W1 ) S53—3 Key ( SE5 ) ( W1 ) S54—4 Key ( SE5 ) ( W1 ) S55—5 Key ( SE5 ) ( W1 ) S56—6 Key ( SE5 ) ( W1 ) S57—7 Key ( SE5 ) ( W1 ) S58—8 Key ( SE5 ) ( W1 ) S59—9 Key ( SE5 ) ( W1 ) S60—Keypad ( SE5 , SE6 ) ( W1 ) S61—Seat Compressor Switch ( SE26 ) S62—Seat Heater Switch ( SE26 ) ( W24 ) S5001—Engine Coolant Loss Level Sensor ( SE13 ) ( W5 ) S5002—Engine Coolant Service Level Sensor ( SE13 ) ( W5 ) V1—Battery Relay Diode ( SE1 ) ( W1 ) V2—Alternator Excitation Diode ( SE3 ) ( W1 ) V3—Load Dump Relay Diode ( SE3 , SE22 ) ( W1 ) V4—Security Diode ( SE2 ) ( W1 ) V5—Starter Cut Relay Diode ( SE3 ) ( W1 ) V6—Auxiliary Power Connector Diode ( SE18 ) ( W1 ) V7—Start Relay Diode ( SE2 ) ( W1 ) V8—Air Conditioner Clutch Diode ( SE22 ) ( W1 ) V9—Pilot Shutoff Diode ( SE3 ) ( W1 ) V10—Starter Protection Diode ( SE1 ) ( W1 ) V11—Accessory Cut Diode ( SE1 ) ( W1 ) V12—Starter Cut Diode ( SE2 ) ( W1 ) V13—Work Light 1 Diode ( SE19 ) ( W1 ) V14—Work Light 2 Diode ( SE19 ) ( W1 ) V20—Pilot Shutoff Switch Diode ( SE3 ) ( W11 ) V22—Pilot Shutoff Solenoid Diode ( SE29 ) ( W75 ) V30—Right Solenoid Diode B ( SE27 ) ( W61 ) V31—Right Solenoid Diode A ( SE27 ) ( W61 ) V32—Left Solenoid Diode B ( SE27 ) ( W61 ) V33—Left Solenoid Diode A ( SE27 ) ( W61 ) V40—Selector Valve Solenoid Valve Diode ( SE8 ) ( W17 ) V41—Secondary Relief Solenoid Valve Diode ( SE9 ) ( W17 ) V43—2-Speed Activation Solenoid Valve Diode ( SE9 ) ( W17 ) V44—Starter Relay Diode ( W27 ) ( SE2 ) W1—Cab Harness ( W1 ) W2—Machine Harness ( W2 ) W3—Monitor Harness ( W3 ) W4—Engine Harness ( W4 ) W5—Engine Interface Harness ( W5 ) W8—Pump Harness ( W8 ) W10—Service ADVISOR™ Remote (SAR) Switch Harness ( W10 ) W11—Pilot Shutoff Switch Harness ( W11 ) W13—Auxiliary Fuse Box ( W13 ) W14—Heated Air Seat Harness ( W14 ) W15—Multi-Function Pilot Control Lever Harness ( W15 ) <- Go to Section TOC





W16—Travel Alarm Cancel Switch Harness ( W16 ) W17—Attachment Harness ( W17 ) W19—Rear Camera Harness ( W19 ) W21—Pilot Shutoff Valve Harness ( W21 ) W22—Auxiliary 3-Button Cancel Switch Harness ( W22 ) W23—Reversing Fan Switch Harness ( W23 ) W24—Seat Heater Switch Harness ( W24 ) W26—Travel Alarm Harness ( W26 ) W27—Starter Harness ( W27 ) W29—Starter Switch Harness ( W29 ) W35—Cab Harness Ground 1 ( W1 ) W36—Cab Harness Ground 2 ( W1 ) W37—Cab Harness Ground 3 ( W1 ) W38—Fuel Injector Harness ( W38 ) W41—Heater and Air Conditioner Harness ( W41 ) W43—Engine Interface Harness Ground ( W5 ) W60—Radio Antenna ( SE18 ) W61—Auxiliary Solenoid Harness ( W61 ) W75—Auxiliary Function Lever (AFL) Harness ( W75 ) W76—Auxiliary Function Lever (AFL) Solenoid Harness ( W76 ) W6002—Modular Telematices Gateway (MTG) Harness ( W6002 ) W6003—Satellite (SAT) Harness ( W6003 ) X1—Service ADVISOR™ Diagnostic Connector ( SE12 ) ( W2 ) X2—MPDr 6-Pin Connector ( SE6 ) ( W1 ) X3—Cab Harness-to-Machine Harness 100-Pin Connector ( SE3 , SE4 , SE6 , SE16 , SE17 ) ( W1 ) ( W2 ) X5—Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 ( SE4 , SE11 ) ( W2 ) X6—Machine Harness-to-Engine Interface Harness 1-Pin Connector ( SE10 ) ( W2 ) X7—Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 ( W2 ) X8—Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 ( SE21 ) ( W2 ) X10—Machine Controller 8-Pin Connector A ( SE19 ) ( W1 ) X11—Machine Controller 20-Pin Connector B ( SE19 ) ( W1 ) X14—Engine Control Unit (ECU)-to-Engine Harness Connector 1 ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 ) X15—Engine Control Unit (ECU)-to-Engine Harness Connector 2 ( SE10 , SE11 , SE12 , SE13 , SE14 , SE15 ) ( W5 ) X17—Cab Harness-to-Monitor Harness Connector ( W1 ) ( W3 ) X18—Monitor 12-Pin Connector C ( SE6 ) ( W3 ) X19—Monitor 2-Pin Connector G ( SE6 ) ( W3 ) X20—Monitor Controller 28-Pin Connector A ( SE4 , SE5 , SE6 ) ( W1 ) X21—Monitor Controller 36-Pin Connector B ( SE4 , SE5 , SE6 ) ( W1 ) X22—Monitor Controller 16-Pin Connector D ( SE4 , SE5 , SE6 ) ( W1 ) X23—Monitor Controller 12-Pin Connector C ( SE4 , SE5 , SE6 ) ( W3 ) X24—Monitor Controller 2-Pin Connector G ( SE4 , SE5 , SE6 ) ( W3 ) X25—Cab Harness Auxiliary Power Connector 1 ( SE18 ) ( W1 ) X26—Optional Connector ( SE17 , SE26 , SE28 , SE30 ) ( W1 ) ( W15 ) or ( W75 ) X27—Cab Harness-to-Switch Connector 1 ( SE20 ) ( W1 ) X28—Cab Harness-to-Switch Connector 2 ( SE5 , SE6 ) ( W1 ) X29—Cab Harness-to-Switch Connector 3 ( SE6 , SE7 ) ( W1 ) X30—Cab Harness-to-Switch Connector 4 ( SE5 ) ( W1 ) X31—Cab Harness-to-Main Controller 31-Pin Connector A ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X32—Cab Harness-to-Main Controller 24-Pin Connector B ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X33—Cab Harness-to-Main Controller 17-Pin Connector C ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X34—Cab Harness-to-Main Controller 30-Pin Connector D ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X35—Cab Harness-to-Main Controller 24-Pin Connector E ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X36—Cab Harness-to-Main Controller 26-Pin Connector F ( SE7 , SE8 , SE9 , SE10 ) ( W1 ) X37—Cab Harness-to-Exhaust Filter Switch Harness Connector (not used) ( W1 ) X39—Cab Harness-to-Window Switch Connector ( SE16 ) ( W1 ) X40—Pump Harness-to-Machine Harness Connector ( SE7 , SE8 , SE9 ) ( W2 ) ( W8 ) X43—Optional Fuse Connector ( W1 ) ( W13 ) X44—Optional Light Connector ( SE17 , SE26 ) ( W1 ) ( W13 ) X45—Option 2 12-Pin Connector (not used) ( W1 ) X46—Attachment Connector ( W2 ) ( W17 ) X47—Cab Harness-to-Key Switch Harness Connector ( W1 ) ( W29 ) <- Go to Section TOC





X50—Cab Harness-to-Travel Alarm Cancel Switch Harness Connector ( W1 ) ( W16 ) X51—Air Conditioner 4-Pin Connector ( W1 ) ( W41 ) X52—Air Conditioner 10-Pin Connector ( SE23 ) ( W1 ) ( W41 ) X53—Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) ( W14 ) ( W24 ) X54—Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) ( SE26 ) ( W13 ) X55—Front Cab Light 1 Connector (marked CAB LAMP FRONT) ( SE26 ) ( W13 ) X56—Front Cab Light 2 Connector (marked CAB LAMP FRONT +2) ( SE25 ) ( W13 ) X57—Rear Cab Light Connector (marked CAB LAMP REAR) ( SE25 ) ( W13 ) X58—Warning Light Connector (marked WARNING LAMP) ( SE25 ) ( W13 ) X59—Satellite Communication Connector (marked IMOBI) ( SE25 ) ( W13 ) X60—12-Volt Power Supply Connector (marked 12V UNIT) ( SE25 ) ( W13 ) X61—Quick Hitch Connector (marked QUICK HITCH) ( SE25 ) ( W13 ) X62—Cab Auxiliary Power Connector 2 (marked AUX_2) ( SE25 ) ( W13 ) X63—Cab Auxiliary Power Connector 3 (marked AUX_3) ( SE25 ) ( W13 ) X64—Machine Harness-to-Rear Camera Harness Connector ( SE6 ) ( W2 ) ( W19 ) X65—Cab Harness-to-Pilot Shutoff Switch Harness Connector ( SE6 ) ( W1 ) ( W21 ) X67—Machine Harness Auxiliary Power Connector ( W2 ) X73—Cab Harness-to-Speakers Connector ( SE18 ) ( W1 ) X74—Cab Harness-to-Remote Service ADVISOR™ Remote (SAR) Switch Harness Connector ( W1 ) ( W10 ) X75—Cab Harness-to-Pilot Shutoff Valve Harness Connector ( W1 ) ( W21 ) X76—Cab Harness Connector 1 (not used) ( SE4 ) ( W1 ) X77—Radio Auxiliary Connector ( SE18 ) ( W1 ) X78—Optional Switch ( W1 ) X79—Engine Interface-to-Engine Harness Connector 1 ( W4 ) ( W5 ) X80—Engine Interface-to-Engine Harness Connector 2 ( W4 ) ( W5 ) X81—Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector ( W15 ) ( W22 ) X82—Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector ( W15 ) ( W22 ) X83—Cab Harness-to-Reversing Fan Switch Harness Connector ( W1 ) ( W23 ) X86—Machine Harness-to-Travel Alarm Harness Connector ( W2 ) ( W26 ) X91—Not Used ( SE7 ) ( W8 ) X90—Machine Harness-to-Hydraulic Oil Temperature Switch Connector ( SE4 ) ( W2 ) X97—Pump Harness Splice Connector ( SE8 , SE9 ) ( W8 ) X98—Machine Harness Splice Connector ( W2 ) X99—Cab Ground Splice ( W1 ) X100—Air Conditioner Controller 32-Pin Connector ( W41 ) X135—Pilot Shutoff Harness Splice 1 ( W11 ) X136—Pilot Shutoff Harness Splice 2 ( W11 ) X137—Pilot Shutoff Harness Splice 3 ( W11 ) X160—1356 YEL Splice (later models) ( W5 ) X161—1357 GRN Splice (later models) ( W5 ) X174—Engine Harness-to-Engine Interface Harness Connector ( W4 ) ( W5 ) X175—Machine Harness-to-Starter Harness Connector ( SE2 ) ( W27 ) X200—G01 BLK Splice 1 ( W5 ) X201—P01 RED Splice 1 ( W5 ) X202—R02 BLK Splice 1 ( W5 ) X203—M13 LT GRN Splice 1 ( W5 ) X204—M12 YEL Splice 1 ( W5 ) X205—M12 YEL Splice 2 ( W5 ) X206—M13 LT GRN Splice 2 ( W5 ) X207—R02 BLK Splice 2 ( W5 ) X208—M12 YEL Splice 3 ( W5 ) X209—5491 BLK Splice 1 ( W38 ) X210—5496 BLK Splice 2 ( W38 X240—5804 YEL Splice 1 ( W4 ) X241—5805 GRN Splice 1 ( W4 ) X242—5804 YEL Splice 2 ( W4 ) X243—5805 GRN Splice 2 ( W4 ) X244—5804 YEL Splice 3 ( W4 ) X245—5805 GRN Splice 3 ( W4 ) X246—5774 YEL Splice ( W4 ) X247—5441 BRN Splice ( W4 ) <- Go to Section TOC





X248—5446 LT BLU Splice ( W4 ) X296—8A PUR Splice ( W38 ) X297—7A BRN Splice ( W38 ) X300—7 RED/BLK Splice ( W41 ) X301—17 RED/BLU Splice ( W41 ) X302—25 BRN/RED Splice ( W41 ) X303—26 BLK Splice ( W41 ) X335—BRN Splice ( W38 ) X336—PUR Splice ( W38 ) X350—5479 WHT Splice ( W4 ) X351—5410 BLK Splice (SHIELD) ( W4 ) X352—5437 PUR Splice ( W4 ) X353—5474 YEL Splice ( W4 ) X354—5414 YEL Splice ( W4 ) X357—5466 LT BLU Splice ( W4 ) X358—5774 YEL Splice ( W4 ) X359—5441 BRN Splice ( W4 ) X360—5446 LT BLU Splice ( W4 ) X361—5804 YEL Splice 1 ( W4 ) X362—5805 DK GRN Splice 3 ( W4 ) X365—5804 YEL Splice 1 ( W4 ) X366—5805 DK GRN Splice 1 ( W4 ) X400—E03 WHT Splice ( W27 ) X401—P21 RED Splice ( W27 ) X534—Right Auxiliary Solenoid Connector (marked SR/H) ( SE27 , SE29 ) ( W61 ) ( W15 ) or ( W75 ) X535—Left Auxiliary Solenoid Connector (marked SL/H) ( SE27 , SE29 ) ( W61 ) ( W15 ) or ( W75 ) X536—Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) ( SE28 ) ( W75 ) X537—Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) ( SE28 ) ( W75 ) X574—Auxiliary Function Lever (AFL) Connector 1 ( SE10 , SE29 ) ( W1 ), ( W75 ) X575—Auxiliary Function Lever (AFL) Connector 2 ( SE10 ) ( W1 ) X577—Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector ( SE29 ) ( W75 ), ( W76 ) X5000—Engine Harness-to-Fuel Injector Harness 8-Pin Connector ( W38 ) X5001—Static Ground ( W4 ) X5010—Engine Harness-to-Front Engine Harness 8-Pin Connector ( W4 ) X5014—Engine Harness-to-Air Sensor Harness 6-Pin Connector (dual turbo) (not used) ( W4 ) X5015—Engine Interface Harness-to-Engine Harness 40-Pin Connector 1 ( W4 ) ( W5 ) X5016—Engine Interface Harness-to-Engine Harness 40-Pin Connector 2 ( W4 ) ( W5 ) X5030A—DRAIN ( W5 ) X5808—P01-2 RED Splice ( W5 ) X5809—G01-3 BLK Splice ( W5 ) X5810—PM13-3 LT GRN Splice ( W5 ) X5811—PM12-3 YEL Splice ( W5 ) X5812—PR02-3 BLK Splice ( W5 ) X5813—M13-2 LT GRN Splice ( W5 ) X5814—M12-2 YEL Splice ( W5 ) X5815—R02-2 BLK Splice ( W5 ) X5816—P307 RED Splice ( W5 ) X5817—P01 RED Splice ( W5 ) X5818—G01 BLK Splice 1 ( W5 ) X5819—R02 BLK Splice ( W5 ) X5820—M12 YEL Splice ( W5 ) X5821—M13 LT GRN Splice ( W5 ) X5822—G01 BLK Splice 2 ( W5 ) X5823—5437 PUR Splice ( W5 ) X5824—5474 YEL Splice ( W5 ) X6007—JDLink™ Harness Ground 1 ( SE21 ) ( W4 ) X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector ( SE21 ) ( W4 ) ( W6002 ) X6015—Satellite (SAT) Module Control Unit 48-Pin Connector ( SE21 ) ( W5 ) X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector ( SE21 ) ( W5 ) ( W6003 ) X6019— Modular Telematics Gateway (MTG) Connector ( SE21 ) ( W5 ) ( W6002 ) <- Go to Section TOC





X6022—Cab Harness-to-Exhaust Filter Solenoid Harness Connector (not used) ( W2 ) Y1—Electronic Injector 1 (cylinder 1) ( SE12 ) ( W38 ) Y2—Electronic Injector 2 (cylinder 2) ( SE12 ) ( W38 ) Y3—Electronic Injector 3 (cylinder 3) ( SE12 ) ( W38 ) Y4—Electronic Injector 4 (cylinder 4) ( SE12 ) ( W38 ) Y9—Reversing Fan Solenoid ( SE13 ) ( W5 ) Y10—Pilot Shutoff Solenoid ( SE2 ) ( W1 ) Y11—Air Conditioner Compressor Clutch ( SE22 ) ( W2 ) Y19—Ether Start Aid ( SE14 ) ( W5 ) Y20—Pump 2 Flow Rate Limit Solenoid (marked SB) ( SE7 ) ( W8 ) Y21—Torque Control Solenoid (marked ST) ( SE7 ) ( W8 ) Y22—Dig Regenerative Solenoid (marked SF) ( SE7 ) ( W2 ) Y23—Arm Regenerative Solenoid (marked SC) ( SE8 ) ( W2 ) Y24—Power Dig Solenoid (marked SG) ( SE8 ) ( W2 ) Y24—Power Dig/Travel Speed Solenoid (marked SG) ( SE8 ) ( W2 ) Y25—Travel Speed Solenoid (marked SI) ( SE8 ) ( W2 ) Y27—Arm 2 Flow Control Solenoid (marked SD) ( SE8 ) ( W2 ) Y34—Right Solenoid (marked SR/H) ( SE27 ) ( W61 ) Y35—Left Solenoid (marked SL/H) ( SE27 ) ( W61 ) Y40—Selector Valve Solenoid Valve ( SE8 ) ( W17 ) Y41—Secondary Relief Solenoid Valve ( SE9 ) ( W17 ) Y44—Flow Rate Adjustment Solenoid Valve ( SE8 ) ( W17 ) Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A) ( SE30 ) ( W76 ) Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B) ( SE30 ) ( W76 ) Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC) ( SE30 ) ( W76 ) Y5005—Variable Speed Fan Solenoid ( SE13 ) ( W5 ) Y5401—Intake Air Throttle ( SE11 , SE12 ) ( W4 )






System Functional Schematic System Functional Schematic (S.N. —040754)






130G System Functional Schematic (SE1—SE3) (1 of 9) (S.N. —040754)





LEGEND: F4 F7 F18 F45 F60 F61 G1 G2 G3 K1 K2 K4 K5 K11 K12 K13 K19 K34 K35 M1 R13 S1 S3 S4 V1 V2 V3 V4 V5 V7 V9 V10 V11 V12 V44 V20 X175 Y10



Solenoid 20 A Fuse (marked SOLENOID) Start Position Signal 5 A Fuse (marked START) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Pilot Shutoff Solenoid Relay Starter Cut Relay Security Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Alternator Resistor Key Switch Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Start Relay Diode Pilot Shutoff Diode Starter Protection Diode Accessory Cut Diode Starter Cut Diode Starter Relay Diode Pilot Shutoff Switch Diode Machine Harness-to-Starter Harness Connector Pilot Shutoff Solenoid










LEGEND: A4 A10 A12 B18 B27 E5 E6 E7 E8 F9 F14 F17 H2 H3 K3 S10 S20 S21 S22 S23 S24 S25 S26 S27 S40 S50 S51 S52 S53 S54 S55 S56 S57 S58 S59 S60 X2 X3 X18 X19 X20 X21 X22 X23 X24 X28 X29 X30 X64 X76 X90



Monitor Controller (DSZ) Monitor Rear Camera Fuel Level Sensor Hydraulic Oil Filter Restriction Switch (if equipped) Switch Back Light 1 Switch Back Light 2 Switch Back Light 3 Switch Back Light 4 Radio Backup 10 A Fuse (marked BACK UP) Monitor 5 A Fuse (marked MONITOR) Power On 5 A Fuse (marked POWER ON) Security Alarm Monitor Warning Alarm Security Alarm Relay Work Light Switch Seat Belt Switch Blower Motor Speed Switch Temperature Control/Mode Switch Radio Volume and Power Switch Radio Tuning Switch Monitor Dial Back Button Home Button Hydraulic Oil Temperature Switch (if equipped) 0 Key 1 Key 2 Key 3 Key 4 Key 5 Key 6 Key 7 Key 8 Key 9 Key Keypad MPDr 6-Pin Connector Cab Harness-to-Machine Harness 100-Pin Connector Monitor 12-Pin Connector C Monitor 2-Pin Connector G Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Machine Harness-to-Rear Camera Harness Connector Cab Harness Connector 1 (not used) Machine Harness-to-Hydraulic Oil Temperature Switch Connector










LEGEND: A3 B30 B31 B32 B33 B34 B35 B36 B37 B38 B40 B60 B61 F5 F10 H4 R15 S8 S11 S12 S13 V40 V41 V43 X29 X31 X32 X33 X34 X35 X36 X40 X90 X91 X97 Y20 Y21 Y22 Y23 Y24 Y27 Y40 Y41 Y43 Y44


Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Hydraulic Oil Temperature Sensor Attachment Pressure Sensor Arm Out Pressure Sensor Travel Alarm 5 A Fuse (marked OPT. 1 ALT) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Travel Alarm Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Selector Valve Solenoid Valve Diode Secondary Relief Solenoid Valve Diode 2-Speed Activation Solenoid Valve Diode Cab Harness-to-Switch Connector 3 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Pump Harness-to-Machine Harness Connector Not Used Not Used Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST) Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD) Selector Valve Solenoid Valve Secondary Relief Solenoid Valve 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve






130G System Functional Schematic (SE10—SE12) (4 of 9 (S.N. —040754)





LEGEND: A1 A3 B82 B5100 B5101 B5107 B5206 B5208 B5209 B5301 B5302 B5600 M13 R12 S7 X1 X14 X15 X31 X32 X33 X34 X35 X36 Y1 Y2 Y3 Y4



Engine Control Unit (ECU) Main Controller (MCZ) Ambient Air Temperature Sensor 2 Fuel Rail Pressure Sensor Engine Oil Pressure Sensor Inlet Fuel Pressure Sensor Manifold Air Temperature (MAT) Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Water-in-Fuel Sensor High Pressure Fuel Pump CAN 0 Termination Resistor Power Dig Switch Service ADVISOR ™ Diagnostic Connector Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Electronic Injector 1 (cylinder 1) Electronic Injector 2 (cylinder 2) Electronic Injector 3 (cylinder 3) Electronic Injector 4 (cylinder 4)










LEGEND: A1 B16 B53 F8 S15 S5001 S5002 X14 X15 Y9 Y19 Y5005



Engine Control Unit (ECU) Air Filter Restriction Switch Fan Speed Sensor Engine Control Unit (ECU) 30 A Fuse (marked ECU) Reversing Fan Switch Engine Coolant Loss Level Sensor Engine Coolant Service Level Sensor Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Reversing Fan Solenoid Ether Start Aid Variable Speed Fan Solenoid





130G Functional Schematic (SE16—SE18) (6 of 9) (S.N. —040754)





LEGEND: A6 A8 B25 B26 E1 E2 F1 F2 F6 F12 F13 F15 F20 F62 G5 K6 K7 K8 K9 M5 M6 R9 S28 V6 W60 X3 X25 X26 X39 X44 X73 X77



Radio 12-Volt Power Converter Right Speaker Left Speaker Work Light Boom Light Work and Boom Lights 20 A Fuse (marked LAMP) Windshield Wiper and Washer 10 A Fuse (marked WIPER) 12-Volt Power Outlet 10 A Fuse (marked OPT. 2 ALT) Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Cab Auxiliary Power Connector One 10 A Fuse (marked AUX) Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Wiper Motor Assembly Circuit Breaker 12-Volt Power Outlet Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Windshield Wiper Motor Windshield Washer Motor Lighter Window Switch Auxiliary Power Connector Diode Radio Antenna Cab Harness-to-Machine Harness 100-Pin Connector Cab Harness Auxiliary Power Connector 1 Optional Connector Cab Harness-to-Window Switch Connector Optional Light Connector Cab Harness-to-Speakers Connector Radio Auxiliary Connector





130G Functional Schematic (SE19—SE21) (7 of 9) (S.N. —040754)





LEGEND: A5 A11 A6000 A6001 A6002 A6003 E3 E9 E10 F6000 F6001 F6002 R10 R11 S2 S9 S14 V13 V14 X8 X10 X11 X27 X6007 X6014 X6015 X6016 X6019



Data Converter Machine Controller (BCZ) Modular Telematics Gateway (MTG) Controller (if equipped) GPS/Cellular Antenna Satellite (SAT) Module Control Unit (if equipped) Satellite (SAT) Antenna Cab Dome Light Key Switch Light Switch Back Light 5 JDLink ™ Unswitched Power 7.5 A Fuse JDLink™ Ground 7.5 A Fuse JDLink™ Switched Power 7.5 A Fuse Interface CAN Resistor 1 Interface CAN Resistor 2 (later models) Cab Dome Light Switch Windshield Wiper and Washer Switch Door Switch Work Light 1 Diode Work Light 2 Diode Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Switch Connector 1 JDLink™ Harness Ground 1 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Satellite (SAT) Module Control Unit 48-Pin Connector Engine Interface Harness-to-Satellite (SAT) Harness Modular Telematics Gateway (MTG) Connector










LEGEND: A7 B20 B21 B22 B23 B24 B41 B55 F3 F19 K10 K15 K17 K18 M7 M9 M10 M11 R16 R17 S5 V8 X52 Y11



Air Conditioner Controller (ACF) Air Conditioner High/Low Pressure Switch Solar Sensor Ambient Air Temperature Sensor High Note Horn Low Note Horn Air Conditioner Freeze Control Switch Air Recirculation Sensor Air Conditioner and Heater 20 A Fuse (marked HEATER) Horn 10 A Fuse (marked HORN) Horn Relay Air Conditioner Blower Motor Relay Max Hi Relay Air Conditioner Compressor Clutch Relay Air Conditioner and Heater Blower Motor Air Conditioner and Heater Internal and External Servomotor Air Conditioner and Heater Blower Port Change Servomotor Air Conditioner and Heater Mixer Servomotor Blower Motor Transistor Blower Motor Resistor Horn Switch Air Conditioner Clutch Diode Air Conditioner 10-Pin Connector Air Conditioner Compressor Clutch










LEGEND: B80 B81 F21 F22 F23 F24 F25 F26 F27 F31 F32 F33 F34 K20 K30 K31 K32 K33 M12 R18 S30 S31 S32 S33 S34 S35 S61 S62 V30 V31 V32 V33 X26 X44 X54 X55 X56 X57 X58 X59 X60 X61 X62 X63 X534 X535 Y34 Y35


Seat Temperature Switch 1 Seat Temperature Switch 2 Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) IMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) Seat Heater Relay Right Solenoid Relay B Right Solenoid Relay A Left Solenoid Relay B Left Solenoid Relay A Seat Air Compressor Motor Seat Heater (marked SEAT HEATER) Right Pilot Control Lever Switch B (marked B) Right Pilot Control Lever Switch A (marked A) Left Pilot Control Lever Switch B (marked B) Left Pilot Control Lever Switch A (marked A) Right Enable Switch Left Enable Switch Seat Compressor Switch Seat Heater Switch Right Solenoid Diode B Right Solenoid Diode A Left Solenoid Diode B Left Solenoid Diode A Optional Connector Optional Light Connector Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) Front Cab Light 1 Connector (marked CAB LAMP FRONT) Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) Rear Cab Light Connector (marked CAB LAMP REAR) Warning Light Connector (marked WARNING LAMP) Satellite Communication Connector (marked IMOBI) 12-Volt Power Supply Connector (marked 12V UNIT) Quick Hitch Connector (marked QUICK HITCH) Cab Auxiliary Power Connector 2 (marked AUX_2) Cab Auxiliary Power Connector 3 (marked AUX_3) Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H) Right Solenoid (marked SR/H) Left Solenoid (marked SL/H)

System Functional Schematic (S.N. 040755— )






System Functional Schematic (SE1—SE3) (1 of 10) (S.N. 040755— )





LEGEND: F4 F7 F18 F45 F60 F61 G1 G2 G3 K1 K2 K4 K5 K11 K12 K13 K19 K34 K35 M1 R13 S1 S3 S4 V1 V2 V3 V4 V5 V7 V9 V10 V11 V12 V44 V20 X65 X175 Y10



Solenoid 20 A Fuse (marked SOLENOID) Start Position Signal 5 A Fuse (marked START) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Pilot Shutoff Solenoid Relay Starter Cut Relay Security Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Alternator Resistor Key Switch Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Start Relay Diode Pilot Shutoff Diode Starter Protection Diode Accessory Cut Diode Starter Cut Diode Starter Relay Diode Pilot Shutoff Switch Diode Cab Harness-to-Pilot Shutoff Switch Harness Connector Machine Harness-to-Starter Harness Connector Pilot Shutoff Solenoid










LEGEND: A4 A10 A12 B18 B27 E5 E6 E7 E8 F9 F14 F17 H2 H3 K3 S10 S20 S21 S22 S23 S24 S25 S26 S27 S40 S50 S51 S52 S53 S54 S55 S56 S57 S58 S59 S60 X2 X3 X18 X19 X20 X21 X22 X23 X24 X28 X29 X30 X64 X76 X90



Monitor Controller (DSZ) Monitor Rear Camera Fuel Level Sensor Hydraulic Oil Filter Restriction Switch (if equipped) Switch Back Light 1 Switch Back Light 2 Switch Back Light 3 Switch Back Light 4 Radio Backup 10 A Fuse (marked BACK UP) Monitor 5 A Fuse (marked MONITOR) Power On 5 A Fuse (marked POWER ON) Security Alarm Monitor Warning Alarm Security Alarm Relay Work Light Switch Seat Belt Switch Blower Motor Speed Switch Temperature Control/Mode Switch Radio Volume and Power Switch Radio Tuning Switch Monitor Dial Back Button Home Button Hydraulic Oil Temperature Switch (if equipped) 0 Key 1 Key 2 Key 3 Key 4 Key 5 Key 6 Key 7 Key 8 Key 9 Key Keypad MPDr 6-Pin Connector Cab Harness-to-Machine Harness 100-Pin Connector Monitor 12-Pin Connector C Monitor 2-Pin Connector G Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Machine Harness-to-Rear Camera Harness Connector Cab Harness Connector 1 (not used) Machine Harness-to-Hydraulic Oil Temperature Switch Connector










LEGEND: A3 B30 B31 B32 B33 B34 B35 B36 B37 B38 B40 B60 B61 F5 F10 F11 H4 R15 S8 S11 S12 S13 V40 V41 V43 X29 X31 X32 X33 X34 X35 X36 X40 X90 X91 X97 Y20 Y21 Y22 Y23 Y24 Y27 Y40 Y41 Y43 Y44


Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Hydraulic Oil Temperature Sensor Attachment Pressure Sensor Arm Out Pressure Sensor Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Travel Alarm 5 A Fuse (marked TRAVEL ALARM) Travel Alarm Engine Speed Dial Auto-Idle Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Selector Valve Solenoid Valve Diode Secondary Relief Solenoid Valve Diode 2-Speed Activation Solenoid Valve Diode Cab Harness-to-Switch Connector 3 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Pump Harness-to-Machine Harness Connector Not Used Not Used Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST) Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig/Travel Speed Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD) Selector Valve Solenoid Valve Secondary Relief Solenoid Valve 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve











LEGEND: A1 A3 B82 B5100 B5101 B5107 B5206 B5208 B5209 B5301 B5302 B5600 M13 R12 S7 X1 X14 X15 X31 X32 X33 X34 X35 X36 X574 X575 Y1 Y2 Y3 Y4



Engine Control Unit (ECU) Main Controller (MCZ) Ambient Air Temperature Sensor 2 Fuel Rail Pressure Sensor Engine Oil Pressure Sensor Inlet Fuel Pressure Sensor Manifold Air Temperature (MAT) Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Water-in-Fuel Sensor High Pressure Fuel Pump CAN 0 Termination Resistor Power Dig Switch Service ADVISOR ™ Diagnostic Connector Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Auxiliary Function Lever (AFL) Connector 1 Auxiliary Function Lever (AFL) Connector 2 Electronic Injector 1 (cylinder 1) Electronic Injector 2 (cylinder 2) Electronic Injector 3 (cylinder 3) Electronic Injector 4 (cylinder 4)










LEGEND: A1 B16 B53 F8 S15 S5001 S5002 X14 X15 Y9 Y19 Y5005



Engine Control Unit (ECU) Air Filter Restriction Switch Fan Speed Sensor Engine Control Unit (ECU) 20 A Fuse (marked ECU) Reversing Fan Switch Engine Coolant Loss Level Sensor Engine Coolant Service Level Sensor Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Reversing Fan Solenoid Ether Start Aid Variable Speed Fan Solenoid










LEGEND: A6 A8 B25 B26 E1 E2 F1 F2 F6 F12 F13 F15 F20 F62 G5 K6 K7 K8 K9 M5 M6 R9 S28 V6 W60 X3 X25 X26 X39 X73 X77



Radio 12-Volt Power Converter Right Speaker Left Speaker Work Light Boom Light Work and Boom Lights 20 A Fuse (marked LAMP) Windshield Wiper and Washer 10 A Fuse (marked WIPER) 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Cab Auxiliary Power Connector One 10 A Fuse (marked AUX) Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Wiper Motor Assembly Circuit Breaker 12-Volt Power Outlet Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Windshield Wiper Motor Windshield Washer Motor Lighter Window Switch Auxiliary Power Connector Diode Radio Antenna Cab Harness-to-Machine Harness 100-Pin Connector Cab Harness Auxiliary Power Connector 1 Optional Connector Cab Harness-to-Window Switch Connector Cab Harness-to-Speakers Connector Radio Auxiliary Connector










LEGEND: A5 A11 A6000 A6001 A6002 A6003 E3 E9 E10 F6000 F6001 F6002 R10 R11 S2 S9 S14 V13 V14 X8 X10 X11 X27 X6007 X6014 X6015 X6016 X6019



Data Converter Machine Controller (BCZ) Modular Telematics Gateway (MTG) Controller (if equipped) GPS/Cellular Antenna Satellite (SAT) Module Control Unit (if equipped) Satellite (SAT) Antenna Cab Dome Light Key Switch Light Switch Back Light 5 JDLink ™ Unswitched Power 7.5 A Fuse JDLink™ Ground 7.5 A Fuse JDLink™ Switched Power 7.5 A Fuse Interface CAN Resistor 1 Interface CAN Resistor 2 (later models) Cab Dome Light Switch Windshield Wiper and Washer Switch Door Switch Work Light 1 Diode Work Light 2 Diode Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Switch Connector 1 JDLink™ Harness Ground 1 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Satellite (SAT) Module Control Unit 48-Pin Connector Engine Interface Harness-to-Satellite (SAT) Harness Modular Telematics Gateway (MTG) Connector










LEGEND: A7 B20 B21 B22 B23 B24 B41 B55 F3 F19 K10 K15 K17 K18 M7 M9 M10 M11 R16 R17 S5 V8 X52 Y11



Air Conditioner Controller (ACF) Air Conditioner High/Low Pressure Switch Solar Sensor Ambient Air Temperature Sensor High Note Horn Low Note Horn Air Conditioner Freeze Control Switch Air Recirculation Sensor Air Conditioner and Heater 20 A Fuse (marked HEATER) Horn 10 A Fuse (marked HORN) Horn Relay Air Conditioner Blower Motor Relay Max-Hi Relay Air Conditioner Compressor Clutch Relay Air Conditioner and Heater Blower Motor Air Conditioner and Heater Internal and External Servo Motor Air Conditioner and Heater Blower Port Change Servo Motor Air Conditioner and Heater Mixer Servo Motor Blower Motor Transistor Blower Motor Resistor Horn Switch Air Conditioner Clutch Diode Air Conditioner 10-Pin Connector Air Conditioner Compressor Clutch










LEGEND: B80 B81 F21 F22 F23 F24 F25 F26 F31 F32 F33 F34 K20 K30 K31 K32 K33 M12 R18 S30 S31 S32 S33 S34 S35 S61 S62 V30 V31 V32 V33 X26 X44 X54 X55 X56 X57 X58 X59 X61 X62 X63 X534 X535 Y34 Y35


Seat Temperature Switch 1 Seat Temperature Switch 2 Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) IMMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX_3) Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX_2) Seat Heater Relay Right Solenoid Relay B Right Solenoid Relay A Left Solenoid Relay B Left Solenoid Relay A Seat Air Compressor Motor Seat Heater (marked SEAT HEATER) Right Pilot Control Lever Switch B (marked B) Right Pilot Control Lever Switch A (marked C) Left Pilot Control Lever Switch B (marked B) Left Pilot Control Lever Switch A (marked C) Right Enable Switch Left Enable Switch Seat Compressor Switch Seat Heater Switch Right Solenoid Diode B Right Solenoid Diode A Left Solenoid Diode B Left Solenoid Diode A Optional Connector Optional Light Connector Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) Front Cab Light 1 Connector (marked CAB LAMP FRONT) Front Cab Light 2 Connector (marked CAB LAMP FRONT +2) Rear Cab Light Connector (marked CAB LAMP REAR) Warning Light Connector (marked WARNING LAMP) Satellite Communication Connector (marked IMOBI) Quick Hitch Connector (marked QUICK HITCH) Cab Auxiliary Power Connector 2 (marked AUX_2) Cab Auxiliary Power Connector 3 (marked AUX_3) Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H) Right Solenoid (marked SR/H) Left Solenoid (marked SL/H)












LEGEND: B68 Secondary Hydraulic Oil Temperature Sensor B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) K31 Right Solenoid Relay A K32 Left Solenoid Relay B K33 Left Solenoid Relay A S7 Power Dig Switch S29 Auxiliary Function Lever (AFL) Proportional Control Switch S31 Right Pilot Control Lever Switch S34 Right Enable Switch S35 Left Enable Switch S45 Auxiliary Function Enable Switch (marked AFL_SW) V22 Pilot Shutoff Solenoid Diode X26 Optional Connector X534 Right Auxiliary Solenoid Connector (marked SR/H) X535 Left Auxiliary Solenoid Connector (marked SL/H) X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) X537 Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) X574 Auxiliary Function Lever (AFL) Connector 1 X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC)






Cab Harness (W1) Component Location IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Cab Harness (W1) Component Location (S.N. —040754)






Cab Harness (W1) Component Location (S.N. —040754)





LEGEND: A3 A4 A5 A6 A7 A8 A11 E3 F50 F51 G5 H2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K15 K17 K18 R9 R10 R15 S1 S5 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S18 S20 S21 S22 S23 S24 S25 S26 S27 S34 S60 S62 V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11


Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Radio Air Conditioner Controller (ACF) 12-Volt Power Converter Machine Controller (BCZ) Cab Dome Light Fuse Box Auxiliary Fuse Box 12-Volt Power Outlet Security Alarm Load Dump Relay Pilot Shutoff Solenoid Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Air Conditioner Blower Motor Relay Max Hi Relay Air Conditioner Compressor Clutch Relay Lighter Interface CAN Resistor 1 Engine Speed Dial Key Switch Horn Switch Power Dig Switch Auto-Idle Switch Windshield Wiper and Washer Switch Work Light Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Door Switch Reversing Fan Switch Exhaust Filter Parked Cleaning Switch Service ADVISOR ™ Remote (SAR) Switch Seat Belt Switch Blower Motor Speed Switch Temperature Control/Mode Switch Radio Volume and Power Switch Radio Tuning Switch Monitor Dial Back Button Home Button Right Enable Switch Keypad Seat Heater Switch Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Auxiliary Power Connector Diode Start Relay Diode Air Conditioner Clutch Diode Pilot Shutoff Diode Starter Protection Diode Accessory Cut Diode





V12 V13 V14 W1 W9 W10 W16 W22 W23 W24 W29 W35 W36 W37 X2 X3 X10 X11 X17 X20 X21 X22 X25 X26 X27 X28 X29 X30 X31 X32 X33 X35 X36 X39 X43 X44 X45 X47 X50 X51 X52 X53 X65 X73 X74 X75 X76 X77 X78 X83 X99


Starter Cut Diode Work Light 1 Diode Work Light 2 Diode Cab Harness Exhaust Filter Parked Cleaning Switch Harness Service ADVISOR™ Remote (SAR) Switch Harness Travel Alarm Cancel Switch Harness Auxiliary 3-Button Cancel Switch Harness Reversing Fan Switch Harness Seat Heater Switch Harness Starter Switch Harness Cab Harness Ground 1 Cab Harness Ground 2 Cab Harness Ground 3 MPDr 6-Pin Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Monitor Harness Connector Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Cab Harness Auxiliary Power Connector Optional Connector Cab Harness-to-Switch Connector 1 Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Cab Harness-to-Window Switch Optional Fuse Connector Optional Light Connector Option 2 12-Pin Connector (not used) Cab Harness-to-Key Switch Harness Connector Cab Harness-to-Travel Alarm Cancel Switch Harness Connector Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) Cab Harness-to-Pilot Shutoff Switch Harness Connector Cab Harness-to-Speakers Cab Harness-to-Remote Service ADVISOR™ Remote (SAR) Switch Harness Cab Harness-to-Pilot Shutoff Valve Harness Connector Cab Harness Connector 1 (not used) Radio Auxiliary Connector Optional Switch Cab Harness-to-Reversing Fan Switch Harness Cab Ground Splice

Cab Harness (W1) Component Location (S.N. 040755— )






Cab Harness (W1) Component Location (S.N. 040755— )





LEGEND: A3 A4 A5 A6 A8 A11 E3 F50 F51 G5 H2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 R9 R10 R15 S1 S5 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S18 S21 S22 S23 S24 S25 S26 S27 S34 S60 S62 V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14 W1 W3


Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Radio 12-Volt Power Converter Machine Controller (BCZ) Cab Dome Light Fuse Box Fuse Box 2 12-Volt Power Outlet Security Alarm Load Dump Relay Pilot Shutoff Solenoid Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Lighter Interface CAN Resistor 1 Engine Speed Dial Key Switch Horn Switch Power Dig Switch Auto-Idle Switch Windshield Wiper and Washer Switch Work Light Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Door Switch Reversing Fan Switch Exhaust Filter Parked Cleaning Switch Service ADVISOR™ Remote (SAR) Switch Blower Motor Speed Switch Temperature Control/Mode Switch Radio Volume and Power Switch Radio Tuning Switch Monitor Dial Back Button Home Button Right Enable Switch Keypad Seat Heater Switch Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Auxiliary Power Connector Diode Start Relay Diode Air Conditioner Clutch Diode Pilot Shutoff Diode Starter Protection Diode Accessory Cut Diode Starter Cut Diode Work Light 1 Diode Work Light 2 Diode Cab Harness Monitor Harness





W9 W10 W16 W22 W23 W24 W29 W35 W36 W37 X1 X2 X3 X10 X11 X17 X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X30 X31 X32 X33 X34 X35 X36 X37 X39 X42 X45 X47 X50 X51 X52 X54 X55 X56 X57 X58 X59 X61 X62 X63 X65 X73 X74 X75 X76 X77 X78 X81 X83 X99 X573 X574 X575


Exhaust Filter Parked Cleaning Switch Harness Service ADVISOR™ Remote (SAR) Switch Harness Travel Alarm Cancel Switch Harness Auxiliary 3-Button Cancel Switch Harness Reversing Fan Switch Harness Seat Heater Switch Harness Starter Switch Harness Cab Harness Ground 1 Cab Harness Ground 2 Cab Harness Ground 3 Service ADVISOR ™ Diagnostic Connector WinDr 6-Pin Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Machine Harness Connector Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G Cab Harness Auxiliary Power Connector 1 (marked AUX+/-) Optional Connector Cab Harness-to-Switch Connector 1 Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Cab Harness-to-Exhaust Filter Switch Harness Connector Cab Harness-to-Window Switch CAN 1 Connector Option 2 12-Pin Connector (not used) Cab Harness-to-Key Switch Harness Connector Cab Harness-to-Travel Alarm Cancel Switch Harness Connector Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) Front Cab Light 1 Connector (marked CAB LAMP FRONT) Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) Rear Cab Light Connector (marked CAB LAMP REAR) Warning Light Connector (marked WARNING LAMP) Satellite Communication Connector (marked IMMOBI) Quick Hitch Connector (marked QUICK HITCH) Cab Auxiliary Power Connector 2 (marked AUX. 2) Cab Auxiliary Power Connector 3 (marked AUX. 3) Cab Harness-to-Pilot Shutoff Switch Harness Connector Cab Harness-to-Speakers Connector Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness (marked SDV-SW) Cab Harness-to-Pilot Shutoff Valve Harness Connector Cab Harness Connector 1 (marked HMST, not used) Radio Auxiliary Connector Optional Switch Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector Cab Harness-to-Reversing Fan Switch Harness (marked VSF-SW) Cab Ground Splice Exhaust Solenoid Harness Connector (not used) Auxiliary Function Lever (AFL) Connector 1 Auxiliary Function Lever (AFL) Connector 2






Cab Harness (W1) Wiring Diagram IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Cab Harness (W1) Wiring Diagram (S.N. —040754)






Cab Harness (W1) Wiring Diagram (1 of 4) (S.N. —040754)
















LEGEND: 1 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 S7 V1 V4 V7 V8 V10 V13 V14 W35 W36 X10 X11 X17 X20 X21 X22 X27 X28 X29 X30 X37 X47 X74 X76 X78


Continued on Sheet 2 Load Dump Relay Pilot Shutoff Solenoid Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Power Dig Switch Battery Relay Diode Security Diode Start Relay Diode Air Conditioner Clutch Diode Starter Protection Diode Work Light 1 Diode Work Light 2 Diode Cab Harness Ground 1 Cab Harness Ground 2 Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Monitor Harness Connector Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Cab Harness-to-Switch Connector 1 Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Cab Harness-to-Exhaust Filter Switch Harness Connector Cab Harness-to-Key Switch Harness Connector Cab Harness-to- Service ADVISOR ™ Remote (SAR) Switch Harness Connector Cab Harness Connector (not used) Optional Switch











LEGEND: 1 2 A5 E3 H2 K15 K17 K18 R10 V2 V3 V5 V9 V11 V12 X3 X31 X32 X33 X35 X36 X51 X52 X73 X99



Continued on Sheet 1 Continued on Sheet 3 Data Converter Cab Dome Light Security Alarm Air Conditioner Blower Motor Relay Max Hi Relay Air Conditioner Compressor Clutch Relay Interface CAN Resistor 1 Alternator Excitation Diode Load Dump Relay Diode Starter Cut Relay Diode Pilot Shutoff Diode Accessory Cut Diode Starter Cut Diode Cab Harness-to-Machine Harness 100-Pin Connector Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector Cab Harness-to-Speakers Connector Cab Ground Splice










LEGEND: 2 A6 A8 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F50 G5 R9 S5 S14 V6 W37 X2 X25 X26 X39 X43 X44 X45 X50 X65 X75 X77 X83


Continued on Sheet 2 Radio 12-Volt Power Converter Work and Boom Lights 20 A Fuse (marked LAMP) Windshield Wiper and Washer 10 A Fuse (marked WIPER) Air Conditioner and Heater 20 A Fuse (marked HEATER) Solenoid 20 A Fuse (marked SOLENOID) Travel Alarm 5 A Fuse (marked OPT. 1 ALT) 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Start Position Signal 5 A Fuse (marked START) Engine Control Unit (ECU) 30 A Fuse (marked ECU) Radio Backup 10 A Fuse (marked BACK UP) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Not Used Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Monitor 5 A Fuse (marked MONITOR) Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) Start Aid 20 A Fuse (marked START AID) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Horn 10 A Fuse (marked HORN) Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Fuse Box 12-Volt Power Outlet Lighter Horn Switch Door Switch Auxiliary Power Connector Diode Cab Harness Ground 3 MPDr 6-Pin Connector Cab Harness Auxiliary Power Connector 1 Optional Connector Cab Harness-to-Window Switch Connector Optional Fuse Connector Optional Light Connector Option 2 12-Pin Connector (not used) Cab Harness-to-Travel Alarm Cancel Switch Harness Connector Cab Harness-to-Pilot Shutoff Switch Harness Connector Cab Harness-to-Pilot Shutoff Valve Harness Connector Radio Auxiliary Connector Cab Harness-to-Reversing Fan Switch Harness Connector

Cab Harness (W1) Wiring Diagram (S.N. 040755— )






Cab Harness (W1) Wiring Diagram (1 of 5) (S.N. 040755— )

















LEGEND: 1 Continued on sheet 3 A6 Radio A8 12-Volt Power Converter F1 Work and Boom Lights 20 A Fuse (marked LAMP) F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER) F3 Air Conditioner and Heater 20 A Fuse (marked HEATER) F4 Solenoid 20 A Fuse (marked SOLENOID) F5 Optional and Attachment Connector 20 A Fuse (marked OPT. 1 ALT) F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) F7 Start Position Signal 5 A Fuse (marked START) F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) F9 Radio Backup 10 A Fuse (marked BACK UP) F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM) F12 Radio and Dome 5 A Fuse (marked RADIO) F13 Lighter 10 A Fuse (marked LIGHTER) F14 Monitor 5 A Fuse (marked MONITOR) F15 Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) F16 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) F17 Power On 5 A Fuse (marked POWER ON) F18 Idle Stop 5 A Fuse (marked IDLE STOP) F19 Horn 10 A Fuse (marked HORN) F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT) F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER) F22 Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) F24 IMOBI 5 A Fuse (marked IMOBI) F25 Quick Hitch 5 A Fuse (marked QUICK HITCH) F26 Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) F27 Not Used F28 Not Used F29 Not Used F30 Not Used F31 Seat Compressor 10 A Fuse (marked SEAT COMPR) F32 Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) F33 Warning Lamp 10 A Fuse (marked WARNING LAMP) F34 Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) F35 Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG) F36 Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used) F37 Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used) F38 Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used) F39 Not Used F40 Not Used F50 Fuse Box F51 Fuse Box 2 G5 12-Volt Power Outlet R9 Lighter S5 Horn Switch S14 Door Switch V6 Auxiliary Power Connector Diode W37 Cab Harness Ground 3 X1 Service ADVISOR ™ Diagnostic Connector X2 WinDr. 6-Pin Connector X25 Cab Harness Auxiliary Power Connector 1 (marked AUX+/-) X26 Optional Connector X34 Cab Harness-to-Main Controller 30-Pin Connector D X35 Cab Harness-to-Main Controller 24-Pin Connector E X36 Cab Harness-to-Main Controller 26-Pin Connector F X39 Cab Harness-to-Window Switch Connector X45 Option 2 12-Pin Connector (not used) X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT) X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) X57 Rear Cab Light Connector (marked CAB LAMP REAR) X58 Warning Light Connector (marked WARNING LAMP) <- Go to Section TOC




X59 X61 X62 X63 X65 X75 X77 X83


Satellite Communication Connector (marked IMMOBI) Quick Hitch Connector (marked QUICK HITCH) Cab Auxiliary Power Connector 2 (marked AUX 2) Cab Auxiliary Power Connector 3 (marked AUX 3) Cab Harness-to-Pilot Shutoff Switch Harness Connector Cab Harness-to-Pilot Shutoff Valve Harness Connector Radio Auxiliary Connector Cab Harness-to-Reversing Fan Switch Harness Connector (marked VSF-SW)











LEGEND: 1 2 A5 E3 H2 R10 V2 V3 V5 V9 V11 V12 X3 X31 X32 X33 X51 X52 X73 X99 X573



Continued on sheet 2 Continued on sheet 4 Information Controller (ICF) Cab Dome Light Security Alarm Interface CAN Resistor 1 Alternator Excitation Diode Load Dump Relay Diode Starter Cut Relay Diode Pilot Shutoff Diode Accessory Cut Diode Starter Cut Diode Cab Harness-to-Machine Harness 100-Pin Connector Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector Cab Harness-to-Speakers Connector Cab Ground Splice Exhaust Solenoid Harness Connector (not used)










LEGEND: 2 3 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 V1 V4 V7 V8 V10 V13 V14 W36 X10 X11 X17 X42 X78 X574 X575



Continued on sheet 3 Continued on sheet 5 Load Dump Relay Pilot Shutoff Solenoid Relay Security Alarm Relay Starter Cut Relay Security Relay Windshield Wiper Relay Work Light Relay Boom Light Relay Windshield Washer Relay Horn Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Battery Relay Diode Security Diode Start Relay Diode Air Conditioner Clutch Diode Starter Protection Diode Work Light 1 Diode Work Light 2 Diode Cab Harness Ground 2 Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Cab Harness-to-Monitor Harness Connector CAN 1 Connector Optional Switch Auxiliary Function Lever (AFL) Connector 1 Auxiliary Function Lever (AFL) Connector 2











LEGEND: 3 Continued on sheet 4 S7 Power Dig Switch W35 Cab Harness Ground 1 X20 Monitor Controller 28-Pin Connector A X21 Monitor Controller 36-Pin Connector B X22 Monitor Controller 16-Pin Connector D X27 Cab Harness-to-Switch Connector 1 X28 Cab Harness-to-Switch Connector 2 X29 Cab Harness-to-Switch Connector 3 X30 Cab Harness-to-Switch Connector 4 X37 Cab Harness-to-Exhaust Filter Switch Harness Connector X47 Cab Harness-to-Key Switch Harness Connector X74 Cab Harness-to- Service ADVISOR ™ Remote (SAR) Switch Harness Connector (marked SDV-SW) X76 Cab Harness Connector 1 (marked HMST, not used)






Machine Harness (W2) Component Location IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

Machine Harness (W2) Component Location (1 of 2) LEGEND: B18 B20 <- Go to Section TOC

Fuel Level Sensor Air Conditioner High/Low Pressure Switch Section 9015 page 95



B22 B23 B24 B27 B30 B31 B32 B33 B34 B40 E1 E2 F45 F60 F61 G3 K19 K34 M1 S40 V44 W2 W27 X1 X5 X6 X7 X8 X40 X46 X64 X67 X86 X90 X98 X175 X6022 Y11 Y22 Y23 Y24 Y27



Ambient Air Temperature Sensor High Note Horn Low Note Horn Hydraulic Oil Filter Restriction Switch (if equipped) Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Hydraulic Oil Temperature Sensor Work Light Boom Light Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Alternator Battery Relay Starter Relay Starter Motor Hydraulic Oil Temperature Switch (if equipped) Starter Relay Diode Machine Harness Starter Harness Service ADVISOR ™ Diagnostic Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 1-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Pump Harness-to-Machine Harness Connector Attachment Connector Machine Harness-to-Rear Camera Harness Connector Machine Harness Auxiliary Power Connector Machine Harness-to-Travel Alarm Harness Connector Machine Harness-to-Hydraulic Oil Temperature Switch Connector Machine Harness Splice Connector Machine Harness-to-Starter Harness Connector Cab Harness-to-Exhaust Filter Solenoid Harness Air Conditioner Compressor Clutch Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD)





Machine Harness (W2) Component Location (2 of 2) LEGEND: B18 B20 B22 B30 B31 B32 B33 B34 F45 F60 F61 G3 K34 M1 M6 R13 W2 <- Go to Section TOC

Fuel Level Sensor Air Conditioner High/Low Pressure Switch Ambient Air Temperature Sensor Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Alternator Starter Relay Starter Motor Windshield Washer Motor Alternator Resistor Machine Harness Section 9015 page 97



W27 X1 X3 X5 X6 X7 X8 X19 X40 X46 X64 X86 X90 X98 X175 X6022 Y11



Starter Harness Service ADVISOR ™ Diagnostic Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 1-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Monitor 2-Pin Connector G Pump Harness-to-Machine Harness Connector Attachment Connector Machine Harness-to-Rear Camera Harness Connector Machine Harness-to-Travel Alarm Harness Connector Machine Harness-to-Hydraulic Oil Temperature Switch Connector Machine Harness Splice Connector Machine Harness-to-Starter Harness Connector Cab Harness-to-Exhaust Filter Solenoid Harness Air Conditioner Compressor Clutch





Machine Harness (W2) Wiring Diagram






Machine Harness (W2) Wiring Diagram (1 of 2)





LEGEND: 1 B18 B23 B24 B30 B31 B32 B33 B34 B40 E1 E2 X46 X67 X90 X98 Y22 Y23 Y24 Y27



Continued on Sheet 2 Fuel Level Sensor High Note Horn Low Note Horn Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Hydraulic Oil Temperature Sensor Work Light Boom Light Attachment Connector Machine Harness Auxiliary Power Connector Machine Harness-to-Hydraulic Oil Temperature Switch Connector Machine Harness Splice Connector Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD)





Machine Harness (W2) Wiring Diagram (2 of 2)





LEGEND: 1 B20 B22 F60 F61 G3 K19 M6 R13 X1 X3 X5 X6 X7 X8 X40 X64 X86 X175 X6022 Y11



Continued on Sheet 1 Air Conditioner High/Low Pressure Switch Ambient Air Temperature Sensor Alternator 65 A Fuse Battery 45 A Fuse Alternator Battery Relay Windshield Washer Motor Alternator Resistor Service ADVISOR ™ Diagnostic Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 1-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Pump Harness-to-Machine Harness Connector Machine Harness-to-Rear Camera Harness Connector Machine Harness-to-Travel Alarm Harness Machine Harness-to-Starter Harness Connector Cab Harness-to-Exhaust Filter Solenoid Harness (not used) Air Conditioner Compressor Clutch





Monitor Harness (W3) Component Location

Monitor Harness (W3) Component Location LEGEND: A4 A10 B21 H3 W1 W3 X17 X18 X19 X23 X24


Monitor Controller (DSZ) Monitor Solar Sensor Monitor Warning Alarm Cab Harness Monitor Harness Cab Harness-to-Monitor Harness Monitor 12-Pin Connector C Monitor 2-Pin Connector G Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G





Monitor Harness (W3) Wiring Diagram

Monitor Harness (W3) Wiring Diagram LEGEND: B21 H3 X17 <- Go to Section TOC

Solar Sensor Monitor Warning Alarm Cab Harness-to-Monitor Harness Section 9015 page 105



X18 X19 X23 X24



Monitor 12-Pin Connector C Monitor 2-Pin Connector G Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G





Engine Harness (W4) Component Location

Engine Harness (W4) Component Location (right side) LEGEND: A1 B5206 M1 <- Go to Section TOC

Engine Control Unit (ECU) Manifold Air Temperature (MAT) Sensor Starter Motor Section 9015 page 107



R12 W4 W30 W38 X14 X15 X174 X5000 Y1 Y2 Y3 Y4



CAN 0 Termination Resistor Engine Harness Static Ground Fuel Injector Harness Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Engine Harness-to-Engine Interface Harness Connector Engine Harness-to-Fuel Injector Harness 8-Pin Connector Electronic Injector 1 (cylinder 1) Electronic Injector 2 (cylinder 2) Electronic Injector 3 (cylinder 3) Electronic Injector 4 (cylinder 4)





Engine Harness (W4) Component Location (left side) LEGEND: B5100 B5101 B5208 B5209 B5301 <- Go to Section TOC

Fuel Rail Pressure Sensor Engine Oil Pressure Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Section 9015 page 109



B5302 M13 W4



Camshaft Position Sensor High Pressure Fuel Pump Engine Harness





Engine Harness (W4) Wiring Diagram






Engine Harness (W4) Wiring Diagram (1 of 2)





LEGEND: 1 M1 R12 W30 X14 X15 X174 X240 X241 X242 X243 X244 X245 X246 X247 X248



Continued on Sheet 2 Starter Motor CAN 0 Termination Resistor Static Ground Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Engine Harness-to-Engine Interface Harness Connector G01 BLK Splice 1 G04 BLK Splice 2 P99 RED Splice 1 P01 RED Splice 2 R02 BLK Splice 3 M13 GRN Splice 1 M12 YEL Splice 1 R92 BLK Splice 4 5446 LT BLU Splice





Engine Harness (W4) Wiring Diagram (2 of 2)





LEGEND: 1 B5100 B5101 B5206 B5208 B5209 B5301 B5302 M13 X5000



Continued on Sheet 1 Fuel Rail Pressure Sensor Engine Oil Pressure Sensor Manifold Air Temperature (MAT) Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor High Pressure Fuel Pump Engine Harness-to-Fuel Injector Harness 8-Pin Connector





Engine Interface Harness (W5) Component Location

Engine Interface Harness (W5) Component Location LEGEND: B16 B53 B82 B5107 B5600 F6000 F6001 F6002 R11 S5001 S5002 W5 W43 <- Go to Section TOC

Air Filter Restriction Switch Fan Speed Sensor Ambient Air Temperature Sensor 2 Inlet Fuel Pressure Sensor Water-in-Fuel Sensor JDLink ™ Unswitched Power 7.5 A Fuse JDLink™ Ground 7.5 A Fuse JDLink™ Switched Power 7.5 A Fuse Interface CAN Resistor 2 (later models) Engine Coolant Loss Level Sensor Engine Coolant Service Level Sensor Engine Interface Harness Engine Interface Harness Ground Section 9015 page 116



X5 X6 X7 X8 X174 X6016 X6019 Y9 Y19 Y5005



Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 1-Pin Connector 2 Machine Harness-to-Engine Interface Harness 8-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Engine Harness to Engine Interface Harness Connector Engine Interface Harness-to-Satellite (SAT) Harness Modular Telematics Gateway (MTG) Connector Reversing Fan Solenoid Ether Start Aid Variable Speed Fan





Engine Interface Harness (W5) Wiring Diagram

Engine Interface Harness (W5) Wiring Diagram (1 of 2)






Engine Interface Harness (W5) Wiring Diagram (2 of 2)





LEGEND: B16 B53 B82 B5107 B5600 F6000 F6001 F6002 R11 S5001 S5002 X5 X6 X7 X8 X160 X161 X174 X200 X201 X202 X203 X204 X205 X206 X207 X208 X6016 X6019 Y9 Y19 Y5005



Air Filter Restriction Switch Fan Speed Sensor Ambient Air Temperature Sensor 2 Inlet Fuel Pressure Sensor Water-in-Fuel Sensor JDLink™ Unswitched Power 7.5 A Fuse JDLink ™ Ground 7.5 A Fuse JDLink™ Switched Power 7.5 A Fuse Interface CAN Resistor 2 (later models) Engine Coolant Loss Level Sensor Engine Coolant Service Level Sensor Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 1-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 2 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 1356 YEL Splice 1357 GRN Splice Engine Harness-to-Engine Interface Harness Connector M12A YEL Splice M13A GRN Splice R02A BLK Splice 1 P01A RED Splice 1 G01A BLK Splice 2 P01B RED Splice 2 P307 RED Splice 3 G01B BLK Splice 3 R99A BLK Splice 4 Engine Interface Harness-to-Satellite (SAT) Connector Modular Telematics Gateway (MTG) Connector Reversing Fan Solenoid Ether Start Aid Variable Speed Fan Solenoid





Pump Harness (W8) Component Location

Pump Harness (W8) Component Location (1 of 2) LEGEND: B36 B38 W8 <- Go to Section TOC

Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pump Harness Section 9015 page 121



X40 X97 Y20 Y21


Pump Harness-to-Machine Harness Connector Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST)

Pump Harness (W8) Component Location (2 of 2) LEGEND: B35 <- Go to Section TOC

Pump 1 Delivery Pressure Sensor Section 9015 page 122



B36 B37 B38 W8 Y20 Y21



Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Pump Harness Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST)





Pump Harness (W8) Wiring Diagram

Pump Harness (W8) Wiring Diagram LEGEND: B35 B36 B37 <- Go to Section TOC

Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Section 9015 page 124



B38 X40 X97 Y20 Y21


Pump 2 Control Pressure Sensor Pump Harness-to-Machine Harness Connector Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST)

Service ADVISOR™ Remote (SAR) Harness (W10) Component Location See Cab Harness (W1) Component Location . (Group 9015.)






Service ADVISOR™ Remote (SAR) Harness (W10) Wiring Diagram

Service ADVISOR ™ Remote (SAR) Harness (W10) Wiring Diagram LEGEND: S18 X74

Service Advisor™ Remote (SAR) Switch Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness






Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Component Location LEGEND: S3 S4 V20 W11 X65


Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Pilot Shutoff Switch Diode Pilot Shutoff Switch Harness Cab Harness-to-Pilot Shutoff Switch Harness Connector





Pilot Shutoff Switch Harness (W11) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Wiring Diagram





LEGEND: S3 S4 V20 X65 X135 X136 X137


Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Pilot Shutoff Switch Diode Cab Harness-to-Pilot Shutoff Switch Harness Connector Pilot Shutoff Harness Splice 1 Pilot Shutoff Harness Splice 2 Machine Harness-to-Starter Harness Connector

Auxiliary Fuse Box Harness (W13) Component Location See Cab Harness (W1) Component Location . (Group 9015.)






Auxiliary Fuse Box Harness (W13) Wiring Diagram Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. —040754)

Auxiliary Fuse Box Harness (W13) Wiring Diagram






LEGEND: F21 Heated Air Seat 10 A Fuse (marked SEAT HEATER) F22 Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) F23 Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) F24 12 Volt Power Unit 10 A Fuse (marked 12V UNIT) F25 IMOBI 5 A Fuse (marked IMOBI) F26 Quick Hitch 5 A Fuse (marked QUICK HITCH) F27 Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) F31 Seat Compressor 10 A Fuse (marked SEAT COMPR) F32 Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) F33 Warning Lamp 10 A Fuse (marked WARNING LAMP) F34 Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) F51 Auxiliary Fuse Box X43 Optional Fuse Connector X44 Optional Light Connector X54 Auxiliary Fuse Box Harness-to-Heated Air Sear Harness 3-Pin Connector (marked SEAT HEATER) X55 Front Cab Light 1 Connector (marked CAB LAMP FRONT) X56 Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) X57 Rear Cab Light Connector (marked CAB LAMP REAR) X58 Warning Light (marked WARNING LAMP) X59 Satellite Communication Connector (marked IMOBI) X60 12 Volt Power Supply (marked 12V UNIT) X61 Quick Hitch Connector (marked QUICK HITCH) X62 Cab Auxiliary Power Connector 2 (marked AUX_2) X63 Cab Auxiliary Power Connector 3 (marked AUX_3)

Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. 040755— ) See Cab Harness (W1) Wiring Diagram . (Group 9015-15.)






Heated Air Seat Harness (W14) Component Location

Heated Air Seat Harness (W14) Component Location LEGEND: K20 Seat Heater Relay M12 Seat Air Compressor R18 Seat Heater (marked SEAT HEATER) <- Go to Section TOC




S62 W14 W24 X53 X54


Seat Heater Switch Heated Air Seat Harness Seat Heater Switch Harness Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) Auxiliary Fuse Box Harness-to-Heated Air Sear Harness 3-Pin Connector (marked SEAT HEATER)






Heated Air Seat Harness (W14) Wiring Diagram

Seat Heater Switch Harness (W14) Wiring Diagram LEGEND: K20 Seat Heater Relay M12 Seat Air Compressor Motor R18 Seat Heater (marked SEAT HEATER) X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) X54 Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)






Multi-Function Pilot Control Lever Harness (W15) Component Location

Multi-Function Pilot Control Lever Harness (W15) Component Location LEGEND: K30 K31 K32

Right Solenoid Relay B Right Solenoid Relay A Left Solenoid Relay B





K33 S30 S31 S32 S33 S34 S35 W15 W22 X26 X81 X82 X534 X535


Left Solenoid Relay A Right Pilot Control Lever Switch B (marked B) Right Pilot Control Lever Switch A (marked C) Left Pilot Control Lever Switch B (marked B) Left Pilot Control Lever Switch A (marked C) Right Enable Switch Left Enable Switch Multi-Function Pilot Control Lever Harness Auxiliary 3-Button Cancel Switch Harness Optional Connector (2 used) Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H)






Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram

Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram





LEGEND: K30 K31 K32 K33 S30 S31 S32 S33 X26 X81 X82 X534 X535


Right Solenoid Relay B Right Solenoid Relay A Left Solenoid Relay B Left Solenoid Relay A Right Pilot Control Lever Switch B (marked B) Right Pilot Control Lever Switch A (marked A) Left Pilot Control Lever Switch B (marked B) Left Pilot Control Lever Switch A (marked A) Optional Connector Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Right Auxiliary Solenoid (marked SR/H) Connector Left Auxiliary Solenoid (marked SL/H) Connector

Travel Alarm Cancel Switch Harness (W16) Component Location See Cab Harness (W1) Component Location . (Group 9015-10.)






Travel Alarm Cancel Switch Harness (W16) Wiring Diagram

Travel Alarm Cancel Switch Harness (W16) Wiring Diagram LEGEND: S13 X50


Travel Alarm Cancel Switch Cab Harness-to-Travel Alarm Cancel Switch Harness Connector





Attachment Harness (W17) Component Location

Attachment Harness (W17) Component Location LEGEND: B60 B61 V40 <- Go to Section TOC

Attachment Pressure Sensor Arm Out Pressure Sensor Selector Valve Solenoid Valve Diode Section 9015 page 140



V41 V43 W17 W32 X46 X87 Y40 Y41 Y43 Y44



Secondary Relief Solenoid Valve Diode 2-Speed Activation Solenoid Valve Diode Attachment Harness 2-Speed Harness Attachment Connector Attachment Harness-to-Two Speed Harness Connector Selector Valve Solenoid Valve Secondary Relief Solenoid Valve 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve





Attachment Harness (W17) Wiring Diagram

Attachment Harness (W17) Wiring Diagram





LEGEND: B60 V40 V41 X46 X87 Y40 Y41



Attachment Pressure Sensor Selector Valve Solenoid Valve Diode Secondary Relief Solenoid Valve Diode Attachment Connector Attachment Harness-to-Two Speed Harness Connector Selector Valve Solenoid Valve Secondary Relief Solenoid Valve





Rear Camera Harness (W19) Component Location

Rear Camera Harness (W19) LEGEND: A12 W19 X64


Rear Camera Camera Harness Machine Harness-to-Rear Camera Harness Connector





Rear Camera Harness (W19) Wiring Diagram

Rear Camera Harness (W19) Wiring Diagram LEGEND: A12 X64


Rear Camera Machine Harness-to-Rear Camera Harness Connector





Pilot Shutoff Valve Harness (W21) Component Location

Pilot Shutoff Valve Harness (W21) Component Location LEGEND: W21 X75 Y10


Pilot Shutoff Valve Harness Cab Harness-to-Pilot Shutoff Valve Harness Connector Pilot Shutoff Solenoid





Pilot Shutoff Valve Harness (W21) Wiring Diagram

Pilot Shutoff Valve Harness (W21) Wiring Diagram LEGEND: X75 Y10

Cab Harness-to-Pilot Shutoff Valve Harness Connector Pilot Shutoff Solenoid

Auxiliary 3-Button Cancel Switch Harness (W22) Component Location See Multi-Function Pilot Control Lever Harness (W15) Component Location . (Group 9015-10.)






Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram

Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram LEGEND: S34 S35 X81 X82

Right Enable Switch Left Enable Switch Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness

Reversing Fan Switch Harness (W23) Component Location See Cab Harness (W1) Component Location . (Group 9015.)






Reversing Fan Switch Harness (W23) Wiring Diagram

Reversing Fan Switch Harness (W23) Wiring Diagram LEGEND: S15 X83

Reversing Fan Switch Cab Harness-to-Reversing Fan Switch Harness

Seat Heater Switch Harness (W24) Component Location See Heated Air Seat Harness (W14) Component Location . (Group 9015-10.)






Seat Heater Switch Harness (W24) Wiring Diagram

Seat Heater Switch Harness (W24) Wiring Diagram LEGEND: S62 Seat Heater Switch X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)






Travel Alarm Harness (W26) Component Location

Travel Alarm Harness (W26) Component Location LEGEND: H4 W2 W26 X86


Travel Alarm Machine Harness Travel Alarm Harness Machine Harness-to-Travel Alarm Harness





Travel Alarm Harness (W26) Wiring Diagram

Travel Alarm Harness (W26) Wiring Diagram LEGEND: H4 X86


Travel Alarm Machine Harness-to-Travel Alarm Harness





Starter Harness (W27) Component Location

Starter Harness (W27) Component Location LEGEND: F45 K34 K35 M1 V44 W27 X175


Starter In-Line 30 A Fuse Starter Relay Starter Protection Relay Starter Motor Starter Relay Diode Starter Harness Machine Harness-to-Starter Harness Connector





Starter Harness (W27) Wiring Diagram

Starter Harness (W27) Wiring Diagram LEGEND: F45 K34 K35 M1 <- Go to Section TOC

Starter In-Line 30 A Fuse Starter Relay Starter Protection Relay Starter Motor Section 9015 page 154



V44 X175 X400 X401


Starter Relay Diode Machine Harness-to-Starter Harness Connector E03 WHT Splice P21 RED Splice

Starter Switch Harness (W29) Component Location See Cab Harness (W1) Component Location . (Group 9015.)






Starter Switch Harness (W29) Wiring Diagram

Starter Switch Harness (W29) Wiring Diagram LEGEND: S1 X47

Key Switch Cab Harness-to-Key Switch Harness Connector

2-Speed Harness (W32) Component Location See Attachment Harness (W17) Component Location . (Group 9015-10.)






2-Speed Harness (W32) Wiring Diagram

2-Speed Harness (W32) Wiring Diagram LEGEND: B61 V43 X87 <- Go to Section TOC

Arm Out Pressure Sensor 2-Speed Activation Solenoid Valve Diode Attachment Harness-to-Two Speed Harness Connector Section 9015 page 157



Y43 Y44


2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve

Fuel Injector Harness (W38) Component Location See Engine Harness (W4) Component Location . (Group 9015.)






Fuel Injector Harness (W38) Wiring Diagram

Fuel Injector Harness (W38) Wiring Diagram LEGEND: X209 X210 X5000 <- Go to Section TOC

5491 BLK Splice 1 5496 BLK Splice 2 Engine Harness-to-Fuel Injector Harness 8-Pin Connector Section 9015 page 159



Y1 Y2 Y3 Y4



Electronic Injector 1 (cylinder 1) Electronic Injector 2 (cylinder 2) Electronic Injector 3 (cylinder 3) Electronic Injector 4 (cylinder 4)





Heater and Air Conditioner Harness (W41) Component Location

Heater and Air Conditioner Harness (W41) Component Location LEGEND: A7 B41 B55 M7 M9 M10 M11 R16 R17 W41 X51 X52


Air Conditioner Controller (ACF) Air Conditioner Freeze Control Switch Air Recirculation Sensor Air Conditioner and Heater Blower Motor Air Conditioner and Heater Internal and External Servomotor Air Conditioner and Heater Blower Port Change Servomotor Air Conditioner and Heater Mixer Servomotor Blower Motor Transistor Blower Motor Resistor Heater and Air Conditioner Harness Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector





Heater and Air Conditioner Harness (W41) Wiring Diagram

Heater and Air Conditioner Harness (W41) Wiring Diagram





LEGEND: A7 B41 B55 M7 M9 M10 M11 R16 R17 X51 X52 X418 X419 X420 X421 X422



Air Conditioner Controller (ACF) Air Conditioner Freeze Control Switch Air Recirculation Sensor Air Conditioner and Heater Blower Motor Air Conditioner and Heater Internal and External Servomotor Air Conditioner and Heater Blower Port Change Servomotor Air Conditioner and Heater Mixer Servomotor Blower Motor Transistor Blower Motor Resistor Air Conditioner 4-Pin Connector Air Conditioner 10-Pin Connector 978 BLK Splice BLK/RED Splice BLK/YEL Splice 979 RED Splice RED/BLK Splice





Auxiliary Solenoid Harness (W61) Component Location

Auxiliary Solenoid Harness (W61) Component Location LEGEND: V30 V31 V32 V33 W15 W61 W75 X534 X535 Y34 Y34A Y34B Y35 <- Go to Section TOC

Right Solenoid Diode B Right Solenoid Diode A Left Solenoid Diode B Left Solenoid Diode A Multi-Function Pilot Control Lever Harness Auxiliary Solenoid Harness Auxiliary Function Lever (AFL) Harness Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H) Right Solenoid (marked SR/H) Right Solenoid Connector A (marked SR/H) Right Solenoid Connector B (marked SR/H) Left Solenoid (marked SR/H) Section 9015 page 164



Y35A Y35B



Left Solenoid Connector A (marked SR/H) Left Solenoid Connector B (marked SR/H)





Auxiliary Solenoid Harness (W61) Wiring Diagram

Auxiliary Solenoid Harness (W61) Wiring Diagram LEGEND: V30 V31 V32 <- Go to Section TOC

Right Solenoid Diode B Right Solenoid Diode A Left Solenoid Diode B Section 9015 page 166



V33 X450 X451 X452 X534 X535 Y34A Y34B Y35A Y35B



Leftt Solenoid Diode A GO5 BLK Splice HO1 GRN Splice HO2 GRN Splice Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H) Right Solenoid Connector A (marked SR/H) Right Solenoid Connector B (marked SR/H) Left Solenoid Connector A (marked SR/H) Left Solenoid Connector B (marked SR/H)





Auxiliary Function Lever (AFL) Harness (W75) Component Location

Auxiliary Function Lever (AFL) Harness (W75) Component Location LEGEND: K31 Right Solenoid Relay A (marked RSW1) K32 Left Solenoid Relay B (marked LSW1) K33 Left Solenoid Relay A (marked LSW3) <- Go to Section TOC




S5 S7 S29 S31 S32 S33 S34 S35 S45 V22 W75 X26 X534 X535 X536 X537 X574 X577


Horn Switch Power Dig Switch Auxiliary Function Lever (AFL) Proportional Control Switch Right Pilot Control Lever Switch Left Pilot Control Lever Switch B (marked B) Left Pilot Control Lever Switch A (marked C) Right Enable Switch (marked ON/OFF) Left Enable Switch (marked ON/OFF) Auxiliary Function Enable Switch (marked AFL_SW) Pilot Shutoff Solenoid Diode Auxiliary Function Lever (AFL) Harness Optional Connector (2 used) Right Auxiliary Solenoid Connector (marked SR/H) Left Auxiliary Solenoid Connector (marked SL/H) Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) Auxiliary Function Lever (AFL) Connector 1 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector






Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram

Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram






LEGEND: K31 Right Solenoid Relay A (marked RSW1) K32 Left Solenoid Relay B (marked LSW1) K33 Left Solenoid Relay A (marked LSW3) S5 Horn Switch S7 Power Dig Switch S34 Right Enable Switch (marked ON/OFF) S35 Left Enable Switch (marked ON/OFF) S45 Auxiliary Function Enable Switch (marked AFL_SW) V22 Pilot Shutoff Solenoid Diode X26 Optional Connector X534 Right Auxiliary Solenoid Connector (marked SR/H) X535 Left Auxiliary Solenoid Connector (marked SL/H) X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) X537 Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) X574 Auxiliary Function Lever (AFL) Connector 1 X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector






Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location LEGEND: B68 Secondary Hydraulic Oil Temperature Sensor <- Go to Section TOC




B85 W75 W76 X577 Y61 Y62 Y66


Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) Auxiliary Function Lever (AFL) Harness Auxiliary Function Lever (AFL) Solenoid Harness Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector Auxiliary Function Lever (AFL) Solenoid A (marked 1A) Auxiliary Function Lever (AFL) Solenoid B (marked 1B) Secondary Pilot Shutoff Solenoid Valve (marked PiC)






Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram

Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram LEGEND: B68 Secondary Hydraulic Oil Temperature Sensor B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector <- Go to Section TOC




Y61 Y62 Y66


Auxiliary Function Lever (AFL) Solenoid A (marked 1A) Auxiliary Function Lever (AFL) Solenoid B (marked 1B) Secondary Pilot Shutoff Solenoid Valve (marked PiC)

Modular Telematics Gateway (MTG) Harness (W6002) Component Location See Engine Interface Harness (W5) Component Location . (Group 9015-10.)






Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram

Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram LEGEND: X6014 X6019

Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Modular Telematics Gateway (MTG) Connector

Satellite (SAT) Harness (W6003) Component Location See Engine Interface Harness (W5) Component Location . (Group 9015-10.)





Group 15: Sub-System Diagnostics

Satellite (SAT) Harness (W6003) Wiring Diagram

Satellite (SAT) Harness (W6003) Wiring Diagram LEGEND: X6015 X6016


Satellite (SAT) Module Control Unit 48-Pin Connector JDLink ™ Harness-to-Satellite (SAT) Harness





Group 15 - Sub-System Diagnostics Controller Area Network (CAN) Theory of Operation






Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. —040754)





LEGEND: A1 A3 A4 A5 A6 A7 A11 A6000 R10 R11 R12 X1 X3 X5 X8 X11 X15 X20 X31 X36 X52 X174 X6014 X6019



Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Radio Air Conditioner Controller (ACF) Machine Controller (BCZ) Modular Telematics Gateway Controller (MTG) Interface CAN Resistor 1 Interface CAN Resistor 2 (later models) CAN 0 Termination Resistor Service ADVISOR™ Diagnostic Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Machine Controller 20-Pin Connector B Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 26-Pin Connector F Air Conditioner 10-Pin Connector Engine Harness-to-Engine Interface Harness Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Modular Telematics Gateway (MTG) Connector





Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. 040755— )





LEGEND: A1 A3 A4 A5 A6 A7 A11 A6000 R10 R11 R12 X1 X3 X5 X8 X11 X15 X20 X34 X52 X174 X6014 X6019


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Radio Air Conditioner Controller (ACF) Machine Controller (BCZ) Modular Telematics Gateway Controller (MTG) Interface CAN Resistor 1 Interface CAN Resistor 2 CAN 0 Termination Resistor Service ADVISOR™ Diagnostic Connector Cab Harness-to-Machine Harness 100-Pin Connector Machine Harness-to-Engine Interface Harness 8-Pin Connector 1 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3 Machine Controller 20-Pin Connector B Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Cab Harness-to-Main Controller 30-Pin Connector D Air Conditioner 10-Pin Connector Engine Harness-to-Engine Interface Harness Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Modular Telematics Gateway (MTG) Connector

Controller Area Network (CAN) Overview— The controller area network (CAN) provides a standardized means for electronic controllers and other devices to communicate with each other. The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite to each other to overcome noise interference and minimize communication errors. The high and low wires, and sometimes a ground wire, are woven together which provides an additional method of reducing interference and thus helps the devices communicate with minimal errors. When woven together with a ground wire the three wires are commonly referred to as a twisted triple. The 120 ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors. The CAN is an arbitration-based system. This means a low priority message always allows a high priority message to go first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first is able to transmit its signal. When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the lowest ID has higher priority to access the bus. The device that loses arbitration immediately retransmits its signal when the device with the higher priority has completed its transmission. This machine contains four CAN circuits: CAN 0, CAN 1, interface CAN, and engine CAN. CAN 0— The CAN 0 circuit provides the communication link for the following devices: Engine Control Unit (ECU) (A1) Main Controller (MCZ) (A3) Monitor Controller (DSZ) (A4) Modular Telematics Gateway (MTG) Controller (A6000) Operations and functions of the individual devices on CAN 0 are covered separately. For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) CAN 0 also includes the following components: Service ADVISOR ™ Diagnostic Connector (X1) CAN 0 Termination Resistor (R12) CAN 0 utilizes two terminating resistors; CAN 0 termination resistor (R12) and one located inside monitor controller (DSZ) (A4), which is not accessible. <- Go to Section TOC





The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application . (Group 9015-20.) CAN 1— The CAN 1 circuit provides the communication link for the following devices: Main Controller (MCZ) (A3) Monitor Controller (DSZ) (A4) Data Converter (A5) Radio (A6) Air Conditioner Controller (ACF) (A7) Machine Controller (BCZ) (A11) Operations and functions of the individual devices on CAN 1 are covered separately. For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) For the BCZ, see Machine Controller (BCZ) Circuit Theory of Operation . (Group 9015-15.) CAN 1 utilizes two terminating resistors; one is located inside monitor controller (DSZ) (A4), and one is located inside machine controller (BCZ) (A11). These resistors are not accessible. Interface CAN— The interface CAN circuit provides the communication link for the following devices: Data Converter (A5) Modular Telematics Gateway (MTG) Controller (A6000) Service ADVISOR Diagnostic Connector (X1) The interface CAN allows the data converter (A5) to relay information from CAN 1 to the modular telematics gateway (MTG) and the Service ADVISOR ™ diagnostic connector (X1). The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application . (Group 9015-20.)






Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Theory of Operation Schematic





LEGEND: A1 A3 A4 A5 F7 F8 F9 F10 F14 F17 F18 F45 F60 F61 G1 G2 G3 K1 K4 K11 K12 K13 K19 K34 K35 M1 R13 S1 S3 S4 V1 V2 V3 V4 V5 V7 V9 V10 V11 V12 V44 V20 W37 X14 X15 X20 X21 X22 X33 X35 X36 X175 Y19


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Start Position Signal 5 A Fuse (marked START) Engine Control Unit (ECU) 30 A Fuse (marked ECU) Radio Backup 10 A Fuse (marked BACK UP) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Monitor 5 A Fuse (marked MONITOR) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Starter Cut Relay Idle Stop Relay Accessory Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Alternator Resistor Key Switch Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Start Relay Diode Pilot Shutoff Diode Starter Protection Diode Accessory Cut Diode Starter Cut Diode Starter Relay Diode Pilot Shutoff Switch Diode Cab Harness Ground 3 Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Machine Harness-to-Starter Harness Connector Ether Start Aid

Unswitched power is supplied to the following components: Battery Relay (K19) Key Switch (S1) [from Battery 45 A Fuse (F61)] Main Controller (MCZ) (A3) [from Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)(F10)] Data Converter (A5) [from Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) (F10)] Engine Control Unit (ECU) (A1) [from Engine Control Unit (ECU) 30 A Fuse (marked ECU) (F8)] Monitor Controller (DSZ) (A4) [from Radio Backup 10 A Fuse (marked BACK UP) (F9)] Load Dump Relay (K1)






Ignition ON When key switch (S1) is placed in the ON position, current is applied from key switch pin ACC to pin 3 of accessory cut relay (K12). Utilizing the normally closed s of accessory cut relay, power is supplied through accessory cut diode (V11), next through monitor 5 A Fuse (F14) to pin 17 of the monitor controller (DSZ) (A4), powering up the DSZ. Key switch pin M also receives power, supplying idle stop relay (K11), accessory cut relay (K12), and key cut relay (K13) through idle stop 5 A fuse (F18). Utilizing the normally closed s of key cut relay, power is ed through pin 3 of key cut relay, next through load dump relay diode (V3), then to pin S of battery relay (K19), energizing the battery relay. Ground is provided to pin E of battery relay from cab harness ground 3 (W37). When energized, the battery relay allows current to through to pin B of starter motor (M1) and pin 3 of starter relay (K34). Power is also ed through to alternator 65 A fuse (F60) providing a path from pin B of alternator (G3) to the batteries (G1 and G2). Power through pin 3 of key cut relay is also provided through power on 5 A fuse (F17) at pin 7 of data converter (A5) 17-pin connector, pin 4 of cab harness-to-main controller 24-pin connector E (X35), and pin 16 of monitor controller 28-pin connector A (X20), indicating the key switch is in the ON/START position. Pin D+ of alternator (G3) also receives power from power on 5 A fuse through alternator excitation diode (V2), and alternator resistor (R13). The alternator excitation diode (V2) allows current to flow in only one direction and the alternator resistor (R13) limits excitation current to the alternator to protect the excitation circuit. Engine Start When key switch (S1) is moved to the START position, power is applied from key switch pin ST to pins 1 and 3 of starter cut relay (K4) and through start position signal 5 A fuse (F7) to pin 17 of monitor controller 28-pin connector A (X20), indicating the key switch is in the START position. Utilizing the normally closed s of starter cut relay, power is ed to pin 3 of starter protection relay (K35). With battery relay (K19) energized from the ignition ON position, power is supplied to pin B of starter motor (M1) through starter in-line 30 A fuse (F45), pin 5 of the starter protection relay (K35), and pin 3 of starter relay (K34). Starter relay (K34) is a normally open relay which closes when power is present on relay pin 1 and ground is present on relay pin 2. The energized starter relay provides power from battery relay (K19) to pin S of starter motor (M1) through starter relay diode (V44). When power is present on starter motor pins B and S, the starter rotates thus cranking the engine. When the starter relay is de-energized, starter relay s are opened, removing power from starter pin S, stopping the starter motor from turning. Utilizing the normally closed s of the starter cut relay (K4), power is ed to pin 3 of the starter protection relay (K35). Applied power is then transferred through the normally closed s of the starter protection relay (K35) (pin 1) and energizes the starter relay (K34) (pin 1). Starter cut relay is energized when power from the key switch is present at pin 1 and ground on pin 2, thus preventing the start motor from cranking the engine. The starter can be disabled based on the following components: Monitor controller (DSZ) (A4). Pilot shutoff switches (S3 and S4). Main controller (MCZ) (A3). Engine control unit (ECU) (A1). A ground from the monitor controller (DSZ) (A4) is the result of a security code violation or machine warning alarm. When a warning alarm or security code error is detected, pin 16 of monitor controller 16-pin connector D (X22) is connected to ground. When a fault in the pilot shutoff circuit is detected, pin 10 of monitor controller 36-pin connector B (X21) is connected to ground. With either pin 16 or pin 10 of the monitor controller connected to ground the starter cut relay (K4) is energized through security diode (V4), removing the start signal from the starter protection relay (K35) and starter relay (K34). With no start signal at starter relay, the relay remains de-energized, removing power from pin S of starter motor (M1), preventing engine from starting. A ground pin C2 (X15) from the engine control unit (ECU) (A1) is based on engine run status. This prevents the starter from engaging while the engine is running. Ground is removed from pin 2 of the starter protection relay (K35) by the engine control unit, opening the relay and not allowing current to . A ground from pilot shutoff switches or the main controller is the result of the pilot shutoff lever in the unlocked (DOWN) position or an error in the pilot shutoff circuit. When pilot shutoff switches 1 and 2 (S3 and S4) are closed, pilot shutoff lever in the unlocked (DOWN) position, pin 2 of starter cut relay is connected to ground through starter cut relay diode (V5), removing the start signal from the starter relay. With no start signal at starter relay, the relay remains de-energized, removing power <- Go to Section TOC





from pin S of starter motor. This prevents activation of starter motor when pilot shutoff lever is in the unlocked (DOWN) position. For more information, see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) When the engine is running, the main controller (MCZ) (A3) will ground pin 2 of starter cut relay (K4). This opens the normally closed s of the starter cut relay, removing the start signal from starter protection relay (K35) and starter relay (K34). This prevents the starter from engaging while the engine is running. When the engine is not running, the main controller will not ground starter cut relay. A ground from the engine control unit (ECU) (A1) is based on engine run status. This prevents the starter from engaging while the engine is running. Ground is removed from pin 2 of the starter protection relay (K35) by the engine control unit, opening the relay. Security diode (V4), starter cut relay diode (V5), pilot shutoff diode (V9), starter protection diode (V10), accessory cut diode (V11), starter cut diode (V12), starter relay diode (V44), and pilot shutoff switch diode (V20) work as logic gates to allow more than one device to control one circuit without backfeeding other circuits. Auto-Ether Cold Start If the engine control unit (ECU) determines the fuel temperature is below a specified temperature, the ECU sends current from pin H4 of engine control unit (ECU)-to-engine harness connector (X14) energizing the ether start aid (Y19). Ether flows from the canister to the intake manifold and mixes with intake air. When the ether/air mixture reaches the combustion chamber it mixes with diesel fuel. Ether ignites at a lower temperature than diesel fuel, therefore, inside the combustion chamber the ether ignites first, heating the diesel fuel and aiding in combustion. Ether shall be deactivated if 750 rpm engine speed has been exceeded. For more information on the electrical control of auto-ether injection, see Cold Weather Starting Aid . (Group 9010-05.) Ether Start Time Starting Time

Fuel Temperature

10 Seconds

-3°C (27°F)

0 Seconds

-2.9°C (26°F)

Charging Circuit Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running. Pin B of the alternator is connected to battery positive (+) through alternator 65 A fuse (F60) when the battery relay (K19) is energized. When key switch (S1) is in the ON position, key cut relay (K13) is de-energized allowing current to flow from pin M of key switch to power on 5 A fuse (F17). The current then flows through alternator excitation diode (V2) and alternator resistor (R13) to pin D+ of the alternator. Current from pin D+ of the alternator flows through the alternator field windings, causing excitation of the windings. The engine control unit (ECU) monitors battery and alternator system voltage. When low voltage is indicated, the ECU sends a message via the controller area network (CAN) to the monitor controller (DSZ) (A4) to activate the alternator or battery indicator light. For more information, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Auto Shutdown Circuit The auto shutdown feature allows the main controller (MCZ) to automatically turn off ignition power and stop the engine if the machine has been operating in auto-idle for 1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes (depending on setting). The time duration is selectable by accessing the SETTINGS MENU/AUTO SHUTDOWN menu in the monitor service menu. See Main Menu—Setting Menu—Auto Shutdown . (Operators Manual.) When key switch (S1) is in the ON position, current from pin M of key switch flows through idle stop 5 A fuse (F18) to pin 1 of idle stop relay (K11). Ground is available at pin 5 of idle stop relay. When engine has been operating in auto-idle for a set amount of time (1, 2, 3, 4, 5, 10, 15, 20, 25, or 30 minutes), the main controller (MCZ) connects pin 5 of cab harness-to-main controller 17-pin connector C (X33) to ground, energizing idle stop relay (K11). Providing ground to pin 3 of idle stop relay (K11). When all of the following conditions have been met: <- Go to Section TOC





Engine operating in auto-idle for set amount of time. Pilot shutoff switch in the LOCKED down position. Auto shutdown enabled. Engine coolant temperature less than 100°C (212°F). With idle stop relay (K11) energized, ground is provided to accessory cut relay (K12) and key cut relay (K13), energizing the relays, removing power from the ignition ON and accessory (ACC) circuits. With no power on the ignition circuit, the controllers are powered down, including the engine control unit (ECU), stopping the engine. Load Dump Circuit The load dump circuit consists of load dump relay (K1) and load dump relay diode (V3). When the alternator (G3) is generating electricity, this causes the monitor controller to put pin 8 of monitor controller 16-pin connector D (X22) to ground, energizing load dump relay (K1). With load dump relay (K1) energized, battery power is applied through pins 3 and 5 to battery relay (K19). Monitor controller (DSZ) (A4) pin 8 retains a ground path for load dump relay (K1) until alternator (G3) stops producing output voltage, keeping the battery relay (K19) energized, providing a path to the batteries (G1 and G2) for any power produced by the alternator (G3) as the engine slows to a stop. Then the ground path is removed from load dump relay, and battery relay (K19) is de-energized. For more information, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)






Monitor Controller (DSZ) Circuit Theory of Operation






Monitor Controller (DSZ) Circuit Schematic (1 of 2)





LEGEND: A1 A3 A4 A5 A6 A7 A11 F7 F9 F14 F17 F18 F45 F60 F61 G1 G2 G3 H2 H3 K1 K3 K4 K12 K13 K19 K34 K35 M1 R13 S1 V1 V2 V3 V7 V10 V11 V44 W37 X11 X15 X20 X21 X22 X31 X36 X52 X175


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Data Converter Radio Air Conditioner Controller (ACF) Machine Controller (BCZ) Start Position Signal 5 A Fuse (marked START) Radio Backup 10 A Fuse (marked BACK UP) Monitor 5 A Fuse (marked MONITOR) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Security Alarm Monitor Warning Alarm Load Dump Relay Security Alarm Relay Starter Cut Relay Accessory Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Alternator Resistor Key Switch Battery Relay Diode Alternator Excitation Diode Load Dump Relay Diode Start Relay Diode Starter Protection Diode Accessory Cut Diode Starter Relay Diode Cab Harness Ground 3 Machine Controller 20-Pin Connector B Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 26-Pin Connector F Air Conditioner 10-Pin Connector Machine Harness-to-Starter Harness Connector

Monitor Controller (DSZ) (A4)— The monitor controller (DSZ) contains the monitor software and interprets inputs from various sensors, buttons, and switches. Information sent over the controller area network (CAN) from other controllers is sent to the DSZ where it is then displayed on the monitor. The DSZ uses the CAN 1 to communicate with the data converter (A5), radio (A6), air conditioner controller (ACF) (A7), and machine controller (BCZ) (A11) through pins A25 and A26 of DSZ. The DSZ also communicates on CAN 0 with the engine control unit (ECU) (A1), and the main controller (MCZ) (A3) through pins A23 and A24 of DSZ. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Monitor Controller (DSZ) (power and ground)— Unswitched battery power is available through battery 45 A fuse (F61) and radio backup 10 A fuse (F9) to pin B18 of the monitor controller (DSZ). Battery power from battery 45 A fuse is also provided to pins 1 and 3 of load dump relay (K1). Ground is provided to pins A22, B11, B35, and B36 of the DSZ. When key switch (S1) is in the accessory (ACC) position, current flows from pin ACC of key switch, to accessory cut relay (K12). Utilizing the normally closed s of accessory cut relay, current flows through accessory cut diode (V11), through monitor <- Go to Section TOC





5 A fuse (F14) to pin B17 of the DSZ. Accessory power enables the radio and air conditioning and heating electronic features to operate without powering up the other vehicle controllers. When the key switch is in the ignition ON position, current flows to pin M in addition to pin ACC. Current from pin M flows to key cut relay (K13) directly to pin 3 and through idle stop 5 A fuse (F18) to pin 1 of key cut relay and pin 1 of accessory cut relay. Utilizing the normally closed s of the key cut relay, current flows through load dump relay diode (V3), to pin 5 of load dump relay and to battery relay (K19), energizing the battery relay. Current from key cut relay also flows through power on 5 A fuse (F17) to pin A16 of the DSZ, powering up the DSZ. When the key switch is in the START position, current flows to pin ST in addition to pin M. Current from key switch pin ST flows to pins 1 and 3 of starter cut relay (K4), and through start position signal 5 A fuse (F7) to pin A17 of the DSZ, indicating the key switch is in the START position. Anti-Theft Security— The anti-theft security circuit consists of security alarm relay (K3) and security alarm (H2). Battery power is provided to pin 1 of security alarm relay and to pin 1 of the security alarm through radio backup 10 A fuse (F9). When an invalid code has been entered, ground is provided to pin 2 of security alarm relay from pin D15 of the monitor controller (DSZ), energizing the security alarm relay, and activating the security alarm. When the anti-theft security circuit is active, ground is provided to starter cut relay (K4), disabling the starter motor (M1), preventing the machine from starting. For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) Monitor Warning Alarm— The monitor warning alarm (H3) sounds when certain diagnostic trouble codes (DTCs) or machine conditions exist which could damage the machine. The monitor warning alarm receives switched power from power on 5 A fuse (F17). Ground is provided from pin D7 of monitor controller (DSZ), activating the alarm. Alternator Voltage Indicator— The alternator alarm indicator is monitored by the engine control unit (ECU). When the alternator excitation field voltage is below charging level, the ECU sends a message over the controller area network (CAN) to the monitor controller (DSZ). The DSZ then illuminates the alternator warning indicator. For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) The monitor controller also uses this signal from the ECU to activate the load dump circuit. When a voltage decrease is monitored by the ECU, and the key switch is in the OFF position, pin D8 of the DSZ is placed to ground, energizing load dump relay (K1). With the load dump relay energized and the key switch in the OFF position, voltage from the alternator is allowed to return to the batteries (G1 and G2) as the engine slows to a stop. For more information on the load dump circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) Check Engine Indicator— The check engine indicator will come ON if there is an engine problem. The engine may run at reduced power to protect the engine but still allow the machine to be moved. For more information on the engine control unit (ECU) and sensors, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) For more information on ECU diagnostic trouble codes, see Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)






Monitor Controller (DSZ) Circuit Schematic (2 of 2)





LEGEND: A4 A10 A12 B18 B27 E5 E6 E8 S20 S21 S22 S23 S24 S25 S26 S27 S40 S50 S51 S52 S53 S54 S55 S56 S57 S58 S59 S60 X2 X3 X18 X19 X20 X21 X22 X23 X24 X28 X29 X30 X65 X90


Monitor Controller (DSZ) Monitor Rear Camera Fuel Level Sensor Hydraulic Oil Filter Restriction Switch (if equipped) Switch Back Light 1 Switch Back Light 2 Switch Back Light 4 Seat Belt Switch Blower Motor Speed Switch Temperature Control/Mode Switch Radio Volume and Power Switch Radio Tuning Switch Monitor Dial Back Button Home Button Hydraulic Oil Temperature Switch (if equipped) 0 Key 1 Key 2 Key 3 Key 4 Key 5 Key 6 Key 7 Key 8 Key 9 Key Keypad MPDr 6-Pin Connector Cab Harness-to-Machine Harness 100-Pin Connector Monitor 12-Pin Connector C Monitor 2-Pin Connector G Monitor Controller 28-Pin Connector A Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Monitor Controller 12-Pin Connector C Monitor Controller 2-Pin Connector G Cab Harness-to-Switch Connector 2 Cab Harness-to-Switch Connector 3 Cab Harness-to-Switch Connector 4 Cab Harness-to-Pilot Shutoff Switch Harness Connector Machine Harness-to-Hydraulic Oil Temperature Switch Connector

Monitor (A10)— The monitor (A10) communicates directly with the monitor controller (DSZ) (A4). The monitor receives power from pin C3 and ground from pin C5 of the DSZ. The DSZ sends voltage from pin C2 of the DSZ, to the monitor, indicating how dark or bright to set the backlight on the monitor depending on operator setting. The monitor has a built-in temperature sensor which is not accessible. The monitor temperature sensor provides an indication to pin C6 of the DSZ, if the monitor temperature is too high. Pin C1 of the DSZ illuminates the alert light when an alert or diagnostic trouble code (DTC) is present. The monitor controller outputs video signal from the rear camera (A12) on pins G1 and G2 of the DSZ to the monitor when the rear camera is active. Rear Camera (A12)— The rear camera (A12) communicates directly with the monitor controller (DSZ). Power is provided to the rear camera from pin D2 and ground is provided from pin D3 of the DSZ. The rear camera sends the video signal to pins D1 and D9 of the DSZ. The DSZ then outputs the video signal to the monitor. MPDr Application— The MPDr application communicates directly with the monitor controller (DSZ). The monitor controller communicates via the controller area network (CAN) with the other electronic controllers to provide information to MPDr. The DSZ provides MPDr with 5 V power from pin A1 and serial communication from pins A13 and A28. For more information on MPDr, see MPDr Application . (Group 9015-20.) Fuel Level Indicator— The fuel level sensor (B18) provides a variable resistance to the fuel gauge as fuel level changes in the tank. Once the sensor is at a high enough resistance at pin A18 of monitor controller (DSZ), the fuel level indicator notification <- Go to Section TOC





will activate, indicating a low level of fuel. Item

Measurement

Specification

Fuel Level Indicator Light

Resistance

Illuminates Above 82—88 ohms

Hydraulic Oil Filter Restriction Indicator— Ground is ed to pin B13 of monitor controller (DSZ) (A4) when hydraulic oil temperature switch (if equipped) (S40) and hydraulic oil filter restriction switch (if equipped) (B27) are closed (hydraulic oil temperature is above 24°C [75°F] and a plugged hydraulic oil filter is sensed). When this condition exists for a minimum of 5—10 seconds, the hydraulic oil filter restriction indicator will illuminate. Blower Motor Speed Switch (S21)— The blower motor speed switch (S21) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the blower motor speed switch grounds pin B29 of monitor controller (DSZ) turning the blower motor ON and OFF. Rotating the blower motor speed switch left or right adjusts blower motor speed by sending a pulse width modulated (PWM) signal to pins A3 and A4 of the DSZ. The monitor controller communicates these inputs to the air conditioner controller (ACF) via the controller area network (CAN). For more information, see Cab Heater and Air Conditioner . (Operator’s Manual.) Temperature Control/Mode Switch (S22)— The temperature control/mode switch (S22) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the temperature control/mode switch grounds pin B28 of monitor controller (DSZ), cycling through the different air vent modes. Rotating the temperature control/mode switch left or right adjusts air temperature by sending a pulse width modulated (PWM) signal to pins A5 and A6 of the DSZ. The monitor controller communicates these inputs to the air conditioner controller (ACF) via the controller area network (CAN). For more information, see Cab Heater and Air Conditioner . (Operator’s Manual.) Radio Volume and Power Switch (S23)— The radio volume and power switch (S23) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the radio volume and power switch grounds pin B31 of monitor controller (DSZ), turning the radio ON and OFF. Rotating the radio volume and power switch left or right adjusts radio volume by sending a pulse width modulated (PWM) signal to pins A11 and A12 of the DSZ. The monitor controller communicates these inputs to the radio (A6) via the controller area network (CAN). For more information, see Operating the AM/FM Radio . (Operator’s Manual.) Radio Tuning Switch (S24)— The radio tuning switch (S24) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the radio tuning switch grounds pin B30 of monitor controller (DSZ), cycling through the AM and FM radio frequencies. Rotating the radio tuning switch left or right adjusts radio frequency to the desired station by sending a pulse width modulated (PWM) signal to pins A7 and A9 of the DSZ. The monitor controller communicates these inputs to the radio (A6) via the controller area network (CAN). For more information, see Operating the AM/FM Radio . (Operator’s Manual.) Monitor Dial (S25)— The monitor dial (S25) is a hall effect sensor which offers infinite 360 degree rotation. Pressing the monitor dial grounds pin B27 of monitor controller (DSZ), selecting the highlighted option on the monitor (A10). Rotating the monitor dial left or right moves the current selection on the monitor UP and DOWN by sending a pulse width modulated (PWM) signal to pins A8 and A10 of the DSZ. For more information, see Switch Functions . (Operator’s Manual.) Back Button (S26)— The back button (S26) grounds pin B25 of monitor controller (DSZ), returning the monitor to the previous menu. For more information, see Switch Functions . (Operator’s Manual.) Home Button (S27)— The home button (S27) grounds pin B26 of monitor controller (DSZ), returning the monitor to the default screen. For more information, see Switch Functions . (Operator’s Manual.) Keypad (S60)— Keypad (S60) contains numerical keys 0—9 (S50—S59, respectively). Keypad also contains switch back <- Go to Section TOC





light 1 (E5) which provides backlighting for the individual keys. The keypad is used to input the anti-theft security code and other various parameters into the monitor controller (DSZ). For more information, see Switch Functions . (Operator’s Manual.)






Engine Control Unit (ECU) Circuit Theory of Operation






Engine Control Unit (ECU) Circuit Schematic (1 of 2) (S.N. —040754)





LEGEND: A1 A3 A4 A6000 F6 F8 F18 F20 F45 F60 F61 G1 G2 G3 K1 K4 K13 K19 K34 K35 M1 R12 S1 S15 V1 V3 V7 V10 V44 W37 X1 X14 X15 X20 X22 X31 X33 X36 X175



Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Modular Telematics Gateway (MTG) Controller 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Engine Control Unit (ECU) 30 A Fuse (marked ECU) Idle Stop 5 A Fuse (marked IDLE STOP) Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Starter Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor CAN 0 Termination Resistor Key Switch Reversing Fan Switch Battery Relay Diode Load Dump Relay Diode Start Relay Diode Starter Protection Diode Starter Relay Diode Cab Harness Ground 3 Service ADVISOR™ Diagnostic Connector Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Machine Harness-to-Starter Harness Connector





Engine Control Unit (ECU) Circuit Schematic (1 of 2) (S.N. 040755— )





LEGEND: A1 A3 A4 A6000 F6 F8 F18 F20 F45 F60 F61 G1 G2 G3 K1 K4 K13 K19 K34 K35 M1 R12 S1 S15 V1 V3 V7 V10 V44 W37 X1 X14 X15 X20 X22 X33 X34 X36 X175


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Modular Telematics Gateway (MTG) Controller Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) Idle Stop 5 A Fuse (marked IDLE STOP) Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Starter Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor CAN 0 Termination Resistor Key Switch Reversing Fan Switch Battery Relay Diode Load Dump Relay Diode Start Relay Diode Starter Protection Diode Starter Relay Diode Cab Harness Ground 3 Service ADVISOR™ Diagnostic Connector Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector F Machine Harness-to-Starter Harness Connector

Engine Control Unit (ECU) (A1)— The engine control unit (ECU) uses information received from various sensors to determine the correct amount of fuel and injection timing based on load, temperatures, and operator input. Some of the data calculated by the ECU is transmitted across the controller area network (CAN) to the main controller (MCZ) (A3), monitor controller (DSZ) (A4), and modular telematics gateway (MTG) controller (A6000). The DSZ forwards much of the information across the CAN data line to the monitor where it is displayed on the appropriate screen. →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information concerning the MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) For information concerning the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) For information concerning the CAN, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens, the ECU generates a diagnostic trouble code (DTC). For a complete list of engine diagnostic trouble codes, see Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.) For additional information on John Deere PowerTech ™ engines and components for engine model 6068HT069 or 6068HT085 see the following component technical manual (CTM). See PowerTech™, PowerTech™ Plus, and PowerTech™ E 4.5L and 6.8L Diesel Engines—Base Engine . (CTM104.) <- Go to Section TOC





See PowerTech™ E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel Systems with Denso HPCR . (CTM502.) Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The Snapshot information is categorized in two types: Snapshot Capture and Snapshot Recording. For more information, see Snapshot Instructions . (CTM104.) or (CTM502.) The following data is captured automatically for storing each code in the fault buffer: MAP Engine Speed Percent Load at Current Speed Coolant Temperature Vehicle Speed Engine Hours (first and last occurrence) Engine Mode The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to determine the pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU determine the air density for calculating the correct air-fuel ratio. This sensor cannot be repaired or replaced without replacing the entire ECU. The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to determine the internal temperature of the ECU. If the ECU temperature exceeds specification, the ECU limits the speed of the engine in an attempt to protect the ECU from permanent damage. This sensor cannot be repaired or replaced without replacing the entire ECU. The ECU allows for programming and diagnostic tests using Service ADVISOR ™ as follows: Programming—The ECU can be programmed by ing the latest programs from the software delivery system (SDS). Compression Test—This test is used to determine the relative compression of each cylinder. The engine is cranked while being provided with no fuel. The angular period of the crankshaft is measured near TDC, and again past TDC. The periods can be converted to velocities, and the relative decelerations can be calculated from the difference in the velocities. The deceleration is a function of the pressure in the cylinder. By comparing the result from each cylinder, cylinders with relatively low compression can be identified. Cylinder Cutout-Misfire Test—This test provides the capability to cut out fuel to individual cylinders and provide a programmable fuel command to the other cylinders for a programmable number of cylinder firing events. The total time for the number of firing events is determined and made available to Service ADVISOR for analysis. ECU Power Up (Power and Ground) (S.N. —040754)— Unswitched battery power is available at pins M1, M4, L1, and L4 of engine control unit (ECU)-to-engine harness connector 2 (X15), through engine control unit (ECU) 30 A fuse (F8). Ground is provided at pins M3, L3, L2, and M2 of engine control unit (ECU)-to-engine interface harness connector 2. When key switch (S1) is in the ON position, current flows from pin M of key switch through idle stop 5 A fuse (F18) to pins 1 and 3 of key cut relay (K13). Utilizing the normally closed s of the key cut relay, current is ed to pin B2 of engine control unit (ECU)-to-engine harness connector 2 (X15) through power on 5 A fuse (F17), causing the ECU to power up. When key switch (S1) is in the START position, current flows from pin ST through the normally closed s of starter cut relay (K4) then through pin 3 and 1 of starter protection relay (K35) and onto pin 1 of starter relay (K34) to energize the relay. With the starter relay pins 3 and 4 energized, power is supplied to pin S of starter motor (M1), thus cranking the engine. Once the ECU has determined the engine has started, pin C2 of engine control unit (ECU)-to-engine harness connector 2 (X15) is grounded, providing ground to starter protection relay (K35), de-energizing the starter relay (K34). With the starter relay deenergized, the start signal is removed from pin 4 on the starter relay, thus disengaging the starter motor. For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) ECU Power Up (Power and Ground) (S.N. 040755— )— Unswitched battery power is available at pins M1, M4, L1, and L4 of engine control unit (ECU)-to-engine harness connector 2 (X15), through engine control unit (ECU) 20 A fuse (F8). Ground is provided at pins M3, L3, L2, and M2 of engine control unit (ECU)-to-engine interface harness connector 2. When key switch (S1) is in the ON position, current flows from pin M of key switch through idle stop 5 A fuse (F18) to pins 1 and 3 of key cut relay (K13). Utilizing the normally closed s of the key cut relay, current is ed to pin B2 of engine control unit (ECU)-to-engine harness connector 2 (X15) through power on 5 A fuse (F17), causing the ECU to power up. When key switch (S1) is in the START position, current flows from pin ST through the normally closed s of starter cut relay (K4) then through pin 3 and 1 of starter protection relay (K35) and onto pin 1 of starter relay (K34) to energize the relay. <- Go to Section TOC





With the starter relay pins 3 and 4 energized, power is supplied to pin S of starter motor (M1), thus cranking the engine. Once the ECU has determined the engine has started, pin C2 of engine control unit (ECU)-to-engine harness connector 2 (X15) is grounded, providing ground to starter protection relay (K35), de-energizing the starter relay (K34). With the starter relay deenergized, the start signal is removed from pin 4 on the starter relay, thus disengaging the starter motor. For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) Hydraulic Variable Speed Fan with Reversing Function (S.N. —040754)— The hydraulic variable speed fan with reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit (ECU) automatically controls the speed of the fan by monitoring the following: Engine Coolant Temperature Charge Air Cooler Outlet Temperature Hydraulic Oil Temperature Ambient Air Temperature Air Conditioning State (On-Off) Fuel Temperature The engine coolant temperature sensor (B5208) and charge air cooler outlet temperature sensor (B5204) are hard-wired to the engine control unit (ECU). The hydraulic oil temperature (B40) is hard-wired to the main controller (MCZ) (A3), and continuously transmits information across the controller area network (CAN) to communicate with the ECU. For more information on the hydraulic oil temperature sensor, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) The air conditioner compressor clutch (Y11) is hard-wired to the air conditioner controller (ACF) (A7), and continuously transmits information via CAN to communicate with the monitor controller (DSZ) (A4), which then forwards the information via CAN to the ECU. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) →NOTE: If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.

The engine control unit (ECU) uses certain reference values in the form of look-up tables for each of the temperatures and the air conditioning state to determine the fan speed for each input. The ECU then selects the highest fan speed required and sends current out pin J4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to variable speed fan solenoid (Y5005). Static ground is provided to variable speed fan solenoid at all times. The amount of current the ECU provides the variable speed fan solenoid is inversely dependent on the calculated fan speed and compared to a predefined look-up table. Zero current commands maximum fan speed. For hydraulic operation of the fan, see Fan Drive Hydraulic System Operation . (Group 9025-05.) The reversing fan function reverses the fan direction to purge the cooling system of debris. The reversing fan function can be operated in manual or automatic mode via reversing fan switch (S15). Switched power is ed from the alternator (G3) to the reversing fan switch through power outlet 20 A fuse (F6). When the reversing fan switch is pressed to the AUTOMATIC position, current flows to pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15). The ECU then automatically reverses fan direction every 30 minutes unless the cycle time is changed. If the engine has been running for 60 minutes and the hydraulic oil temperature has exceeded 12°C (53.6°F), the ECU will begin the reversing sequence. When the reversing fan timer in the ECU reaches full count, the ECU begins the reversing sequence as follows: 1. The ECU ramps up the current to variable speed fan solenoid (Y5005) to slow the fan to minimum fan speed (approximately 300 rpm). 2. When fan speed is at minimum, the ECU sends current out pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to the reversing fan solenoid (Y9), energizing the solenoid. This causes the fan to reverse direction. 3. With the fan now operating in the reverse direction, the ECU ramps down the current applied to the variable speed fan solenoid (Y5005) until maximum fan speed (approximately 1800 rpm) is reached. 4. The ECU operates the fan at maximum speed in reverse direction for 15 seconds, then ramps up the variable speed fan solenoid current until the fan is at minimum speed. 5. When the fan slows to minimum speed, the ECU stops sending current to the reversing fan solenoid (Y9), causing the fan to change back to forward direction. <- Go to Section TOC





6. With the fan operating in the forward direction, the ECU ramps down the variable speed fan solenoid current until the normal operating fan speed is obtained. When the reversing fan has completed a cycle, the reversing sequence cannot be activated again for 1 minute. If the reversing fan is in the automatic mode when the manual mode is activated, the reversing fan timer is stopped and then started again after the reversing fan sequence is completed. When a manual reverse cycle is complete, the function returns to the automatic mode. Optional Connector and Reversing Fan Hydraulic Variable Speed Fan with Reversing Function (S.N. 040755— )— The hydraulic variable speed fan with reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit (ECU) automatically controls the speed of the fan by monitoring the following: Engine Coolant Temperature Charge Air Cooler Outlet Temperature Hydraulic Oil Temperature Ambient Air Temperature Air Conditioning State (On-Off) Fuel Temperature The engine coolant temperature sensor (B5208) and charge air cooler outlet temperature sensor (B5204) are hard-wired to the engine control unit (ECU). The hydraulic oil temperature (B40) is hard-wired to the main controller (MCZ) (A3), and continuously transmits information across the controller area network (CAN) to communicate with the ECU. For more information on the hydraulic oil temperature sensor, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) The air conditioner compressor clutch (Y11) is hard-wired to the air conditioner controller (ACF) (A7), and continuously transmits information via CAN to communicate with the monitor controller (DSZ) (A4), which then forwards the information via CAN to the ECU. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) →NOTE: If a fault condition exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.

The engine control unit (ECU) uses certain reference values in the form of look-up tables for each of the temperatures and the air conditioning state to determine the fan speed for each input. The ECU then selects the highest fan speed required and sends current out pin J4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to variable speed fan solenoid (Y5005). Static ground is provided to variable speed fan solenoid at all times. The amount of current the ECU provides the variable speed fan solenoid is inversely dependent on the calculated fan speed and compared to a predefined look-up table. Zero current commands maximum fan speed. For hydraulic operation of the fan, see Fan Drive Hydraulic System Operation . (Group 9025-05.) The reversing fan function reverses the fan direction to purge the cooling system of debris. The reversing fan function can be operated in manual or automatic mode via reversing fan switch (S15). Switched power is ed from the alternator (G3) to the reversing fan switch through optional connector and reversing fan 20 A fuse (F6). When the reversing fan switch is pressed to the AUTOMATIC position, current flows to pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15). The ECU then automatically reverses fan direction every 30 minutes unless the cycle time is changed. If the engine has been running for 60 minutes and the hydraulic oil temperature has exceeded 12°C (53.6°F), the ECU will begin the reversing sequence. When the reversing fan timer in the ECU reaches full count, the ECU begins the reversing sequence as follows: 1. The ECU ramps up the current to variable speed fan solenoid (Y5005) to slow the fan to minimum fan speed (approximately 300 rpm). 2. When fan speed is at minimum, the ECU sends current out pin K4 of engine control unit (ECU)-to-engine harness connector 2 (X15) to the reversing fan solenoid (Y9), energizing the solenoid. This causes the fan to reverse direction. 3. With the fan now operating in the reverse direction, the ECU ramps down the current applied to the variable speed fan <- Go to Section TOC





solenoid (Y5005) until maximum fan speed (approximately 1800 rpm) is reached. 4. The ECU operates the fan at maximum speed in reverse direction for 15 seconds, then ramps up the variable speed fan solenoid current until the fan is at minimum speed. 5. When the fan slows to minimum speed, the ECU stops sending current to the reversing fan solenoid (Y9), causing the fan to change back to forward direction. 6. With the fan operating in the forward direction, the ECU ramps down the variable speed fan solenoid current until the normal operating fan speed is obtained. When the reversing fan has completed a cycle, the reversing sequence cannot be activated again for 1 minute. If the reversing fan is in the automatic mode when the manual mode is activated, the reversing fan timer is stopped and then started again after the reversing fan sequence is completed. When a manual reverse cycle is complete, the function returns to the automatic mode.






Engine Control Unit (ECU) Circuit Schematic (2 of 2)





LEGEND: A1 B16 B53 B82 B5100 B5101 B5107 B5206 B5208 B5209 B5301 B5302 B5600 M13 S5001 S5002 X14 X15 X5000 Y1 Y2 Y3 Y4 Y9 Y19 Y5005


Engine Control Unit (ECU) Air Filter Restriction Switch Fan Speed Sensor Ambient Air Temperature Sensor Fuel Rail Pressure Sensor Engine Oil Pressure Sensor Inlet Fuel Pressure Sensor Manifold Air Temperature (MAT) Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Water-in-Fuel Sensor High Pressure Fuel Pump Engine Coolant Loss Level Sensor Engine Coolant Service Level Sensor Engine Control Unit (ECU)-to-Engine Harness Connector 1 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Engine Harness-to-Fuel Injector Harness 8-Pin Connector Electronic Injector 1 (cylinder 1) Electronic Injector 2 (cylinder 2) Electronic Injector 3 (cylinder 3) Electronic Injector 4 (cylinder 4) Reversing Fan Solenoid Ether Start Aid Variable Speed Fan Solenoid

Fuel Rail Pressure Sensor (B5100)— The fuel rail pressure sensor (B5100) sends a pressure equivalent signal to the engine control unit (ECU). The ECU monitors fuel pressure to control the amount and timing of fuel being transferred from the high pressure fuel pump to the high pressure common rail (HPCR). The ECU uses this signal input to determine if fuel rail pressure is adequate for the current operating condition. The ECU will command more or less fuel from the high pressure fuel pump by altering the signal to the suction control valve (Y5002). The ECU also uses this sensor to determine if there is an electronic injector problem by measuring the drop of pressure in the HPCR during each injection. The fuel rail pressure sensor is used for engine protection. The fuel rail pressure sensor uses pin D3 for supply voltage, pin E2 for ground, and pin E3 for signal on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104.) or (CTM502.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Engine Oil Pressure Sensor (B5101)— The engine oil pressure sensor (B5101) sends an oil pressure equivalent signal to the engine control unit (ECU). The ECU uses this signal to determine if engine oil pressure is adequate for the current operating conditions. The ECU monitors oil pressure for engine protection purposes. The engine oil pressure sensor uses pin F3 for supply voltage on engine control unit (ECU)-to-engine harness connector 1 (X14). The engine oil pressure sensor uses pin A3 for signal on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.) <- Go to Section TOC





For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Intake Manifold Pressure Senor (B5104)— Intake manifold pressure sensor (B5104) is used to help calculate the amount of airflow into the engine. The intake manifold pressure sensor also supplies the engine control unit (ECU) with a direct measurement of turbo boost. The intake manifold pressure sensor uses pin G4 for supply voltage, pin L2 for ground, and pin D2 for signal on engine control unit (ECU)-to-engine harness connector 2 (X15). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.) Crankshaft Position Sensor (B5301)— The crankshaft position sensor (B5301) is an inductive type pickup sensor that detects teeth on the crankshaft timing gear. The crankshaft timing gear is composed of 78 evenly-spaced teeth. Two of the teeth are ground back 1/2 the width of the teeth from the front of the gear. These partially ground-off teeth help the engine control unit (ECU) determine when cylinder number one or six is at top dead center (TDC) of its compression stroke. The ECU uses the crankshaft position input to determine engine speed and the angular position of the crankshaft in its 360 degree field of rotation. The ECU also uses this signal to calculate engine (crankshaft) speed and sends this information across the controller area network (CAN) to the monitor controller (DSZ) (A4), where it appears on the monitor display as engine rpm. Based on information from the crankshaft position and camshaft position sensors, the ECU calculates precisely to control the timing and duration of fuel injection. If there is a problem with the crankshaft position sensor, the ECU will use the camshaft position sensor to determine engine timing. This may require prolonged engine cranking to start the engine. The crankshaft position sensor uses pin B4 for signal and pin D4 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how speed sensors operate, see Measuring Speed . (CTM104) or (CTM502.) Camshaft Position Sensor (B5302)— The camshaft position sensor (B5302) is used to determine engine speed and when each cylinder is at top dead center (TDC) of the compression stroke. The ECU uses this information to determine injection timing. Camshaft position sensor consists of a permanent magnet, coil, and yoke. It is mounted near the inner camshaft gear which contains seven webs. During engine rotation, an AC voltage pulse is induced in the coil as each web es by the sensor. There are seven pulses per camshaft revolution. The circular distance between two of the webs is smaller, by detecting this difference the ECU determines when cylinder number one is at TDC of its compression stroke. The camshaft speed signal circuit is shielded from electro-magnetic interference (EMI). If there is a problem with the camshaft position sensor, the ECU will use the crankshaft position sensor to determine engine timing. This may require prolonged engine cranking to start the engine The camshaft position sensor uses pin E4 for signal and pin A4 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)






For information on how speed sensors operate, see Measuring Speed . (CTM104) or (CTM502.) Water-in-Fuel Sensor (B5600)— The water-in-fuel sensor (B5600) is located on the bottom of the primary fuel filter in the water separator bowl. When water is detected in the fuel, a signal is sent to the engine control unit (ECU). The water-in-fuel sensor uses the resistance of fuel and water in the fuel system along with the principle that water is a better conductor than fuel. If water is present, the voltage will be lower. The ECU monitors water-in-fuel for engine protection. The water-in-fuel sensor uses pin B2 signal and pin D2 for power on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Water-in-Fuel Alarm— The engine control unit (ECU) (A1) monitors the water-in-fuel sensor (B5600) for water in the fuel. When water is present, the engine control unit will ground connector X14 pin B2, grounding monitor controller (A4) pin C12. When monitor controller (A4) pin C12 is grounded, the monitor will display the water-in-fuel indicator to notify the operator of the water-in-fuel condition. Engine Coolant Loss Level Sensor (S5001)— The engine coolant loss level sensor (S5001) is a reed switch that extends from the bottom of the surge tank. A float in the tank changes position with coolant level. When the coolant level falls, the ring magnet on the bottom of the float moves to the bottom of the tank, below the switch position. The magnetic field is removed, the switch will open, a diagnostic trouble code (DTC) will be set, and the engine will be derated. The engine coolant loss level sensor uses pin J1 for signal on engine control unit (ECU)-to-engine harness connector 2 (X15). →NOTE: For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.) (Group 1915-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Engine Coolant Service Level Sensor (S5002)— The engine coolant service level sensor (S5002) is a reed switch that extends from the bottom of the surge tank. A float in the tank changes position with coolant level. When the coolant level falls, the ring magnet on the bottom of the float moves to the bottom of the tank, below the switch position. A diagnostic trouble code (DTC) will be set. The purpose of the sensor is to inform of a moderately low coolant level when the ignition is turned on. Once the engine is running, the sensor is only used for mismatch detection with engine coolant loss level sensor (S5001). The associated float in the surge tank is longer than the float associated with the coolant loss level sensor (S5001). The magnet for the engine coolant service level sensor will fall to the bottom of the surge tank sooner if engine coolant level decreases. The engine coolant service level sensor uses pin E3 for signal on engine control unit (ECU)-to-engine harness connector 2 (X15). →NOTE: For component location, see Engine Interface Harness (W5) Component Location . (Group 9015-10.)

For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Fan Speed Sensor (B53)— The fan speed sensor (B53) sends the engine control unit (ECU) with the fan speed in revolutions <- Go to Section TOC





per minute (RPM). The ECU uses the fan speed sensor for more precise control of the fan speed. The fan speed sensor uses pin A3 for supply voltage, pin C3 for ground, and pin H1 for signal on engine control unit (ECU)-toengine harness connector 2 (X15). Inlet Fuel Pressure Sensor (B5107)— The inlet fuel pressure sensor (B5107) sends a pressure equivalent signal to the engine control unit (ECU). The ECU monitors fuel pressure to determine if fuel is continuously ing through the low pressure side of the fuel system, or if there is a leak or blockage in it. Based on inlet fuel pressure sensor inputs, the ECU controls the low pressure fuel pump speed to maintain the desired pressure. The inlet fuel pressure sensor uses pin D2 for supply voltage, pin C2 for ground, and pin B3 for signal on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM104) or (CTM502.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Manifold Air Temperature (MAT) Sensor (B5206)— The manifold air temperature (MAT) sensor (B5206) is used to measure the temperature of the air in the intake manifold. The MAT sensor helps the ECU calculate the correct fueling for the engine. The ECU also uses this sensor for engine protection purposes. The MAT sensor uses pin D2 for signal and pin C2 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Engine Coolant Temperature Sensor (B5208)— The engine coolant temperature sensor (B5208) monitors the coolant temperature for engine protection. Depending on the severity of the temperature increase, the engine control unit (ECU) transmits a diagnostic trouble code (DTC) for either moderate or extreme temperature levels. The engine is derated for each level of temperature severity. When the ECU determines the coolant temperature is too low for the current operating conditions, it will set a DTC. This normally indicates a thermostat that is stuck open. The engine coolant temperature sensor uses pin C4 for signal and pin C2 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104.) or (CTM502.) Fuel Temperature Sensor (B5209)— The fuel temperature sensor (B5209) input is used by the engine control unit (ECU) to calculate fuel density and adjust fuel delivery. <- Go to Section TOC





The fuel temperature sensor uses pin F4 for signal and pin C2 for ground on engine control unit (ECU)-to-engine harness connector 1 (X14). →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM104) or (CTM502.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104) or (CTM502.) Electronic Injectors (Y1—Y4)— The electronic injectors (Y1—Y4) are controlled by the engine control unit (ECU) for injection timing and amount of fuel, by energizing and de-energizing the electronic injectors. For more information on the electronic injectors, see Electronic Injector (EI) Operation . (CTM104) or (CTM502.) →NOTE: For component location, see Engine Harness (W4) Component Location . (Group 9015-10.)

Engine Control Unit (S.N. —040754)— The engine control unit (ECU) (A1) manages the engine with input from main controller (MCZ) and sensors located on the engine. The ECU is supplied with unswitched power through connector X15 and engine control unit 30 amp fuse (F8). The ECU is turned on by a power on 5 amp fuse (F17) through pin B2 of connector X15. The ECU communicates with the MCZ through a CAN (controller area network). The CAN connects to ECU through pins A1, B1, and K2 of connector X15. If there is a malfunction with the ECU or one of the sensor circuits it is connected to the ECU, it will illuminate an indicator on the monitor controller (A4) to notify the operator of the problem. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Engine Control Unit (S.N. 040755— )— The engine control unit (ECU) (A1) manages the engine with input from main controller (MCZ) and sensors located on the engine. The ECU is supplied with unswitched power through connector X15 and engine control unit 20 amp fuse (F8). The ECU is turned on by a power on 5 amp fuse (F17) through pin B2 of connector X15. The ECU communicates with the MCZ through a CAN (controller area network). The CAN connects to ECU through pins A1, B1, and K2 of connector X15. If there is a malfunction with the ECU or one of the sensor circuits it is connected to the ECU, it will illuminate an indicator on the monitor controller (A4) to notify the operator of the problem. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Engine Speed Control— The engine speed dial allows for manual adjustment of the engine speed through the main controller (MCZ) to the engine control unit (ECU) (A1). A variable voltage of 0 to 5 volts is sent from the engine speed dial to the MCZ. The MCZ uses this information along with the status of the power mode button, work mode switch, auto-idle switch and information from the pressure sensors to create an engine speed output signal. The engine speed output signal from the MCZ is used by the ECU to set the engine speed. The engine speed dial uses terminals 2, 3, and 4 in connector X27. Terminal 2 in connector X27 is the power wire which goes to MCZ connector X31 pin D1. Terminal 3 in connector X27 is a signal wire which goes to MCZ connector X30 pin C1, and to monitor controller connector X21 pin C4. Terminal 4 in connector X27 is a ground wire which goes to MCZ connector X31 pin D6, and monitor controller (A4) connector X21 pin C10. For information on auto-idle and power modes ECO, PWR, and H/P, see Engine Speed Control System Operation . (Group 9010-05.) Variable Speed Fan— The variable speed fan cools the machine′s systems by a hydraulic pump and motor controlled by a proportional solenoid. This provides machine efficiency and reduced fan noise levels by only operating the fan at the minimum speed necessary to cool the machine systems. The engine control unit (ECU) uses inputs from the engine coolant temperature sensor (B5208) at terminal C4 of ECU-to-engine harness connector 1 (X14), turbocharger boost temperature sensor (B7) at terminals D2 and G4 of ECU-to-engine harness connector 2 (X15), hydraulic oil temperature sensor via controller area network (CAN), and ambient air temperature sensor, if air conditioner is ON, via CAN to determine the proper fan speed. The input that requires the most cooling takes precedence over the other inputs and the fan is run at a speed sufficient to cool the warmest input. If any of the three temperature sensor inputs are invalid, the fan will run at maximum speed to ensure proper cooling. Temperature thresholds and proportional solenoid duty cycles (fan speeds) are preprogrammed into the ECU and cannot be changed. The proportional fan solenoid is driven from engine control unit (ECU) terminals C1, D2, and J4 of connector X15. <- Go to Section TOC





Fan Speed Temperature Thresholds Engine Control Unit (ECU) Sensor Input

Temperature

Coolant Temperature

90°C (194°F)

Hydraulic Oil Temperature

80°C (176°F)

Ambient Air Temperature (when A/C is ON)

15°C (60°F)*

Intake Air Temperature

52°C at 25°C ambient (126°F at 77°F ambient)**

*When the air conditioner is ON and the ambient air temperature is over 15°C (60°F) the engine fan will increase to 1200 rpm. **The engine control unit measures the intake air temperature and adds a constant value to it at ambient temperatures above 25°C (77°F). In this application, the constant value is 27°C (49°F) above ambient air temperature when ambient air temperature is above 25°C (77°F). At temperatures below 25°C (77°F), the engine control unit uses the constant of 52°C (126°F) for the fan speed calculations. For example: • at 20°C (68°F) ambient temperature, the ECU calculated temperature would be 52°C (126°F) • at 26°C (79°F) ambient temperature, the ECU calculated temperature would be 53°C (128°F) • at 30°C (86°F) ambient temperature, the ECU calculated temperature would be 57°C (135°F)

Variable Speed Fan Reversing Function (if equipped) (S.N. —040754)— The variable speed fan reversing option switches the direction of the cooling fan to help clear the cooling package of debris buildup. A complete reversing cycle takes approximately 2 minutes with the fan running for 60 seconds at full speed in reverse during that time. The variable speed fan reversing operation can be activated in two ways, manual or automatic mode. The fan reversing switch (S15) applies power from power outlet 20 amp fuse (F6) to engine control unit (ECU) terminal F2 of connector X15 for manual mode or engine control unit (ECU) terminal E1 of connector X15 for automatic mode. The manual mode position on the switch is a momentary position and the automatic position on the switch is a detent position. The reversing fan solenoid (Y9) is powered by engine control unit (ECU) terminal K4 on connector X15. In manual mode, the fan may be reversed by pressing the fan reversing switch (S15) momentarily to the manual position. If the engine is running and hydraulic oil temperature is above 12°C (53°F), the fan will reverse. In automatic reverse mode, the fan will reverse every 60 minutes when the fan reversing switch (S15) is in the automatic position. The hydraulic oil temperature must be above 12°C (53°F), and the engine speed must be greater than 1000 rpm for 60 minutes. Once a reversing cycle has been started, it cannot be stopped unless the engine control unit (ECU) is powered down. After a reversing cycle completes, the ECU prevents reactivation of the reversing circuit for 1 minute and the automatic reversing mode timer is reset to 60 minutes. If the fan reversing switch (S15) is held in the manual position for 160 seconds or more, a diagnostic trouble code (DTC) will occur and the manual reversing mode is deactivated. Continuously holding the fan reversing switch in the manual position will not trigger a second cycle. The switch must be cycled to trigger a new reverse cycle. Variable Speed Fan Reversing Function (if equipped) (S.N. 040755— )— The variable speed fan reversing option switches the direction of the cooling fan to help clear the cooling package of debris buildup. A complete reversing cycle takes approximately 2 minutes with the fan running for 60 seconds at full speed in reverse during that time. The variable speed fan reversing operation can be activated in two ways, manual or automatic mode. The fan reversing switch (S15) applies power from optional connector and reversing fan 20 amp fuse (F6) to engine control unit (ECU) terminal F2 of connector X15 for manual mode or engine control unit (ECU) terminal E1 of connector X15 for automatic mode. The manual mode position on the switch is a momentary position and the automatic position on the switch is a detent position. The reversing fan solenoid (Y9) is powered by engine control unit (ECU) terminal K4 on connector X15. In manual mode, the fan may be reversed by pressing the fan reversing switch (S15) momentarily to the manual position. If the engine is running and hydraulic oil temperature is above 12°C (53°F), the fan will reverse. In automatic reverse mode, the fan will reverse every 60 minutes when the fan reversing switch (S15) is in the automatic position. The hydraulic oil temperature must be above 12°C (53°F), and the engine speed must be greater than 1000 rpm for 60 minutes. Once a reversing cycle has been started, it cannot be stopped unless the engine control unit (ECU) is powered down. After a reversing cycle completes, the ECU prevents reactivation of the reversing circuit for 1 minute and the automatic reversing mode timer is reset to 60 minutes. If the fan reversing switch (S15) is held in the manual position for 160 seconds or more, a diagnostic trouble code (DTC) will occur and the manual reversing mode is deactivated. Continuously holding the fan reversing switch in the manual position will not trigger a second cycle. The switch must be cycled to trigger a new reverse cycle. Engine Warm-Up— When the coolant temperature is below 0°C (32°F), the engine control unit (ECU) (A1) will run the engine at 1200 rpm for 12 minutes to warm up the engine. After the 12 minute warm-up period, the engine will return to slow idle <- Go to Section TOC





unless the main controller (MCZ) is requesting the warm-up routine for the hydraulic oil. When the hydraulic oil temperature is below 0°C (32°F), the MCZ sends a signal to ECU to increase engine speed to 1400 rpm for 15 minutes. See Engine Speed Control System Operation for more information on Auto Warm-Up Control. (Group 9010-05.) Power Limiting— The engine control unit (ECU) (A1) has a built-in engine protection program. The ECU will derate the amount of fuel that is delivered to the engine when sensor inputs exceed normal operating ranges. For a list of these fault codes and derate percentages, see Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)






Main Controller (MCZ) Circuit Theory of Operation Main Controller (MCZ) Circuit Theory of Operation (S.N. —040754)






Main Controller (MCZ) Circuit Schematic (1 of 2) (S.N. —040754)





LEGEND: A1 A3 A4 F4 F10 F17 F18 F45 F60 F61 G1 G2 G3 K1 K4 K13 K19 K34 K35 M1 S1 V1 V3 V7 V10 V44 W37 X15 X20 X22 X31 X33 X35 X36 X175


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Solenoid 20 A Fuse (marked SOLENOID) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Starter Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Key Switch Battery Relay Diode Load Dump Relay Diode Start Relay Diode Starter Protection Diode Starter Motor Diode Cab Harness Ground 3 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Machine Harness-to-Starter Harness Connector






Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. —040754)





LEGEND: A3 B30 B31 B32 B33 B34 B35 B36 B37 B38 B40 B60 B61 H4 R15 S7 S8 S11 S12 S13 X29 X31 X32 X33 X35 X36 X40 X90 X91 X97 Y20 Y21 Y22 Y23 Y24 Y27


Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Hydraulic Oil Temperature Sensor Attachment Pressure Sensor Arm Out Pressure Sensor Travel Alarm Engine Speed Dial Power Dig Switch Auto-Idle Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Cab Harness-to-Switch Connector 3 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Pump Harness-to-Machine Harness Connector Not Used Not Used Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST) Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD)

Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine: Boom Up Pressure Sensor (B30) Arm In Pressure Sensor (B31) Front Attachment Pressure Sensor (B32) Swing Pressure Sensor (B33) Travel Pressure Sensor (B34) Pump 1 Delivery Pressure Sensor (B35) Pump 1 Control Pressure Sensor (B36) Pump 2 Delivery Pressure Sensor (B37) Pump 2 Control Pressure Sensor (B38) Hydraulic Oil Temperature Sensor (B40) Engine Speed Dial (R15) Auto-Idle Switch (S8) Travel Speed Switch (S11) Power Mode Button (S12) The MCZ controls the following solenoids: Pump 2 Flow Rate Limit Solenoid (SB) (Y20) Torque Control Solenoid (ST) (Y21) Dig Regenerative Solenoid (SF) (Y22) Arm Regenerative Solenoid (SC) (Y23) Power Dig Solenoid (SG/SI) (Y24) Arm 2 Flow Control Solenoid (SD) (Y27) Main Controller Power Up (Power and Ground)— Unswitched battery power is available at pins 3 and 4 of the main <- Go to Section TOC





controller (MCZ) through controller 5 A fuse (F10). Ground is provided to pins 1, 2, 5, and 6 of the MCZ. When key switch (S1) is in the ON position, current flows from pin M of key switch to pin 3 of key cut relay (K13) and through idle stop 5 A fuse (F18) to pin 1 of key cut relay. Utilizing the normally closed s of the key cut relay, current is ed to pin 10 of the MCZ through power on 5 A fuse (F17), causing the MCZ to power up. With the battery relay (K19) energized, current flows through alternator 65 A fuse (F60), to pin B of alternator (G3). From pin B of alternator, current flows through solenoid 20 A fuse (F4) to pins 2, 5, and 6 of the MCZ. Engine Speed Dial (R15)— The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial. The main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.) Power Mode Button (S12)— The power mode button (S12) allows the operator to cycle through three power modes: ECO (economy), PWR (power) or H/P (high power). ECO power mode reduces engine speed to 1630 rpm to reduce fuel consumption versus PWR mode. H/P mode delivers more power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller (MCZ) sends an engine speed request to the engine control unit (ECU) via the controller area network (CAN). The engine control unit monitors several sensors in the engine and makes adjustments to maintain the engine speed requested by the MCZ. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) Travel Mode (HP)— When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller (MCZ) at pin 13. The MCZ then activates the power dig solenoid (SG/SI) (Y24), depending on the status of the travel pressure sensor (B34), the front attachment pressure sensor (B32), the pump control pressure sensors (B36 and B38), and the pump delivery pressure sensors (B35 and B37). The power dig solenoid is a proportional solenoid that is controlled by pins 5 and 15 of the MCZ. The power dig solenoid is activated when: Engine speed dial (R15) is in fast idle position Travel pressure sensor is sensing pressure (travel function actuated) Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated) Either pump 1 or pump 2 delivery pressure low Either pump 1 or pump 2 control pressure high Activation of the power dig solenoid sends pilot pressure to the travel speed change switch in the travel motors. When the travel speed switch (S11) is in the slow (turtle) speed (2) position, the power dig solenoid valve (SG) (Y24) is de-energized. Pressure at the travel speed change valve changes the displacement of the travel motors allowing for fast travel speed. Since both delivery pressure must be low and both control pressure must be high, the travel motor will not shift to fast speed when one track is lifted off the ground. If the machine is traveling in fast travel speed and a dig or swing function is operated, the machine will remain in fast travel speed, but will slow travel speed as hydraulic oil is routed to other functions. For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.) A/I (Auto-Idle) Mode— A/I (Auto-Idle) is a feature that reduces engine speed when hydraulic functions are not operated for more than 4 seconds. When the auto-idle switch (S8) is turned to A/I (auto-idle), the switch sends a ground to the main controller (MCZ) to pin 14 of the MCZ. The MCZ communicates the selected mode through the controller area network (CAN) to the DSZ, updating the monitor with the current mode. When the engine speed dial is set to an engine speed above auto-idle speed, the MCZ will reduce the engine speed to auto-idle speed if hydraulic functions are not operated for more than 4 seconds. If engine speed dial is set to an engine speed below auto-idle speed, the engine speed will not increase or decrease after 4 seconds. The MCZ receives the pressure signal from the front attachment pressure sensor (B32) in the swing park brake circuit or the travel pressure sensor (B34) to sense if a hydraulic function has been operated. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Hydraulic Oil Warm-Up Circuit— When hydraulic oil temperature is below 0°C (32°F), the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the hydraulic oil. The MCZ receives oil temperature from the hydraulic oil temperature sensor (B40), located in the hydraulic oil tank. The MCZ will activate the warmup circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F). <- Go to Section TOC





For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.) Engine Coolant Warm-Up Circuit— When engine coolant temperature is below predefined point, the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the engine coolant. The MCZ receives coolant temperature via the controller area network (CAN) from the ECU. The MCZ will activate the warm-up circuit for 12 minutes or until the coolant temperature rises to 25°C (77°F). Idle Speed-Up Circuit— The idle speed-up circuit prevents the engine from hunting when travel or front attachment operation is performed while the engine is running at a speed between slow idle and idle speed-up speed. When the travel or front attachment operation is performed while the engine is between slow idle and idle speed-up speed, the main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). The ECU then increases the engine speed to the idle speed-up speed. Pilot Shut-Off Idle Speed-Up Circuit— When engine speed dial (R15) is in the slow idle position and the pilot shut-off lever is in the unlocked (DOWN) position, the main controller (MCZ) activates the pilot shut-off idle speed up circuit. The MCZ sends the equivalent to target engine speed to the ECU via the controller area network (CAN), which increases the engine speed by 100 rpm from the slow idle speed in order to prevent engine stall during a control lever operation. Engine Starting Idle Speed-Up Circuit— The engine starting idle speed-up circuit increases the engine speed and increases the engine oil pressure when the engine starts. The engine starting idle speed-up circuit will not activate if the engine speed dial (R15) is set above 1150 rpm. When active, the engine starting idle speed-up circuit sends the signals equivalent to the target engine speed to the engine control unit (ECU) via the controller area network (CAN). The idle speed-up circuit will remain active for 15 seconds. Engine speed will then return to the engine speed set by the engine speed dial. Travel Torque Up— The torque control solenoid valve may also be activated during a travel function. At slow engine speeds, the torque control solenoid valve is activated and both pumps are moved to maximum displacement. This reduces the oil flow difference between the two hydraulic pumps and therefore reduces machine mistracking at low engine speeds. At fast engine speeds, the torque control solenoid may also be activated to slightly increase pump oil flow to improve the travel function. The torque control solenoid (Y21) is a proportional solenoid and is controlled by a pulse width modulated signal from pins 3 and 16 of the main controller (MCZ). Auto Shutdown Circuit— The auto shutdown circuit automatically stops the engine in order to reduce fuel consumption when the operation is not carried out in a fixed time. The main controller (MCZ) sends the auto shutdown signal to the monitor controller (DSZ) via the controller area network (CAN) when the following conditions have been met: Pilot shutoff switch in the LOCKED position Auto shutdown enabled Engine coolant temperature less than 100°C (212°F) The MCZ then reduces engine speed to slow idle, and provides ground to the idle stop relay, accessory cut relay, and key cut relay, thus de-energizing the battery relay (K19), turning the machine off. For more information on the auto shutdown circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) Work Modes— The monitor controller (DSZ) contains several work modes that are communicated by the controller area network (CAN) to the main controller (MCZ). The MCZ can adjust pump delivery and engine speed depending on the work mode or attachment selected. Pump flow and engine speeds can be adjusted with the monitor controller or by using MPDr. Hydraulic Oil Overheat Alarm Circuit— The hydraulic oil overheat alarm circuit sounds the monitor alarm when the hydraulic oil temperature increases beyond the specified value. The main controller (MCZ) monitors hydraulic oil temperature utilizing hydraulic oil temperature sensor (B40). When hydraulic oil temperature increases, and remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) via the controller area network (CAN). The monitor controller sounds the alarm and displays the hydraulic oil overheat alarm on the monitor. For more information, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) Travel Alarm Circuit— The travel alarm sounds during travel operation. When the main controller (MCZ) receives the signal from travel pressure sensor (B34), it sends power to travel alarm (H4), activating the alarm. After traveling continuously for more than 13 seconds, the alarm can be deactivated using travel alarm cancel switch (S13). Pump 2 Flow Rate Limit Solenoid (SB) (Y20)— The pump 2 flow rate limit solenoid valve (SB) (Y20) limits the pump 2 <- Go to Section TOC





displacement when an auxiliary (attachment) function is used. The pump 2 flow rate limit solenoid is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins 8 and 15 of the main controller (MCZ). The MCZ activates the pump 2 flow rate limit solenoid valve when pilot pressure is present at the attachment pressure sensor (optional) and a work mode other than dig mode is selected in the monitor. The flow rate for each attachment mode can be adjusted using MPDr. Fine adjustments to the pump 2 flow rate can be made through the monitor. →NOTE: Flow rates and adjustments in MPDr and the monitor are approximate. Actual flow rates may vary. The auxiliary flow combiner may greatly affect MPDr flow adjustments if activated.

Torque Control Solenoid (ST) (Y21)— The torque control solenoid (ST) (Y21) valve helps control pump displacement in response to changes in engine load. As engine load increases, the torque control solenoid valve is deactivated reducing the pump displacement and therefore reducing engine load and prevents engine stall. As engine load decreases, the torque control solenoid is activated increasing pump displacement therefore increasing the efficiency of the machine. The main controller (MCZ) monitors the difference between target engine speed as set by the MCZ and the actual engine speed as read by the ECU and communicated to the MCZ over controller area network (CAN). As engine speed varies above or below target speed, the MCZ adjusts the signal to the torque control solenoid valve to change the pump displacement to utilize the maximum efficiency of the engine without allowing the engine to stall. The torque control solenoid is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins 3 and 16 of the MCZ. Under most conditions, the torque control solenoid is activated to some degree. For more information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.) Dig Regenerative Solenoid (SF) (Y22)— The dig regenerative solenoid valve (SF) (Y22) redirects oil from the boom cylinder rod end to the arm cylinder head end during a boom up and arm in function. This helps improve arm control and prevents arm cylinder cavitation during the combined function. The dig regenerative solenoid is a proportional solenoid that is controlled by a pulse width modulated signal from pins 4 and 13 of the main controller (MCZ). The MCZ activates the dig regenerative solenoid valve (SF) when the following conditions have been met: Pump 1 and pump 2 delivery pressure high Pressure at arm in pressure sensor Pressure at boom up pressure sensor When the dig regenerative solenoid valve is activated, pilot oil from the dig regenerative solenoid valve shifts the dig regenerative valve in the control valve. This allows oil from the boom cylinder rod end to combine with oil in the arm cylinder head end. For more information, see Dig Regenerative Valve Circuit Operation . (Group 9025-05.) Arm Regenerative Solenoid (SC) (Y23)— The arm regenerative solenoid valve (SC) (Y23) combines the return oil from the arm cylinder rod end with the supply oil to the arm cylinder head end. This helps prevent arm hesitation or cavitation in the arm in circuit during a combined arm in and swing or boom up function. The arm regenerative solenoid is a proportional solenoid that is controlled by a pulse width modulated signal from pins 5 and 14 of the main controller (MCZ). The MCZ activates the arm regenerative solenoid valve (SC) when the following conditions have been met: Either pump 1 or pump 2 delivery pressure low Arm in pressure sensor sensing high pressure (arm in function fully actuated) Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated) When the arm regenerative solenoid valve is activated, pilot oil from the arm regenerative solenoid valve shifts the arm regenerative valve in the control valve. This blocks the return oil from the arm cylinder rod end from returning to the hydraulic oil tank and combines it with the oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid valve also shifts the arm flow control valve, limiting the oil to the second arm spool to preserve oil flow to other functions in the control valve. For more information, see Arm Regenerative Valve Circuit Operation . (Group 9025-05.) Power Dig Solenoid (SG) (Y24)— The power dig solenoid (SG) (Y24) increases digging force by temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin 27 of the main controller (MCZ). The MCZ then <- Go to Section TOC





energizes dig solenoid (SG) for a maximum of 8 seconds. The power dig solenoid (SG) is a proportional solenoid and is controlled by a pulse width modulated signal from pins 5 and 15 of the MCZ. When the power dig solenoid is activated, pilot oil from the power dig solenoid flows to the top of the main relief and power dig valve. The pilot oil pressure pushes the piston in the main relief and power dig valve down, increasing the pressure setting. The main hydraulic system now operates at the power dig higher operating pressure. For more information, see Main Relief Valve Circuit Operation . (Group 9025-05.) Arm 2 Flow Control Solenoid (SD) (Y27)— The arm 2 flow control solenoid (SD) (Y27) maintains boom raise operating speed when operating digging (boom raise and arm roll in). The arm 2 flow control solenoid is a proportional solenoid that is controlled by a pulse width modulated signal from pins 6 and 16 of the main controller (MCZ). The MCZ activates the arm 2 flow control solenoid (SD) when the following conditions have been met: Pump 1 and pump 2 delivery pressure high Arm in pressure sensor sensing pressure Boom up pressure sensor sensing pressure When arm 2 flow control solenoid valve is activated, pilot oil is delivered, shifting arm 2 flow control valve. Arm 2 flow control valve reduces pressure oil from pump 1 to arm 2 spool, maintaining boom raise operating speed.

Main Controller (MCZ) Circuit Theory of Operation (S.N. 040755— )






Main Controller (MCZ) Circuit Schematic (1 of 2) (S.N. 040755— )





LEGEND: A1 A3 A4 F4 F10 F17 F18 F45 F60 F61 G1 G2 G3 K1 K4 K13 K19 K34 K35 M1 S1 V1 V3 V7 V10 V44 W37 X15 X20 X22 X31 X33 X35 X36 X175


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Solenoid 20 A Fuse (marked SOLENOID) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Line 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Load Dump Relay Starter Cut Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Key Switch Battery Relay Diode Load Dump Relay Diode Start Relay Diode Starter Protection Diode Starter Motor Diode Cab Harness Ground 3 Engine Control Unit (ECU)-to-Engine Harness Connector 2 Monitor Controller 28-Pin Connector A Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Machine Harness-to-Starter Harness Connector






Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. 040755— )





LEGEND: A3 B30 B31 B32 B33 B34 B35 B36 B37 B38 B40 B60 B61 H4 R15 S7 S8 S11 S12 S13 X29 X31 X32 X33 X34 X35 X36 X40 X97 Y20 Y21 Y22 Y23 Y24 Y27


Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Hydraulic Oil Temperature Sensor Attachment Pressure Sensor Arm Out Pressure Sensor Travel Alarm Engine Speed Dial Power Dig Switch Auto-Idle Switch Travel Speed Switch Power Mode Button Travel Alarm Cancel Switch Cab Harness-to-Switch Connector 3 Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F Pump Harness-to-Machine Harness Connector Pump Harness Splice Connector Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST) Dig Regenerative Solenoid (marked SF) Arm Regenerative Solenoid (marked SC) Power Dig/Travel Speed Solenoid (marked SG) Arm 2 Flow Control Solenoid (marked SD)

Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine: Boom Up Pressure Sensor (B30) Arm In Pressure Sensor (B31) Front Attachment Pressure Sensor (B32) Swing Pressure Sensor (B33) Travel Pressure Sensor (B34) Pump 1 Delivery Pressure Sensor (B35) Pump 1 Control Pressure Sensor (B36) Pump 2 Delivery Pressure Sensor (B37) Pump 2 Control Pressure Sensor (B38) Hydraulic Oil Temperature Sensor (B40) Engine Speed Dial (R15) Auto-Idle Switch (S8) Travel Speed Switch (S11) Power Mode Button (S12) The MCZ controls the following solenoids: Pump 2 Flow Rate Limit Solenoid (SB) (Y20) Torque Control Solenoid (ST) (Y21) Dig Regenerative Solenoid (SF) (Y22) Arm Regenerative Solenoid (SC) (Y23) Power Dig/Travel Speed Solenoid (SG) (Y24) Arm 2 Flow Control Solenoid (SD) (Y27) Main Controller Power Up (Power and Ground)— Unswitched battery power is available at pins E5 and E6 of the main controller (MCZ) through data converter and main controller battery power 5 A fuse (F10). Ground is provided to pins E1, E2, <- Go to Section TOC





F4, F5, and F6 of the MCZ. When key switch (S1) is in the ON position, current flows from pin M of key switch to pin 3 of key cut relay (K13) and through idle stop 5 A fuse (F18) to pin 1 of key cut relay. Utilizing the normally closed s of the key cut relay current is ed to pin E4 of the MCZ through power on 5 A fuse (F17), causing the MCZ to power up. With the battery relay (K19) energized, current flows through alternator 65 A fuse (F60), to pin B of alternator (G3). From pin B of alternator, current flows through solenoid 20 A fuse (F4) to pins F1, F2, and F3 of the MCZ. Engine Speed Dial (R15)— The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial. The main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.) Power Mode Button (S12)— The power mode button (S12) allows the operator to cycle through three power modes: ECO (economy), PWR (power) or H/P (high power). ECO power mode reduces engine speed to 1630 rpm to reduce fuel consumption versus PWR mode. H/P mode delivers more power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller (MCZ) sends an engine speed request to the engine control unit (ECU) via the controller area network (CAN). The engine control unit monitors several sensors in the engine and makes adjustments to maintain the engine speed requested by the MCZ. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) Travel Mode (HP)— When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller (MCZ) at pin F11. The MCZ then activates the power dig/travel speed solenoid (SG) (Y24), depending on the status of the travel pressure sensor (B34), the front attachment pressure sensor (B32), the pump control pressure sensors (B36 and B38), and the pump delivery pressure sensors (B35 and B37). The power dig/travel speed solenoid (SG) (Y24) is a proportional solenoid that is controlled by pins E15 and E21 of the MCZ. The power dig/travel speed solenoid (SG) (Y24) is activated when: Engine speed dial (R15) is in fast idle position Travel pressure sensor is sensing pressure (travel function actuated) Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated) Either pump 1 or pump 2 delivery pressure low Either pump 1 or pump 2 control pressure high Activation of the power dig/travel speed solenoid (SG) (Y24) sends pilot pressure to the travel speed change switch in the travel motors. When the travel speed switch (S11) is in the slow (turtle) speed (2) position, the power dig/travel speed solenoid (SG) (Y24) is de-energized. Pressure at the travel speed change valve changes the displacement of the travel motors allowing for fast travel speed. Since both delivery pressures must be low and both control pressures must be high, the travel motor will not shift to fast speed when one track is lifted off the ground. If the machine is traveling in fast travel speed and a dig or swing function is operated, the machine will remain in fast travel speed, but will slow travel speed as hydraulic oil is routed to other functions. For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.) A/I (Auto-Idle) Mode— A/I (Auto-Idle) is a feature that reduces engine speed when hydraulic functions are not operated for more than 4 seconds. When the auto-idle switch (S8) is turned to A/I (auto-idle), the switch sends a ground to the main controller (MCZ) to pin F7 of the MCZ. The MCZ communicates the selected mode through the controller area network (CAN) to the DSZ, updating the monitor with the current mode. When the engine speed dial is set to an engine speed above auto-idle speed, the MCZ will reduce the engine speed to auto-idle speed if hydraulic functions are not operated for more than 4 seconds. If engine speed dial is set to an engine speed below auto-idle speed, the engine speed will not increase or decrease after 4 seconds. The MCZ receives the pressure signal from the front attachment pressure sensor (B32) in the swing park brake circuit or the travel pressure sensor (B34) to sense if a hydraulic function has been operated. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Hydraulic Oil Warm-Up Circuit— When hydraulic oil temperature is below 0°C (32°F), the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the hydraulic oil. The MCZ receives oil temperature from the hydraulic oil temperature sensor (B40), located in the hydraulic oil tank. The MCZ will activate the warmup circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F). <- Go to Section TOC





For more information on engine speed control, see Engine Speed Control System Operation . (Group 9010-05.) Engine Coolant Warm-Up Circuit— When engine coolant temperature is below predefined point, the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the engine coolant. The MCZ receives coolant temperature via the controller area network (CAN) from the ECU. The MCZ will activate the warm-up circuit for 12 minutes or until the coolant temperature rises to 25°C (77°F). Idle Speed-Up Circuit— The idle speed-up circuit prevents the engine from hunting when travel or front attachment operation is performed while the engine is running at a speed between slow idle and idle speed-up speed. When the travel or front attachment operation is performed while the engine is between slow idle and idle speed-up speed, the main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). The ECU then increases the engine speed to the idle speed-up speed. Pilot Shut-Off Idle Speed-Up Circuit— When engine speed dial (R15) is in the slow idle position and the pilot shut-off lever is in the unlocked (DOWN) position, the main controller (MCZ) activates the pilot shut-off idle speed up circuit. The MCZ sends the equivalent to target engine speed to the ECU via the controller area network (CAN), which increases the engine speed by 100 rpm from the slow idle speed in order to prevent engine stall during a control lever operation. Engine Starting Idle Speed-Up Circuit— The engine starting idle speed-up circuit increases the engine speed and increases the engine oil pressure when the engine starts. The engine starting idle speed-up circuit will not activate if the engine speed dial (R15) is set above 1150 rpm. When active, the engine starting idle speed-up circuit sends the signals equivalent to the target engine speed to the engine control unit (ECU) via the controller area network (CAN). The idle speed-up circuit will remain active for 15 seconds. Engine speed will then return to the engine speed set by the engine speed dial. Travel Torque Up— The torque control solenoid (ST) (Y21) valve may also be activated during a travel function. At slow engine speeds, the torque control solenoid (ST) (Y21) valve is activated and both pumps are moved to maximum displacement. This reduces the oil flow difference between the two hydraulic pumps and therefore reduces machine mistracking at low engine speeds. At fast engine speeds, the torque control solenoid (ST) (Y21) may also be activated to slightly increase pump oil flow to improve the travel function. The torque control solenoid (ST) (Y21) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins B1 and B2 of the main controller (MCZ). Auto Shutdown Circuit— The auto shutdown circuit automatically stops the engine in order to reduce fuel consumption when the operation is not carried out in a fixed time. The main controller (MCZ) sends the auto shutdown signal to the monitor controller (DSZ) via the controller area network (CAN) when the following conditions have been met: Pilot shutoff switch in the LOCKED position Auto shutdown enabled Engine coolant temperature less than 100°C (212°F) The MCZ then reduces engine speed to slow idle, and provides ground to the idle stop relay, accessory cut relay, and key cut relay thus de-energizing the battery relay (K19), turning the machine off. For more information on the auto shutdown circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) Work Modes— The monitor controller (DSZ) contains several work modes that are communicated by the controller area network (CAN) to the main controller (MCZ). The MCZ can adjust pump delivery and engine speed depending on the work mode or attachment selected. Pump flow and engine speeds can be adjusted with the monitor controller or by using MPDr. Hydraulic Oil Overheat Alarm Circuit— The hydraulic oil overheat alarm circuit sounds the monitor alarm when the hydraulic oil temperature increases beyond the specified value. The main controller (MCZ) monitors hydraulic oil temperature utilizing hydraulic oil temperature sensor (B40). When hydraulic oil temperature increases, and remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) via the controller area network (CAN). The monitor controller sounds the alarm and displays the hydraulic oil overheat alarm on the monitor. For more information, see Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.) Travel Alarm Circuit— The travel alarm sounds during travel operation. When the main controller (MCZ) receives the signal from travel pressure sensor (B34), it sends power to travel alarm (H4), activating the alarm. After traveling continuously for more than 13 seconds, the alarm can be deactivated using travel alarm cancel switch (S13). Pump 2 Flow Rate Limit Solenoid (SB) (Y20)— The pump 2 flow rate limit solenoid (SB) (Y20) valve limits the pump 2 <- Go to Section TOC





displacement when an auxiliary (attachment) function is used. The pump 2 flow rate limit solenoid (SB) (Y20) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins A6 and A7 of the main controller (MCZ). The MCZ activates the pump 2 flow rate limit solenoid (SB) (Y20) valve when pilot pressure is present at the attachment pressure sensor (optional) and a work mode other than bucket mode is selected in the monitor. The flow rate for each attachment mode can be adjusted using MPDr. Fine adjustments to the pump 2 flow rate can be made through the monitor. →NOTE: Flow rates and adjustments in MPDr and the monitor are approximate. Actual flow rates may vary. The auxiliary flow combiner may greatly affect MPDr flow adjustments if activated.

Torque Control Solenoid (ST) (Y21)— The torque control solenoid (ST) (Y21) valve helps control pump displacement in response to changes in engine load. As engine load increases, the torque control solenoid (ST) (Y21) valve is deactivated reducing the pump displacement and therefore reducing engine load and prevents engine stall. As engine load decreases, the torque control solenoid (ST) (Y21) is activated increasing pump displacement therefore increasing the efficiency of the machine. The main controller (MCZ) monitors the difference between target engine speed as set by the MCZ and the actual engine speed as read by the ECU and communicated to the MCZ over controller area network (CAN). As engine speed varies above or below target speed, the MCZ adjusts the signal to the torque control solenoid (ST) (Y21) valve to change the pump displacement to utilize the maximum efficiency of the engine without allowing the engine to stall. The torque control solenoid (ST) (Y21) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins A2 and A3 of the MCZ. Under most conditions, the torque control solenoid (ST) (Y21) is activated to some degree. For more information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.) Dig Regenerative Solenoid (SF) (Y22)— The dig regenerative solenoid (SF) (Y22) valve redirects oil from the boom cylinder rod end to the arm cylinder head end during a boom up and arm in function. This helps improve arm control and prevents arm cylinder cavitation during the combined function. The dig regenerative solenoid (SF) (Y22) is a proportional solenoid that is controlled by a pulse width modulated (PWM) signal from pins A14 and A15 of the main controller (MCZ). The MCZ activates the dig regenerative solenoid (SF) (Y22) valve when the following conditions have been met: Pump 1 and pump 2 delivery pressure high Pressure at arm in pressure sensor Pressure at boom up pressure sensor When the dig regenerative solenoid (SF) (Y22) valve is activated, pilot oil from the dig regenerative solenoid (SF) (Y22) valve shifts the dig regenerative valve in the control valve. This allows oil from the boom cylinder rod end to combine with oil in the arm cylinder head end. For more information, see Dig Regenerative Valve Circuit Operation . (Group 9025-05.) Arm Regenerative Solenoid (SC) (Y23)— The arm regenerative solenoid (SC) (Y23) valve combines the return oil from the arm cylinder rod end with the supply oil to the arm cylinder head end. This helps prevent arm hesitation or cavitation in the arm in circuit during a combined arm in and swing or boom up function. The arm regenerative solenoid (SC) (Y23) is a proportional solenoid that is controlled by a pulse width modulated (PWM) signal from pins A10 and A11 of the main controller (MCZ). The MCZ activates the arm regenerative solenoid (SC) (Y23) valve when the following conditions have been met: Either pump 1 or pump 2 delivery pressure low Arm in pressure sensor sensing high pressure (arm in function fully actuated) Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated) When the arm regenerative solenoid (SC) (Y23) valve is activated, pilot oil from the arm regenerative solenoid (SC) (Y23) valve shifts the arm regenerative valve in the control valve. This blocks the return oil from the arm cylinder rod end from returning to the hydraulic oil tank and combines it with the oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid (SC) (Y23) valve also shifts the arm flow control valve, limiting the oil to the second arm spool to preserve oil flow to other functions in the control valve. For more information, see Arm Regenerative Valve Circuit Operation . (Group 9025-05.) Power Dig/Travel Speed Solenoid (SG) (Y24)— The power dig/travel speed solenoid (SG) (Y24) increases digging force by <- Go to Section TOC





temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin A27 of the main controller (MCZ). The MCZ then energizes power dig/travel speed solenoid (SG) (Y24) for a maximum of 8 seconds. The power dig/travel speed solenoid (SG) (Y24) is a proportional solenoid and is controlled by a pulse width modulated (PWM) signal from pins A12 and A13 of the MCZ. When the power dig/travel speed solenoid (SG) (Y24) is activated, pilot oil from the power dig/travel speed solenoid (SG) (Y24) flows to the top of the main relief and power dig valve. The pilot oil pressure pushes the piston in the main relief and power dig valve down, increasing the pressure setting. The main hydraulic system now operates at the power dig higher operating pressure. For more information, see Main Relief Valve Circuit Operation . (Group 9025-05.) Arm 2 Flow Control Solenoid (SD) (Y27)— The arm 2 flow control solenoid (SD) (Y27) maintains boom raise operating speed when operating digging (boom raise and arm roll in). The arm 2 flow control solenoid (SD) (Y27) is a proportional solenoid that is controlled by a pulse width modulated (PWM) signal from pins A8 and A9 of the main controller (MCZ). The MCZ activates the arm 2 flow control solenoid (SD) (Y27) when the following conditions have been met: Pump 1 and pump 2 delivery pressure high Arm in pressure sensor sensing pressure Boom up pressure sensor sensing pressure When arm 2 flow control solenoid (SD) (Y27) valve is activated, pilot oil is delivered, shifting arm 2 flow control valve. Arm 2 flow control valve reduces pressure oil from pump 1 to arm 2 spool, maintaining boom raise operating speed.

Auxiliary Function Lever (AFL) Theory of Operation






Auxiliary Function Lever (AFL) Theory of Operation






LEGEND: A3 Main Controller (MCZ) B68 Secondary Hydraulic Oil Temperature Sensor B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT) K31 Right Solenoid Relay A (marked RSW1) S7 Power Dig Switch S29 Auxiliary Function Lever (AFL) Proportional Control Switch S31 Right Pilot Control Lever Switch S45 Auxiliary Function Enable Switch (marked AFL_SW) V22 Pilot Shutoff Solenoid Diode W36 Cab Harness Ground 2 W37 Cab Harness Ground 3 X31 Cab Harness-to-Main Controller 31-Pin Connector A X32 Cab Harness-to-Main Controller 24-Pin Connector B X33 Cab Harness-to-Main Controller 17-Pin Connector C X36 Cab Harness-to-Main Controller 26-Pin Connector F X536 Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) X574 Auxiliary Function Lever (AFL) Connector 1 X577 Auxiliary Function Lever (AFL) Harness-to-Auxiliary Function Lever (AFL) Solenoid Harness Connector Y61 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) Y62 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) Y66 Secondary Pilot Shutoff Solenoid Valve (marked PiC) Auxiliary Function Lever (AFL)— The main controller (MCZ) provides control for AFL control. For more information on MCZ, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) Auxiliary hydraulic functions are controlled by the MCZ with inputs from the following components: B68—Secondary Hydraulic Oil Temperature Sensor B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) S29—Auxiliary Function Lever (AFL) Proportional Control Switch S45—Auxiliary Function Enable Switch (marked AFL_SW) After the MCZ processes received input signals, output signals are sent to the solenoids to control hydraulic speed and volume with the following components: Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A) Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B) Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC) →NOTE: AFL will work only when pilot control shutoff lever is in the (DOWN) unlocked position. If a cycle of the pilot control shutoff lever is done, AFL will need to be activated again.

By pressing the auxiliary function enable switch (S45), ground is supplied at pin F22. The MCZ provides ground at pin C6, activating the secondary pilot shutoff solenoid valve (Y66) which is a normally closed solenoid. When the operator actuates AFL proportional control switch (S29) on the right pilot control lever, a proportional signal is sent to the MCZ. The MCZ converts this signal and energizes the appropriate AFL solenoid to allow flow to the attachment in the requested speed and volume. The MCZ monitors secondary hydraulic oil temperature utilizing secondary hydraulic oil temperature sensor (B68) through pin C7 of the MCZ and grounded through pins F16 and F17 of the MCZ. When hydraulic oil temperature increases or decreases and remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) (A4) via the controller area network (CAN). The MCZ monitors hydraulic oil pressure utilizing AFL solenoid pressure sensor through pin B2 of the MCZ and grounded through pins F25 and F26 of the MCZ. When hydraulic oil pressure increases and remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) (A4) via the controller area network (CAN).






Machine Controller (BCZ) Circuit Theory of Operation The machine controller (BCZ) controls lighting, windshield wiper, and windshield washer circuits. For more information on windshield wiper and washer circuit theory of operation, see Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) For more information on lighting circuit theory of operation, see Lighting Circuit Theory of Operation . (Group 9015-15.)






Windshield Wiper and Washer Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation





LEGEND: A4 A10 A11 E1 E10 F1 F2 F10 F17 F60 F61 F62 G1 G2 K6 K7 K9 K13 K19 M5 M6 S1 S9 S28 V3 X3 X10 X11 X18 X20 X23 X27 X30 X39


Monitor Controller (DSZ) Monitor Machine Controller (BCZ) Work Light Switch Back Light 5 Lights 20 A Fuse Windshield Wiper and Washer 10 A Fuse (marked WIPER) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Power On 5 A Fuse (marked POWER ON) Alternator 65 A Fuse Battery 45 A Fuse Wiper Motor Assembly Circuit Breaker Battery Battery Windshield Wiper Relay Work Light Relay Windshield Washer Relay Key Cut Relay Battery Relay Windshield Wiper Motor Windshield Washer Motor Key Switch Windshield Wiper and Washer Switch Window Switch Load Dump Relay Diode Cab Harness-to-Machine Harness 100-Pin Connector Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Monitor 12-Pin Connector C Monitor Controller 28-Pin Connector A Monitor Controller 12-Pin Connector C Cab Harness-to-Switch Connector 1 Cab Harness-to-Switch Connector 4 Cab Harness-to-Window Switch

The machine controller (BCZ) (A11) receives unswitched power at pin A4 of machine controller 8-pin connector A (X10) from information controller and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin B19 of the BCZ through key cut relay (K13) with the key switch (S1) in the ON position. Switched power is also supplied to windshield wiper relay (K6) and windshield washer relay (K9). The BCZ is grounded at pin A8 of machine controller 8-pin connector A. The windshield wiper and washer circuit has four modes of operation: Windshield wiper ON (continuous) Windshield wiper INT (intermittent) Windshield wiper OFF (park) Windshield washer Operation of the windshield wiper and washer circuit is controlled by signals from the BCZ and the state of the windshield wiper motor (M5) internal position status switch. Windshield Wiper Continuous Operation— When windshield wiper and washer switch (S9) is placed in the ON position, the BCZ grounds pin B9 at predetermined intervals. When pin B9 is grounded, the windshield wiper relay (K6) is energized. →NOTE: Window switch (S28) must be connected for windshield wiper to operate.

Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When windshield wiper relay is energized, pin L of the windshield wiper motor is grounded, and the windshield wiper motor operates. The windshield wiper motor drives a pitman arm assembly which moves the windshield wiper blade back and forth across the windshield. When the windshield wiper is operating the BCZ and monitor controller (DSZ) (A4) communicate through controller area <- Go to Section TOC





network (CAN). The DSZ sends a signal to the monitor (A10) which displays the operation of the windshield wiper and washer switch. For more information on CAN theory of operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Windshield Wiper Intermittent Operation— When windshield wiper and washer switch (S9) is placed in INT position, BCZ intermittently grounds pin B9. The monitor controller (DSZ) (A4) controls windshield wiper delay time. →NOTE: Window switch (S28) must be connected for windshield wiper to operate.

Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When windshield wiper relay is energized, pin L of the windshield wiper motor is grounded, and the windshield wiper motor operates. The windshield wiper motor drives a pitman arm assembly which moves the windshield wiper blade back and forth across the windshield. When the windshield wiper is operating, the BCZ and DSZ communicate through controller area network (CAN). The DSZ sends a signal to the monitor (A10) which displays the operation of the windshield wiper and washer switch. For more information on CAN theory of operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.). Windshield Wiper Park Operation— When windshield wiper and washer switch (S9) is turned to the OFF position, windshield wiper motor (M5) continues to run until a cam driven switch inside the windshield wiper assembly opens and removes power from the windshield wiper motor. The cam driven switch applies ground to the windshield wiper motor pin S, causing the motor to run until a cam in the pitman arm assembly moves the windshield wiper to the left side of the windshield into the park position. When the windshield wiper motor reaches the park position, ground is removed from motor pin S by the internal switch, and the windshield wiper motor stops. Windshield Washer Operation— When windshield wiper and washer switch (S9) is pressed, the BCZ grounds pin A5. When pin A5 is grounded the windshield washer relay (K9) is energized. Power is supplied to windshield washer motor (M6) from windshield wiper and washer 10 amp fuse (F2) through pins 3 and 5 of energized windshield washer relay. The windshield washer motor drives the pump to spray fluid from the windshield washer fluid reservoir onto the windshield. When the windshield wiper and washer switch is released, ground is removed from pin A5 of BCZ, and the washer motor stops.






Lighting Circuit Theory of Operation

Lighting Circuit Theory of Operation





LEGEND: A4 A10 A11 E1 E2 E3 E9 F1 F9 F10 F12 F17 F60 F61 G1 G2 K7 K8 K12 K13 K19 S1 S2 S10 S14 V3 V11 V12 V13 V14 X3 X10 X11 X18 X20 X23 X27 X29


Monitor Controller (DSZ) Monitor Machine Controller (BCZ) Work Light Boom Light Cab Dome Light Key Switch Light Work and Boom Lights 20 A Fuse (marked LAMP) Radio Backup 10 A Fuse (marked BACK UP) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Radio and Dome 5 A Fuse (marked RADIO) Power On 5 A Fuse (marked POWER ON) Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Work Light Relay Boom Light Relay Accessory Cut Relay Key Cut Relay Battery Relay Key Switch Cab Dome Light Switch Work Light Switch Door Switch Load Dump Relay Diode Accessory Cut Diode Starter Cut Diode Work Light 1 Diode Work Light 2 Diode Cab Harness-to-Machine Harness 100-Pin Connector Machine Controller 8-Pin Connector A Machine Controller 20-Pin Connector B Monitor 12-Pin Connector C Monitor Controller 28-Pin Connector A Monitor Controller 12-Pin Connector C Cab Harness-to-Switch Connector 1 Cab Harness-to-Switch Connector 3

The machine controller (BCZ) (A11) receives unswitched power at pin A4 of machine controller 8-pin connector A (X10) from data converter and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin B19 of the BCZ through key cut relay (K13) with the key switch (S1) in the ON position. The BCZ is grounded at pin A8 of machine controller 8pin connector A. Work Light Operation— Turning the work light switch (S10) to position 1 activates the work light (E1). When key switch (S1) is in the ON position, current from pin M of the key switch is ed to pin 3 of key cut relay (K13). Utilizing the normally closed s of key cut relay, power is ed through power on 5 A fuse (F17) to pin 1 of work light relay (K7). When work light switch is in position 1, ground is supplied to pin A6 through work light 1 diode (V13) and to pin B7 of machine controller 20-pin connector A (X10). Energizing work light relay, illuminates the work light. The BCZ communicates the work light switch position to the monitor controller (DSZ) (A4) via the controller area network (CAN). The DSZ then updates the monitor (A10) with the current work light operation. For more information on CAN theory of operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Boom Light Operation— Turning the work light switch (S10) to position 2 will activate the work light and boom light (E2). When key switch (S1) is in the ON position, current from pin M of the key switch is ed to pin 3 of key cut relay (K13). Utilizing the normally closed s of key cut relay, power is ed through power on 5 A fuse (F17) to pin 1 of work light relay (K7) and boom light relay (K8). When work light switch is in position 2, ground is supplied to pins A2 and A6 of machine controller 8-pin connector A (X10) through work light 2 diode (V14) and to pin B17 of machine controller 20-pin connector B (X11). This energizes the work light relay and boom light relay, illuminating the work light and boom light. The BCZ communicates the work light switch position to the monitor controller (DSZ) (A4) via the controller area network (CAN). The DSZ then updates the monitor (A10) with the current work light operation. For more information on CAN theory of <- Go to Section TOC





operation, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.) Cab Dome Light (E3) Continuous Operation— The cab dome light (E3) receives unswitched power through radio backup 10 A fuse (F9). While cab dome light switch (S2) is in the ON position, ground from pin B10 of the machine controller (BCZ) is supplied to the cab dome light, illuminating the cab dome light. Cab Dome Light (E3) Door Position Operation— The cab dome light (E3) and key switch light (E9) receive unswitched power through radio backup 10 A fuse (F9). While cab dome light switch (S2) is in the DOWN position, ground from pin A7 of the machine controller (BCZ) controls cab dome light and key switch light illumination. Door switch (S14) provides ground to pin B18 of the BCZ while the cab door is closed. While the BCZ detects ground at pin B18, no ground is provided to pin A7, thus the cab dome light and key switch light remain off. When the door of the cab is open, the door switch is disconnected from ground. With no ground detected from the door switch at pin B18, the BCZ provides ground to pin A7, illuminating the cab dome light and key switch light for 30 seconds. After 30 seconds the BCZ removes ground from pin A7 and the cab dome light and key switch light turn off.






Travel Alarm Circuit Theory of Operation

Travel Alarm Circuit Schematic (S.N. —040754) LEGEND: A3 B34 F5 H4 S13 X32 X35 X36


Main Controller (MCZ) Travel Pressure Sensor Travel Alarm 5 A Fuse (marked OPT. 1 ALT) Travel Alarm Travel Alarm Cancel Switch Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 24-Pin Connector E Cab Harness-to-Main Controller 26-Pin Connector F





Travel Alarm Circuit Schematic (S.N. 040755— ) LEGEND: A3 B34 F11 H4 S13 <- Go to Section TOC

Main Controller (MCZ) Travel Pressure Sensor Travel Alarm 5 A Fuse (marked TRAVEL ALARM) Travel Alarm Travel Alarm Cancel Switch Section 9015 page 241




The travel alarm circuit consists of: a travel pressure sensor (B34), main controller (MCZ) (A3), travel alarm (H4), and a travel alarm cancel switch (S13). The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the travel levers are moved. When the travel levers are moved, travel pressure sensor (B34) senses pilot pressure and sends a signal to the MCZ. When signal is received from travel pressure sensor, the MCZ provides access to ground to the travel alarm (H4) pin 1, activating the alarm. When pressed, the travel alarm cancel switch (S13) applies ground to pin 3 of the travel alarm (H4). The travel alarm cancel switch (S13) must be pressed and released in order to cancel the alarm. The travel alarm must sound for 13 seconds before the travel alarm cancel switch will deactivate it. When the control levers are returned to the neutral position, the travel alarm (H4) is reset.






Pilot Shutoff Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation Schematic





LEGEND: A1 A3 A4 F4 F18 F45 F60 F61 G1 G2 G3 K2 K4 K5 K13 K19 K34 K35 M1 S1 S3 S4 V1 V3 V4 V5 V7 V9 V10 V44 V20 X21 X22 X32 X33 X175 Y10


Engine Control Unit (ECU) Main Controller (MCZ) Monitor Controller (DSZ) Solenoid 20 A Fuse (marked SOLENOID) Idle Stop 5 A Fuse (marked IDLE STOP) Starter In-Lne 30 A Fuse Alternator 65 A Fuse Battery 45 A Fuse Battery Battery Alternator Pilot Shutoff Solenoid Relay Starter Cut Relay Security Relay Key Cut Relay Battery Relay Starter Relay Starter Protection Relay Starter Motor Key Switch Pilot Shutoff Switch 1 Pilot Shutoff Switch 2 Battery Relay Diode Load Dump Relay Diode Security Diode Starter Cut Relay Diode Start Relay Diode Pilot Shutoff Diode Starter Protection Diode Starter Relay Diode Pilot Shutoff Switch Diode Monitor Controller 36-Pin Connector B Monitor Controller 16-Pin Connector D Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Machine Harness-to-Starter Harness Connector Pilot Shutoff Solenoid

The pilot shutoff circuit enables or disables (unlocks or locks) the pilot oil thus enabling or disabling the machine hydraulics. The pilot shutoff circuit consists of the pilot shutoff switches 1 and 2 (S3 and S4), pilot shutoff switch diode (V20), pilot shutoff solenoid (Y10), pilot shutoff solenoid relay (K2), security relay (K5), monitor controller (DSZ) (A4), security diode (V4), and start relay diode (V7). With key switch (S1) in the ON position, current is applied from key switch pin M supplying key cut relay (K13) through idle stop 5 A fuse (F18). Utilizing the normally closed s of key cut relay, power is ed through pin 3 of key cut relay, next through load dump relay diode (V3), and to pin S of battery relay (K19), energizing the battery relay. Ground is provided to pin E of battery relay. When energized, the battery relay allows current to through alternator 65 A fuse (F60) providing power to pin B of alternator (G3). Power from pin B of alternator es through solenoid 20 A fuse (F4) to pilot shutoff solenoid relay (K2), security relay (K5), and pilot shutoff solenoid (Y10). When the pilot shutoff lever is moved to the unlocked (DOWN) position, pin 10 of monitor controller 36-pin connector B (X21) detects a ground though pilot shutoff switch diode (V20) indicating that both pilot shutoff switches are in the same position. This allows the monitor to diagnose if there is a malfunction with one of the switches. When the pilot shutoff lever is in the unlocked (DOWN) position, ground es through the pilot shutoff switches, through starter cut relay diode (V5) to pilot shutoff solenoid relay, energizing the relay. When pilot shutoff solenoid relay is excited, the ground circuit in pilot shutoff solenoid (Y10) is connected to ground through pilot shutoff solenoid relay and security relay (K5), thus energizing the solenoid allowing pressure oil from the pilot pump to be supplied to the pilot valve. When the pilot shutoff lever is in the unlocked (DOWN) position, ground is provided to the starter cut relay (K4) through starter cut relay diode (V5), energizing starter cut relay. When starter cut relay is energized, starter relay (K34) is de-energized, removing the start signal from starter motor (M1), preventing the engine from cranking. For more information on the neutral engine start circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.) With the pilot shutoff lever in the unlocked (DOWN) position, ground is also provided to pin 13 of cab harness-to-main controller 26-Pin connector F (X36) of the <- Go to Section TOC





main controller (MCZ) (A3), indicating the pilot shutoff lever is in the unlocked (DOWN) position. When the pilot shutoff lever is in the locked (UP) position, ground is not detected at pilot shutoff solenoid relay (K2). The relay remains de-energized thus, the pilot shutoff solenoid (Y10) is de-energized and the pilot hydraulics are disabled (locked). When the monitor security is active, pin 16 of monitor controller 16-pin connector D (X22) is grounded, energizing the starter cut relay (K4) and security relay (K5) through security diode (V4). Energized security relay removes ground to pilot shutoff solenoid relay (K2). When the pilot shutoff lever is in the unlocked (DOWN) position (pilot shutoff solenoid relay energized), the ground path to the pilot shutoff solenoid is broken, preventing the pilot hydraulics from being enabled (unlocked). This keeps the machine from being operated when the security system is active.






Attachment Control Circuit Theory of Operation

Attachment Control Circuit Schematic (S.N. —040754) LEGEND: A3 B60 B61 <- Go to Section TOC

Main Controller (MCZ) Attachment Pressure Sensor Arm Out Pressure Sensor Section 9015 page 246



F5 F60 V40 V41 V43 X31 X32 X33 X35 X36 X46 Y40 Y41 Y43 Y44



Travel Alarm 5 A Fuse (marked OPT. 1 ALT) Alternator 65 A Fuse Selector Valve Solenoid Valve Diode Secondary Relief Solenoid Valve Diode 2-Speed Activation Solenoid Valve Diode Cab Harness-to-Main Controller 31-Pin Connector A Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 24-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector E Attachment Connector Selector Valve Solenoid Valve Secondary Relief Solenoid Valve 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid





Attachment Control Circuit Schematic (S.N. 040755— ) LEGEND: A3 B32 B60 B61 F5

Main Controller (MCZ) Front Attachment Pressure Sensor (marked FRT) Attachment Pressure Sensor Arm Out Pressure Sensor Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT.)





F60 V40 V41 V42 V43 X32 X33 X34 X36 X46 X87 Y40 Y41 Y42 Y43 Y44


Alternator 65 A Fuse Selector Valve Solenoid Valve Diode Secondary Relief Solenoid Valve Diode Accumulator Solenoid Valve Diode 2-Speed Activation Solenoid Valve Diode Cab Harness-to-Main Controller 24-Pin Connector B Cab Harness-to-Main Controller 17-Pin Connector C Cab Harness-to-Main Controller 30-Pin Connector D Cab Harness-to-Main Controller 26-Pin Connector F Attachment Connector Attachment Harness-to-2-Speed Harness Connector Selector Valve Solenoid Valve Secondary Relief Solenoid Valve Accumulator Solenoid Valve 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid

The main controller (MCZ) (A3) and monitor allow for the selection of up to eleven attachments plus the standard bucket mode. Only one attachment mode may be selected at one time. The machine will return-to-bucket mode when the machine is powered down and restarted; however, this can be changed with MPDr, Service ADVISOR ™ , and the monitor to return the machine to the attachment that was last selected when the machine was powered down. Each attachment selection (1—11) can be customized using MPDr, Service ADVISOR™, and the monitor. To customize options in the monitor, see Service Menu . (Group 9015-16.) MPDr and Service ADVISOR™ can adjust: Attachment name Attachment number Pump flow Engine speed Secondary relief selection Return oil flow selection 2-speed selection The monitor can slightly adjust pump 2 flow rate or boom-up, arm-in, swing and travel priority over attachment flow depending on the options selected. To view the attachment specifications on the monitor, select an attachment from the work mode menu. The monitor will display: Attachment name (Breaker, Crusher, Pulverizer, Vibrating Hammer, Other) Attachment number (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11) Pump flow Engine speed Secondary relief selection (ON or OFF) Return oil flow selection (O/T or C/V) 2-speed selection (ON or OFF)






LEGEND: 1 Bucket Mode 2 ATT 1 (attachment 1) 3 ATT 2 (attachment 2) 4 ATT 3 (attachment 3) 5 ATT 4 (attachment 4) 6 Attachment Name 7 Attachment Number

Work Mode Screen Attachment Name— The available attachment names are as follows: Breaker 1—Hydraulic Breaker 1 (BR) Breaker 2—Hydraulic Breaker 2 (BR) Crusher 1—Primary Crusher 1 (CR) Pulverizer 1—Secondary Crusher 1 (PU) Vibratory Hammer 1—Vibrating Hammer 1 (VI) Other 1—Other Equipment (UN) [Removal from monitor screen—(Non)] Crusher 1—Primary Crusher 1 (CR) is considered a heavier crusher than Pulverizer 1—Secondary Crusher 1 (PU). When Crusher 1—Primary Crusher is selected, more priority is given to boom, arm, swing and travel functions over the attachment function in a combined arm-out, arm-out boom-up, swing or travel function and attachment function.






LEGEND: 8 ATT 1 Type (attachment 1)

Attachment Type Attachment Number— Each attachment can be assigned a number from 1-5. Each attachment also has a dynamic number that is defined to help differentiate attachments with the same name. For example, ATT 1 (attachment 1) and ATT 2 (attachment 2) could both be set up as breaker 1. The number associated with the attachment name can be changed to any number from 1 through 5. ATT 2 (attachment 2) breaker 1 could be changed to ATT 2 (attachment 2) breaker 2 (3, 4, or 5) to distinguish between the beakers for ATT 1 (attachment 1) and ATT 2 (attachment 2). LEGEND: 9 ATT 1 Pump 1 Maximum Flow Rate






Attachment Adjustment—Pump Flow Rate Maximum Pump Flow— The maximum pump flow can be adjusted using MPDr, Service ADVISOR™, and the monitor. Adjustments made to pump flow are only approximate values. The machine is not designed to measure pump flow and therefore the values in MPDr, Service ADVISOR™, and the monitor are calculated approximations. Actual flow must be measured using a flowmeter to accurately adjust pump flow. See Pump Flow Test . (Group 9025-25.) Pump 1 and pump 2 flow rates can be adjusted individually. If 2-speed is not selected (OFF), only pump 2 is used to run the attachment. In this mode, only adjustments to pump 2 will affect the flow to the attachment. Pump 2 flow rate adjustments are controlled by the main controller (MCZ) with the pump 2 flow rate limit solenoid. For more information, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) If 2-speed is selected (ON), both pumps 1 and 2 are used to run the attachment. With 2-speed ON, flow from pump 1 is combined with flow from pump 2 in the control valve. In this mode, both pumps may be adjusted to control the flow of the attachment. The monitor will display the combined flow rates of pump 1 and pump 2. See Service Menu . (Group 9015-16.) →NOTE: The 2-speed will not work properly unless appropriate kits are installed on machine.

Pump flow or flow priority may also be finely adjusted in the monitor. If 2-speed is not selected (OFF), small adjustments can be made to the pump 2 flow rate. Adjustments are only approximate and relative to the overall selected flow. Actual flow must be measured using a flowmeter to accurately set pump flow. If 2-speed is selected (ON), small adjustments can be made to the priority of oil flow. The priority can be adjusted to favor the attachment or the boom-up, arm-out, swing and travel functions. Adjustments are only approximate and relative to the overall selected flow. Actual flow must be measured using a flow meter to accurately set pump flow. See Pump Flow Test (Group 9025-25.) See Service Menu . (Group 9015-16.) LEGEND: 10

ATT 1 Engine Speed

ATT 1 Engine Speed Maximum Engine Speed— The maximum engine speed for an attachment may be adjusted using MPDr, Service ADVISOR™, and the monitor. The engine will reduce speed when a work mode with reduced engine speed is selected on the monitor. The engine will run at the preset speed regardless if the attachment is operated or not. The maximum engine speed for an attachment cannot be set higher than the fast idle speed of the machine.






LEGEND: 12 ATT 1 Selector Valve Setting

ATT 1 Selector Valve

→NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.

Valve Selector (Selector Valve)— The selector valve icon on the monitor controls the selector valve solenoid valve (Y40). The selector valve solenoid valve receives power from the optional and attachment connector 5 A fuse (F5) and is grounded by the main controller (MCZ) by pin C4. When the monitor displays “0,” the return oil from the attachment flows through the control valve before it returns to the hydraulic oil tank. When the monitor displays “1,” the return oil from the attachment flows directly to the hydraulic oil tank, bying the control valve. The selector valve solenoid valve can be adjusted for each attachment using MPDr, Service ADVISOR™, and the monitor. The valve selector will default to “0” or control valve in bucket mode (no attachment selected). The selector valve solenoid valve diode (V40) suppresses voltage spikes created when the solenoid valve is activated or deactivated. →NOTE: Accumulator control will not work properly unless appropriate kits are installed on machine.

Accumulator— The accumulator controls the accumulator solenoid valve (Y42). The accumulator solenoid valve is powered by the optional and attachment connector 5 A fuse (F5) and grounded by the main controller (MCZ) by pin C17. When the accumulator is ON, the accumulator solenoid valve is activated, pilot oil is sent to the accumulator control valve. The accumulator shutoff valve shifts, connecting the accumulators to the supply and return lines of the attachment hydraulic circuit. The accumulators help reduce the shock of oil pressure and buffers vibrations when certain types of attachments are used, such as breakers. When the accumulator is OFF, the accumulator solenoid valve is deactivated and the accumulators are isolated from the attachment hydraulic oil circuit. The accumulator status for each attachment can be adjusted using MPDr, Service ADVISOR™, and the monitor. The accumulator solenoid valve diode (V42) suppresses voltage spikes created when the solenoid valve is activated or <- Go to Section TOC





deactivated. LEGEND: 13 ATT 1 Auxiliary Flow Combiner Valve Setting

ATT 1 Auxiliary Flow Combiner Valve

→NOTE: The 2-speed control will not work properly unless appropriate kits are installed on machine.

2-Speed Selector and Auxiliary Flow Combiner Valve— The 2-speed selector icon on the monitor controls the 2-speed activation solenoid valve (Y43). The 2-speed activation solenoid valve is powered by optional and attachment connector 5 A fuse (F5) and grounded by the main controller (MCZ) pin C3. The flow rate adjustment solenoid valve (Y44) is powered by MCZ pin B12 and grounded by pin B11. When activated, the 2-speed activation solenoid valve sends pilot oil to the by shutoff valve blocking hydraulic oil from pump 1 from returning to the hydraulic oil tank. The activated 2-speed activation solenoid valve also sends pilot oil to the auxiliary flow combiner valve to combine oil flow from pump 1 with that of pump 2. This allows for combined oil flow from pump 1 and pump 2 to operate the attachment. When 2-speed is activated, the flow rate adjustment solenoid valve can also be activated. When an arm-out, boom-up, swing or travel function is actuated in combination with the attachment function, the flow rate adjustment solenoid valve is activated. When the flow rate adjustment solenoid valve is activated, pilot oil is routed to the auxiliary flow rate control valve. This adjusts the auxiliary flow rate control valve to provide more or less priority to the arm-out, boom-up, swing and travel functions over the attachment function. The main controller (MCZ) can vary the signal to the flow rate adjustment solenoid valve to vary the pilot oil pressure at the auxiliary flow rate control valve. This allows for adjustment of the priority of the attachment function over arm-out, boom-up, swing and travel. The 2-speed selector status can be adjusted for each attachment using MPDr, Service ADVISOR™, and the monitor. Adjustments to the priority level can be made in the monitor in the attachment adjustment menu. See Service Menu . (Group 9015-16.) The 2-speed activation solenoid valve diode (V43) suppresses voltage spikes created when the solenoid valve is energized and de-energized.





Group 16: Monitor Operation

LEGEND: 11

ATT 1 Relief Valve Setting

ATT 1 Relief Valve Secondary Hydraulic Relief Selector— The secondary hydraulic relief selector icon in the monitor controls the secondary relief solenoid valve (Y41). The secondary relief solenoid valve receives power from the optional and attachment connector 5 A fuse (F5) and is grounded by the main controller (MCZ) pin C16. When the secondary relief solenoid valve is activated, pilot oil shifts the secondary relief shutoff valve, routing hydraulic oil from the high pressure lines of the attachment to the secondary relief valve. The relief pressure of the circuit will then be equal to the lowest setting of the two relief valves in the circuit. The secondary hydraulic relief selector status can be adjusted for each attachment using MPDr, Service ADVISOR™, and the monitor. The secondary relief solenoid valve diode (V41) suppresses voltage spikes created when the solenoid valve is energized and de-energized.






Group 16 - Monitor Operation Service Menu How to Display Service Menu [1] LEGEND: 1 2 3 4 5

Key Pad Key Switch BACK Button HOME Button Monitor Dial

Right Console Turn key switch (2) on and wait until the default screen appears on the monitor. [2] - Hold the number nine key on the key pad (1) and press the monitor dial (5). [3] - The service menu option will now be displayed at the bottom of the main menu. [4] - Rotate monitor dial and highlight service menu. Press monitor dial to access to the following systems: 1. 2. 3. 4. 5. 6. 7.

Troubleshooting Monitoring Controller Version Issued Warning Record Operation Machine Setting Monitor Setting

[5] - Use the BACK button (3) to return to the service menu.

Troubleshooting [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight troubleshooting. Press monitor dial to enter the troubleshooting menu. [3] - Rotate monitor dial to highlight the following systems. Engine <- Go to Section TOC





Main Monitor Information Air Conditioner Press monitor dial to view the trouble codes for systems. [4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)






Monitoring →NOTE: Items listed in the monitoring section may not be in the same order as the monitor on the machine.

[1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight monitoring. Press monitor dial to enter the monitoring menu. [3] - Rotate monitor dial to highlight a system in the monitoring selections: Engine Main Wiper/Light Air Conditioner Start Clear (Hold) [4] - Press the monitor dial to select the monitoring item to be viewed in the “Start” monitoring system. List of Engine Monitoring Items List of Engine Monitoring Items Item

Unit

Data

Engine Torque

%

Input signal from ECU -1

Actual Engine Speed

min

Input signal from crank speed sensor and cam angle sensor

Boost Pressure

kPa

Input signal from boost pressure signal

Coolant Temperature

°C

Input signal from coolant temperature sensor

Fuel Temperature

°C

Input signal from fuel temperature sensor

Engine Oil Pressure

kPa

Input signal from oil pressure sensor

Boost Temperature

°C

Input signal from boost temperature sensor

Battery Voltage

V

Input signal from ECU

Coolant Temp (Meter)

°C

Input signal from coolant temperature sensor (coolant temperature gauge)

List of Main Controller Monitoring Items List of Main Controller Monitoring Items Item

Unit

Data

min

-1

Input signal from engine control dial

min

-1

Input signal from ECU

Engine Speed Deviation

min

-1

Difference between actual engine speed and requested engine speed

EC Dial

V

Input signal from engine control dial


°C

Input signal from hydraulic oil temperature sensor

Hydraulic Oil Temperature (Pilot) ° C

Input signal from hydraulic oil temperature sensor

Tgt Pump 1 Flow Rate

L

Command signal to maximum pump 1 flow rate limit control solenoid valve

Tgt Pump 2 Flow Rate

L

Demand Engine Speed Actual Engine Speed

Command signal to maximum pump 2 flow rate limit control solenoid valve

cm

3

Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor

Tgt Pump 2 Displacement

cm

3


Pump 1 Load Factor

%


Pump 2 Load Factor

%


Tgt Pump 1 Displacement






List of Main Controller Monitoring Items Item

Unit

Data

Pump 1 Delivery Pressure

MPa

Input signal from pump 1 delivery pressure sensor

Pump 2 Delivery Pressure

MPa

Input signal from pump 2 delivery pressure sensor

ADD Pump Delivery Press*

MPa

Input signal from ADD pump delivery pressure sensor

Pump 1 Control Pressure

MPa

Input signal from pump 1 control pressure

Pump 2 Control Pressure

MPa

Input signal from pump 2 control pressure

Boom Cyl. Bottom Press*

MPa

Input signal from pressure sensor (bottom pressure)

Boom Cyl. Rod Pressure*

MPa

Input signal from pressure signal (rod pressure)

Boom Raise Pilot Pressure

MPa

Input signal from pressure sensor (boom raise)

Arm Roll-In Pilot Pressure

MPa

Input signal from pressure sensor (arm roll-in)

Bucket Roll-In Pilot Pressure

MPa

Input signal from pressure sensor (front)

Travel Pilot Pressure

MPa

Input signal from pressure sensor (travel)

Front ATT Pilot Pressure

MPa

Input signal from pressure sensor (front)

Swing Pilot Pressure

MPa

Input signal from pressure sensor (swing)

ATT 1 Pilot Pressure*

MPa

Input from pressure sensor (auxiliary 1)

ATT 2 Pilot Pressure*

MPa

Input from pressure sensor (auxiliary 2)

Arm Roll-Out Pilot Pressure*

MPa

Input from pressure sensor (arm roll-out)

Pumps 1&2 Torque P/S O/P

MPa

Control signal to pump 1 and 2 torque control solenoid valve

Pump 2 Flw Limit P/S Output

MPa

Control signal to maximum pump 2 flow rate limit control solenoid valve

Arm Regen P/S Output

MPA

Control signal to four spool solenoid valve unit (SC) output

Pressure Boost P/S Output

MPa

-

Digging Regen P/S O/P

MPa

Control signal to four spool solenoid valve unit (SF)

Pump 1 Flw Limit P/S Output

MPa

Control signal to maximum pump 1 flow rate limit control solenoid

Analog Output 14

MPa

-

Analog Output 15

MPa

-

Analog Output 16

MPa

-

Auxil Flw Cont P/S Output

MPa

Control signal to auxiliary flow rate control solenoid valve

Brk Relief P/S Output*

MPa

-

Power Digging P/S Output

MPa

Control signal to four spool solenoid valve unit (SG)

Travel Mode P/S Output

MPa

Control signal to four spool solenoid valve unit (SI)

Pumps 1&2 Torque P/S O/P FB

mA

from pump 1 and 2 torque control solenoid valve output

Pump 2 Flw Limit P/S O/P FB

mA

from maximum pump 2 flow rate limit control solenoid valve output

Arm 2 Flw Cont P/S O/P FB

mA

-

Arm Regen P/S Output FB

mA

from four spool solenoid valve unit (SC) output

Pressure Boost P/S Output FB

mA

-

Digging Regen P/S O/P FB

mA

from four spool solenoid valve unit (SF) output

Arm 1 Flw Cont P/S O/P FB

mA

-

Pump 1 Flw Limit P/S O/P FB

mA

from maximum pump 1 flow rate limit control solenoid valve output

Analog Output FB 14

mA

-

Analog Output FB 15

mA

-

Analog Output FB 16

mA

-

Auxil Flw Cont P/S O/P FB

mA

from auxiliary flow rate control solenoid valve output

Digital Input 7

OFF/ON -

PCSL Lever Switch

OFF/ON Pilot shut-off switch ON/OFF status

Breaker Control Switch

OFF/ON -

Power Boost Switch

OFF/ON Power digging switch ON/OFF status

Engine Oil Level Switch

OFF/ON Engine oil level switch ON/OFF status

Power Mode Button

OFF/ON Power mode button operating status






List of Main Controller Monitoring Items Item

Unit

Data

Travel Mode SW

LO/HI

Travel mode switch selection status

Auto-Idle Stop Switch

OFF/ON Auto-idle switch ON/OFF status

Digital Input 15

OFF/ON -

Digital Input 14

OFF/ON -

Digital Input 13

OFF/ON -

Digital Input 12

OFF/ON -

Digital Input 8

OFF/ON -

Digital Input 23

OFF/ON -

Digital Input 22

OFF/ON -

Digital Input 21

OFF/ON -

Digital Input 20

OFF/ON -

Digital Input 19

OFF/ON -

Digital Input 18

OFF/ON -

Digital Input 17

OFF/ON -

Line Filter Restriction SW*

OFF/ON Clogged line filter status

Digital Input 29

OFF/ON -

Digital Input 28

OFF/ON -

Digital Input 27

OFF/ON -

Digital Input 26

OFF/ON -

Digital Input 25

OFF/ON -

Digital Input 24

OFF/ON -

Swing Alarm

OFF/ON Swing Alarm ON/OFF status

Travel Alarm

OFF/ON Travel alarm ON/OFF status

Auto-Idle Stop Relay

OFF/ON Auto-idle stop relay ON/OFF status

3-Port Valve

OFF/ON Three Port valve ON/OFF Status

2-speed Combined Flow*

OFF/ON Two Speed combined flow control valve ON/OFF status

ON/OFF Valve Output 11

OFF/ON -


OFF/ON -


OFF/ON -

→NOTE: *: Optional

List of Wiper/Light Controller Monitoring Items List of Wiper/Light Controller Monitoring Items Item

Unit

Data

Wiper 1 Input

V

Input signal from wiper switch

Wiper 2 Input

V

Input signal from wiper switch

Washer 1 Switch

OFF/ON

Washer 1 switch ON/OFF status

Washer 2 Switch

OFF/ON

Washer 2 switch ON/OFF status

Work Light 1 Switch

OFF/ON

Work light switch 1 ON/OFF status

Work Light 2 Switch

OFF/ON

Work light switch 2 ON/OFF status

Cab Light Switch

OFF/ON

Cab light switch ON/OFF status

Wiper 1 Output

OFF/ON

Wiper relay ON/OFF status

Wiper 2 Output

OFF/ON

Wiper relay ON/OFF status

Washer 1 Output

OFF/ON

Washer relay ON/OFF status






List of Wiper/Light Controller Monitoring Items Item

Unit

Data

Washer 2 Output

OFF/ON

Washer relay ON/OFF status

Work Light 1 Output

OFF/ON

Work light relay 1 ON/OFF status

Work light 2 Output

OFF/ON

Work light relay 2 ON/OFF status

Cab Light 1 Output

OFF/ON

Cab light ON/OFF status

Cab Light 2 Output

OFF/ON

Cab light ON/OFF status

List of Air Conditioner Unit Monitoring Items List of Air Conditioner Unit Monitoring Items Item

Unit

Data

Compressor Operation

OFF/ON

Compressor operating status

Outdoor Air Temperature

°C

Input signal from ambient temperature sensor

Indoor Air Temperature

°C

Amount of Insolation

W/m

Input signal from air conditioner unit 2

Input signal from solar radiation sensor

[5] - Rotate monitor dial to highlight Start. Press the monitor dial to view the monitoring items that were selected. [6] - Rotate monitor dial to highlight Clear (Hold). Press the monitor dial to delete the monitoring items that were selected. [7] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

Controller Version [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight controller version. Press monitor dial to enter the controller version menu. [3] - The version of each controller will appear. [4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)

Issued Warning Record [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight issued warning record. Press monitor dial to enter the issued warning record menu. [3] - The logo and trouble of 10 alarms that were issued recently will be displayed. See Main Menu—Alarm List . (Operator′s Manual.) [4] - Highlight alarm and press monitor dial to view the time of when the alarm occurred and was solved. [5] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)






Operation [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight operation. Press monitor dial to enter operation menu. [3] - The hour meters will be displayed. Hour Meters Hour Meters Hour Meter (Integral Pert)

hr.

Hour Meter (Decimal Part)

hr.

Brk Hr-Meter (Int Part)

hr.

Brk Hr-Meter (Decimal Part)

hr.

ATT Hr-Meter (Int Part)

hr.

ATT Hr-Meter (Dec Part)

hr.

Travel Hr-Meter (Int Part)

hr.

Travel Hr-Meter (Dec Part)

hr.

Task Hr-Meter (Int Part)

hr.

Task Hr-Meter (Dec Part)

hr.

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)






Machine Setting [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight machine setting. Press monitor dial to enter machine setting menu. [3] - Rotate monitor dial to highlight a setting in the machine setting selections. Press monitor dial to change machine setting. List of Machine Setting Items (Constant Change) List of Machine Setting Items (Constant Change) Item Li Speed Al Speed PWR Mode Speed

Unit

Data

min

-1

Adjustment of slow idle speed.

min

-1

Adjustment of auto-idle engine speed.

min

-1

Adjustment of PWR mode fast idle engine speed.

Power Mode Memory Selection

0, 1

Setting of power mode with key switch on. 0: OFF (In case power mode is H/P mode with the key switch OFF, PWR mode is selected when turning the key switch on. In case power mode is ECO or PWR mode with the key switch OFF, ECO or PWR mode is kept when turning the key switch on.) 1: On (The power mode when turning the key switch OFF is kept.)

Heater Control Selection

0, 1

ON/OFF of heater control. 0: OFF 1: ON

Work Mode Memory Selection

0, 1

ON/OFF of attachment mode. 0: OFF 1: ON

Power Mode Selection

0—4

Setting of power mode selection. 0: ECO, PWR mode: Selected 1: ECO mode: Fixed 2: PWR mode: Fixed 3: ECO, PWR, H/P mode: Selected 4: H/P mode: Fixed

Auto Shut-Down Control

0—2

Setting of auto shut-down control with the key switch ON. 0: OFF when starting 1: ON when starting 2: Previous setting is held

Auto Shut-Down Set Time Holding

0, 1

The time until starting shut down control is held. 0: Settable 1: Unsettable

0—10

Selection of air conditioner specification. 0: Unused (without an air conditioner) 1: STD Cab (middle) (with an air conditioner) 2: STD Cab (middle) (without an air conditioner) 3: STD Cab (large) (with an air conditioner) 4: STD Cab (large) (without an air conditioner) 5: US Cab (7 t class) (with an air conditioner) 6: US Cab (7 t class) (without an air conditioner) 7: US Cab (10 t class) (with an air conditioner) 8: US Cab (10 t class) (without an air conditioner) 9: US Cab (20 t class) (with an air conditioner) 10: US Cab (20 t class) (without an air conditioner)

Air Conditioner Control Mode

ATT Speed Deceleration Waiting Time ms

The time when the increased engine speed is held at attachment operation speed increased control.

List of Setting Item (Attachment Constant Change) List of Setting Item (Attachment Constant Change) Item

ATT 1 Type


Unit

Data

0—7

Kinds of attachments: 0: Unset 1: Breaker 2: Pulverizer 3: Crusher 4: Vibrating Hammer 5: Others 6: Grapple 7: Clamshell





List of Setting Item (Attachment Constant Change) Item

Unit

Data

ATT1 No.

1—5

Selection of attachments setting No. 1: 1 2: 2 3: 3 4: 4 5: 5

ATT1 Pump 1 Maximum Flow Rate

L/min

Adjustment of maximum pump 1 flow rate when using attachment.


L/min



L/min


ATT1 Engine Speed

min

-1

Adjustment of engine speed when using attachment.

ATT1 Relief Valve (OPT)

0—2

Selection of breaker relief solenoid valve, auxiliary overload relief solenoid valve. 0: Both are disabled 1: ATT relief is enabled 2: Breaker relief is enabled

ATT1 Selector Valve (OPT)

0, 1

Selection of return circuit connection of selector valve. 0: C/V 1: O/T

ATT1 Auxiliary Flow Combiner Valve

0, 1

Setting of auxilliary flow combiner valve selection. 0: OFF 1: ON

List of Adjustment (Attachment Constant Change) List of Adjustment (Attachment Constant Change) ATT1 Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT1 Type

0—7

-

0—7

1

ATT1 No.

1—5

-

1—5

1


L/min

0.5

112—224

224


L/min

0.5

112—224

224

10

-500—100

0

-1

ATT1 Engine Speed

min


0—2

-

0—2

0


0, 1

-

0, 1

1

ATT1 Auxiliary Flow Combiner Valve (OPT)

0, 1

-

0, 1

0

Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT2 Type

0—7

-

0—7

1

ATT2 No.

1—5

-

1—5

2


L/min

0.5

112—224

224


L/min

0.5

112—224

224

10

-500—100

0

List of Adjustment (Attachment Constant Change) List of Adjustment (Attachment Constant Change) ATT2

-1

ATT2 Engine Speed

min


0—2

-

0—2

0


0, 1

-

0, 1

1


0, 1

-

0, 1

0

Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT3 Type

0—7

-

0—7

2

ATT3 No.

1—5

-

1—5

1


L/min

0.5

112—224

224







List of Adjustment (Attachment Constant Change) ATT3 Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value


L/min

0.5

112—224

224

10

-500—100

0

-1

ATT3 Engine Speed

min


0—2

-

0—2

1


0, 1

-

0, 1

0


0, 1

-

0, 1

1

Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT4 Type

0—7

-

0—7

3

ATT4 No.

1—5

-

1—5

1


L/min

0.5

112—224

224


L/min

0.5

112—224

224

10

-500—100

0


-1

ATT4 Engine Speed

min


0—2

-

0—2

1


0, 1

-

0, 1

0


0, 1

-

0, 1

1

Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT5 Type

0—7

-

0—7

6

ATT5 No.

1—5

-

1—5

1


L/min

0.5

112—224

224


L/min

0.5

112—224

224

10

-500—100

0


-1

ATT5 Engine Speed

min


0—2

-

0—2

1


0, 1

-

0, 1

0


0, 1

-

0, 1

0

List of Adjustment (Attachment Constant Change) List of Adjustment (Attachment Constant Change) ATT6—11 Item

Unit

Minimum Adjustment

Adjustable Range

Initial Value

ATT6—11 Type

0—7

-

0—7

0

ATT6—11 No.

1—5

-

1—5

0

ATT6—11 Pump 1 Maximum Flow Rate

L/min

0.5

112—224

224

ATT6—11 Pump 2 Maximum Flow Rate

L/min

0.5

112—224

224

10

-500—100

0

-1

ATT6—11 Engine Speed

min

ATT6—11 Relief Valve (OPT)

0—2

-

0—2

1

ATT6—11 Selector Valve (OPT)

0, 1

-

0, 1

0

ATT6—11 Auxiliary Flow Combiner Valve (OPT)

0, 1

-

0, 1

0






Monitor Setting [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight monitor setting. Press monitor dial to enter monitor setting menu. [3] - Rotate monitor dial to highlight a setting in the monitor setting selections. Press monitor dial to change monitor setting. List of Monitor Setting Items List of Monitor Setting Items Item

Unit

Details

Initial Value

Start Up Screen Image

0: System Starting 1: HITACHI 2: John Deere 3: System Starting (Fixed) 4: REC

-

1

Startup Screen Control

0: Auto-control: OFF 1: Auto-control: ON

-

1

Work Mode

0: Void 1: Exist

With or without function

1

Setting Menu

0: Void 1: Exist


1

Date and Time

0: Void 1: Exist


1

Attachment Adjust

0: Void 1: Exist


1

Attachment Name Input

0: Void 1: Exist


1

Breaker Alarm

0: Void 1: Exist


1

Auto Shut-down

0: Void 1: Exist


1

Sub Meter Selection

0: Void 1: Exist


1

Rear View Camera Monitor

0: Void 1: Exist


0

Display Item Selection

0: Void 1: Exist


1

Brightness Adjustment

0: Void 1: Exist


1

Language

0: Void 1: Exist


1

Unit Selection

0: Void 1: Exist


1

Main Menu Sequence Change

0: Void 1: Exist


1

Information Menu

0: Void 1: Exist


1

Operation

0: Void 1: Exist


1

Maintenance

0: Void 1: Exist


1

Operation Permission

0: Inhibited 1: Permission

-

1

Engine Oil

0: Un-displayed 1:0 Permission

Display

1

Engine Oil Filter


Display

1

Hydraulic Oil


Display

1





Group 20: References

List of Monitor Setting Items Item

Unit

Details

Initial Value

Pilot Hydraulic Oil Filter


Display

1

Hydraulic Oil Full-Flow Filter


Display

1

Pump Transmission Oil


Display

1

Travel Reduction Gear Oil


Display

1

Swing Reduction Gear Oil


Display

1

Swing Motor Drain Filter


Display

1

Swing Bearing Grease


Display

1

Air Cleaner Element


Display

1

Fuel Filter


Display

1

Air Conditioner Filter


Display

1

Line Filter


Display

1

Setting 1


Display

1

setting 2


Display

1

Troubleshooting

0: Void 1: Exist


1

Monitoring

0: Void 1: Exist


1

[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)






Group 20 - References Reading Diagnostic Trouble Codes with Monitor Display [1] - Access service menu. See Service Menu . (Group 9015-16.) [2] - Rotate monitor dial to highlight troubleshooting. Press monitor dial to enter the troubleshooting menu. [3] →NOTE: The monitor can display up to 20 diagnostic trouble codes for each controller.

The amount of currently generated diagnostic trouble codes (DTC) are displayed at the right side of each item in parenthesis. Rotate monitor dial to highlight the following systems: Engine (00) Main (00) Monitor (00) Information (00) Air Conditioner (00) [4] - Press monitor dial to view the trouble codes present for the highlighted system. For more information on the displayed DTCs see: See Main Controller (MCZ) Diagnostic Trouble Codes . (Group 9001-10.) See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.) See Monitor Controller (DSZ) Diagnostic Trouble Codes . (Group 9001-30.) See Air Conditioner Controller (ACF) Diagnostic Trouble Codes . (Group 9001-40.) [5] - Use the BACK button to return to the troubleshooting screen and select another system.

Service ADVISOR™ Diagnostic Application The Service ADVISOR ™ application is what technicians use to diagnose and troubleshoot equipment. The application allows technicians to quickly and easily find information and solve equipment problems. The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program controllers, when possible. The Connection-Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program controllers. With a connection established, the Readings menu allows a technician to add or remove a reading, set a readings baseline, and create and check recording triggers. With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code often are in a procedural format with links so the technician can work to correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code details. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)






Service ADVISOR™ Connection Procedure (S.N. —040754) [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated. [3] LEGEND: 1 Diagnostic Connector 2 Service Laptop 3 PDM-to-Service Laptop Cable 4 PDM 5 PDM-to-Machine Cable

Service ADVISOR™ Machine Connection Open left-side compartment behind cab and remove cap from diagnostic connector (1). [4] - Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include: Electronic Data Link (EDL) Stand-Alone USB Device EDL Using Bluetooth ™ Parallel Data Module (PDM) PDM with USB Adaptor [5] - Make sure power indicator light displays on EDL or PDM, depending on connection method. If power indicator light does not display, check fuse to diagnostic connector. [6] - Turn machine key switch to ON position. [7] - Refer to Service ADVISOR ™ system instructions to to service laptop and connect to machine. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

(S.N. 040755— ) [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated. [3] -






LEGEND: 1 Diagnostic Connector 2 Service Laptop 3 PDM-to-Service Laptop Cable 4 PDM 5 PDM-to-Machine Cable

Service ADVISOR™ Machine Connection Remove fuse box cover. [4] - Remove cap from diagnostic connector (1). [5] - Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include: Electronic Data Link (EDL) Stand-Alone USB Device EDL Using Bluetooth ™ Parallel Data Module (PDM) PDM with USB Adaptor [6] - Make sure power indicator light displays on EDL or PDM, depending on connection method. If power indicator light does not display, check fuse to diagnostic connector. [7] - Turn machine key switch to ON position. [8] - Refer to Service ADVISOR ™ system instructions to to service laptop and connect to machine. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)






Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Service ADVISOR™—Diagnostic Trouble Codes LEGEND: 1 2 3 4

Diagnostics Shortcut Bar Connected Diagnostic Trouble Codes Folder Readings Tab Connected Diagnostic Trouble Codes Tab

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Connect service laptop to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) [3] - Open Service ADVISOR ™ and display appropriate model information. [4] - From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1). [5] - Click the Connected Diagnostic Trouble Codes folder (2). [6] -






Connection Options Dialog Box Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK. [7] -

Select Readings Adapter Dialog Box LEGEND: 5 Available Adaptors Drop-Down List 6 Selected Models List 7 Change Selected Models Button On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not, select correct adapter from drop-down list (5). Options include: Electronic Data Link (EDL) Stand-alone USB Device Electronic Data Link (EDL) Using Bluetooth ™ Parallel Data Module (PDM) Parallel Data Module (PDM) With USB Adapter [8] - Make sure to select the correct machine to connect to, shown in the Selected Models list (6) display list. If not, click the Change Selected Models button (7). [9] - Click OK to connect to machine. [10] - After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab (4) display.






[11] - Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for servicing that diagnostic trouble code. [12] →NOTE: Use the lock topic feature within Service ADVISOR to open multiple windows if machine is transmitting more than one diagnostic trouble code. Refer to Service ADVISOR system instructions for using this feature.

Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.

MPDr Application MPDr is an application that helps technicians diagnose and troubleshoot machines. MPDr provides access to machine diagnostic trouble codes, their descriptions and limited troubleshooting procedures. MPDr can also display and record live readings for the different controllers on the machine. Special functions in certain controllers may also be manipulated with MPDr. The special functions available to manipulate vary by controller and by machine model. MPDr is also used to set up some controllers after a controller has been replaced or after other work has been performed on the machine regarding a controller. For more information, see MPDr Operation Manual.






MPDr Connection Procedure [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated. [3] LEGEND: 1

Cover

Fuse Box Cover Remove fuse box cover (1). [4] →NOTE: If the service laptop is not equipped with a serial COM port, a USB-to-serial adapter cable will be required to simulate a COM port for use with MPDr.

LEGEND: 2 MPDr Connector 3 Service Laptop 4 TH3100010 MPDr Cable 5 4668565 RS232C Cable 6 USB-to-Serial Adapter Cable

MPDr Connection Procedure (USB-to-serial adapter cable shown) Connect service laptop (3) to MPDr connector (2) using TH3100010 MPDr Cable (4), 4668565 RS232C Cable (5), and USB-toserial adapter cable (6) if needed. MPDr Cable <- Go to Section TOC





TH3100010 Provide connection from machine to RS232C cable for use with MPDr RS232C Cable 4668565 Provide connection from MPDr cable to computer for use with MPDr [5] - Turn machine key switch to the ON position. [6] - Refer to the MPDr Operation Manual to complete connection procedure.






Fuse Test Fuse Test (S.N. —040754)


Work and Boom Lights 20 A Fuse (marked LAMP) Windshield Wiper and Washer 10 A Fuse (marked WIPER) Air Conditioner and Heater 20 A Fuse (marked HEATER) Solenoid 20 A Fuse (marked SOLENOID) Travel Alarm 5 A Fuse (marked OPT. 1 ALT) 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) Start Position Signal 5 A Fuse (marked START) Engine Control Unit (ECU) 30 A Fuse (marked ECU) Radio Backup 10 A Fuse (marked BACK UP) Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) Not Used Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Monitor 5 A Fuse (marked MONITOR) Cab Auxiliary Power Connector One 10 A Fuse (marked AUX) Start Aid 20 A Fuse (marked START AID) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Horn 10 A Fuse (marked HORN) Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Some symptoms may indicate an expensive component malfunction, when in fact a fuse has malfunctioned. Machine functions can be performed without test equipment to determine if fuses have malfunctioned. If certain circuits or components operate, fuses are considered to be OK.






Fuse Test Fuse Test Fuse

Test

Results of Fuse Malfunction

F1—Work and Boom Lights 20 A Fuse (marked LAMP)

Turn key switch ON. Turn light switch to first or second position. If work or boom lights operate, fuse is OK.

Work and boom lights will not operate.

F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER)

Turn key switch ON. Turn windshield wiper ON. If wiper operates, fuse is OK.

Windshield wiper will not operate.

F3—Air Conditioner and Heater 20 A Fuse (marked HEATER)

Turn key switch ON. Press blower speed switch. If blower operates in any speed, fuse is OK.

Heater or air conditioner blower will not operate.

F4—Solenoid 20 A Fuse (marked SOLENOID)

If hydraulic system functions normally, fuse is OK.

Travel and stick functions will not operate.

F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT)

Turn key switch to START. Place pilot shutoff lever to unlocked (DOWN) position. Push travel pedals or levers forward. If travel alarm sounds, fuse is OK.

Travel alarm will not operate.

F6—12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)

Check with multimeter.

12 volt power outlet will not operate.

F7—Start Position Signal 5 A Fuse (marked START)

If start aid works, fuse is OK.

Engine starts hard when cold. Start aid will not operate.

F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU)

Turn key switch to START. If engine starts and display lights, fuse is OK.

Display will not light and engine will not start.

F9—Radio Backup 10 A Fuse (marked BACK UP)

Turn key switch to ON. If radio presets are retained, fuse is OK.

Radio will not retain presets.

F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)

Turn engine ON. If monitor alarm does not sound continuously, fuse is OK.

Monitor alarm will sound continuously.

F12—Radio and Dome 5 A Fuse (marked RADIO)

Turn key switch ON. If radio operates, fuse is OK.

Radio and dome light will not operate.

F13—Lighter 10 A Fuse (marked LIGHTER)

Turn key switch ON. Push lighter. If lighter gets hot, fuse is OK.

Lighter will not operate.

F14—Monitor 5 A Fuse (marked MONITOR)

Turn key switch ON. If monitor operates, fuse is OK.

Monitor will not operate.

F15—Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)


Cab auxiliary power connector will not operate.

F16—Start Aid (marked SA)


Start aid will not operate.

F17—Power On 5 A Fuse (marked POWER ON)

Turn key switch to START. If engine starts, fuse is OK.

Engine will not start.

F18—Idle Stop 5 A Fuse (marked IDLE STOP)


Controller protection will not operate.

F19—Horn 10 A Fuse (marked HORN)

Turn key switch ON. Press horn switch. If horn operates, fuse is OK.

Horn will not operate.

F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT)


Optional equipment will not operate.







Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) IMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) Not Used Not Used Not Used Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) Not Used Not Used Not Used Not Used Not Used Not Used


Test


F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER)



F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT)



F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)



F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT)



F25—IMOBI 5 A Fuse (marked IMOBI)



F26—Quick Hitch 5 A Fuse (marked QUICK HITCH)








F27—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3)



F31—Seat Compressor 10 A Fuse (marked SEAT COMPR)



F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2)



F33—Warning Lamp 10 A Fuse (marked WARNING LAMP)



F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2)




Test


F60—Alternator 65 A Fuse


Alternator will not charge electrical system.

F61—Battery 45 A Fuse

Turn key switch to START. If engine cranks, fuse is OK.

Engine will not crank.

F5002—Fuel Transfer Pump 15 A Fuse


Engine will run out of fuel.

F6000— JDLink ™ Unswitched Power 7.5 A Fuse


JDLink will not operate.

F6001—JDLink™ Ground 7.5 A Fuse



F6002—JDLink™ Switched Power 7.5 A Fuse



(S.N. 040755— )

Fuse Block 1 LEGEND: F1 Work and Boom Lights 20 A Fuse (marked LAMP) F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER) F3 Air Conditioner and Heater 20 A Fuse (marked HEATER) F4 Solenoid 20 A Fuse (marked SOLENOID) F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT) F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) F7 Start Position Signal 5 A Fuse (marked START) F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) F9 Radio Backup 10 A Fuse (marked BACK UP) F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) <- Go to Section TOC




F11 F12 F13 F14 F15 F16 F17 F18 F19 F20


Travel Alarm 5 A Fuse (marked TRAVEL ALARM) Radio and Dome 5 A Fuse (marked RADIO) Lighter 10 A Fuse (marked LIGHTER) Monitor 5 A Fuse (marked MONITOR) Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) 12-Volt Power Unit 10 A Fuse (marked 12V UNIT) Power On 5 A Fuse (marked POWER ON) Idle Stop 5 A Fuse (marked IDLE STOP) Horn 10 A Fuse (marked HORN) Optional Equipment 5 A Fuse (marked OPT. 3 BATT)

Some symptoms may indicate an expensive component malfunction, when in fact a fuse has malfunctioned. Machine functions can be performed without test equipment to determine if fuses have malfunctioned. If certain circuits or components operate, fuses are considered to be OK. Fuse Test Fuse Test Fuse

Test


F1—Work and Boom Lights 20 A Fuse (marked LAMP)

Turn key switch ON. Turn light switch to first or second position. If work or boom lights operate, fuse is OK.

Work and boom lights will not operate.

F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER)

Turn key switch ON. Turn windshield wiper ON. If wiper operates, fuse is OK.

Windshield wiper will not operate.

F3—Air Conditioner and Heater 20 A Fuse (marked HEATER)

Turn key switch ON. Press blower speed switch. If blower operates in any speed, fuse is OK.

Heater or air conditioner blower will not operate.

F4—Solenoid 20 A Fuse (marked SOLENOID)

If hydraulic system functions normally, fuse is OK.

Travel and stick functions will not operate.

F5—Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT)



F6—Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)



F7—Start Position Signal 5 A Fuse (marked START)



F8—Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)

Turn key switch to START. If engine starts and display lights, fuse is OK.

Display will not light and engine will not start.

F9—Radio Backup 10 A Fuse (marked BACK UP)

Turn key switch to ON. If radio presets are retained, fuse is OK.

Radio will not retain presets.

F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)

Turn engine ON. If monitor alarm does not sound continuously, fuse is OK.

Monitor alarm will sound continuously.

F11—Travel Alarm 5 A Fuse (marked TRAVEL ALARM)

Turn key switch to START. Place pilot shutoff lever to unlocked (DOWN) position. Push travel pedals or levers forward. If travel alarm sounds, fuse is OK.

Travel alarm will not operate.

F12—Radio and Dome 5 A Fuse (marked RADIO)

Turn key switch ON. If radio operates, fuse is OK.

Radio and dome light will not operate.

F13—Lighter 10 A Fuse (marked LIGHTER)

Turn key switch ON. Push lighter. If lighter gets hot, fuse is OK.

Lighter will not operate.

F14—Monitor 5 A Fuse (marked MONITOR)

Turn key switch ON. If monitor operates, fuse is OK.

Monitor will not operate.

F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX)


Cab auxiliary power connector will not operate.

F16—12-Volt Power Unit 10 A Fuse (marked 12V UNIT)


12-Volt Power Outlet will not operate.

F17—Power On 5 A Fuse (marked POWER ON)

Turn key switch to START. If engine starts, fuse is OK.

Engine will not start.

F18—Idle Stop 5 A Fuse (marked IDLE STOP)


Controller protection will not operate.

F19—Horn 10 A Fuse (marked HORN)

Turn key switch ON. Press horn switch. If horn operates, fuse is OK.

Horn will not operate.

F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT)









Heated Air Seat 10 A Fuse (marked SEAT HEATER) Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) IMOBI 5 A Fuse (marked IMOBI) Quick Hitch 5 A Fuse (marked QUICK HITCH) Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) Not Used Not Used Not Used Not Used Seat Compressor 10 A Fuse (marked SEAT COMPR) Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Warning Lamp 10 A Fuse (marked WARNING LAMP) Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG) Engine Control Unit (ECU) 20 A Fuse (marked ECU P2, not used) Engine Control Unit (ECU) 20 A Fuse (marked ECU P3, not used) Fuel Transfer Pump/Controllers 20 A Fuse (marked ECU P4, not used) Not Used Not Used


Test


F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER)



F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT)



F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)



F24—IMOBI 5 A Fuse (marked IMOBI)



F25—Quick Hitch 5 A Fuse (marked QUICK HITCH)



F26—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3)








F31—Seat Compressor 10 A Fuse (marked SEAT COMPR)



F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2)



F33—Warning Lamp 10 A Fuse (marked WARNING LAMP)



F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2)



F35—Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG)


Service ADVISOR ™ will not connect to machine.


Test


F60—Alternator 65 A Fuse


Alternator will not charge electrical system.

F61—Battery 45 A Fuse

Turn key switch to START. If engine cranks, fuse is OK.

Engine will not crank.

F63—Glow Plug 50 A Fuse



F5002—Fuel Transfer Pump 15 A Fuse


Engine will run out of fuel.

F6000— JDLink ™ Unswitched Power 7.5 A Fuse



F6001—JDLink™ Ground 7.5 A Fuse



F6002—JDLink™ Switched Power 7.5 A Fuse








Relay Test

Relay Test For location of relays: See Cab Harness (W1) Component Location . (Group 9015-10.) See Machine Harness (W2) Component Location . (Group 9015-10.) See Heated Air Seat Harness (W14) Component Location . (Group 9015-10.) See Multi-Function Pilot Control Lever Harness (W15) Component Location . (Group 9015-10.) See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Connect a multimeter to terminals 1 and 2. About 420—460 ohms must be measured. If not, relay has malfunctioned. [3] - Connect multimeter to terminals 3 and 4. Less than 0.4 ohms must be measured. If not, relay has malfunctioned. [4] - Connect multimeter to terminals 3 and 5, then 4 and 5. Multimeter must read open in both connections. If not, relay has malfunctioned. [5] IMPORTANT: To prevent possible relay damage, do not connect relay directly to battery. Use a fused power source such as auxiliary power connector (X25) in cab or external power supply.

Connect 24 volts (+) to terminal 1, ground (-) terminal 2. [6] - Connect multimeter to terminals 3 and 5. Multimeter must read less than 0.4 ohms. If not, relay has malfunctioned.






Pressure Sensor Test Pressure Sensor Resistance Test [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - A suspect pressure sensor can be checked by switching positions with a known good sensor. If the problem follows the suspect pressure sensor, it has malfunctioned. If the problem remains, the harness has malfunctioned. [3] - To check a pressure sensor using a multimeter, remove it from the machine. Multimeter Measure resistance on electrical component [4] →NOTE: Resistance values for pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37) may vary widely.

To the sensor′s functionality, use the on-board monitor or in Service ADVISOR ™ , check for diagnostic trouble codes to monitor the sensor′s output. See Monitoring . (Group 9015-16.) See SERVICE ADVISOR™ Diagnostic Application . (Group 9015-20.) [5] - Measure resistance as indicated. Resistance may vary from one sensor to another. Item

Measurement

Specification

Resistance

5—15 kilo-ohms (Pins 1—2)

Pressure Sensor Resistance Ranges Pump 1 Control Pressure Sensor (B36)

30—50 kilo-ohms (Pins 2—3) Pump 2 Control Pressure Sensor (B38)

Resistance

5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)

Boom Up Pressure Sensor (B30)

Resistance

Front Attachment Pressure Sensor (B32)

Resistance

5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3) 5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)

Travel Pressure Sensor (B34)

Resistance

5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)

Swing Pressure Sensor (B33)

Resistance

Arm In Pressure Sensor (B31)

Resistance

5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3) 5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)

For location of pressure sensors, see Machine Harness (W2) Component Location and see Pump Harness (W8) Component Location . (Group 9015-10.) Pressure Sensor Voltage Test [1] - No voltage at pressure sensors will generate diagnostic trouble codes. Disconnect harness connector from a pressure <- Go to Section TOC





sensor. [2] - With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector. Item

Measurement

Specification

Pump 1 Control Pressure Sensor (B36)

Voltage

4.5—5.5 volts

Pump 1 Delivery Pressure Sensor (B35)

Voltage

4.5—5.5 volts

Pump 2 Control Pressure Sensor (B38)

Voltage

4.5—5.5 volts

Pump 2 Delivery Pressure Sensor (B37)

Voltage

4.5—5.5 volts

Boom Up Pressure Sensor (B30)

Voltage

4.5—5.5 volts

Arm In Pressure Sensor (B31)

Voltage

4.5—5.5 volts

Front Attachment Pressure Sensor (B32)

Voltage

4.5—5.5 volts

Travel Pressure Sensor (B34)

Voltage

4.5—5.5 volts

Swing Pressure Sensor (B33)

Voltage

4.5—5.5 volts

Pressure Sensor Voltage Ranges

Multimeter To measure voltage [3] - If voltage is lower or no voltage is present, check wiring. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) See Pump Harness (W8) Wiring Diagram . (Group 9015-10.)

Solenoid Test [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem follows the suspect solenoid, it has malfunctioned. If the problem remains, the harness has malfunctioned. [3] - To check a solenoid using an ohmmeter, remove it from the machine. [4] - Measure resistance as indicated. Resistance may vary from one solenoid to another. Item

Measurement

Specification

Resistance

42—58 ohms

Excavator Solenoids Pilot Shut-Off Solenoid (Y10)






Proportional Solenoid Test [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - A solenoid with a potential problem may be tested by switching connections with a known, proper functioning solenoid. If the problem follows the solenoid, replace solenoid. If the problem remains, inspect connections and test appropriate harness. See Machine Harness (W2) Component Location . (Group 9015-10.) See Engine Interface Harness (W5) Component Location . (Group 9015-10.) See Pump Harness (W8) Component Location . (Group 9015-10.) See Attachment Harness (W17) Component Location . (Group 9015-10.) [3] - Remove solenoid from machine prior to testing with an ohmmeter. [4] - Measure resistance between pins on the solenoid and record results. Compare recorded resistance value to specification below. If solenoid is not within specification, replace solenoid. Item

Measurement

Specification

Reversing Fan Solenoid (Y9)

Resistance

37—46 ohms

Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20)

Resistance

20—24 ohms

Torque Control Solenoid (marked ST) (Y21)

Resistance

20—24 ohms

Dig Regenerative Solenoid (marked SF) (Y22)

Resistance

20—24 ohms

Arm Regenerative Solenoid (marked SC) (Y23)

Resistance

20—24 ohms

Power Dig Solenoid (marked SG) (Y24) (S.N. —XXXXXX)

Resistance

20—24 ohms

Power Dig/Travel Speed Solenoid (marked SI) (Y24) (S.N. XXXXXX— )

Resistance

20—24 ohms

Arm 2 Flow Control Solenoid (marked SD) (Y27)

Resistance

20—24 ohms

Selector Valve Solenoid Valve (Y40)

Resistance

44—54 ohms

Secondary Relief Solenoid Valve (Y41)

Resistance

17.5—21.5 ohms

Accumulator Solenoid Valve (Y42)

Resistance

17.5—21.5 ohms

2-Speed Activation Solenoid Valve (Y43)

Resistance

17.5—21.5 ohms

Variable Speed Fan Solenoid (Y5005)

Resistance

37—46 ohms

Main Controller Solenoids






Temperature Sensor Test Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JDG1478 Digital Multimeter

[1] - To check a temperature sensor using a JDG1478 Digital Multimeter, remove sensor from machine. Digital Multimeter JDG1478 Measure resistance on electrical component [2] - Measure resistance as indicated. Resistance may vary from one sensor to another. Ambient Air Temperature Sensor Ranges Ambient Air Temperature Sensor (B22) Ranges Resistance

Temperature

9900 ohms

0°C 32°F

1600 ohms

40°C 104°F

Hydraulic Oil Temperature Sensor Ranges Hydraulic Oil Temperature Sensor (B40) Ranges Resistance

Temperature

13 840—16 330 ohms

-20°C -4°F

5740 ohms

0°C 32°F

2320—2590 ohms

20°C 68°F

1150 ohms

40°C 104°F

584 ohms

60°C 140°F

310—326 ohms

80°C 176°F

Air Recirculation Sensor Ranges Air Recirculation Sensor (B55) Ranges Resistance

Temperature

9900 ohms

0°C 32°F

1600 ohms

40°C 104°F

See Machine Harness (W2) Component Location for ambient air temperature sensor (B22) location, see Pump Harness (W8) Component Location for hydraulic oil temperature sensor (B40) location, and see Heater and Air Conditioner Harness (W41) Component Location for air recirculation sensor (B55) location. (Group 9015-10.)






Alternator Test

Common Alternator Circuit LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Battery Alternator Key Switch To Accessories ACC Alternator Excitation Diode Excitation Terminal (marked D+) B+ Exciter Diodes Positive Diodes Negative Diodes Stator Excitation Winding (field) Regulator AC Terminal (marked W) To Display Module (indicator lamp)

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [1] - 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater [ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]

. [2] - With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater [ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]

. [3] - If voltage from previous steps is below 13.5 VDC <- Go to Section TOC





[ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]

, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire to D+ terminal). [4] - With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC . [5] - Repeat above steps with lights on to load the alternator. [6] - If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit. [1] - 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. ]

. [2] - With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. ]

. [3] - If voltage from previous steps is below 27.5 VDC [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. ]

, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC or greater, check for an open diode, wiring problem, or blown fuse in the alternator excitation circuit (wire to D+ terminal). [4] - With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC . [5] - Repeat above steps with lights on to load the alternator. [6] - If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.






Electrical Component Checks The following checks can be used to test electrical components in all machine circuits.

Component Checks ( 1 ) Key Switch Check

Action: LEGEND: 1 2 3 4 5 6

B Terminal G1 Terminal G2 Terminal ACC Terminal M Terminal ST Terminal

Key Switch Check Remove starter switch harness (W29) from key switch (S1). See Starter Switch Harness (W29) Component Location . (Group 9015-10.) Turn key switch to the ACC position. Measure continuity between key switch terminals 1 to 4. Turn key switch to the ON position. Measure continuity between key switch terminals 1 to 5 and 1 to 4. Turn key switch to the START position. Measure continuity between key switch terminals 1 to 6, 1 to 5, and 1 to 3. Multimeter To read continuity. sss: Is continuity measured between terminals?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Key switch is OK. Check the wiring harness. See Cab Harness (W1) Wiring Diagram and see Starter Switch Harness (W29) Wiring Diagram . (Group 9015-10.) NO:Key switch has malfunctioned. Replace the key switch. See Key Switch Remove and Install . (Group 9015-20.) <- Go to Section TOC





( 2 ) Battery Relay Check

Action:

Battery Relay Check Disconnect machine harness (W2) from battery relay (K19). See Machine Harness (W2) Component Location . (Group 9015-10.) Connect 24 volts to small terminal S and ground small terminal E. sss: Does the relay click? Connect the multimeter to large terminals A and B. Multimeter To read continuity. sss: Is continuity measured?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Battery relay is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Battery relay malfunctioned. Replace the relay. ( 3 ) Battery Voltage Check

Action:






Voltage Check Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and (+) positive battery terminal connected to machine harness. Multimeter To read voltage. sss: Are 24 to 28 volts measured?

Result: YES:Batteries are OK. NO:Batteries are undercharged. Charge batteries. See Using Battery Charger . (Operator′s Manual.) ( 4 ) Alternator and Battery Fuse Check

Action: LEGEND: 1 2

Locking Tab Lift Direction

Alternator and Battery Fuse Check Press locking tab on side of fuse and lift from holder. Connect a multimeter to female terminals inside fuse. Multimeter To read continuity. sss: Does the multimeter read continuity?







Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Fuse is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Fuse malfunctioned. Replace the fuse. See Fuse and Relay Specifications . (Group 9015-10.) ( 5 ) Diode Check

Action:

Diode Check Remove diode from connector. Test diode using diode test function of multimeter. Multimeter To test diode. sss: Does the multimeter beep? Reverse multimeter probes. sss: Does the multimeter beep?

Result: YES:If multimeter beeps in both checks, diode malfunctioned. Replace the diode. NO:If multimeter does not beep in either check, diode malfunctioned. Replace the diode. NO:If multimeter beeps in one check and not the other, diode is OK. ( 6 ) Travel Alarm Check <- Go to Section TOC





Action:

Travel Alarm Harness Check

Multimeter To read voltage and continuity. Disconnect travel alarm harness (W26) from travel alarm (H4). See Travel Alarm Harness (W26) Component Location . (Group 9015-10.) Connect multimeter to travel alarm connector pin B and frame ground. Turn key switch to ON position. sss: Is battery voltage measured? Connect multimeter to travel alarm connector pin D and frame ground. sss: Is continuity measured? Connect multimeter to travel alarm connector pin A and frame ground. sss: Is continuity measured when the travel alarm cancel switch is pressed?


Measurement

Specification


Torque

10 N·m 89 lb.-in.

Result: YES:Travel alarm has malfunctioned. Replace the travel alarm. See Travel Alarm Remove and Install . (Group 9015-20.) NO:If battery voltage is not measured, check travel alarm 5 A fuse. See Fuse and Relay Specifications . (Group 9015-10.) <- Go to Section TOC





NO:Check travel alarm cancel switch. See Travel Alarm Cancel Switch Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Check the travel alarm cancel switch harness and machine harness. See Travel Alarm Cancel Switch Harness (W16) Wiring Diagram , see Travel Alarm Harness (W26) Wiring Diagram , and see Machine Harness (W2) Wiring Diagram . (Group 9015-10.) ( 7 ) Monitor Warning Alarm Check

Action: Disconnect monitor harness (W3) from monitor warning alarm (H3). See Monitor Harness (W3) Component Location . (Group 9015-10.) Connect 24 volts to terminal 1 and ground terminal 2. sss: Does monitor warning alarm sound?

Result: YES:Alarm is OK. Check power on 5 A fuse. See Fuse and Relay Specifications . (Group 9015-10.) YES:Check wiring harness. See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Alarm malfunction. Replace monitor warning alarm. See Monitor Harness (W3) Component Location . (Group 9015-10.) ( 8 ) CAN Bus Terminator Check

Action: Turn key switch OFF. Disconnect harness from CAN bus terminator.

CAN Bus Terminator Measure resistance across terminator pins. Multimeter To read continuity. sss: Does the multimeter read 105—135 ohms? <- Go to Section TOC





Result: YES:CAN bus terminator is OK. NO:CAN bus terminator malfunctioned. Replace the CAN bus terminator. ( 9 ) Alternator Resistor Check

Action: Turn key switch OFF. Disconnect harness from alternator resistor (R13). LEGEND: 1 2

Terminal 1 Terminal 2

Alternator Resistor Measure resistance across resistor terminals 1 and 2. Multimeter To read continuity. sss: Does the multimeter read 1350—1650 ohms?

Result: YES:Alternator resistor is OK. NO:Alternator resistor malfunctioned. Replace the alternator resistor.






Battery Remove and Install [1] CAUTION:

Prevent personal injury from exploding battery. Keep sparks and flames away from batteries. Always remove grounded (-) battery clamp first and replace it last.

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)

Battery Connections





LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13


Battery (2 used) Wing Nut (4 used) Washer (8 used) Cover (2 used) Spacer (4 used) Nut (4 used) Clamp Bracket (2 used) Bolt (4 used) Positive Cable Jumper Cable Negative Cable Cap Screw

[2] - Remove wing nuts (2) and washers (3). [3] - Remove covers (4) and brackets (8). [4] - Disconnect cables (10—12). [5] - Remove batteries (1). [6] - Check cables and clamps for wear or corrosion. batteries are fully charged. [7] IMPORTANT: Prevent electrical system damage. If one battery in a 24-volt system has malfunctioned, replace both batteries.

Install batteries. [8] - Connect cables. [9] - Install brackets and covers. [10] - Install washers and wing nuts.






Rear Cover Remove and Install [1] -

Rear Cover Assembly LEGEND: 1 2 3 4 5 6 7 8 9 10 11 <- Go to Section TOC

Plug (2 used) Cap Screw (3 used) Right Cover Cap Screw Cap Screw Left Cover Plug (2 used) Cap Screw (2 used) Upper Rear Cover Cap Screw (2 used) Washer (2 used) Section 9015 page 299




12 Plug (3 used) 13 Cap Screw (3 used) 14 Lower Rear Cover G5 12 Volt Power Outlet R9 Lighter Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.) [2] - Remove plugs (1) and cap screws (2). [3] - Remove right cover (3). [4] - Remove cap screws (4 and 5). [5] - Tag and disconnect lighter (R9) and 12 volt power outlet (G5) from cab harness and remove left cover (6). [6] - Remove plugs (7) and cap screws (8). [7] - Remove upper rear cover (9). [8] - Remove plugs (12) and cap screws and washers (10, 11 and 13). [9] - Remove lower rear cover (14). [10] - Repair or replace as necessary. [11] - Install lower rear cover (14). [12] - Install cap screws and washers (10, 11 and 13) and plugs (12). [13] - Install upper rear cover (9). [14] - Install cap screws (8) and plugs (7). [15] - Connect lighter (R9) and 12 volt power outlet (G5) to cab harness and install left cover (6). [16] - Install cap screws (4 and 5). [17] - Install right cover (3). [18] - Install cap screws (2) and plugs (1).






Main Controller (MCZ) Remove and Install (S.N. —040754) [1] LEGEND: 1 Cap Screw (4 used) 2 Screw (4 used) 3 Cap Screw (2 used) 4 MCZ Bracket 5 Relay Bracket A3 Main Controller (MCZ) X31 Cab Harness-to-Main Controller 31-Pin Connector A X32 Cab Harness-to-Main Controller 24-Pin Connector B X33 Cab Harness-to-Main Controller 17-Pin Connector C X35 Cab Harness-to-Main Controller 24-Pin Connector D X36 Cab Harness-to-Main Controller 26-Pin Connector E

Main Controller (MCZ) Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Disconnect battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] - Remove cap screws (3) and set aside relay bracket (5). [5] - Tag and disconnect electrical connectors (X31— X33, X35, and X36). See Cab Harness (W1) Component Location . (Group 9015-10.) [6] - Remove cap screws (1) and remove MCZ bracket (4). [7] - Remove screws (2) and main controller (MCZ) (A3) from bracket. [8] - Repair or replace as necessary. [9] - Install MCZ on to bracket and screws. [10] - Install MCZ bracket and cap screws. [11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.) [12] - Install relay bracket and cap screws.






[13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [14] - Connect battery negative (-) cable.

(S.N. 040755— ) [1] LEGEND: 1 Cap Screw (4 used) 2 Screw (4 used) 3 Cap Screw (2 used) 4 MCZ Bracket 5 Relay Bracket A3 Main Controller (MCZ) X31 Cab Harness-to-Main Controller 31-Pin Connector A X32 Cab Harness-to-Main Controller 24-Pin Connector B X33 Cab Harness-to-Main Controller 17-Pin Connector C X34 Cab Harness-to-Main Controller 30-Pin Connector D X35 Cab Harness-to-Main Controller 24-Pin Connector E X36 Cab Harness-to-Main Controller 26-Pin Connector F

Main Controller (MCZ) Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Disconnect battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] - Remove cap screws (3) and set aside relay bracket (5). [5] - Tag and disconnect electrical connectors (X31—X36). See Cab Harness (W1) Component Location . (Group 9015-10.) [6] - Remove cap screws (1) and remove MCZ bracket (4). [7] - Remove screws (2). Remove main controller (MCZ) (A3) from relay bracket. [8] - Repair or replace as necessary. [9] - Install main controller in bracket. Install screws. [10] - Install MCZ bracket and cap screws. [11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.) [12] - Install relay bracket and cap screws. [13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.) <- Go to Section TOC





[14] - Connect battery negative (-) cable.






Machine Controller (BCZ) Remove and Install [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Disconnect battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] LEGEND: 1 2 3 A7

Screw (4 used) Screw (4 used) Bracket Air Conditioner Controller (ACF)

Air Conditioner Controller Disconnect air conditioner controller (ACF) connector (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) [5] - Remove screws (1) and ACF. [6] - Remove screws (2) and bracket (3). [7] LEGEND: 4 A11



Screw (2 used) Machine Controller (BCZ)




Machine Controller (BCZ) Remove screws (4) and lift up machine controller (BCZ) (A11). [8] LEGEND: A11 Machine Controller (BCZ) X10 Machine Controller 8-Pin Connector A X11 Machine Controller 20-Pin Connector B

Machine Controller (BCZ) Disconnect electrical connectors; machine controller 8-pin connector A (X10) and machine controller 20-pin connector B (X11). [9] - Remove machine controller. [10] - Repair or replace as necessary. [11] - Connect electrical connectors and install machine controller and screws. [12] - Install bracket and screws. [13] - Install air conditioner controller (ACF) (A7) and screws. [14] - Connect air conditioner controller connector (A7). [15] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [16] - Connect battery negative (-) cable.






Engine Control Unit (ECU) Remove and Install [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Disconnect battery negative (-) cable. [3] LEGEND: 1 Cap Screw (2 used) A1 Engine Control Unit (ECU) R12 CAN 0 Termination Resistor Engine Control Unit (ECU)-to-Engine Harness X14 Connector 1 Engine Control Unit (ECU)-to-Engine Harness X15 Connector 2

Engine Control Unit (ECU) Tag and disconnect engine control unit (ECU) electrical connectors (X14 and X15) from ECU (A1). See Engine Harness (W4) Component Location . (Group 9015-10.) [4] - Remove cap screws (1) and remove ECU. [5] - Repair or replace as necessary. [6] - Install ECU (A1) and cap screws. [7] - Connect ECU electrical connectors. See Engine Harness (W4) Component Location . (Group 9015-10.) [8] - Connect battery negative (-) cable.

Data Converter Remove and Install [1] -






LEGEND: 1 A5

Screw (3 used) Data Converter

Data Converter Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Disconnect battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] - Disconnect data converter (A5). See Cab Harness (W1) Component Location . (Group 9015-10 [5] - Remove screws (1) and data converter. [6] - Repair or replace as necessary. [7] - Install data converter and screws. [8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [9] - Connect battery negative (-) cable.






Monitor Controller (DSZ) Remove and Install IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Item

Measurement

Specification


Torque

10 N·m 89 lb.-in.

[1] LEGEND: 1 Cap Screw (4 used) A4 Monitor Controller (DSZ) X20 Monitor Controller 28-Pin Connector A X21 Monitor Controller 36-Pin Connector B X22 Monitor Controller 16-Pin Connector D X23 Monitor Controller 12-Pin Connector C X24 Monitor Controller 2-Pin Connector G

Monitor Controller (DSZ) Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Remove battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] - Disconnect electrical connectors (X20—X24) from monitor controller (DSZ) (A4). [5] - Remove cap screws (1) and monitor controller (DSZ). [6] - Repair or replace as necessary. [7] - Install monitor controller (DSZ) and cap screws. [8] - Connect electrical connectors to monitor controller (DSZ). See Cab Harness (W1) Component Location and see Monitor Harness (W3) Component Location . (Group 9015-10.) [9] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)






[10] - Connect battery negative (-) cable.






Air Conditioner Controller (ACF) Remove and Install [1] LEGEND: 1 Cap Screw (4 used) A7 Air Conditioner Controller (ACF)

Air Conditioner Controller (ACF) Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.) [2] - Remove battery negative (-) cable. [3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [4] - Disconnect air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) [5] - Remove cap screws (1) and remove ACF. [6] - Repair or replace as necessary. [7] - Install ACF and caps screws. [8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.) [9] - Connect battery negative (-) cable.

Key Switch Remove and Install LEGEND: 1 S1



Cap Screw (3 used) Key Switch




Key Switch [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Remove right switch console. See Right Switch Console Remove and Install . (Group 9015-20.) [3] - Disconnect key switch (S1). See Cab Harness (W1) Component Location . (Group 9015-10.) [4] - Remove cap screws (1) and remove key switch. [5] - Repair or replace as necessary. [6] - Install key switch and cap screws. [7] - Connect key switch. See Cab Harness (W1) Component Location . (Group 9015-10.) [8] - Install right switch console. See Right Switch Console Remove and Install . (Group 9015-20.)






Right Switch Console Remove and Install

Right Switch Console (pilot control lever not shown) LEGEND: 1 2 3 4 5 6 7 8 9 10

Cap Screw (2 used) Armrest Storage Compartment Cap Screw (3 used) Rear Switch Console Cap Screw (2 used) Pilot Control Lever Bezel Cap Screw (2 used) Right Switch Console Right Switch Console Bezel

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) <- Go to Section TOC





[2] - Remove cap screws (1) and armrest (2). [3] - Remove storage compartment (3). [4] - Remove cap screws (4). [5] - Disconnect cab harness (W1) electrical connectors from rear switch console (5). See Cab Harness (W1) Component Location . (Group 9015-10.) [6] - Remove rear switch console. [7] - Pull pilot control lever boot up and remove cap screws (6). [8] - Remove pilot control lever bezel (7). [9] - Remove cap screws (8). [10] - Disconnect cab harness (W1) electrical connectors from right switch console (9). See Cab Harness (W1) Component Location . (Group 9015-10.) [11] - Remove right switch console. [12] - Repair or replace as necessary. [13] - Connect cab harness electrical connectors to right switch console and install right switch console and cap screws. See Cab Harness (W1) Component Location . (Group 9015-10.) [14] - Install pilot control lever bezel and pilot control lever boot. [15] - Connect cab harness electrical connectors to rear switch console and install rear switch console and cap screws. See Cab Harness (W1) Component Location . (Group 9015-10.) [16] - Install storage compartment. [17] - Install armrest and cap screws.






Left Switch Console Remove and Install

Left Switch Console (pilot control lever not shown) LEGEND: 1 2 3 4 5

Cap Screw (2 used) Washer (2 used) Armrest Cap Screw (3 used) Left Switch Console

[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Remove cap screws (1) and washers (2). [3] - Remove armrest (3). [4] - Pull pilot control lever boot up and remove cap screws (4). [5] - Lift to remove left switch console (5). [6] - Tag and disconnect cab harness (W1) electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)






[7] - Repair or replace as necessary. [8] - Connect cab harness electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.) [9] - Install left switch console. [10] - Install cap screws and pilot control lever boot. [11] - Install armrest. [12] - Install cap screws and washers.

Travel Alarm Remove and Install LEGEND: 1 H4 W26

Cap Screw (2 used) Travel Alarm Travel Alarm Harness

Travel Alarm [1] →NOTE: Travel alarm (H4) is located in the hydraulic pump compartment below the main hydraulic pump.

Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Disconnect travel alarm (H4). See Travel Alarm Harness (W26) Component Location . (Group 9015-10.) [3] - Remove cap screws (1) and remove travel alarm. [4] - Repair or replace as necessary. [5] - Install travel alarm and cap screws. [6] - Connect electrical connector to (H4).

Disconnect Tab Retainer Connectors






IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to controllers or other components may result. Disconnect connectors only when instructed during a test or check. DO NOT pull on wires to disconnect connector or damage to wires or connector may result. Grasp both halves of the connector to pull connector apart.

[1] LEGEND: A

Retainer Tab

Retainer Tab Push retainer tab (A). [2] - While holding tab in, grasp other half of connector and pull connector halves apart. [3] - To connect, push connector halves together until retainer “clicks”.

Disconnecting Spring Wire Clip Connectors

Spring Wire Clip Connectors [1] - Remove wire clip from connector.






Grasp connector; move connector halves from side-to-side as they′re being pulled apart. Do not pull on wiring leads. [2] - To reconnect, install wire clip on connector half, push connector halves together until wire retainer “clicks” over tabs.






Replace DEUTSCH™ Connectors

Deutsch ™ Connector Extractor Tool

Slide Extractor Tool [1] - Select correct size extractor tool for size of wire to be removed: JDG361 Extractor Tool for 12 to 14 gauge wire. JDG362 Extractor Tool for 16 to 18 gauge wire. JDG363 Extractor Tool for 20 gauge wire. [2] - Start correct size extractor tool over wire at handle (A). [3] - Slide extractor tool rearward along wire until tool tip snaps onto wire. [4] IMPORTANT: Do NOT twist tool when inserting in connector.

Slide extractor tool along wire into connector body until it is positioned over terminal . [5] - Pull wire out of connector body, using extractor tool. [6] IMPORTANT: Install in proper location using correct size grommet.






Push Push straight into connector body until positive stop is felt. [7] - Pull on wire slightly to be certain is locked in place. [8] - Transfer remaining wires to correct terminal in new connector.






Replace DEUTSCH™ Rectangular or Triangular Connectors [1] →NOTE: Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch™ connectors can be serviced using the same procedure.

LEGEND: 1 2

Connector Locking Wedge

Removing Locking Wedge Pull connector (1) apart. Inspect and clean connector seal and s. [2] - Remove locking wedge (2) from connector using hook on JDG1383 service tool. DEUTSCH ™ Connector Service Tool JDG1383 Remove secondary lock. [3] LEGEND: 3 Primary Locking Latches

Releasing Primary Latch






Removing Wire Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool. [4] - Gently pull wire out from back of connector. [5] - Replace connector as necessary. See Install DEUTSCH™ . (Group 9015-20.) [6] - Install wire terminal back into connector until it clicks into place. [7] →NOTE: Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to terminals.

Install locking wedge until it snaps into place.






Install DEUTSCH™

Crimper [1] - Strip 6 mm (1/4 in.) insulation from wire. [2] - Adjust selector (A) on JDG360 Crimper for correct wire size. [3] - Loosen lock nut (B) and turn adjusting screw (C) in until it stops. [4] IMPORTANT: Select proper size "sleeve" or "pin" to fit connector body.

Adjusting Screw Insert (A) and turn adjusting screw (D) until is flush with cover (B). [5] - Tighten lock nut (C). [6] IMPORTANT: must remain centered between indentors while crimping.






Crimp Insert wire in and crimp until handle touches stop. [7] - Release handle and remove . [8] IMPORTANT: If all wire strands are not crimped into , cut off wire at and repeat installation procedures. →NOTE: Readjust crimping tool for each crimping procedure.

Inspect Deutsch ™ Inspect to be certain all wires are in crimped barrel.






Replace WEATHER PACK™ Connector

Terminal

IMPORTANT: Identify wire color locations with connector terminal letters.

[1] - Open connector body. [2] - Insert JDG364 Extraction Tool over terminal in connector body. [3] - Hold extractor tool fully seated and pull wire from connector body. →NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal from connector.

[4] IMPORTANT:

Weather Pack ™ Connector Body Carefully spread lances to assure good seating on connector body. →NOTE: Connector bodies are "keyed" for proper mating. Be sure s are in proper alignment.

Push into new connector body until fully seated. [5] - Pull on wire slightly to be certain is locked in place.






[6] - Transfer remaining wires to correct terminal in new connector. [7] - Close connector body.






Install WEATHER PACK™

Correct Size Cable

Strip Insulation

→NOTE: Cable seals are color coded for three sizes of wire: Green - 18 to 20 gauge wire Gray - 14 to 16 gauge wire Blue - 10 to 12 gauge wire

[1] - Slip correct size cable seal on wire. [2] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation. [3] →NOTE: s have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18 to 20 gauge wire

Put proper size on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator. [4] -






IMPORTANT:

Weather Pack ™ Installation Proper installation for "sleeve" (A) and "pin” (B) is shown.

Secure cable seal to as shown, using JDG783 Terminal Applicator.






Replace (Pull Type) Metri-Pack™ Connectors LEGEND: A B C D E

Connector “T” Pin Body Socket Locking Tab Push Terminal

Connector

Socket

Terminals Disconnect the Metri-Pack ™ connector (A). Remove tie bands and tape. Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C). →NOTE: Use JDG777 [ Included in JT07195A Electrical Repair Kit ]

Terminal Extraction Tool or “T” pin to remove terminals. Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward. Remove “T” pin and push terminal (E) out of socket. Remove terminal, cut strip and crimp wire through connector. Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body socket.






→NOTE: Terminal will seat only one way. If terminal does not pull into the connector body socket, check to make sure terminal is aligned correctly.

Replace (Push Type) Metri-Pack™ Connectors LEGEND: A B C D E

Connector Lock Extraction Tool JDG777 Connector Body Socket Terminal Locking Tab

Push Type Connector Disconnect the Metri-Pack ™ connector. Remove the tie bands and tape. Remove the connector lock (A), and mark wire colors for identification. Identify wire color locations with connector terminal letters. Insert JDG776 or JDG777 [ Included in JT07195A Electrical Repair Kit ]

Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward. →NOTE: Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK® terminals. Use JDG777 Extraction Tool with 150 series METRI-PACK® terminals.

Remove extraction tool and pull terminal (D) out of the socket. Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position. terminal into connector body socket until terminal locks.






Replace CINCH™ Connectors [1] LEGEND: 1 Extraction Tool 2 Secondary Lock Locking Tabs 3 Secondary Lock

Unlock Secondary Lock of Cinch ™ Connector Remove extraction tool (1) from the loading side of connector. [2] - Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab. →NOTE: After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to hold it in the unlocked position while unlocking the second locking tab.

[3] LEGEND: 3

Secondary Lock

Remove Secondary Lock Remove secondary lock (3). [4] -






Removing Terminals Insert pointed side of extraction tool into the cavity so that the flat side of tool faces secondary lock cavity (4). This will release the primary locking tab. [5] - Gently pull wire out of the connector. [6] - Repair/Replace terminals as necessary using procedure in this group. [7] - Insert and wire into connector until it clicks. [8] - Install secondary lock.






Install CINCH™ [1] -

Tool Position For Insertion LEGEND: A Top of Tool B C Locator D Wire E Micro Timer Slot F Junior Timer Slot G I Wire Tab J Insulation Tab Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool handles together and allow them to open fully. Crimper JDG708 Install Cinch ™ s [2] IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned .

Position the so that the mating end of the (G) is on the locator side of the tool (C). Wire and insulation tabs (I and J) should point to top of tool (A). Butt wire tab (I) against the movable locator (C). <- Go to Section TOC





[3] - Hold the in position and squeeze the tool handles together until ratchet engages sufficiently to hold the in position. Do NOT deform wire and insulation tabs (I and J). [4] - Insert stripped wire into insulation and wire tabs until it is butted against locator (C). [5] - Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped . [6] - Install into connector. (Go to procedure in this group.)






Repair 32 and 48 Way CINCH™ Connectors [1] LEGEND: A B C D

Tab Locking Cam Cover Locks Cover

Cinch ™ Connector

CINCH™ Cover Lock Tabs

CINCH™ Cover Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox. [2] - Move cover locks (C) slightly outward with a small screwdriver. [3] - Remove cover (D) away from wires. [4] -






LEGEND: A

Terminal Lock

Terminal Lock Pull terminal lock (A) out as far as it will go, but do not force its removal. [5] →NOTE: JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for smaller 20 gauge holes (A), and 1.5 for larger 16 and 18 gauge holes (B).

LEGEND: A B C D E

20 Gauge Holes 16 & 18 Gauge Holes Holes Terminal Hole Terminal

Connector Holes

CINCH™ Connector Terminal Holes






CINCH™ Terminal Extraction Tool Insert JDG1725 Terminal Extractor Tool Flexbox Terminal Repair Kit

JDG1744 JDG1744 [ Includes JDG1725 Terminal Removal Tool and JDG1727 Crimping Tool ]

Repair CINCH™ wire connectors into holes (C) next to terminal opening (D) to unlock terminal. [6] - Pull wire and terminal (E) from connector body. [7] LEGEND: A CINCH™ Terminal Crimping Tool B Terminal Receptacle C Terminal D Wire

Crimp terminal






CINCH™ Terminal Crimping Tool

Terminal Crimping Tool Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire. [8] - Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism until it bottoms out. Then allow it to open completely [9] - With tool in ready position (open handle), open terminal receptacle (B). [10] - Insert terminal (C) into proper wire gauge window, crimp wings facing up. [11] - Close terminal receptacle (B). [12] - Squeeze handle until two clicks are heard. [13] - Insert stripped wire (D) into terminal. [14] - Hold wire stationary and squeeze tool together until ratchet releases. [15] - Remove terminated wire from tool. [16] - Terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position. [17] - Push terminal lock closed. [18] - Install cover. <- Go to Section TOC



POWER TRAIN


[19] - Install connector to controller and close connector body locking cam.

Remove Connector Body from Blade Terminals

Blade Terminals [1] - Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off. [2] - Be sure to bend locking tang back to its original position (B) before installing connector body.






Section 9020 - POWER TRAIN Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Track Adjuster and Recoil Spring Operation ......................................................................................... 1 Travel Gear Case Operation ................................................................................................................. 3 Group 15 - Diagnostic Information ........................................................................................................ 4 Noisy or Loose Track Chain Diagnostic Procedure ................................................................................ 4 Tight Track Chain Diagnostic Procedure ............................................................................................... 4 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure ............................................... 5 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure .......... 5 Bent Track Shoes Diagnostic Procedure ............................................................................................... 6 ‘Popping” of Track Diagnostic Procedure ............................................................................................. 7 Cracked Track Link Diagnostic Procedure ............................................................................................ 8 Chipped Link Rails Diagnostic Procedure .............................................................................................. 9 Individual Undercarriage Component Wear Diagnostic Procedure ....................................................... 9 Measure Swing Bearing Wear ............................................................................................................. 11



Section 9020 - POWER TRAIN


Group 05 - Theory of Operation Track Adjuster and Recoil Spring Operation

Track Adjuster and Recoil Spring LEGEND: 1 2 3 4 5 6 7 8 9

Grease Fitting Valve Grease Relief age Cylinder Yoke Front Idler Piston Recoil Spring Grease

The track adjuster and recoil spring is ed by the track frame. Shock loads on the track and front idler (6) are absorbed by the recoil spring (8). To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease pushes the piston (7) against the yoke moving the front idler (6) out, reducing track sag. The grease fitting (1) is protected from excess pressure by a check ball.

CAUTION:

Prevent possible injury from high pressure grease. DO NOT remove grease fitting (1) from valve (2).


Section 9020 page 1




Increasing track sag is accomplished by loosening the valve (2) to release grease from the cylinder through the grease relief age (3). When releasing grease from the cylinder, only loosen the valve (2).


Section 9020 page 2




Travel Gear Case Operation

Travel Gear Case Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Ring Gear Second Stage Carrier Second Stage Sun Gear First Stage Carrier First Stage Sun Gear (input shaft) First Stage Planetary Gear Second Stage Planetary Gear Bearing Nut Sprocket Drum Travel Motor Housing Bearing Cone and Cup (2 used) Travel Motor Valve Housing Thrust Pad

The travel gear case is a two-stage planetary reduction gear system. It converts high speed, low torque from travel motor into low speed, high torque rotation. The gear case is interchangeable from right side to left side of machine. The travel gear case housing is fastened to the track frame. The travel motor drive shaft is connected to first stage sun gear (input shaft) (5) by a spline coupler. Travel motion is transferred from first stage sun gear to sprocket (9) by two planetary gear sets that mesh with the ring gear (1). As the first stage sun gear is rotated, it rotates the first stage planetary gear (6), causing the first stage carrier (4) to rotate. The first stage carrier is connected to second stage sun gear (3). The second stage sun gear meshes with second stage planetary gear (7). Second stage planetary gears are connected to second stage carrier (2). The second stage carrier is fastened to the gear case housing and does not rotate. The rotation is transferred to the ring gear. The ring gear, drum (10), and sprocket are fastened together and turn as one unit which rotates the track to move the machine. A replaceable thrust pad (14) is used in the gear case cover to keep the first stage sun gear in position.


Section 9020 page 3




Group 15 - Diagnostic Information Noisy or Loose Track Chain 81

Noisy or Loose Track Chain Diagnostic Procedure ( 1 ) Incorrect Track Sag Adjustment

Action: Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.) Is track sag within specification?

Result: YES:Go to Loose Track Shoes. NO:Adjust track sag. ( 2 ) Loose Track Shoes

Action: Remove loose track shoes to clean material from between track shoes and links. Install track shoes and tighten cap screws in proper sequence. See Track Shoe Remove and Install . (Group 0130.) Are track shoes properly installed and clean of debris?

Result: YES:Go to Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve. NO:Clean and install track shoes properly. ( 3 ) Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve

Action: Check that grease fittings and valves are tight. Replace grease fittings or relief valves. See Track Adjuster and Recoil Spring Disassemble and Assemble for seal replacement. (Group 0130.) Are grease fittings, relief valves, or seals leaking?

Result: YES:Replace grease fitting, relief valve or seals as necessary. NO:Diagnostic checkout complete. Tight Track Chain 81

Tight Track Chain Diagnostic Procedure ( 1 ) Material Packing in Sprocket

Action: Clean material from sprockets. Is sprocket free of material?


Section 9020 page 4




Result: YES:Go to Track Sag Less Than Specification. NO:Clean material from sprockets. ( 2 ) Track Sag Less Than Specification


Result: YES:Diagnostic checkout complete. NO:Adjust track sag. Frequent Track Chain Sag Adjustment Required 81

Frequent Track Chain Sag Adjustment Required Diagnostic Procedure ( 1 ) Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve

Action: Check that grease fittings and valve are tight. Replace grease fittings or relief valve. See Track Adjuster and Recoil Spring Disassemble and Assemble for seal replacement. (Group 0130.) Are grease fittings, relief valves, or seals leaking?

Result: YES:Replace grease fitting, relief valve or seals as necessary. NO:Diagnostic checkout complete. Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers 81

Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure ( 1 ) Loose Plugs, Worn or Damaged O-rings, or Metal Faced Seals

Action: Check for loose, worn or damaged plugs, O-rings, or metal faced seals. Are plugs, O-rings or metal faced seals leaking?

Result: YES:Repair plugs, O-rings, or metal faced seals. See Front Idler Remove and Install , see Track Roller Remove and Install , or see Track Carrier Roller Remove and Install . (Group 0130.) NO:Diagnostic checkout complete.


Section 9020 page 5




Bent Track Shoes 81

Bent Track Shoes Diagnostic Procedure ( 1 ) Excessive Gro Wear

Action: Measure gro height specification for rebuilding or replacing track shoes. See 130G Three Bar Gro Height . (SP326VOL1 Undercarriage Appraisal Manual.) Is gro height to specification?

Result: YES:Go to Loose Track Shoes. NO:Repair or replace track shoes. See Track Shoe Remove and Install . (Group 0130.) ( 2 ) Loose Track Shoes

Action: Remove loose track shoes to clean material from between track shoes and links. Install track shoes and tighten cap screws in proper sequence. See Track Shoe Remove and Install . (Group 0130.) Are track shoes properly installed?

Result: YES:Go to Excessive High Speed Operation On Rough and Rocky Terrain. NO:Install track shoes properly. ( 3 ) Excessive High Speed Operation On Rough and Rocky Terrain

Action: Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch . (Operator′s Manual.) Is travel speed switch in slow seed (turtle) mode?

Result: YES:Diagnostic checkout complete NO:Place travel speed switch in slow speed (turtle) mode.


Section 9020 page 6




“Popping” of Track 81

“Popping” of Track Diagnostic Procedure ( 1 ) High Travel Loads in Reverse

Action: High travel speeds in reverse can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize travel loads in reverse. Are travel loads in reverse minimized?

Result: YES:Go to Material Packing in Sprocket. NO:Minimize travel loads in reverse. ( 2 ) Material Packing in Sprocket




Result: YES:Diagnostic checkout complete. NO:Adjust track sag.


Section 9020 page 7




Cracked Track Link 81

Cracked Track Link Diagnostic Procedure ( 1 ) Material Packing in Sprocket




Result: YES:Go to Excessive High Speed Operation On Rough and Rocky Terrain. NO:Adjust track sag. ( 3 ) Excessive High Speed Operation On Rough and Rocky Terrain

Action: Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch . (Operator′s Manual.) Is travel speed switch in slow seed (turtle) mode?

Result: YES:Go to Track Shoes too Wide for Ground Conditions. NO:Place travel speed switch in slow speed (turtle) mode. ( 4 ) Track Shoes too Wide for Ground Conditions

Action: Use the narrowest possible shoes for required flotation. Are the narrowest possible shoes for required flotation being used?

Result: YES:Diagnostic checkout complete. NO:Select the narrowest shoes possible for required flotation.


Section 9020 page 8




Chipped Link Rails 81

Chipped Link Rails Diagnostic Procedure ( 1 ) Repeated High Impacts With Roller Tread On Flanges Caused by a Loose or Snaky Track


Result: YES:Go to Track Shoes too Wide for Ground Conditions. NO:Adjust track sag. ( 2 ) Track Shoes too Wide for Ground Conditions

Action: Use the narrowest possible shoes for required flotation. Are the narrowest possible shoes for required flotation being used?

Result: YES:Go to Correct Track Chain Pitch. NO:Select the narrowest shoes possible for required flotation. ( 3 ) Correct Track Chain Pitch

Action: Check track chain pitch specifications. See 130G Track Chain Pitch . (SP326VOL1 Undercarriage Appraisal Manual.) Is track chain pitch within specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace track chain as necessary. See Track Chain Remove and Install . (Group 0130.) Individual Undercarriage Component Wear 81

Individual Undercarriage Component Wear Diagnostic Procedure ( 1 ) Some Wear is Normal

Action: Measure components to determine if they can be rebuilt using weld. See Component Rebuild . (SP326VOL1 Undercarriage Appraisal Manual.) Is component wear within specification?

Result: YES:Diagnostic checkout complete. <- Go to Section TOC

Section 9020 page 9




NO:Repair or replace components as necessary.






Measure Swing Bearing Wear Specifications SPECIFICATIONS Swing Bearing Swing Bearing Play

0.2—1.00 mm normal 0.008—0.039 in. normal

Swing Bearing Play

2.80 mm maximum allowable 0.110 in. maximum allowable

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Dial Indicator

[1] CAUTION:

Avoid personal injury or death. Stay clear of moving parts. Position dial indicator so it can be seen while the operator can see you. →NOTE: Two people are needed to take the measurement. One to operate the machine and one to take the readings.






Dial Indicator Location






Machine Positions for Check Check that swing bearing-to-main frame cap screws are tightened to specification. [2] - Check that swing bearing is lubricated with the specified grease. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease . (Operator′s Manual.) [3] - Check that bearing rotation is smooth and without noise. [4] →NOTE: Readings vary depending on the location of dial indicator base with respect to the swing bearing tower. To obtain an accurate reading, the base for dial indicator must be attached to the tower or as close to it as possible.

Install dial indicator with needle point ing bottom face of bearing outer race and base attached to the swing bearing tower or as close to it as possible. Dial Indicator To measure swing bearing play. [5] - Move boom and arm to the position shown with bucket off the ground. Bucket must be empty. <- Go to Section TOC



HYDRAULIC SYSTEM


[6] - Turn dial indicator to zero. [7] - Lower the boom to raise front idlers off the ground approximately 500 mm (20 in.). [8] - Record dial indicator reading. Item

Measurement

Specification

Play

0.2—1.00 mm normal

Swing Bearing Swing Bearing

0.008—0.039 in. normal Play

2.80 mm maximum allowable 0.110 in. maximum allowable

If play is more than specified, check for wear to balls, spacers, and bearing race. See Swing Bearing Remove and Install . (Group 4350.)






Section 9025 - HYDRAULIC SYSTEM Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Hydraulic System Operation ................................................................................................................. 1 Fan Drive Hydraulic System Operation ................................................................................................. 2 Pilot System Operation ......................................................................................................................... 4 Pilot Pump, Pressure Regulating Valve, and Filter Operation ............................................................... 6 Pilot Shutoff Solenoid Valve Operation ................................................................................................. 7 Pilot Control Valve Operation ............................................................................................................. 12 Travel Pilot Control Valve Operation ................................................................................................... 14 Pilot Operation of Control Valve Operation ......................................................................................... 17 Pilot Signal Manifold Operation ........................................................................................................... 18 Pump 1, Pump 2, and Drive Gear Case Operation .............................................................................. 28 Pump 1 and Pump 2 Regulator Operation .......................................................................................... 32 Engine Speed Sensing Control Circuit Operation ................................................................................ 39 Control Valve Operation ..................................................................................................................... 41 Control Valve Check Valves Identification and Operation ................................................................... 53 Main Relief Valve Circuit Operation .................................................................................................... 56 Circuit Relief and Anticavitation Valve Operation ............................................................................... 60 Travel Flow Combiner Valve Operation .............................................................................................. 62 Auxiliary Flow Combiner Valve and By Shutoff Valve Operation ................................................. 67 Boom Lower Meter-In Cut Valve Operation ......................................................................................... 72 Boom Regenerative Valve Circuit Operation ...................................................................................... 76 Dig Regenerative Valve Circuit Operation .......................................................................................... 78 Arm Regenerative Valve Circuit Operation ......................................................................................... 85 Bucket Regenerative Valve Circuit Operation ..................................................................................... 92 Boom and Arm Reduced Leakage Valves Operation ........................................................................... 94 Arm 1 Flow Rate Control Valve Circuit Operation ............................................................................... 97 Arm 2 Flow Rate Control Valve Circuit Operation ............................................................................. 103 Bucket Flow Rate Control Valve Circuit Operation ............................................................................ 109 Boom Flow Rate Control Valve Circuit Operation .............................................................................. 115 Auxiliary Flow Rate Control Valve Circuit Operation ......................................................................... 121 Blade Circuit Operation—If Equipped ............................................................................................... 127 Swing Reduction Gear Case Operation ............................................................................................. 130 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .................................... 131 Swing Motor Park Brake Release Circuit Operation .......................................................................... 134 Center t Operation ...................................................................................................................... 136 Travel Motor and Park Brake Valve Operation .................................................................................. 138 Travel Motor Speed Circuit Operation ............................................................................................... 145 Cylinder Operation ........................................................................................................................... 149 Return Filter Operation ..................................................................................................................... 151 Auxiliary System Operation .............................................................................................................. 151 Auxiliary Pilot Control Valve Operation ............................................................................................. 153 Flow Rate Select Solenoid Valve Operation ...................................................................................... 161 Flow Rate Pressure Reducing Valve Operation ................................................................................. 162 Selector Valve Solenoid Valve Operation .......................................................................................... 163 Selector Valve Operation .................................................................................................................. 163 Auxiliary Shuttle Valve Operation ..................................................................................................... 164 Auxiliary High Flow Line Kit Operation .............................................................................................. 167 Two Way Solenoid Kit Operation ...................................................................................................... 172 Two Pump Combined Flow Kit Operation .......................................................................................... 177 Group 15 - Diagnostic Information .................................................................................................... 185 <- Go to Global Table of contents




All Hydraulic Functions Slow Diagnostic Procedure .......................................................................... 185 Hydraulic Oil Overheats Diagnostic Procedure ................................................................................. 189 No Hydraulic Functions Diagnostic Procedure .................................................................................. 192 Poor Combined Operation Diagnostic Procedure .............................................................................. 194 All Functions Cannot Be Operated Diagnostic Procedure ................................................................. 195 Function Does Not Stop When Control Lever Released Diagnostic Procedure .................................. 196 Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure ........................ 197 All Functions Slow Diagnostic Procedure .......................................................................................... 199 Functions Move in Opposite Direction Diagnostic Procedure ............................................................ 200 All Dig Functions Slow or No Power Diagnostic Procedure ................................................................ 201 Some Dig Functions Slow (Not All) Diagnostic Procedure ................................................................. 202 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure .......................... 204 Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle Diagnostic Procedure .................................................................................................................................. 205 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure ................................................................................................................................................... 206 Swing Speed Slow in Both Directions Diagnostic Procedure ............................................................. 208 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure .............................. 210 Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure .......................................... 212 Swing Function Does Not Operate Diagnostic Procedure ................................................................. 214 Travel Park Brakes Do Not Apply Diagnostic Procedure ................................................................... 215 Track Will Not Move in One Direction Diagnostic Procedure ............................................................. 216 Track Will Not Move in Either Direction Diagnostic Procedure .......................................................... 218 Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure ....................................... 220 Slow Travel Speed or Low Power Diagnostic Procedure ................................................................... 222 Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure .................................. 224 Travel is ‘Jerky” Diagnostic Procedure .............................................................................................. 225 Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure ................................................................................................................. 226 Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure ......... 226 Pump 1, Pump 2, and Pilot Pump Line Identification ........................................................................ 227 Control Valve Line Identification ....................................................................................................... 229 Swing Motor Line Identification ........................................................................................................ 232 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern ...................... 233 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern ........................ 235 Pilot Signal Manifold-to-Control Valve Line Connection .................................................................... 237 Travel System Component Location ................................................................................................. 240 Travel Hydraulic System Line Connection ........................................................................................ 242 Blade Hydraulic System Component Location .................................................................................. 244 Auxiliary Attachment Schematic ...................................................................................................... 246 Auxiliary System Line Connections ................................................................................................... 255 Hydraulic System Schematic ............................................................................................................ 260 Hydraulic System Component Location ............................................................................................ 276 Hydraulic System Line Connections ................................................................................................. 278 Fan Drive System Component Location ............................................................................................ 280 Fan Drive Hydraulic System Schematic ............................................................................................ 282 Group 25 - Tests ................................................................................................................................... 284 JT05800 Digital Thermometer Installation ........................................................................................ 284 JT02156A Digital Pressure and Temperature Analyzer Kit Installation .............................................. 285 Hydraulic Oil Cleanup Procedure ...................................................................................................... 287 Hydraulic Oil Tank Pressure Release Procedure ............................................................................... 289 Hydraulic Oil Warm-Up Procedure .................................................................................................... 291 Pilot Pressure Regulating Valve Test and Adjustment ...................................................................... 293 <- Go to Global Table of contents




Control Valve Spool Actuating Pilot Pressure Test ............................................................................ 297 Dig Regenerative Solenoid Valve Test and Adjustment .................................................................... 300 Arm Regenerative Solenoid Valve Test and Adjustment .................................................................. 305 Power Dig Solenoid Valve Test and Adjustment ............................................................................... 310 Arm 2 Flow Control Solenoid Valve Test and Adjustment ................................................................. 315 Torque Control Solenoid Valve Test and Adjustment ........................................................................ 320 Pump Control Pilot Pressure Signal Test ........................................................................................... 324 Main Relief and Power Dig Valve Test and Adjustment .................................................................... 326 Circuit Relief Valve Test and Adjustment ......................................................................................... 332 Blade Main Relief Valve Test and Adjustment .................................................................................. 338 Swing Motor Crossover Relief Valve Test and Adjustment ............................................................... 343 Travel Motor Crossover Relief Valve Test and Adjustment ............................................................... 348 Pump Regulator Test and Adjustment—Minimum Flow .................................................................... 354 Pump Regulator Test and Adjustment—Maximum Flow ................................................................... 357 Pump Flow Test ................................................................................................................................ 360 Swing Motor Leakage Test ................................................................................................................ 368 Travel Motor Leakage Test ............................................................................................................... 371 Cylinder Drift Test—Boom, Arm, and Bucket .................................................................................... 375 Fan Drive Pump Flow Test ................................................................................................................ 378 Fan Speed Test ................................................................................................................................. 381



Section 9025 - HYDRAULIC SYSTEM


Group 05 - Theory of Operation Hydraulic System Operation Main hydraulic system is an open-center hydraulic system. The main hydraulic pump housing contains two pumps in an in-line configuration; pump 1 and pump 2. The pump 1 end of housing is fastened to the engine flywheel housing. Engine output is transmitted to the pump 1 drive shaft through a flex coupling. Engine output is transmitted from the pump 1 drive shaft to the pump 2 drive shaft and then to the pilot pump drive shaft. The pilot pump is mounted on the pump 2 end of housing. The pumps are driven at engine speed. For additional information, see Pump 1, Pump 2, and Drive Gear Case Operation . (Group 9025-05.) Also, see Pilot Pump, Pressure Regulating Valve, and Filter Operation . (Group 9025-05.) Hydraulic oil flow is through suction screen, out of the hydraulic oil tank, and through the suction line to the pumps. Pump 1 delivers high pressure oil to the front control valve (4-spool). Pump 2 delivers high pressure oil to the rear control valve (5spool). High pressure oil is routed to the motors and cylinders by valve spools for their respective function. Hydraulic oil tank is pressurized to ensure that oil flows from the tank, through the suction line, and into the pumps. For additional information, see Control Valve Operation . (Group 9025-05.) Also, see Control Valve Check Valves Identification and Operation . (Group 9025-05.) Return oil from the motors and cylinders is routed into return ages in control valve by the valve spools. From the return ages, return oil flows out of control valve, through hydraulic oil cooler, through the restriction valve, and then through the return filter in the hydraulic oil tank. The restriction valve is used in the return line after the hydraulic oil cooler to create some back pressure in the return age of control valve. The back pressure ensures a flow of makeup oil to keep the swing motor case full of oil and a flow of oil through the anticavitation valves to prevent cylinder cavitation. For additional information, see Circuit Relief and Anticavitation Valve Operation . (Group 9025-05.) The hydraulic oil cooler by valve opens to route return oil around hydraulic oil cooler and directly to hydraulic oil tank when resistance to flow through oil cooler becomes high because the oil is cold (high viscosity), there is a surge of return oil, or oil cooler becomes plugged. The pressure setting for the by valve is higher than the restriction valve. If equipped, blade pump is mounted in line with fan drive pump. Engine output is transmitted from fan drive pump drive shaft to blade pump drive shaft. Blade pump delivers high pressure oil through blade control valve to blade cylinders. Return oil from blade cylinders is routed through blade control valve directly to return filter in hydraulic oil tank. For additional information, see Blade Circuit Operation—If Equipped . (Group 9025-05.) Also, see Hydraulic System Schematic . (Group 9025-15.)


Section 9025 page 1




Fan Drive Hydraulic System Operation

Fan Drive Hydraulic System Schematic LEGEND: 31 32 34 35 132 133 134 600 604 Y5005


Hydraulic Oil Tank Return Filter Filter By Suction Screen Fan Drive Pump Fan Drive Motor Fan Speed Control Valve High Pressure Oil Return Oil Variable Speed Fan Solenoid

Section 9025 page 2




Fan Drive Hydraulic System Schematic—Reversing (if equipped) LEGEND: 31 32 34 35 132 133 135 600 604 Y9 Y5005

Hydraulic Oil Tank Return Filter Filter By Suction Screen Fan Drive Pump Fan Drive Motor Fan Speed and Reversing Control Valve (if equipped) High Pressure Oil Return Oil Reversing Fan Solenoid Variable Speed Fan Solenoid

Standard Hydraulic Fan Function See Fan Drive Hydraulic System Schematic . (Group 9025-15.) <- Go to Section TOC

Section 9025 page 3




See Fan Drive System Component Location . (Group 9025-15.) A hydraulic-powered cooling fan is used to provide air flow for the machine′s cooling package. The fan drive system consists of: Gear type fan drive pump (132) Fan speed control valve (134) or fan speed and reversing control valve (if equipped) (135) Gear type fan drive motor (133) The fan drive pump is directly driven off the front gear train of the engine. Oil flow to the pump comes from the hydraulic oil tank (31). Return oil (604) from the fan drive motor is routed to the return filter (32) in the hydraulic oil tank. The variable speed fan solenoid (Y5005) regulates oil flow and pressure buildup in the fan drive system. The more oil flow to the fan drive motor, the greater the fan speed. How much oil flow is routed to the fan drive motor, depends on the current applied to the fan speed solenoid valve from the engine control unit (ECU). The ECU uses five parameters to control the current sent to the integrated variable speed fan solenoid. The engine coolant temperature sensor (B4), hydraulic oil temperature sensor (B40), charge air cooler outlet temperature sensor (B5205), fuel temperature sensor (B5), and ambient air temperature sensor (B22) send system temperatures to the ECU. Each temperature input calculates a desired fan speed, the maximum of the fan speeds is used as output to the fan speed control valve. When machine systems are cold, the ECU sends maximum current to the variable speed fan solenoid. This shifts the solenoid valve, to allow most oil flow to be returned to the hydraulic oil tank and by the fan drive motor. The fan drive motor and cooling fan operate at a low speed. As the machine warms up during operation, the ECU decreases the current to the fan speed solenoid valve. The decrease in current applied, causes the solenoid valve to shift and restrict oil flow through the fan speed solenoid valve, increasing oil flow to the fan drive motor. As oil flow to the fan drive motor increases, cooling fan speed increases. When maximum cooling is required, the ECU supplies low current to the variable speed fan solenoid with the solenoid valve at a set minimum current, LOW VOLTAGE fan speed current, the fan drive motor and cooling fan operate at the set maximum speed of LOW VOLTAGE maximum speed. This controlled fan speed is more economical and fuel efficient. During a fan system malfunction or unplugged fan speed solenoid, the ECU supplies no current to the variable speed fan solenoid. With the solenoid valve de-energized, the variable speed fan solenoid is fully shifted to allow maximum oil flow to the fan drive motor. The fan drive motor and cooling fan operate at maximum speed. Reverse Fan Function—If Equipped The optional reversing function, reverses the cooling fan to help clean the machine cooling package of dirt and debris. The reversing function can be initiated manually by the operator, or automatically by the ECU. If set to reverse automatically, the ECU will reverse the fan at a preset interval. For additional information, see Reversing Fan Switch—If Equipped . (Operator′s Manual.) The integrated fan speed and reversing control valve is used with the optional reverse fan function. The control valve controls both fan speed and reversing fan direction. To start a reversing cycle, the ECU first increases current to the variable speed fan solenoid in the fan speed and reversing control valve. The engine control unit briefly applies maximum current to stop the fan, while the reversing fan solenoid valve (Y9) shifts to reverse oil flow. The ECU then removes current to the variable speed fan solenoid, to operate the fan at maximum speed in reverse for a short period of time. The ECU continues to calculate the desired speed for the fan forward inputs. After the reverse cycle completes, the ECU will return to the maximum desired speed. Returning to normal operation, the ECU briefly applies maximum current to the variable speed fan solenoid, while the reversing fan solenoid resets to normal operation.

Pilot System Operation For additional hydraulic system information, see Hydraulic System Schematic . (Group 9025-15.) The pilot system is used to operate control circuits for pump 1 and pump 2 regulators, to shift the control valve spools, to release the swing park brake, and as a supply source for the functions of solenoid valve manifold. The pilot pump supplies oil to the pilot system. From the pilot pump, oil flows to the pilot filter housing. The pilot filter housing houses pilot filter and by valve, and pilot pressure regulating valve. <- Go to Section TOC

Section 9025 page 4




From the pilot filter housing, oil is supplied to solenoid valve manifold where it is used as supply oil for the arm regenerative and travel speed solenoids. From the solenoid valve manifold, oil flows to pilot shutoff solenoid valve and blade signal selector combiner valve (if equipped). When pilot shutoff solenoid valve is activated, oil flows to the left and right pilot control valves, travel pilot control valve, auxiliary pilot control valve (if equipped), blade pilot control valve (if equipped), and pilot signal manifold. When a pilot control valve is activated, oil flows through the pilot control valve, through the pilot signal manifold, to the front or rear control valve and actuates the desired spool, allowing high pressure oil to flow to the desired motor and or cylinders. When a blade function (if equipped) is activated, blade signal selector valve pilot oil flows through the spool, through travel flow combiner shuttle valve, to flow combiner valve in the control valve. When no functions are activated, the oil returns to hydraulic oil tank through the pilot pressure regulating valve.


Section 9025 page 5




Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Pump, Pressure Regulating Valve, and Filter LEGEND: 2 3 4 5 6 7 8 10 11 12 13 14 15 16 28 30

Driven Gear From Hydraulic Pump Suction Line Drive Gear Port PE-to-Pump 1 and 2 Servo Pistons and Regulators Port TA-to-Hydraulic Return Manifold Plug (port PC) Plug (port PG) Regulated Pilot Oil (marked PD)-to-Solenoid Valve Manifold Test Port (marked PF) From Pilot Pump Outlet (marked PA) Pilot Filter Element Pilot Pressure Regulating Valve Spool Spring Shim (as required) Pilot Pump Pilot Pressure Regulating Valve

Pilot filter element (13), by valve, and pilot pressure regulating valve (30) are incorporated into one assembly. Pilot filter by valve senses differential pressure between inlet side and outlet side of filter element. During normal operation, by valve is held closed by a spring and pilot oil flows through filter element to pilot pressure regulating valve and out to pilot circuit. When the filter element becomes plugged, pressure on inlet side increases forcing by valve open. Pilot oil now byes the filter element and unfiltered oil flows to pilot pressure regulating valve spool (14) and out to the pilot circuit. The pilot pressure regulating valve is a relief valve that is used to regulate pilot oil pressure to a constant pressure in pilot oil circuit. When pressure in pilot circuit increases to pressure setting of spring (15), spool is pushed against spring. Regulated pilot oil flows from port PD to solenoid valve manifold (10) and from port PE to pump 1 and 2 servo pistons and regulators (5). Oil not needed to maintain pressure in pilot circuit flows out port TA to hydraulic return manifold (6). For additional hydraulic system information, see Hydraulic System Schematic . (Group 9025-15.)


Section 9025 page 6




Pilot Shutoff Solenoid Valve Operation

Pilot Shutoff Solenoid Valve Port Locations LEGEND: A1 To Right Pilot Control Valve A2 To Travel Pilot Control Valve A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped) A4 To Pilot Signal Manifold Port PI HT Port HT (plugged) P Pilot Oil From Pilot Pump T1 From Travel Pilot Control Valve T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped) T3 From Right Pilot Control Valve T4 Return to Hydraulic Oil Tank The pilot shutoff solenoid valve is a solenoid actuated spool type valve. The solenoid is electrically operated by the pilot control shutoff lever. For additional information, see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)


Section 9025 page 7




De-Energized Pilot Shutoff Solenoid Valve Schematic


Section 9025 page 8




De-Energized Pilot Shutoff Solenoid Valve Section LEGEND: 604 Pilot Oil 609 Return Oil A1 To Right Pilot Control Valve A2 To Travel Pilot Control Valve A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped) A4 To Pilot Signal Manifold Port PI HT Port HT (plugged) P Pilot Oil From Pilot Pump T1 From Travel Pilot Control Valve T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped) T3 From Right Pilot Control Valve T4 To Hydraulic Oil Tank Y10 Pilot Shutoff Solenoid With the pilot control shutoff lever in the locked position, the lever is up. The solenoid for the pilot shutoff solenoid valve is deenergized. Pilot oil from pilot pump (P) is blocked by the spool. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI (A4) are open to the hydraulic oil tank (T4) through the spool. Therefore, no hydraulic function is actuated when a control lever for a pilot control valve is operated.


Section 9025 page 9




Energized Pilot Shutoff Solenoid Valve Schematic






Energized Pilot Shutoff Solenoid Valve Section LEGEND: 604 Return Oil 609 Pilot Oil A1 To Right Pilot Control Valve A2 To Travel Pilot Control Valve A3 To Left Pilot Control Valve and To Blade Pilot Control Valve (if equipped) A4 To Pilot Signal Manifold Port PI HT Port HT (plugged) P Pilot Oil From Pilot Pump T1 From Travel Pilot Control Valve T2 From Left Pilot Control Valve and From Blade Pilot Control Valve (if equipped) T3 From Right Pilot Control Valve T4 To Hydraulic Oil Tank Y10 Pilot Shutoff Solenoid With the pilot control shutoff lever in the unlocked position, the lever is down. The solenoid for the pilot shutoff solenoid is energized. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI (A4) are now open to pilot oil from pilot pump (P). Now operating a control lever actuates a function.






Pilot Control Valve Operation

Pilot Control Valve Metering and Full Stroke LEGEND: 1 Control Lever 2 Plunger 3 Spring Guide 4 Balance Spring 5 Return Spring 6 Orifice 7 Spool 8 Hole (4 used) 9 Housing 10 Work Port 1, 2, 3, or 4-to-Control Valve Pilot Caps 11 Port P From Pilot Shutoff Solenoid Valve 12 Port T-to-Pilot Shutoff Solenoid Valve 13 Deadband Area 14 Initial Movement 604 Return Oil 609 Pilot Oil The left and right pilot control valves regulate the pilot oil (609) pressure to actuate the pilot valves in the pilot signal manifold and to shift the control valve spools to actuate each function. For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.) Also, see Pilot Operation of Control Valve Operation . (Group 9025-05.) Each pilot control valve contains four valves, one for each function. The ports (10, 11, and 12) in housing (9) are identified by numbers and letters next to each port. The valves are pressure-reducing valves controlled by movement of the control lever (1) and plunger (2). Moving the control lever to actuate a function pushes the plunger and spring guide (3) against the balance spring (4) pushing the spool (7) down. The return spring (5) is also compressed by the plunger and spring guide. <- Go to Section TOC





During the initial movement (14), the spool goes through a deadband area (13) where the flow of return oil (604) through the holes (8) to port T is blocked before pilot oil flows from port P through the holes down through the spool to the work port and out to the control valve pilot caps (10). Pilot oil also flows through the orifice (6) to the top of spool to dampen the upward movement of spool. Pilot oil pressure out the work port increases until the pressure is equal to the force of balance spring pushing the spool up until the oil flow through the holes is blocked in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the control lever is again actuated. When the control lever is actuated to full stroke, the plunger s the spool, pushing it down until the plunger s a shoulder in the housing. Oil pressure to the control valve pilot caps is now approximately equal to pilot system pressure. When the control lever is returned to neutral, the spool is pushed up by the return spring, pushing the plunger up. The return springs hold the control lever in the neutral position. When the spool is up, the age to the control valve pilot cap is open to port T and pilot oil from port P is blocked.






Travel Pilot Control Valve Operation

Travel Pilot Control Valve Operation LEGEND: 1 2 3 <- Go to Section TOC

Spool Washer Spring Guide Section 9025 page 14



4 5 6 7 8 9 10 11 12 13 604 609


Plunger Adjustment Screw Cam and Pedal Sleeve Balance Spring Return Spring Port T to Hydraulic Oil Tank Port P From Pilot Shutoff Solenoid Valve Port 1, 2, 3, or 4-to-Control Valve Pilot Cap Travel Pilot Control Valve—Full Stroke Return Oil Pilot Oil

The travel pilot control valve regulates the pilot oil (609) pressure to actuate the pilot valves in the pilot signal manifold and to shift the control valve spools to actuate the travel functions. For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.) Also, see Pilot Operation of Control Valve Operation . (Group 9025-05.) One pilot control valve is used to control the travel functions. The pilot control valve contains four valve assemblies, one for each direction of travel for each track. The valves are pressure-reducing valves controlled by movement of the cams and pedals (6), and push against plunger (4). The ports (10, 11, and 12) in housing are identified by numbers and letters next to each port. In neutral, the spool is pushed up by the return spring (9) pushing the plunger up. The return springs hold the pedal in the neutral position. With the spool up, ports 1, 2, 3, and 4 to control valve pilot cap (12) are open to port T to the hydraulic oil tank (10) through the age and holes in spool. Port P for pilot oil from the pilot shutoff solenoid valve (11) is blocked by the spool. When the pedal is pushed to move the machine, the cam pushes the plunger and spring guide down against the return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down and the holes move through the deadband area, the age from control valve pilot cap to the hydraulic oil tank is closed and then opened to the pilot oil from pilot shutoff solenoid valve. Pilot oil pressure increases until it is equal to the force applied by the balance spring pushing the spool up until the oil flow through the holes is blocked in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the pedal is again actuated. When the pedal and cam is pushed to full stroke, the plunger is pushed down farther by the balance spring, opening the age through the spool to pilot oil pressure. When pressure to the control valve pilot cap is equal to the force applied by the balance spring, the spool moves up until it s the plunger. The plunger holds the spool down so the age through the spool remains open to pilot oil pressure. Oil pressure to the control valve pilot cap now approximately equals pilot oil pressure. LEGEND: 14 15 16 17 18 19 20



Travel Pedal Spring Pin Damper Bracket Gear 2 Gear 1




Travel Pilot Pedal (shockless function) The travel pedal is equipped with a shockless function. The shockless function consists of a bracket (18) connected to the travel pedal (14) and a (17) connected to the bracket with a spring pin (15). Gear 1 (20) is connected to the . When the travel pedal is released while traveling, the spring forces the travel pedal to the neutral position. At this time, gear 1 and gear 2 (19) inside the damper (16) receive resistance due to friction. The travel pedal gradually returns to neutral, preventing a sudden stop due to sudden release of the travel pedal.






Pilot Operation of Control Valve Operation For additional information and reference, see Pilot Signal Manifold Operation . (Group 9025-05.) The left pilot control valve (39), right pilot control valve (40), and travel pilot control valve (38) are connected to the left control valve (5-spool) (74) and right control valve (4-spool) (73) by pilot lines through the pilot signal manifold (41). Actuating a pilot control valve routes pilot oil (609) through the pilot signal manifold to the control valve pilot cap to shift a spool. Boom up function (1), arm in function (4), left travel forward function (9), and right travel forward function (11) are shown energized. Pilot oil also flows through the shuttle valves in the pilot signal manifold and shifts the pilot valves (42—48). For additional information and reference, see Control Valve Operation . (Group 9025-05.) The following valves in the control valve are controlled by pilot oil from the pilot control valves and pilot valves: Auxiliary Flow Combiner Valve (118) Left and Right Travel Valve Spools (110 and 75) Bucket Flow Rate Control Valve (valve and poppet) (77) Bucket Regenerative Spool (78) Boom 1 and Boom 2 Valve Spools (81 and 104) Boom Up Pressure Sensor (B30) Boom Reduced Leakage Valve (valve and check valve) (85) Arm 2 and Arm 1 Spools (97 and 90) Arm In Pressure Sensor (B31) By Shutoff Valve (93) Swing Spool (95) Arm Reduced Leakage Valve (valve and poppet) (101) Auxiliary Spool (107) Auxiliary Flow Rate Control Valve (valve and poppet) (108) Travel Flow Combiner Valve (120) For additional information and reference, see Control Valve Operation and see Travel Motor Speed Circuit Operation . (Group 9025-05.) The following valves in the control valve and left and right travel motors are controlled by the solenoid valves (Y23 and Y24) in the solenoid valve manifold: Arm Regenerative Valve (94) Travel Speed Change Valve (66) →NOTE: Blade is optional.

For additional information and reference, see Blade Circuit Operation—If Equipped . (Group 9025-05.) The blade pilot control valve (150) is connected to the left control valve (74), right control valve (73), and pilot signal manifold (41), blade control valve (144) by pilot lines through blade signal shuttle valve (148). Actuating the blade pilot control valve routes pilot oil through the blade signal shuttle valve to the travel flow combiner valve, to blade control valve, to shift blade spool (140). Pilot oil is also routed to the left control valve to shift by shutoff valve (93) and to front attachment pressure sensor (B32) inside swing parking brake shuttle valve (146).






Pilot Signal Manifold Operation

Pilot Signal Manifold Pilot Valves and Ports LEGEND: 1, A 2, B 3, C 4, D 5, E 6, F 7, G 8, H 9, I 10, J 11, K 12, L 13, M 14, N 41A 41B 42 43 44 45 46 47 48 70 <- Go to Section TOC

Boom Up Boom Down Arm Out Arm In Swing Left Swing Right Bucket Curl Bucket Dump Left Travel Forward Left Travel Reverse Right Travel Forward Right Travel Reverse Plug (auxiliary) Plug (auxiliary) Control Valve Side of Pilot Signal Manifold Pilot Control Valve Side of Pilot Signal Manifold Boom Down Shockless Valve Arm 1 (swing priority) Flow Rate Pilot Valve (port SE) Travel Flow Combiner Pilot Valve (port SL) Swing Park Brake Release Pilot Valve (port SH) Bucket Flow Rate Pilot Valve (port SK) Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) Orifice Section 9025 page 18



B33 B34 DF PH PI SA SB SE SH SK SL SM SN SP


Swing Pressure Sensor Travel Pressure Sensor To Hydraulic Oil Tank Plug From Pilot Shutoff Solenoid Valve To Pump 1 Regulator Remote Control Spool To Pump 2 Regulator Remote Control Spool To Arm 1 (swing priority) Flow Rate Control Valve To Swing Park Brake To Bucket Flow Rate Control Valve To Travel Flow Combiner Valve To Hydraulic Oil Tank Plug (not used) To Solenoid Valve Manifold (port DP)

→NOTE: The numbers 1—14 and letters A—N, DF, TR, S3, SA, SB, SE, SH, SK, SL, SM, SN, SP, PH, and PI are next to the respective ports on the pilot signal manifold.

The pilot signal manifold is in the pilot system between the pilot control valves and the control valve and regulators. The manifold receives a pilot signal from the pilot control valves and sends the signal on multiple paths. One path is used to shift the spools in the control valve and the other sends a signal to the regulators through pump 2 flow rate pilot valve (47) and pump 1 flow rate pilot valve (48). This is done simultaneously, so there is little lag between operation of the pilot control valves, pump stroke, and function movement. The manifold also houses additional pilot valves that provide pilot oil for various other functions. For additional Information, see Hydraulic System Schematic . (Group 9025-15.)






Boom Down Shockless Valve LEGEND: 1 41A 41B 42 50 <- Go to Section TOC

To Bottom Pilot Cap Control Valve Side of Pilot Signal Manifold Pilot Control Valve Side of Pilot Signal Manifold Boom Down Shockless Valve Shuttle Valve Section 9025 page 20



138 139 140 141 142 143 144 145 A


Spring A age 1 Tapered Land Orifice Spring B age 3 Oil Chamber age 2 From Pilot Control Valve—Boom Up

Boom Down Shockless Valve The boom down shockless valve (42) regulates the return oil flow from the pilot cap during boom down operation. Regulating the return oil flow controls the movement of boom 1 and boom 2 spools, to provide precise control of boom down function. Actuating boom up sends pilot oil to pilot signal manifold port A. Pilot oil flows past the tapered land (140) on the boom down shockless valve spool and into the oil chamber (144). The tapered land acts as a variable orifice between the spool and manifold as the spool is shifted back and forth. Pilot oil flows from the oil chamber, through the orifice (141), into age 2 (145), and out port 1 to the control valve pilot cap. Pilot oil also flows through age 3 (143) into spring B (142) cavity and age 1 (139) into spring A (138) cavity. Spring B is the larger spring. The increasing pilot oil pressure shifts the valve spool to the left, opening the age from port A to port 1 and allowing pilot oil to flow unrestricted to the pilot cap shifting the boom 1 and boom 2 valve spools. Actuating boom down sends return oil from the pilot cap to port 1. From port 1 pilot oil flows through age 1 to spring A cavity and through age 2, through the orifice, and into the oil chamber. From the oil chamber, return oil flows through age 3 to spring B cavity and past the tapered land to port A. Because of the pressure drop across the orifice, the return oil pressure in the oil chamber and spring B cavity is less than the return oil pressure in spring A cavity. The increasing return oil pressure shifts the valve spool to the right, causing the tapped land to restrict and then block the flow of return oil from port 1 to port A. When the tapered land blocks the return oil flow, the pressure increases in the oil chamber and spring B cavity. The valve spool now shifts to the left allowing return oil to flow past the tapered land to port A. The opening and closing continues until the return oil is gradually returned through port A, controlling the movement of the boom 1 and boom 2 spools.

Pump 1 or Pump 2 Flow Rate Pilot Valve <- Go to Section TOC




LEGEND: 41A 41B 47 48 50 146 147 148 149 150 151 SA SB


Control Valve Side of Pilot Signal Manifold Pilot Control Valve Side of Pilot Signal Manifold Pump 2 Flow Rate Pilot Valve Spool (port SB) Pump 1 Flow Rate Pilot Valve Spool (port SA) Shuttle Valve To Hydraulic Oil Tank by Port DF Pilot Oil From Actuated Pilot Control Valves Pilot Oil From Actuated Pilot Control Valves Pilot Oil From Port PI Spring Chamber age A Port SA to Pump 1 Regulator Port SB to Pump 2 Regulator

Pump 1 Flow Rate Pilot Valve (SA) and Pump 2 Flow Rate Pilot Valve (SB) The function of pump 1 and pump 2 flow rate pilot valves is to deliver a regulated amount of pilot oil to the pump 1 and pump 2 regulators in proportion to the pilot oil pressure applied to the flow rate pilot valve spools (47 or 48) by the actuated pilot control valves (147). The pilot oil delivered by the flow rate pilot valves is from the pilot control shutoff valve port A4 to the pilot signal manifold through port PI (149). Pump 1 flow rate pilot valve delivers regulated pilot oil to pump 1 through port SA. Pump 2 flow rate pilot valve delivers regulated pilot oil to pump 2 through port SB. The pilot oil from the actuated pilot control valve is routed to the flow rate pilot valves by the shuttle valves. Actuating a function sends pilot oil from the pilot control valve to the pilot signal manifold. The pilot oil flows through the manifold to the control valve pilot cap and within the manifold to the spring chamber (150). The pilot oil pressure in the spring chamber increases, shifting the flow rate pilot valve spool to the right and allowing a regulated amount of pilot oil to flow past the spool to the right end of spool and out the port (SA or SB) to pump regulator through age A (151). The spool is shifted back to the left until the regulated pilot oil pressure equals the oil pressure in the spring chamber and spring force stopping the oil pressure increase to the pump regulator. For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) →NOTE: Ports SA and SB are located on the control valve side of pilot signal manifold (41A) but, for simplification of the schematic, are shown on the pilot control valve side of pilot signal manifold (41B).

When the function is returned to neutral, oil pressure in the spring chamber is released to the hydraulic oil tank through the pilot control valve. The regulated pilot pressure on the right end of spool shifts the spool to the left against the spring, releasing the regulated pilot oil pressure to the hydraulic oil tank by port DF (146). As the regulated pilot oil pressure decreases, the spool is shifted back to the right by the spring until the spring force and oil pressure are equal.

Bucket Flow Rate Pilot Valve LEGEND: 152 153 154 <- Go to Section TOC

Pilot Oil Pressure To Hydraulic Oil Tank To Bucket Flow Rate Valve Section 9025 page 22




155 Pilot Oil Pressure From Boom Up 156 Spring Bucket Flow Rate Pilot Valve (Port SK) Bucket flow rate pilot valve is shifted by the pilot oil pressure (152) from arm in to port D and through the shuttle valves. The pilot valve routes pilot oil pressure from boom up (Port A) (155) to the bucket flow rate valve in the control valve. The bucket flow rate valve restricts the flow of high pressure oil to the bucket spool during arm in and boom up operation to ensure a flow of high pressure oil to the boom 1 spool.

Travel Flow Combiner Pilot Valve LEGEND: 152 Pilot Oil Pressure 153 To Hydraulic Oil Tank 156 Spring 157 To Travel Flow Combiner Valve 158 Control Pressure Pilot Oil Travel Flow Combiner Pilot Valve (Port SL) Travel flow combiner pilot valve is shifted by pilot oil pressure (152) from right travel to port L (right reverse) or port K (right forward) and through the shuttle valves. The pilot valve then routes control pressure pilot oil (158) from the swing park brake release pilot valve to the travel flow combiner valve in the control valve. The control pressure pilot oil is from the pilot shutoff solenoid valve port A4 to the pilot signal manifold through port PI. For additional information, see Travel Flow Combiner Valve Operation . (Group 9025-05.)

Swing Park Brake Release Pilot Valve LEGEND: 152 Pilot Oil Pressure 153 To Hydraulic Oil Tank 156 Spring 158 Control Pressure Pilot Oil 159 To Swing Park Brake Swing Park Brake Release Pilot Valve (Port SH) Swing park brake release pilot valve is shifted by pilot oil pressure (152) from boom up to port A, boom down to port B, arm out to port C, arm in to port D, bucket curl to port G, bucket dump to port H, or auxiliary to port M or N and through the shuttle <- Go to Section TOC





valves. The pilot valve routes control pressure pilot oil (158) out port SH to the swing motor park brake piston through port SH. The control pressure pilot oil is from the pilot shutoff solenoid valve port A4 to the pilot signal manifold through port PI. For additional information, see Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.)

Arm 1 Flow Rate Control Pilot Valve LEGEND: 153 To Hydraulic Oil Tank 156 Spring 160 Arm In Pilot Oil Pressure 161 To Arm 1 Flow Rate Control Valve 162 Swing Pressure Pilot Oil Arm 1 Swing Priority Flow Rate Control Pilot Valve (Port SE) Arm 1 flow rate control pilot valve is shifted by arm in pilot oil pressure (160). The pilot valve then routes swing pressure pilot oil (162) to arm 1 flow rate control valve (161) in the control valve.






Pilot Signal Manifold Shuttle Valve






LEGEND: 20 Check Valve (4 used) 21 Auxiliary Valve (if equipped) 22 Swing and Auxiliary Valve (if equipped) 23 Swing Valve 24 Bucket Valve 25 Arm, Boom Up, Auxiliary Valve (if equipped) 26 Boom, Arm, Bucket, Swing, Auxiliary Valve (if equipped) 27 Boom, Arm, Bucket Valve 28 Boom Up, Arm, Bucket, Left Travel, Swing, Auxiliary Valve (if equipped) 29 Arm, Boom, Bucket, Right Travel Valve 30 Boom Valve 31 Boom, Arm, Bucket, Right Travel Valve 32 Boom, Arm Valve 33 Arm Valve 34 Boom, Arm, Right Travel Valve 35 Right Travel Valve 36 Left Travel, Right Travel Valve 37 Left Travel Valve 38 Travel Pilot Control Valve 39 Left Pilot Control Valve 40 Right Pilot Control Valve 41 Pilot Signal Manifold 42 Boom Down Shockless Valve 43 Swing Priority Flow Rate Pilot Valve (port SE) 44 Travel Flow Combiner Pilot Valve (port SL) 45 Swing Park Brake Release Pilot Valve (port SH) 46 Bucket Flow Rate Pilot Valve (port SK) 47 Pump 2 Flow Rate Pilot Valve (port SB) 48 Pump 1 Flow Rate Pilot Valve (port SA) 134 Pilot Shutoff Valve B33 Swing Pressure Sensor B34 Travel Pressure Sensor Y10 Pilot Shutoff Solenoid Shuttle Valves (21—37) Control pilot oil pressure from the actuated left, right, travel, and auxiliary (if equipped) pilot control valves to the pilot signal manifold is routed by the shuttle valves (21—37) to shift the respective pilot valves (44, 45, 47, and 48) and actuate the swing pressure sensor (B33) and travel pressure sensor (B34). The bucket flow rate pilot valve (46) and swing priority flow rate pilot valve (43) are shifted directly by control pilot oil from port D (arm in function). Actuated Function To Shift Pilot Valve Actuated Function to Shift Pilot Valve Travel Flow Combiner Valve Pilot Valve

Function and Pilot Signal Manifold Ports

Pump 1 Flow Rate Pilot Valve

Pump 2 Flow Rate Pilot Valve

Bucket Flow Rate Pilot Valve

Swing Park Brake Release Pilot Valve

Boom Up, A

X

X

Boom Down, B

X

Arm In, D

X

X

Arm Out, C

X

X

Bucket Curl, G

X

X

Bucket Dump, H

X

X

X X X

X

X

X

Left Swing, E

X

X

X

X

X

Right Swing, F

Right Travel, L, K

Arm 1 (Swing Priority) Flow Rate Pilot Valve

X

Left Travel, I, J

X

Auxiliary, N, M

X

X

There are six outputs of the pilot signal manifold other than providing ages for pilot oil to shift control valve spools.






Six Additional Outputs of Pilot Signal Manifold Six Outputs of Pilot Signal Manifold Output

Input Number 1

Input Number 2

Travel Flow Combiner

Any Dig or Swing Function

Right Travel

Bucket Flow Rate Control

Arm In

Boom Up

Arm 1 (Swing Priority) Flow Rate Control

Arm In

Swing

Release Swing Brake

Any Dig or Swing Function

P1 Flow Rate Control

Right Travel, Boom, Arm or Bucket

P2 Flow Rate Control

Left Travel, Boom, Arm or Swing






Pump 1, Pump 2, and Drive Gear Case Operation

Pump 1, Pump 2, and Pilot Pump LEGEND: 7 11 15

Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons Damper Drive (flex coupling) Pump 1 (4-spool)





16 17 18 28 B35 B36 B37 B38 Y20 Y21


Pump 2 (5-spool) Pump 1 Regulator Pump 2 Regulator Pilot Pump Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST)






Pump 1 and Pump 2 Cross Section LEGEND: 7 15 16 17 18

Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons Pump 1 (4-spool) Pump 2 (5-spool) Pump 1 Regulator Pump 2 Regulator





25 26 27 28 29 30 Y20 Y21


Lever Link Swash Plate Pilot Pump Minimum Displacement Servo Piston (2 used) Maximum Displacement Servo Piston (2 used) Pump 2 Flow Rate Limit Solenoid (marked SB) Torque Control Solenoid (marked ST)

Pump 1 (15) and pump 2 (16) are swash plate type, variable-displacement, axial piston pumps. Pump 1 and pump 2 are identical pumps in an in-line configuration in one housing. The pump 1 drive shaft is connected to the engine flywheel through a damper drive (flex coupling) (11). Pilot pump (28) is a gear pump connected to the output shaft of pump 2. Pump 1, pump 2, and the pilot pump are driven at engine speed. Pressure sensors (B35—B38) and solenoids (Y20 and Y21) are used to control the pump operation. The pumps vary from minimum to maximum displacement, generating the supply oil flow in the hydraulic system depending on the hydraulic demand of the system. Pump 1 regulator (17) and pump 2 regulator (18) control the movement of the minimum displacement servo piston (29) by sending or releasing oil from the piston bores. A constant pilot oil pressure from the pilot pressure regulating valve port (7) is supplied to the maximum displacement servo pistons (30). The servo pistons move the swash plate (27), changing the pump displacement. The pump displacement, or flow rate, is varied by changing the angle of the swash plate with respect to the drive shaft. Increasing the angle increases the distance that each piston travels into and out of the bore, which increases displacement. Decreasing the angle reduces the distance that each piston travels into and out of the bore, which decreases displacement. The movement of the swash plate is transmitted mechanically by the lever (25) and link (26), providing a to the remote control sleeve and load sleeve in the regulators. The sleeves block the flow of pilot oil and traps the oil to the servo piston, stopping swash plate movement at the flow rate in proportion to the control lever actuation. For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) Also, see Hydraulic System Schematic . (Group 9025-15.)






Pump 1 and Pump 2 Regulator Operation

Pump Regulator Component Identification LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Flow Adjusting Cartridge (track cycle time) Maximum Flow Adjusting Screw Spring Remote Control Sleeve Remote Control Spool Piston Minimum Flow Adjusting Screw Load Adjusting Screw (inner spring) Load Adjusting Cartridge (outer spring) Inner Spring Outer Spring Load Sleeve Load Spool Load Piston 2 Load Piston 1 Link

Pump Regulator Component Identification— Function of pump 1 and pump 2 regulators is to control pump 1 and pump 2 flow rates (displacement) in response to various oil pressure signals so pump drive torque does not exceed engine torque. Piston (6) controls the remote control spool (5) movement against spring in response to flow rate valve pilot oil pressure from pump 1 and pump 2 flow rate pilot valves. Actuating control levers or pedals shifts flow rate pilot valves. For additional information, see Pilot Signal Manifold Operation . (Group 9025-05.) Load piston 1 (15) and load piston 2 (14) control the load spool (13) movement against inner and outer springs (8 and 9) in response to pilot oil pressure from torque control solenoid valve and high pressure oil pressure from pump 1 and pump 2. High <- Go to Section TOC





pressure oil pressure from pump 1 is sensed on one shoulder of load piston and from pump 2 on other shoulder. Pilot oil pressure increases or decreases in response to actual engine speed to target engine speed difference or when a travel function is actuated at slow engine speed. For additional information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.) Remote control sleeve (4) and load sleeve (12) are moved by link (16) blocking flow of oil to or from large end of servo piston. Pump 1 and pump 2 regulators are mounted on top of pump housing. Torque control solenoid valve and pump 2 flow rate limit solenoid valve are located in housing on top of pump 2 regulator. Pump 1 and pump 2 regulators are mounted on the top of pump housing. Torque control solenoid, pump 2 flow rate solenoid, and pump 1 flow rate limit solenoid are located in housing on top of pump 2 regulator. For minimum flow adjusting screw (7) tests and adjustments, see Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.) For flow adjusting cartridge (track cycle time) (1) and maximum flow adjusting screw (2) tests and adjustments, see Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)

Pump Regulator Control by Flow Rate Pilot Valve—Increasing LEGEND: 1 2 3 4 <- Go to Section TOC

Flow Adjusting Cartridge (track cycle time) Maximum Flow Adjusting Screw Spring Remote Control Sleeve Section 9025 page 33



5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 600 604 609 611 613


Remote Control Spool Piston Load Adjusting Cartridge (outer spring) Load Adjusting Screw (inner spring) Inner Spring Outer Spring Load Sleeve Load Spool Load Piston 2 Load Piston 1 Link Servo Piston To Large End of Servo Piston Return to Pump Housing Pump 1 Pressure Inlet Pump 2 Pressure Inlet Torque Control Port From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB) Pilot Oil Inlet High Pressure Oil Return Oil Pilot Oil Charge Oil Reduced Pilot Oil

Pump Regulator Control by Flow Rate Pilot Valve Pilot oil (609) from pilot pump is constantly supplied through drilled ages in pump housing to small end of servo pistons, to pilot oil inlet (24) at the pump 1 and pump 2 regulators, and to torque control solenoid valve located on top of pump 2 regulator. Pump flow rate (displacement) is changed by sending pilot oil to or releasing it from the large end of servo piston (17) through the ages to large end of servo piston (18). Pilot oil (609) from pump 1 or 2 flow rate pilot valves (23) in pilot signal manifold is sensed by the piston (6) in its respective regulator. High pressure oil (600) from pump 1 and pump 2 is sensed through drilled ages in pump housing to pump 1 pressure inlet (20) and pump 2 pressure inlet (21) in each pump regulator. Charge oil (611) from torque control solenoid valve is routed through steel lines to torque control port (22) in each pump regulator. Increasing Flow Rate (Displacement) Actuating a control lever or pedal increases the pump control lever or pedal increases the reduced charge or pilot oil (613) pressure from pump 1 and/or flow rate pilot valve to the piston (6). Pilot oil pressure pushes the piston and remote control spool (5) to left against the spring (3). Movement of spool opens the age from large end of servo piston (18) to return to pump housing (19). Primary pilot oil on small end of servo piston pushes piston down, increasing pump angle which increases flow rate (displacement). Movement of the cylinder block, valve plate, and servo piston is transmitted to remote control sleeve (4) and load sleeve (12) by the link (16). Sleeves move left until ages return is closed. Oil at large end of servo piston is now trapped, holding the pump at flow rate (displacement) that is proportional to pressure of pump control pilot oil from pump 1 and/or 2 flow rate pilot valve to the piston. Maximum Flow Rate (Displacement) When control lever or pedal is actuated to full stroke, pilot oil (609) from pump 1 or 2 flow rate pilot valve (port SA or SB) (23) to piston (6) increases to its maximum pressure. Oil pressure pushes the piston to remote control spool to left until spool s maximum flow adjusting screw (2). Movement of spool opens the age from large end of servo piston (18) to return in pump housing (19). Pilot oil on small end of servo piston pushes piston down, increasing pump flow rate (displacement). As flow rate (displacement) increases, servo piston movement is transmitted to remote control sleeve (4) and load sleeve (12) by link (16). Sleeves move left until age to return is closed. Oil at large end of servo piston is now trapped, holding pump at maximum flow rate (displacement). <- Go to Section TOC





Decreasing Flow Rate (Displacement) As control lever or pedal is returned to neutral, reduced pilot oil (613) pressure sensed at piston (6) also decreases. Spring (3) pushes remote control spool and piston to the right. Movement of spool opens a age for pilot oil (609) from pilot oil inlet (24) to flow to large end of servo piston (18). Pilot oil pressure applied to large end of servo piston (17) pushed it up against pilot oil pressure applied to small end decreasing pump flow. Remote control spool continues to move to right in response to decreasing pump pilot oil pressure until it s piston cylinder. As pump flow rate (displacement) decreases, movement of cylinder block, valve plate, and servo piston is transmitted to remote control sleeve (4) and load sleeve (12) by the link (16). Sleeves move right until age for pilot oil is closed. Oil at large end of servo piston is now trapped, holding pump at flow rate (displacement) that is proportional to pressure of pump pilot oil.

Pump Regulator Control by High Pressure Oil Pressure—Decreasing LEGEND: 1 2 3 4 5 6 8 9 10 11 12 13 14 15 <- Go to Section TOC

Flow Adjusting Cartridge (track cycle time) Maximum Flow Adjusting Screw Spring Remote Control Sleeve Remote Control Spool Piston Load Adjusting Cartridge (outer spring) Load Adjusting Screw (inner spring) Inner Spring Outer Spring Load Sleeve Load Spool Load Piston 2 Load Piston 1 Section 9025 page 35



16 17 18 19 20 21 22 23 24 600 604 609 611 613


Link Servo Piston To Large End of Servo Piston Return to Pump Housing Pump 1 Pressure Inlet Pump 2 Pressure Inlet Torque Control Port From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB) Pilot Oil Inlet High Pressure Oil Return Oil Pilot Oil Charge Oil Reduced Pilot Oil

Pump Regulator Control by High Pressure Oil Pressure High pressure oil (600) pressure (load) for each pump is sensed on shoulders of load piston 2 (14) through pump 1 and pump 2 pressure inlets (20 and 21) in each pump regulator. The area of each shoulder is equal. Therefore, force applied through load piston 2 (14) to inner and outer springs (10 and 11) is an average of high pressure oil pressures. Springs are adjusted against the average pressure so flow rate of each pump is approximately equal and uses approximately one-half engine torque. Increasing high pressure oil pressure (load) pushes the load piston 2 and load spool against inner and outer springs, opening age for pilot oil (609) to flow from pilot oil inlet (24), through load sleeve (12) to large end of servo pistons (18). Flow rate decreases until link (16) moves load sleeve and remote control sleeve (4) blocking flow of oil. Flow rate of both pumps decreases so load on pumps does not exceed engine torque. When high pressure oil pressure (load) decreases, the inner and outer springs push the load spool and pistons to the right against the high pressure oil pressure. The movement opens the age for oil to flow from large end of servo piston (18) through load sleeve and remote control sleeve to return to pump housing (19). Flow rate increases until link moves load sleeve and remote control sleeve blocking the flow of oil. Engine torque is not exceeded, even if one pump is loaded relatively high while other pump stays relatively low. As long as a control lever or pedal is held constant, the pump pilot oil (609) pressure from pump 1 or 2 flow rate pilot valve (23) to the piston (6) does not change as high pressure oil pressure changes.






Pump Regulator Control by High Pressure Oil Pressure (torque control solenoid valve)—Decreasing LEGEND: 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 600 604 609 <- Go to Section TOC

Flow Adjusting Cartridge (track cycle time) Maximum Flow Adjusting Screw Spring Remote Control Sleeve Remote Control Spool Piston Load Adjusting Cartridge (outer spring) Load Adjusting Screw (inner spring) Inner Spring Outer Spring Load Sleeve Load Spool Load Piston 2 Load Piston 1 Link Servo Piston To Large End of Servo Piston Return to Pump Housing Pump 1 Pressure Inlet Pump 2 Pressure Inlet Torque Control Port From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB) Pilot Oil Inlet High Pressure Oil Return Oil Pilot Oil Section 9025 page 37



611 613


Charge Oil Reduced Pilot Oil

Pump Regulator Control by Engine Speed Sensing (Torque Control Solenoid Valve) As engine speed changes, the main controller calculates speed difference between target and actual engine speed. Main controller then actuates torque control solenoid valve to increase or decrease torque charge oil (611) pressure to torque control port (22) and load piston 1 (15). As the load on engine increases, speed difference between target and actual engine speed increases. Main controller decreases electrical signal to torque control solenoid valve, which increases torque charge oil (611) pressure to load piston 1. Torque pilot oil along with high pressure oil pressure on load piston 2 (14) shifts load spool (13) so pilot oil (609) flows to large end of servo piston (18), decreasing flow rate (displacement). As flow rate of both pumps decreases, load on engine also decreases allowing actual engine speed to increase. As the load on engine decreases, speed difference between target and actual engine speed decreases. Main controller increases electrical signal to torque control solenoid valve, which decreases torque pilot oil pressure to load piston 1. Inner and outer springs (10 and 11) shifts load spool in response to decreasing torque control pilot oil pressure, releasing oil from large end of servo piston to return to pump housing (19) allowing pump flow (displacement) to increase. As pump flow rate increases, engine output is used more efficiently. Pump Regulator Control by Travel Torque-Up Control (Slow Speed Sensing) The function of travel to torque-up control is to increase the pump flow rate when the travel function is actuated at slow engine speed. Actuating travel function with the engine at slow idle causes the pump to go to maximum displacement. Therefore, pump 1 and 2 flow rates are increased to prevent mistracking, which can occur at the lower flow rate if there are differences between pumps 1 and 2. When the engine speed requested by the engine speed dial is slow, the main controller processes electrical signals from the travel pressure sensor and pump 1 and 2 delivery pressure sensors. Main controller then increases the electrical signal to torque control solenoid valve, which decreases torque charge oil (611) pressure to load piston 1. Inner and outer springs shift the load spool in response to decreasing torque pilot oil pressure, releasing oil from large end of servo piston allowing pump displacement to go to maximum. The pump flow rate increases and the machine does not mistrack at slow engine speed. The increased flow rate continues even if a dig function is actuated while traveling at slow engine speed. For additional information, see Engine Speed Sensing Control Circuit Operation . (Group 9025-05.)






Engine Speed Sensing Control Circuit Operation

Engine Speed Sensing Control Circuit

Torque Control Solenoid LEGEND: 1 2 3 4 5 6 7 17 18 600 604 609 <- Go to Section TOC

Spring Spool Return Spring Inlet Port Sleeve Outlet Port to Load Piston Spool Return Port to Pump Case Pump 1 Regulator Pump 2 Regulator High Pressure Oil Return Oil Pilot Oil Section 9025 page 39



650 A3 B1 B34 B35 B37 R15 Y21


Electrical Voltage Main Controller (MCZ) Crankshaft Position Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Engine Speed Dial Torque Control Solenoid (marked ST)

Engine Speed Sensing Control (Torque Control Solenoid) The function of the engine speed sensing control is to control pump flow rate in response to engine speed changes caused by load variations so the engine output is used efficiently. The main controller (MCZ) (A3) calculates the speed difference between target and actual engine speed. The MCZ then actuates the torque control solenoid (Y21) to change the pump displacement to increase or decrease pump flow rate. Target engine speed is a value set by the position of engine speed dial (R15). Actual engine speed is sensed by the crankshaft position sensor (B1). As a load on the engine increases, the actual engine speed becomes less than the target engine speed. The MCZ decreases the electrical voltage to the torque control solenoid valve, which increases the pilot oil (609) pressure to the load piston 1 in the pump 1 and pump 2 regulators (17 and 18). Pilot oil pressure on load piston 1 and high pressure oil (600) pressure on load piston 2 shifts the load spool (6) so pilot oil flows to the large end of servo piston, decreasing the pump displacement. As the flow rate is reduced, the load on the engine is reduced. As the load on the engine decreases, the actual engine speed becomes greater than the target engine speed. The MCZ increases the electrical voltage to the torque control solenoid valve, which decreases the pilot oil pressure to the load piston in the regulators. The spring (1) shifts the load spool in response to the decreasing pilot oil pressure, releasing oil from the large end of servo piston allowing the pump displacement to increase. As the pump flow rate increases, the engine output is used more efficiently. For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) Travel Torque-Up Control (Slow Speed Sensing) The function of travel torque-up control is to increase the pump flow rate when the travel function is actuated at slow engine speed. Actuating travel function with the engine at slow idle causes the pump to go to maximum displacement. Therefore, pump 1 and 2 flow rates are increased to prevent mistracking, which can occur at the lower flow rate if there are differences between pumps 1 and 2. When the engine speed requested by the engine speed dial (R15) is slow, the main controller processes the electrical signals from the travel pressure sensor (B34), pump 1 delivery pressure sensor (B35), and pump 2 delivery pressure sensor (B37). The main controller sends an increasing electrical voltage to the torque control solenoid which decreases the pilot oil pressure to load piston 1 in the regulators. The springs shift the load spool in response to the decreasing pilot oil pressure, releasing oil from the large end of servo piston allowing pump displacement to increase. At the increased flow rate the machine does not mistrack at slow engine speed. For additional information, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) The increased flow rate continues even if a dig function is actuated while traveling at slow engine speed.






Control Valve Operation

Control Valve—Left 5-Spool Side LEGEND: 73 74 75 76 81 87 89 90 95 97 98 102 103 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Boom Lower Meter-In Cut Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Swing Spool Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Section 9025 page 41



104 107 108 110 117 118 119 149 166


Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve (P1, P2) Auxiliary Function Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Arm Regenerative Cut Valve Bucket Regenerative Cut Valve

Control Valve—Right 4-Spool Side LEGEND: 73 74 75 76 77 79 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Dump Circuit Relief and Anticavitation Valve Section 9025 page 42



80 81 83 84 85 88 90 91 93 94 95 97 100 104 107 110 118 120 121 122


Bucket Curl Circuit Relief and Anticavitation Valve Boom 1 Spool Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve (valve and check valve) Boom Up Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) By Shutoff Valve Arm Regenerative Cut Valve Swing Spool Arm 1 Spool Check Valve (lift check)—Dig Regenerative Circuit Boom 2 Spool Auxiliary Spool Left Travel Spool Auxiliary Function Flow Combiner Valve Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit Check Valve (lift check)—Bucket

The control valve consists of two monoblock valves referred to as the 5-spool control valve (74) and 4-spool control valve (73). The 5-spool control valve and 4-spool control valve are mounted back-to-back so the oil ages in the valves are connected. The spools are selectively fitted. There is a spool in each valve to control the boom (81 and 104), arm (90 and 97), and travel (75 and 110) functions. The spools in 4-spool control valve consist of right travel spool (75), bucket spool (76), boom 1 spool (81), and arm 2 spool (90). The spools in 5-spool control valve consist of left travel spool (110), auxiliary spool (107), boom 2 spool (104), arm 1 spool (97), and swing spool (95). All other functions are supplied by a single spool in one or the other of the valves. All spools are operated by pilot oil pressure. Check valves are used as lift checks and to route high pressure oil between the 4-spool and 5-spool valves for combined operation. The control valve is an open-center type valve. Each valve section controls the flow rate and direction for its hydraulic circuit. For more information, See Hydraulic System Schematic (Group 9025-15.) All valves are accessible from the outside of control valve by removing a plug, cover, or the pilot caps. See Control Valve Line Identification . (Group 9025-15.) For additional information, See Control Valve Check Valves Identification and Operation (Group 9025-05.) For check valve (lift check) and orifice—travel and bucket combiner circuit (122) and check valve—travel flow combiner valve circuit (121) information. See Travel Flow Combiner Valve Operation (Group 9025-05.)






Neutral and Power ages Operation LEGEND: 15 16 52 61 63 <- Go to Section TOC

Pump 1 (4-spool) Pump 2 (5-spool) Swing Motor Right Travel Motor Left Travel Motor Section 9025 page 44



73 74 75 76 81 90 95 97 104 107 110 124 125 126 127 600 604 612


4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Left Travel Spool Hydraulic Oil Cooler By Valve Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder High Pressure Oil Return Oil Combiner Oil

High Pressure oil (600) from pump 1 (15) flows to the right control valve (73). High pressure oil from pump 2 (16) flows to the left control valve (74). When all functions are in neutral, high pressure oil flows through the neutral and power ages for each valve spool section and then into return oil (604) the return age. Neutral and power ages in the left and right control valves are used to route high pressure oil for the combined operation of functions. Combiner oil (612) is connected in combiner ages between arm 1 and 2 spools (97 and 90), and boom 1 and 2 spools (81 and 104), so high pressure oil from both pump 1 and pump 2 flows to the cylinders during a single operation. High pressure oil from pump 2 can be combined with high pressure oil from pump 1 by the auxiliary combiner power age to supply the auxiliary spool (107).

Left and Right Travel Cross Section (from rear) <- Go to Section TOC




LEGEND: 73 74 75 110 111 112


4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Left Travel Spool Check Valve (lift check)—Left Travel Neutral age Check Valve (lift check)—Left Travel Power age

The left and right travel spools (110 and 75) are pilot actuated, three-position, four-way, spool type valves. In neutral, the forward and reverse work ports are connected together and open to the return ages so oil is not trapped between the travel valve spools and the counterbalance valves in the travel motors. The circuit is open to return age so the counterbalance valve is not shifted and travel park brake is not released by thermal expansion of the oil. For additional information, See Travel Motor and Park Brake Valve Operation for more information. (Group 9025-05.) Actuating the travel pilot controller sends pilot oil through the pilot signal manifold to the pilot cap shifting the valve spools. See Pilot Signal Manifold Operation for pilot oil functions in pilot signal manifold. (Group 9025-05.) The travel alarm will sound when traveling in forward or reverse. See Travel Alarm Circuit Theory of Operation . (Group 9015-15. Pump 2 high pressure oil flows through the 5-spool control valve neutral age, through the left travel neutral age lift check valve (112), past the valve spool, and out the work port to the travel motor. When left travel is actuated in combined operation with a dig or swing function, pump high pressure oil flows through the power age, through the travel power age lift check (115) and orifice, past the valve spool, and out the work port to the travel motor. For additional information, See Control Valve Check Valves Identification and Operation (Group 9025-05.) Pump 1 high pressure oil flows from the right control valve neutral age, past the right travel valve spool, and out the work port to the motor. In combined operation with a dig or swing function, high pressure oil from pump 1 also flows to the left travel valve and bucket valve through the flow combiner valve . High pressure oil from pump 2 flows to the boom and arm valves. Return oil from the motors flows past the spools and into the return age. For additional information, See Travel Flow Combiner Valve Operation . (Group 9025-05.)






Auxiliary and Bucket Cross Section (from rear) LEGEND: 73 74 76 77 78 79 80 107 108 109

4-Spool Control Valve 5-Spool Control Valve Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Dump Circuit Relief and Anticavitation Valve Bucket Curl Circuit Relief and Anticavitation Valve Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Plug (2 used)

The bucket spool (76) and auxiliary spool (107) are pilot actuated, three-position, four-way, spool type valves. In neutral, oil is trapped between the work ports and cylinder by the valve spool. Actuating the pilot controller sends pilot oil through the pilot signal manifold to the pilot cap shifting the valve spool. See Pilot Signal Manifold Operation for pilot oil functions in pilot signal manifold. (Group 9025-05.) For bucket dump and curl, pump 1 high pressure oil is routed from the right control valve neutral age, through the bucket flow rate control valve—poppet (76) and bucket flow rate control valve—switch valve (77), past the valve spool, and out to the cylinder. Return oil from the cylinder flows past the spool and into the return age. In combined operation with right propel valve, pump 1 high pressure oil also flows from the right control valve neutral age, through the power age, flow combiner circuit check valve, flow combiner valve and check valve, travel and bucket combined function check valve and orifice, and past the valve spool out to the cylinder. Pump 2 high pressure oil flows to the swing, arm, and boom functions. See the following for more information: <- Go to Section TOC





Check valves— See Control Valve Check Valves Identification and Operation (Group 9025-05.) Travel flow combiner valve— See Travel Flow Combiner Valve Operation (Group 9025-05.) →NOTE: The auxiliary valve is not connected for operation as received from the factory. Plugs are installed in the pilot caps and covers are installed on the work ports. Field kits are available for connecting the valve for auxiliary functions.

The flow of high pressure oil for the auxiliary valve is from pump 2, through the right control valve neutral age, through the power age, through the auxiliary flow rate control valve (108) poppet and switch valve, past the valve spool, and out to the auxiliary function. Return oil from the auxiliary function flows past the valve spool and into the return age. High pressure oil from pump 1 can be combined with high pressure oil from pump 2 by using the by shutoff valve and auxiliary flow combiner valve to operate an auxiliary functions. The pilot lines to the auxiliary flow combiner valve and by shutoff valve are connected to the hydraulic oil tank. For additional information, See Auxiliary Flow Rate Control Valve Circuit Operation . (Group 9025-05.)

Front Cross Section (from rear) LEGEND: 73 74 115 116 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve Main Relief Valve Isolation Check Valve (P1) Main Relief Valve Isolation Check Valve (P2) Section 9025 page 48



118 119 120 121


Auxiliary Function Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit

The front section of 4-spool control valve (15) serves as the inlet for supply oil from pump 1. See the following for more information on the components in front section: See Control Valve Check Valves Identification and Operation (Group 9025-05.) See Main Relief Valve Circuit Operation (Group 9025-05.) See Travel Flow Combiner Valve Operation (Group 9025-05.) See Auxiliary Flow Combiner Valve and By Shut-Off Valve Operation (Group 9025-05.)

Boom 1 and Boom 2 Valve Cross Section (from rear) LEGEND: 73 74 81 82 83 85 89 103 104 105 156 B30 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve Boom 1 Spool Boom Regenerative Valve Boom Flow Rate Control Valve (valve and poppet) Boom Reduced Leakage Valve (valve and check valve) Boom Down Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Check Valve (lift check)—Boom 2 Power Circuit Manual Boom Lower Screw Boom Up Pressure Sensor Section 9025 page 49




See Boom Regenerative Valve Circuit Operation for boom regenerative valve (82). (Group 9025-05.) See Boom Flow Rate Control Valve Circuit Operation for boom flow rate control valve (83). (Group 9025-05.) See Boom and Arm Reduced Leakage Valves Operation for boom reduced leakage valve (valve and check valve) (85). (Group 9025-05.) See Circuit Relief and Anticavitation Valve Operation for boom down and arm out circuit relief and anticavitation valve (89 and 103). (Group 9025-05.) See Control Valve Check Valves Identification and Operation for boom down and arm out circuit relief and anticavitation valve (89 and 103). (Group 9025-05.) See Lower Boom With Engine Stopped for use of manual boom lower screw (156). (Operator′s Manual.) See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for boom up pressure sensor (B30). (Group 9015-10.)

Arm 1 and Arm 2 Valve Cross Section (from rear) LEGEND: 73 74 88 90 91 94 97 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve Boom Up Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Arm Regenerative Valve Arm 1 Spool Section 9025 page 50



98 101 102 B31


Arm 1 Flow Rate Control Valve (valve and poppet) Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm In Pressure Sensor

See Circuit Relief and Anticavitation Valve Operation for boom up and arm in circuit relief and anticavitation valves (88 and 102.) (Group 9025-05.) See Arm 2 Flow Rate Control Valve Circuit Operation for arm 2 flow rate control valve (valve and poppet) (91). (Group 9025-05.) See Arm 1 Flow Rate Control Valve Circuit Operation for arm 1 flow rate control valve (valve and poppet) (98). (Group 9025-05.) See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and poppet) (101). (Group 9025-05.) See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for arm in pressure sensor (B31). (Group 9015-10.)

Swing, Arm Regenerative Cut, and By Shutoff Valve Cross Section (from rear) LEGEND: 73 74 93 95 96 <- Go to Section TOC

4-Spool Control Valve 5-Spool Control Valve By Shutoff Valve Swing Spool Check Valve (lift check)—Swing Neutral age Section 9025 page 51



149


Arm Regenerative Cut Valve

See Arm Regenerative Valve Circuit Operation for arm regenerative cut valve (149). (Group 9025-05.) See Control Valve Check Valves Identification and Operation for check valve (lift check)—swing neutral age (96). (Group 9025-05.) By shutoff valve (93) is used when optional attachments are installed on the machine. See Auxiliary Flow Combiner Valve and By Shut-Off Valve Operation . (Group 9025-05.)






Control Valve Check Valves Identification and Operation

Control Valve Check Valves Schematic





LEGEND: 15 16 36 73 74 75 76 77 78 79 80 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 100 101 102 103 104 105 107 108 110 111 112 113 115 116 117 118 119 120 121 122 123 124 128 149 166


Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Dump Circuit Relief and Anticavitation Valve Bucket Curl Circuit Relief and Anticavitation Valve Boom 1 Spool Boom Regenerative Valve Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve (valve and check valve) Boom Lower Meter-In Cut Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Arm Regenerative Valve Swing Spool Check Valve (lift check)—Swing Neutral age Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Check Valve (lift check)—Boom 2 Power Circuit Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Check Valve (lift check)—Left Travel Neutral age Check Valve (lift check)—Left Travel Power age Orifice—Left Travel Power age Main Relief Valve Isolation Check Valve—5-Spool Main Relief Valve Isolation Check Valve—4-Spool Main Relief and Power Dig Valve Auxiliary Function Flow Combiner Valve Check Valve—Auxiliary Function Flow Combiner Valve Circuit Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit Check Valve (lift check)—Bucket Orifice—Bucket Power Circuit Hydraulic Oil Cooler By Valve Check Valve Arm 1 Regenerative Cut Valve Bucket Regenerative Cut Valve

For location of check valves and orifices in the 4-spool and 5-spool control valves (73 and 74), see Control Valve Operation . (Group 9025-05.) Check Valves (92, 96, and 111): Check valves function as lift checks in the neutral ages. Check Valves (105 and 112): Check valves function as lift checks in the power ages. Check Valve (lift check)—Dig Regenerative Circuit (100): Functions as a lift check for arm in function when dig regenerative solenoid valve is actuated. See Dig Regenerative Valve Circuit Operation for solenoid valve operation. (Group 9025-05.) See Control Valve Operation for location and operation of dig regenerative valve. (Group 9025-05.) <- Go to Section TOC





Orifice—Left Travel Power age (113): Restricts the flow of high pressure oil from pump 2 (16) through the power age to the left travel spool (110). Arm 1 Spool (97) and Arm Regenerative Valve (94): During arm in operation the arm regenerative valve opens when return oil pressure becomes greater than supply oil pressure to provide make-up oil to prevent cavitation in the arm cylinder. See Arm Regenerative Valve Circuit Operation for more information. (Group 9025-05.) Bucket Spool (76) and Bucket Regenerative Valve (78): During bucket curl operation from the full dumped position to the vertical position, the bucket regenerative valve opens when return oil pressure becomes greater than supply oil pressure to provide make-up oil to prevent cavitation in the head end of bucket cylinder. Operational Check: Bucket curl is slow or does not move smoothly in single operation. Check bucket flow rate control valve (valve and poppet) (77). See Bucket Regenerative Valve Circuit Operation and See Bucket Flow Rate Control Valve Circuit Operation for more information. (Group 9025-05.) Boom 1 Spool (81) and Boom Regenerative Valve (82): During boom down operation, the regenerative valve opens when return oil pressure becomes greater than supply oil pressure to provide make-up oil to prevent cavitation in the rod end of boom cylinder. See Boom Regenerative Valve Circuit Operation for more information. (Group 9025-05.) Main Relief Valve Isolation Check Valve—5-Spool (115): One main relief and power dig valve (117) is used to limit the high pressure oil pressure. The higher pressure closes the check valve against the lower pressure so it cannot flow to the lower pressure side of control valve. The higher pressure is sensed by the main relief and power dig valve. Operational Check: Pump 2 (16) high pressure oil pressure becomes hard to increase. To check, operate bucket dump function over relief and check pressure at pump 1. If pressure is less than main relief and power dig valve pressure setting, inspect isolation check valve (115). Also, power and neutral age oil flow pressure for the 5-spool side is high because oil is flowing past the isolation check valve (115). Main Relief Valve Isolation Check Valve—4-Spool (116): Operational Check: Pump 1 (15) high pressure oil pressure becomes hard to increase. Operate swing function at stall and check pressure at pump 2. If pressure is less than swing crossover relief valve pressure setting, inspect the isolation check valve (116). Also, neutral age oil flow pressure for the 4spool side is high because oil is flowing past the isolation check valve (116). Check Valve—Auxiliary Function Flow Combiner Valve Circuit (119): For pump 1 (15) and pump 2 (16) combined flow to the auxiliary spool (107), a pilot line from the auxiliary spool pilot cap must be connected to shift the auxiliary function flow combiner valve (118) and by shutoff valve (93). Check valve closes if high pressure oil in the left control valve (74) power age becomes higher than high pressure oil pressure in the right control valve (73) neutral age. Check Valve—Travel Flow Combiner Valve Circuit (121): Blocks a higher high pressure oil pressure in the left control valve (5-spool) (74) from flowing to the right control valve (4-spool) (73) in travel flow combiner circuit. Operational Check: Machine mistracks to the left, forward or reverse, when traveling and operating a dig function. To check, operate a dig function over relief while traveling. If mistracking stops, inspect check valve (121). Circuit Relief and Anticavitation Valves (79, 80, 88, 89, 102, and 103): The anticavitation valves open when return oil pressure becomes greater than high pressure oil pressure to provide makeup oil to prevent cavitation in the cylinder. Check Valve (lift check) (122) and Orifice (123): The check valve functions as a lift check for the bucket spool (76). High pressure oil flow from pump 1 to the bucket spool is blocked by the right travel spool (75) when actuated. High pressure oil flow from pump 1 to the bucket spool is now through the travel flow combiner valve (120), check valve (121), check valve (122), and orifice (123). The orifice restricts the flow of pump 1 high pressure oil to the bucket spool. Operational Check: Actuate left and right travel and bucket functions. If bucket does not move, inspect check valve and orifice. Hydraulic Oil Cooler By Valve (124): Opens to route return oil around hydraulic oil cooler and directly to hydraulic oil tank when resistance to flow through oil cooler becomes high because the oil is cold (high viscosity), there is a surge of return oil, or oil cooler becomes plugged. The pressure setting for the by valve is higher than the restriction valve. Operational Check: Hydraulic oil continues to run hot. Check for an open by valve.






Main Relief Valve Circuit Operation

Main Relief Valve Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 <- Go to Section TOC

Main Poppet Orifice A Orifice B Seat age A Spring B Piston Pilot Poppet Spring Chamber Spring A Sleeve Normal Operation Relief Operation Section 9025 page 56



117 200 201 600 604 SG


Main Relief and Power Dig Valve From Main Circuit To Return High Pressure Oil Return Oil To Solenoid Valve Manifold (port SG)

The function of main relief and power dig valve (117) is to limit the main hydraulic system operating pressure. The relief valve senses high pressure oil (600) pressure from main circuit (200). For location of main relief and power dig valve location, see Control Valve Operation . (Group 9025-05.) For main relief and power dig valve test and adjustment procedures, see Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.) Pressure from main circuit is routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4). When pressure reaches set pressure of spring B (6), pilot poppet is opened and high pressure oil from age A (5) flows along sleeve (11) to return (201). A pressure difference is caused between main circuit and spring chamber (9) due to orifice A. When pressure difference reaches set pressure of spring A (10), main poppet is opened, allowing main circuit oil flow to return and causing main circuit to reduce pressure. Main poppet is then closed by spring A once below set pressure.











Main Relief Valve Power Dig Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11 117 200 201 600 604 609 SG

Main Poppet Orifice A Orifice B Seat age A Spring B Piston Pilot Poppet Spring Chamber Spring A Sleeve Main Relief and Power Dig Valve From Main Circuit To Return High Pressure Oil Return Oil Pilot Oil From Solenoid Valve Manifold (port SG)

When power dig solenoid (Y24) is active, pilot oil is routed from solenoid valve manifold (port SG) (SG) to main relief and power dig valve (117). Pilot oil presses on piston (7) compressing spring B (6), increasing spring set pressure and relief set pressure. For more information on power dig solenoid, see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)






Circuit Relief and Anticavitation Valve Operation

Circuit Relief and Anticavitation Valve LEGEND: 1 2 3 <- Go to Section TOC

Adjusting Screw Pilot Poppet Spring Pilot Poppet Section 9025 page 60



4 5 6 7 8 9 10 11 12 13 14 15 600 601 604


Main Poppet Main Poppet Spring Orifice Anticavitation Valve Poppet Anticavitation Valve Spring Conical Face From Work Circuit Return age Drain age Closed Relief Valve Relief Operation Anticavitation Operation High Pressure Oil Low Pressure Oil Return Oil

The main function of a circuit relief and anticavitation valve is to protect the components of a work circuit from a pressure spike. When the control valve spool is in neutral, it provides a path for return oil (604) to flow to a cylinder to prevent cavitation. The circuit relief valve is a pilot-operated, poppet-type relief valve. The anticavitation valve poppet (7) also functions as the valve seat for the main poppet (4). Circuit relief and anticavitation valves are used in the bucket, boom, and arm work circuits. The circuit relief valves can be adjusted using the adjusting screw (1). For adjustment procedures, see Circuit Relief Valve Test and Adjustment . (Group 9025-25.) At pressures below the circuit relief valve setting, the relief valve remains closed (13). The main poppet (4) is seated against the anticavitation valve poppet (7). The anticavitation valve poppet is held against the main poppet by the anticavitation valve spring (8) and high pressure oil (600) from the work circuit (10). Oil pressure is sensed on the end of pilot poppet (3) through the orifice (6) in the main poppet. In relief operation, oil pressure in the work circuit exceeds the pressure setting of the pilot poppet spring (2) pushing the pilot poppet off its seat. The oil behind main poppet, flows past the pilot poppet and through the drain age (12) to the return age (11). The oil pressure behind the main poppet is reduced, creating pressure differences across main poppet as oil flows out faster than oil can flow through orifice in the main poppet. The main poppet is pushed open to relieve pressure oil to the return age. The anticavitation valve poppet bottoms against a shoulder and does not follow the main poppet. When the oil pressure in the work circuit decreases below the pressure setting, the pilot poppet is pushed closed by the spring, stopping the flow of oil past the pilot poppet to return. The oil pressure behind the main poppet increases, pushing the main poppet closed against the anticavitation valve poppet. During anticavitation operation, the pressure of oil in the work circuit becomes less than the pressure in the return age. The higher pressure of return oil acts on the conical face (9) of anticavitation valve poppet, pushing it away from the main poppet. Return oil flows from the return age into the work circuit preventing cavitation. The main poppet bottoms against a shoulder and does not follow the anticavitation valve poppet.






Travel Flow Combiner Valve Operation






Travel Flow Combiner Valve Schematic





LEGEND: 4 9 11 15 16 36 61 63 75 76 81 90 91 92 93 95 97 102 103 104 107 110 117 120 121 124 127 144 145 600 604 606 609 B31



Arm In (pilot) Left Travel Forward (pilot) Right Travel Forward (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Right Travel Motor Left Travel Motor Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Swing Spool Arm 1 Spool Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Auxiliary Spool Left Travel Spool Main Relief and Power Dig Valve Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Circuit Oil Cooler By Valve Arm Cylinder To Blade Control Valve From Travel Flow Combiner Shuttle Valve High Pressure Oil Return Oil Trapped Oil Pilot Oil Arm In Pressure Sensor










Travel Flow Combiner Valve LEGEND: 15 110 120 145 600 604 609

From Pump 1 To Left Travel Spool Travel Flow Combiner Valve From Travel Flow Combiner Shuttle Valve High Pressure Oil Return Oil Pilot Oil

When only travel functions are actuated, high pressure oil (600) from pump 2 (16) flows through the neutral age of swing (95), arm 1 (97), boom 2 (104), and auxiliary (107) spools, then through the left travel spool (110) and out to the left travel motor (63). High pressure oil from pump 1 (15) flows through the right travel spool (75) and out to the right travel motor (61). Right travel spool blocks the flow of high pressure oil through the neutral ages of bucket (76), boom 1 (81), and arm 2 (90) spools. The travel flow combiner valve (120) ensures machine does not mistrack during combined travel and front attachment operation by routing high pressure oil from pump 1 to both the left and right travel motors and bucket spool. High pressure oil from pump 2 is dedicated to the boom 2, arm 1, auxiliary, and swing spools. The travel flow combiner valve may also be shifted to combine pump flow for blade operation. See Blade Circuit Operation—If Equipped . (Group 9025-05.) For location of travel flow combiner valve, see Control Valve Operation . (Group 9025-05.) When right travel is in neutral, travel flow combiner valve is held closed by spring pressure, blocking flow of high pressure oil from pump 1 to left travel spool. Actuating a right travel function shifts travel flow combiner valve pilot valve. When a dig function is activated in conjunction with a right travel function, pilot oil (609) from the swing park brake release pilot valve is routed to the travel flow combiner valve, causing the valve to shift. See Pilot Signal Manifold Operation . (Group 9025-05.) With travel flow combiner valve shifted, high pressure oil from the pump 1 now flows through the valve to the left travel spool and travel motor and to bucket spool. Flow combiner valve circuit check valve (119) prevents back flow through the travel flow combiner valve.






Auxiliary Flow Combiner Valve and By Shutoff Valve Operation






Auxiliary Flow Combiner Valve and By Shutoff Valve Schematic





LEGEND: 13 14 15 16 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 119 120 155 170 174 177 178 600 604 609


Auxiliary (pilot) Auxiliary (pilot) Pump 1 (4-spool) Pump 2 (5-spool) 4-Spool Control Valve 5-Spool Left Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve Auxiliary Attachment From Flow Rate Select Solenoid Valve To Flow Rate Select Reducing Valve High-Pressure Oil Return Oil Pilot Oil

→NOTE: Auxiliary flow combiner valve and by shutoff valve will not wok properly unless appropriate kits are installed on machine.

The combined functions of auxiliary flow combiner valve (118) and by shutoff valve (93) combine high-pressure oil (600) flow from pump 1 (15) with pump 2 (16) at the auxiliary spool (107) to increase hydraulic oil flow to auxiliary attachment (174).

Auxiliary Flow Combiner Valve Operation






Auxiliary Flow Combiner Valve LEGEND: 15 107 118 119 177 178 600 604 609

From Pump 1 To Auxiliary Spool Auxiliary Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit From Flow Rate Select Solenoid Valve To Flow Rate Select Reducing Valve High-Pressure Oil Return Oil Pilot Oil

Actuating an auxiliary function with 2-speed activation solenoid valve (Y43) energized routes pilot oil (609) from flow rate select solenoid valve (177) to the auxiliary flow combiner valve, shifting the spool. The auxiliary flow combiner valve works in conjunction with the by shutoff valve. When the by shutoff valve is shifted, pump 1 high-pressure oil in neutral age flow to return age is blocked. High-pressure oil now flows through the auxiliary flow combiner valve and combines with pump 2 oil at the auxiliary spool (107). Check valve—flow combiner valve circuit (119) prevents backflow of oil through the auxiliary flow combiner valve. In combined operation with travel and dig functions, pilot oil from flow rate select reducing valve (178) flows to the auxiliary flow combiner valve. This pilot oil pressure, in addition to spring pressure, causes the auxiliary flow combiner valve to return to <- Go to Section TOC





neutral position and block flow of pump 1 oil to the auxiliary spool.

By Shutoff Valve Operation

By Shutoff Valve LEGEND: 15 31 93 170 600 604 609

From Pump 1 To Hydraulic Oil Tank By Shutoff Valve From Auxiliary Shuttle Valve High-Pressure Oil Return Oil Pilot Oil

When an auxiliary or blade function is actuated, pilot pressure is applied to by shutoff valve, causing the valve to shift. When the by shutoff valve is shifted, pump 1 high-pressure oil in neutral age flow to return age is blocked. High-pressure oil from pump 1 can then be routed through the auxiliary flow combiner valve if equipped with two pump combined flow kit or through the travel flow combiner valve (120) if equipped with blade option.






Boom Lower Meter-In Cut Valve Operation






Boom Lower Meter-In Cut Valve Circuit Operation Schematic





LEGEND: 2 15 16 36 81 82 83 84 85 86 87 88 89 104 117 124 125 128 154 600 602 604 606 609 610


Boom Down (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Boom 1 Spool Boom Regenerative Valve Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve (valve and check valve) Orifice Boom Lower Meter-In Cut Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Boom 2 Spool Main Relief and Power Dig Valve Oil Cooler By Valve Boom Cylinder (2 used) Check Valve To Shuttle Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Regeneration Oil

Boom Lower Meter-In Cut Valve LEGEND: 2 <- Go to Section TOC

Boom Down (pilot) Section 9025 page 74




3 From Boom Cylinders 4 Spring 31 To Hydraulic Oil Tank 83 To Boom Flow Rate Control Valve (valve) 86 Orifice 87 Boom Lower Meter-In Cut Valve 104 To Boom 2 Spool 604 Return Oil 609 Pilot Oil 610 Regeneration Oil The boom lower meter-in cut valve (87), located in the boom lower circuit, controls the boom flow rate control valve (83) and pilot oil (609) to the boom 2 spool (104). During initial boom down (2) operation, pilot oil flows to the boom 2 spool through boom lower meter-in cut valve. During boom down operation the boom lower meter-in cut valve is shifted by high pressure return oil from the boom cylinders (3) when return pressure overcomes spring (4) pressure. With boom meter-in cut valve shifted, boom down pilot oil is blocked to boom 2 spool, causing the spool to return to neutral, and pilot oil is routed to the switch valve in the boom flow rate control valve (83) causing the valve to shift. The poppet of boom flow rate control valve now restricts high pressure oil (600) flow from pump 1 to the boom 1 spool (81). See Boom Flow Rate Control Valve Circuit Operation and see Boom Regenerative Valve Circuit Operation . (Group 9025-05.)






Boom Regenerative Valve Circuit Operation

Boom Regenerative Valve Operation LEGEND: 1 2 3 15 81 82 83 85 87 87A 104 125 125A 125B 600 604 609 610 DD

Boom Up (pilot) Boom Down (pilot) Hole A From Pump 1 Boom 1 Spool Boom Regenerative Valve Boom Flow Rate Control Valve (valve and poppet) Boom Reduced Leakage Valve (valve and check valve) Boom Meter-In Cut Valve From Boom Meter-In Cut Valve From Boom 2 Spool Boom Cylinder (2 used) From Boom Cylinders (head end) To Boom Cylinders (rod end) High Pressure Oil Return Oil Pilot Oil Regeneration Oil To Solenoid Valve Manifold Port DD

The function of the boom regenerative valve (82) is to combine return oil from the boom cylinders (head end) (125A) with supply oil from pump 1 (15) to the boom cylinder rod end to prevent cavitation and improve function controllability. Return oil from boom cylinders (125A) flows back to the control valve top work port and is restricted as it flows past the spool <- Go to Section TOC





to the return age. The return oil also flows through hole A (3) in the valve spool and down the center of spool to the boom regenerative valve. If return oil pressure is higher than supply oil pressure the return oil pressure pushes the boom regenerative valve open allowing oil to combine with the supply oil and flow out the bottom work port to the cylinder. When supply oil pressure becomes higher than return oil pressure, the boom regenerative valve is pushed closed.






Dig Regenerative Valve Circuit Operation






Dig Regenerative Valve Schematic





LEGEND: 1 4 15 16 36 73 74 75 76 81 83 84 90 91 93 95 97 98 100 104 107 110 124 125 127 128 149 600 602 604 606 609 610 650 A3 B30 B31 B35 B37 DZ Y22



Boom Up (pilot) Arm In (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler 4-Spool Control Valve 5-Spool Rear Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) By Shutoff Valve Swing Spool Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Boom 2 Spool Auxiliary Spool Left Travel Spool Oil Cooler By Valve Boom Cylinder (2 used) Arm Cylinder Check Valve Arm 1 Regenerative Cut Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Regenerative Oil Voltage Signal Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor To Solenoid Valve Manifold Port DZ Dig Regenerative Solenoid (marked SF)





Dig Regenerative Valve Section LEGEND: 81 From Boom 1 Spool 84 Dig Regenerative Valve 90 To Arm 2 Spool 100 Check Valve (lift check)—Dig Regenerative Circuit 104 To Boom 2 Spool 604 Return Oil 609 Pilot Oil 610 Regenerative Oil DZ To Solenoid Valve Manifold Port DZ Y22 From Dig Regenerative Solenoid (marked SF) The dig regenerative valve (84) improves arm control and prevents arm cylinder (127) cavitation during the combined operations of boom up and arm in by combining the return oil from boom cylinder (125) rod ends with the pump high pressure oil to the arm cylinder (127). The main controller (MCZ) (A3) sends a voltage signal (650) to the dig regenerative solenoid (Y22) to energize the coil under the following conditions: High pressure at pump 1 delivery pressure sensor (B35) or pump 2 delivery pressure sensor (B37) Pressure at arm in pressure sensor (B31) <- Go to Section TOC





Pressure at boom up pressure sensor (B30) See Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) The solenoid valve then sends pilot oil (609) pressure to shift the dig regenerative valve (84). With the dig regenerative valve shifted, return oil from the boom cylinder rod ends flows through boom 1 spool (81), dig regenerative valve, and check valve (lift check)—dig regenerative circuit and is combined with high pressure oil from hydraulic pump 2 and routed through the arm 1 spool (97) to the arm cylinder head end increasing cylinder speed and preventing cavitation.






Dig Regenerative Solenoid Operation LEGEND: 1 2 3 4 5 <- Go to Section TOC

Solenoid Coil Spool To Valve Function De-Energized Energized Section 9025 page 83




6 Pressure Equals Magnetic Force 29 From Pilot Filter and By Valve 31 To Hydraulic Oil Tank 37 Solenoid Valve Manifold 604 Return Oil 609 Pilot Oil 613 Reduced Pilot Oil Y22 Dig Regenerative Solenoid (marked SF) Y23 Arm Regenerative Solenoid (marked SC) Y24 Power Dig/Travel Speed Solenoid (marked SG) Y27 Arm 2 Flow Control Solenoid (marked SD) The dig regenerative solenoid (marked SF) (Y22) is a proportional-type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse width modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on verses on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port. When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and by valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the right closing the age stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation . (Group 9025-05.) and see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)






Arm Regenerative Valve Circuit Operation






Arm Regenerative Valve Circuit Schematic (arm in and swing left actuated)





LEGEND: 1 3 4 5 6 15 16 36 43 52 73 74 90 91 92 93 94 95 96 97 98 101 102 103 124 127 149 600 602 604 606 609 610 650 A3 B30 B31 B33 B35 B37 DE Y23



Boom Up (pilot) Arm Out (pilot) Arm In (pilot) Swing Left (pilot) Swing Right (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler From Arm 1 Flow Rate Pilot Valve (port SK) Swing Motor 4-Spool Control Valve 5-Spool Control Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Arm Regenerative Valve Swing Spool Check Valve (lift check)—Swing Neutral age Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Oil Cooler By Valve Arm Cylinder Arm 1 Regenerative Cut Valve High-Pressure Oil Low-Pressure Oil Return Oil Trapped Oil Pilot Oil Regenerative Oil Voltage Signal Main Controller (MCZ) Boom Up Pressure Sensor Arm In Pressure Sensor Swing Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor To Solenoid Valve Manifold Port DE Arm Regenerative Solenoid (SC)





Arm Regenerative Valve Section LEGEND: 3 4 94 97 98 <- Go to Section TOC

Arm Out (pilot) Arm In (pilot) Arm Regenerative Valve Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Section 9025 page 88




101 Arm Reduced Leakage Valve (valve and poppet) 127A To Arm Cylinder (head end) 127B From Arm Cylinder (rod end) 149 Arm Regenerative Cut Valve 600 High-Pressure Oil 602 Low-Pressure Oil 604 Return Oil 609 Pilot Oil 610 Regenerative Oil SC From Solenoid Valve Manifold Port SC The arm regenerative valve (94) accelerates arm in speed in order to prevent arm hesitation and cavitation during arm in operation by combining return oil (604) from arm cylinder (rod end) (127B) with supply oil to arm cylinder (head end) (127A). The main controller (MCZ) (A3) sends a voltage signal (650) to arm regenerative solenoid (SC) (Y23) to energize the coil under the following conditions: Low pressure at pump 1 delivery pressure sensor (B35) or pump 2 delivery pressure sensor (B37) High pressure (arm in fully actuated) at arm in pressure sensor (B31) Pressure at swing pressure sensor (B33) or boom up pressure sensor (B30) See Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) During arm in operation, return oil from arm cylinder (rod end) is routed to arm reduced leakage valve (valve and poppet) (101). Return oil pressure unseats the reduced leakage valve poppet, routing return oil through arm 1 spool. See Boom and Arm Reduced Leakage Valve Operation . (Group 9025-05.) With arm regenerative solenoid active, pilot oil (609) shifts the arm regenerative cut valve (149), shifting the valve and blocking the primary flow of cylinder return oil to tank. With arm regenerative cut valve shifted, return oil pressure rises. When return pressure is greater than supply oil pressure, return oil shifts arm regenerative valve (94) and combines with supply oil to arm cylinder (head end).






Arm Regenerative Solenoid Operation LEGEND: 1 2 3 4 5 <- Go to Section TOC





6 Pressure Equals Magnetic Force 29 From Pilot Filter and By Valve 31 To Hydraulic Oil Tank 37 Solenoid Valve Manifold 604 Return Oil 609 Pilot Oil 613 Reduced Pilot Oil Y22 Dig Regenerative Solenoid (marked SF) Y23 Arm Regenerative Solenoid (marked SC) Y24 Power Dig/Travel Speed Solenoid (marked SG) Y27 Arm 2 Flow Control Solenoid (marked SD) The arm regenerative solenoid (marked SC) (Y23) is a proportional-type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ) (A3). The voltage signal is a DC voltage that is turned on and off to form a pulsewidth modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on versus on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port. When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and by valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the right, closing the age stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation . (Group 9025-05.) Also see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)






Bucket Regenerative Valve Circuit Operation

Bucket Regenerative Valve Operation LEGEND: 1 7 8 15 76 77 78 126 126A 126B 166 166A 600 604 609 610

Hole A Bucket Curl (pilot) Bucket Dump (pilot) From Pump 1 Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Cylinder To Bucket Cylinder Head End From Bucket Cylinder Rod End Bucket Regeneration Cut Valve To Bucket Regeneration Cut Valve High Pressure Oil Return Oil Pilot Oil Regeneration Oil

The function of the bucket regenerative valve (78) is to combine return oil from the bucket cylinder rod end (126B) with supply oil from pump 1 (15) to the bucket cylinder head end (126A) to prevent cavitation and improve function controllability. Return oil from the cylinder rod end flows to the control valve top work port and is restricted as it flows past the spool to the return age. The return oil also flows through hole A (1) in the valve spool and down the center of spool to the bucket regenerative valve. If return oil pressure is higher than supply oil pressure the return oil pressure pushes the bucket <- Go to Section TOC





regenerative valve open allowing return oil to combine with the supply oil and flow out the bottom work port to bucket cylinder head end. Supply oil flow to the bucket spool is restricted by the bucket flow rate control valve (valve and poppet) (77) during combined operation. See Bucket Flow Rate Control Valve Circuit Operation for more information. (Group 9025-05.) When supply oil pressure becomes higher than return oil pressure, the bucket regenerative valve is pushed closed.






Boom and Arm Reduced Leakage Valves Operation →NOTE: The operation of boom reduced leakage valve and arm reduced leakage valve is similar. Boom reduced leakage valve operation is depicted.

Boom Reduced Leakage Valve—Neutral LEGEND: 1 2 3 4 5 15 81 81A 85 125 125A 200 201 600 604 606 <- Go to Section TOC

Boom Up (pilot) Boom Down (pilot) Spring A Spring B Orifice From Pump 1 Boom 1 Spool To Boom 1 Spool Boom Reduced Leakage Valve (valve and check valve) Boom Cylinder (2 used) From Boom Cylinder Head Ends Valve Check Valve High Pressure Oil Return Oil Trapped Oil Section 9025 page 94




The function of the boom and arm reduced leakage valves is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve. A reduced leakage valve is used in the boom head end circuit and arm rod end circuit. In neutral, the oil pressure generated in the boom cylinder head end or arm cylinder rod end circuit by the load on the cylinders is routed through the valve (200) and applies pressure to the poppet along with spring A (3) pressure. The check valve (201) is held closed against the seat in the control valve housing trapping the oil in the cylinders. See Control Valve Operation for location in the control valve. (Group 9025-05.)

Boom Reduced Leakage Valve—Boom Down LEGEND: 1 2 3 4 5 15 81 81A 85 125 125A 200 201 600 604 606 609 <- Go to Section TOC

Boom Up (pilot) Boom Down (pilot) Spring A Spring B Orifice From Pump 1 Boom 1 Spool To Boom 1 Spool Boom Reduced Leakage Valve (valve and check valve) Boom Cylinder (2 used) From Boom Cylinder Head Ends Valve Check Valve High Pressure Oil Return Oil Trapped Oil Pilot Oil Section 9025 page 95




Actuating the boom down (2) function routes pilot oil (609) pressure from pilot controller to shift the boom 1 spool (81) and valve (200). The trapped oil pressure in spring A (3) cavity is released past the valve to the hydraulic oil tank. The return oil (604) pressure from the boom cylinder head ends (125A) pushes the check valve (201) off its seat, opening the age for oil to flow to return. The check valve is pushed off its seat because the outside diameter of the upper land at the head end of check valve is slightly larger than the lower land. With the check valve open, return oil from the boom cylinders is routed to return through the boom 1 spool. Orifice (5) decreases pressure in the spring B (4) chamber, preventing the check valve from moving quickly, thus reducing shock during boom down operation.






Arm 1 Flow Rate Control Valve Circuit Operation






Arm 1 Flow Rate Control Valve Circuit Schematic





LEGEND: 4 5 15 16 36 43 52 90 91 92 93 95 96 97 98 102 103 117 124 127 149 600 602 604 606 609 B31 DE


Arm In (pilot) Swing Left (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler From Arm 1 Flow Rate Pilot Valve (port SE) Swing Motor Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Swing Spool Check Valve (lift check)—Swing Neutral age Arm 1 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Main Relief and Power Dig Valve Oil Cooler By Valve Arm Cylinder Arm 1 Regenerative Cut Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Arm In Pressure Sensor To Solenoid Valve Manifold (port DE)

The function of arm 1 flow rate control valve (valve and poppet) (98) is to restrict the flow of high pressure oil (600) from pump 2 (16) to the arm 1 spool (97) to ensure a priority flow of high pressure oil to the swing spool (95) during combined operation.






Arm 1 Flow Rate Control Valve Normal Operation (low load)






Arm 1 Flow Rate Control Valve Normal Operation (high load) LEGEND: 16 43 97 98 200 201 202 600 604 DE

From Pump 2 From Arm 1 Flow Rate Pilot Valve (port SE) To Arm 1 Spool Arm 1 Flow Rate Control Valve Check Valve Poppet Switch Valve High Pressure Oil Return Oil To Solenoid Valve Manifold (port DE)

Normal Operation— High pressure oil (600) from pump 2 (16) opens check valve (200) in poppet (201) of arm 1 flow rate control valve (98) because switch valve (202) is open. High pressure oil flows through the check valve and switch valve to the arm 1 spool (97). As load increases, pressure increases pushing the poppet open and high pressure oil flows through the poppet to arm 1 spool.






Arm 1 Flow Rate Control Valve Combined Operation LEGEND: 16 43 97 98 200 201 202 600 602 604 606 609 DE

From Pump 2 From Arm 1 Flow Rate Pilot Valve (port SE) To Arm 1 Spool Arm 1 Flow Rate Control Valve Check Valve Poppet Switch Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil From Solenoid Valve Manifold (port DE)

Combined Operation— During swing and arm in combined operation, the arm 1 flow rate pilot valve (port SE), in the pilot signal manifold, is shifted by arm in pilot oil (609). The pilot valve then routes a portion of pilot oil from swing function to switch valve (202) of arm 1 flow rate control valve (98). For operation of pilot valves, see Pilot Signal Manifold Operation . (Group 9025-05.) Pilot oil shifts the switch valve, creating trapped oil (606) on backside of poppet (201) which forces the poppet towards the closed position. The poppet now restricts the flow of high pressure oil (600) to arm 1 spool. High pressure oil now flows through the swing spool to the swing motor against the higher load pressure.






Arm 2 Flow Rate Control Valve Circuit Operation






Arm 2 Flow Rate Control Valve Circuit Schematic





LEGEND: 1 4 15 16 36 81 83 84 85 88 89 90 91 92 94 97 98 100 101 102 103 117 124 125 127 149 600 602 604 606 609 B30 B31 DD SI


Boom Up (pilot) Arm In (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Boom 1 Spool Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age Arm Regenerative Valve Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Main Relief and Power Dig Valve Oil Coolet By Valve Boom Cylinder (2 used) Arm Cylinder Arm 1 Regenerative Cut Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Boom Up Pressure Sensor Arm In Pressure Sensor To Solenoid Valve Manifold Port DD To Solenoid Valve Manifold Port SI

The function of arm 2 flow rate control valve (valve and poppet) (91) is to restrict the flow of high pressure oil (600) from pump 1 (15) to the arm 2 spool (90) to ensure a priority flow of high pressure oil to the boom 1 spool (81) during arm in and boom up combined operation. For location of arm 2 flow rate control valve, see Control Valve Operation . (Group 9025-05.)






Arm 2 Flow Rate Control Valve Normal Operation (low load)






Arm 2 Flow Rate Control Valve Normal Operation (high load) LEGEND: 15 From Pump 1 90 To Arm 2 Spool 91 Arm 2 Flow Rate Control Valve (valve and poppet) 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 604 Return Oil DD To Solenoid Valve Manifold Port DD SI To Solenoid Valve Manifold Port SI Normal Operation— High pressure oil (600) from pump 1 (15) opens the check valve (200) in the poppet (201) of arm 2 flow rate control valve (91) because the switch valve (202) is open. High pressure oil flows through the check valve and switch valve to arm 2 spool (90). As the load increases, the pressure increases pushing the poppet open and high pressure oil flows through the poppet to arm 2 spool.






Arm 2 Flow Rate Control Valve (combined operation) LEGEND: 15 From Pump 1 90 To Arm 2 Spool 91 Arm 2 Flow Rate Control Valve (valve and poppet) 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 602 Low Pressure Oil 604 Return Oil 606 Trapped Oil 609 Pilot Oil DD To Solenoid Valve Manifold Port DD SI From Solenoid Valve Manifold Port SI Combined Operation— During combined operation of boom up and arm in the arm 2 flow control solenoid (Y27) is activated. When solenoid is activated pilot oil from solenoid valve manifold port SI (SI) shifts the switch valve (202). See Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) With the switch valve shifted, high pressure oil (600) is trapped on the backside of poppet (201) which forces the poppet towards the closed position. The poppet now restricts the flow of high pressure oil to arm 2 spool. Consequently, more pump 1 high pressure oil is available to the boom 1 spool, maintaining the boom up speed. During combined operation the arm in function is maintained by the arm or dig regenerative circuit. See Arm Regenerative Valve Circuit Operation or see Dig Regenerative Valve Circuit Operation . (Group 9025-05.)






Bucket Flow Rate Control Valve Circuit Operation






Bucket Flow Rate Control Valve Circuit Operation





LEGEND: 1 4 7 15 16 36 46 76 77 78 79 80 81 83 84 85 88 89 90 91 92 94 97 98 100 101 102 103 117 124 125 126 127 149 166 600 602 604 606 609 B30 B31 DD DK SI


Boom Up (pilot) Arm In (pilot) Bucket Curl (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler From Bucket Flow Rate Pilot Valve (port SK) Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Dump Circuit Relief and Anticavitation Valve Bucket Curl Circuit Relief and Anticavitation Valve Boom 1 Spool Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age Arm Regenerative Valve Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Main Relief and Power Dig Valve Oil Coolet By Valve Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder Arm 1 Regenerative Cut Valve Bucket Regenerative Cut Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Boom Up Pressure Sensor Arm In Pressure Sensor To Solenoid Valve Manifold Port DD To Solenoid Valve Manifold Port DK To Solenoid Valve Manifold Port SI

The function of the bucket flow rate control valve (valve and poppet) (77) is to restrict the flow of high pressure oil from pump 1 (15) to the bucket spool (76) during bucket, arm in, and boom up combined operation. Restricting oil flow to the bucket spool ensures a priority flow of high pressure oil to the boom 1 spool (81) during combined operation.






Bucket Flow Rate Control Valve Normal Operation (low load)






Bucket Flow Rate Control Valve Normal Operation (high load) LEGEND: 15 From Pump 1 46 To Bucket Flow Rate Pilot Valve (port SK) 76 To Bucket Spool 77 Bucket Flow Rate Control Valve (valve and poppet) 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 604 Return Oil DK To Solenoid Valve Manifold Port DK Normal Operation— High pressure oil (600) from pump 1 (15) opens the check valve (200) in the poppet (201) of bucket flow rate control valve (77) because the switch valve (202) is open. The high pressure oil flows through the check valve and switch valve to bucket spool (76). As the load increases, the pressure increases pushing the poppet open and high pressure oil flows through the poppet to bucket spool. See Control Valve Operation for bucket flow rate control valve circuit location information. (Group 9025-05.)






Bucket Flow Rate Control Valve Combined Operation LEGEND: 15 From Pump 1 46 From Bucket Flow Rate Pilot Valve (port SK) 76 To Bucket Spool 77 Bucket Flow Rate Control Valve (valve and poppet) 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 602 Low Pressure Oil 604 Return Oil 606 Trapped Oil 609 Pilot Oil DK To Solenoid Valve Manifold Port DK Combined Operation— During combined operation of boom up and arm in, arm in pilot pressure shifts the bucket flow rate pilot valve allowing boom up pilot pressure to flow out port SK of the pilot signal manifold to the bucket flow rate control valve (77). See Pilot Signal Manifold Operation . (Group 9025-05.) Boom up pilot pressure from bucket flow rate pilot valve (port SK) (46) shifts the switch valve (202) trapping oil (606) on the backside of the poppet (201). The poppet now restricts the flow of high pressure oil to the bucket spool (76). High pressure oil (600) now flows to the arm 2 and boom 1 spools to ensure priority flow of high pressure oil to the arm in and boom up functions. During combined operation of arm in and boom up, the arm 2 flow rate control valve circuit is active. Priority is given to the boom up function. See Arm 2 Flow Rate Control Valve Circuit Operation . (Group 9025-05.)






Boom Flow Rate Control Valve Circuit Operation






Boom Flow Rate Control Valve Circuit Schematic





LEGEND: 2 3 15 16 36 81 82 83 85 87 88 89 90 91 92 97 98 101 102 103 104 117 124 125 127 128 149 154 600 602 604 606 609 610 DD


Boom Down (pilot) Arm Out (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Boom 1 Spool Boom Regenerative Valve Boom Flow Rate Control Valve (valve and poppet) Boom Reduced Leakage Valve (valve and check valve) Boom Lower Meter-In Cut Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age Arm 1 Spool Arm 1Flow Rate Control Valve (valve and poppet) Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Main Relief and Power Dig Valve Oil Cooler By Valve Boom Cylinder (2 used) Arm Cylinder Check Valve Arm 1 Regenerative Cut Valve To Shuttle Valve High Pressure Oil Low Pressure Oil Return Oil Trapped Oil Pilot Oil Regeneration Oil To Solenoid Valve Manifold Port DD

The purpose of the boom flow rate control valve (valve and poppet) (83) is to restrict high pressure oil (600) in the circuit to ensure that there will be sufficient high pressure oil for other functions during boom down and to restrict high pressure oil through boom 1 spool (81) during boom down so that boom regenerative valve (82) in boom 1 spool works properly. During boom down, the boom flow rate control valve restricts high pressure oil flow to the boom 1 spool from pump 1 (15). During boom down and other functions, the boom lowers due to its own weight by the boom regenerative circuit and uses high pressure oil from the pump for other functions. This ensures other functions will maintain normal operation. See Boom Regenerative Valve Circuit Operation . (Group 9025-05.)






Boom Flow Rate Control Valve Normal Operation (low load)






Boom Flow Rate Control Valve Normal Operation (high load) LEGEND: 15 From Pump 1 81 To Boom 1 Spool 83 Boom Flow Rate Control Valve (valve and poppet) 87 To Boom Lower Meter-In Cut Valve 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 604 Return Oil DD To Solenoid Valve Manifold Port DD Normal Operation— When boom down is actuated, high pressure oil (600) flows to the 4-spool side of the control valve from pump 1 (15). High pressure oil opens the check valve (200) in the poppet (201) of the boom flow rate control valve (83) because the switch valve (202) is open due to no control pilot oil. High pressure oil flows through boom flow rate control valve without restriction to boom 1 spool (81).






Boom Flow Rate Control Valve Combined Operation LEGEND: 15 From Pump 1 81 To Boom 1 Spool 83 Boom Flow Rate Control Valve (valve and poppet) 87 From Boom Lower Meter-In Cut Valve 200 Check Valve 201 Poppet 202 Switch Valve 600 High Pressure Oil 602 Low Pressure Oil 604 Return Oil 606 Trapped Oil 609 Pilot Oil DD To Solenoid Valve Manifold Port DD Combined Operation— When boom down is actuated, return oil from the boom cylinders is under pressure from the weight of the boom. Return oil pressure causes boom lower meter-in cut valve to shift, routing boom down pilot oil to the boom flow rate control valve (83). See Boom Lower Meter-In Cut Valve Operation (Group 9025-05.) Boom down pilot oil (609) from boom lower meter-in cut valve (87) shifts the switch valve (202) in the boom flow rate control valve. With the switch valve shifted, high pressure oil is trapped on the backside of poppet (201) which forces the poppet towards the closed position. The poppet now restricts the flow of high pressure oil to boom 1 spool. Consequently more pump 1 high pressure oil is available to other functions. When supply oil pressure to boom 1 spool is less than return oil pressure during boom down operation, the return oil will shift the boom regeneration valve (82) and combine with supply oil. See Boom Regenerative Valve Circuit Operation . (Group 9025-05.) <- Go to Section TOC





Auxiliary Flow Rate Control Valve Circuit Operation






Auxiliary Flow Rate Control Valve Circuit Operation





LEGEND: 5 6 13 14 15 16 52 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 119 120 155 170 174 177 178 600 602 604 606 609 DY


Swing Left (pilot) Swing Right (pilot) Auxiliary (pilot) Auxiliary (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Swing Motor 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve Auxiliary Attachment From Flow Rate Select Solenoid Valve (2 used) To Flow Rate Select Reducing Valve High-Pressure Oil Low-Pressure Oil Return Oil Trapped Oil Pilot Oil To Solenoid Valve Manifold Port DY

→NOTE: The auxiliary flow rate control valve will not work properly unless two pump combined flow kit is installed on machine.

The function of the auxiliary flow rate control valve (valve and poppet) (108) is to restrict high-pressure oil (600) flow from pump 2 (16) through the auxiliary spool (107) when used under the following conditions: Two speed on (combined flow on) Pressure on attachment pressure sensor (B60) Combined with any of these inputs: Pressure on arm out pressure sensor (B61) Pressure on arm out pressure sensor (B61) and boom up pressure sensor (B30) Pressure on swing pressure sensor (B33) Pressure on travel pressure sensor (B34) For more information on sensors, see System Functional Schematic . (Group 9015-10.)






Auxiliary Flow Rate Control Valve Normal Operation (low load)






Auxiliary Flow Rate Control Valve Normal Operation (high load) LEGEND: 16 From Pump 2 107 To Auxiliary Spool 108 Auxiliary Flow Rate Control Valve 177 To Flow Rate Select Solenoid Valve 200 Check Valve 201 Poppet 202 Switch Valve 600 High-Pressure Oil 604 Return Oil DY To Solenoid Valve Manifold Port DY Normal Operation— High-pressure oil (600) from pump 2 (16) opens the check valve (200) in the poppet (201) of auxiliary flow rate control valve (108) because the switch valve (202) is open. The high-pressure oil flows through the check valve and switch valve to auxiliary spool (107). As the load increases, the pressure increases, pushing the poppet open, and highpressure oil flows through the poppet to auxiliary spool. For auxiliary flow rate control valve circuit location information, see Control Valve Operation . (Group 9025-05.)






Auxiliary Flow Rate Control Valve Combined Operation LEGEND: 16 From Pump 2 107 To Auxiliary Spool 108 Auxiliary Flow Rate Control Valve 177 From Flow Rate Select Solenoid Valve 200 Check Valve 201 Poppet 202 Switch Valve 600 High-Pressure Oil 602 Low-Pressure Oil 604 Return Oil 606 Trapped Oil 609 Pilot Oil DY To Solenoid Valve Manifold Port DY Combined Operation— Switch valve (202) is shifted by pilot oil (609) from flow rate select solenoid valve (177) when an auxiliary function is combined with one of the following operations: Arm out Arm out and boom up Swing Travel See Flow Rate Select Solenoid Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-05.) Pilot pressure from flow rate select solenoid valve shifts the switch valve creating trapped oil (606) on the backside of the poppet (201). The poppet now restricts the flow of high-pressure oil (600) from pump 2 (16) to the auxiliary spool (107). High pressure-oil from pump 2 flows to arm, boom, swing, or travel spools to ensure priority of oil flow to these functions.






Blade Circuit Operation—If Equipped

Blade Circuit Operation (blade down shown)





LEGEND: 15 16 37A 37B 73 74 75 76 81 90 93 95 97 104 107 110 111 112 113 115 116 117 120 121 140 141 142 143 144 145 146 147 148 150 151 152 153 155 600 604 609 B32 Y10


Pump 1 Pump 2 From Solenoid Valve Manifold From Solenoid Valve Manifold Right Control Valve Left Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Left Travel Spool Check Valve (lift check)—Left Travel Neutral age Check Valve (lift check)—Left Travel Power age Orifice—Left Travel Power age Main Relief Valve Isolation Check Valve—5-Spool Main Relief Valve Isolation Check Valve—4-Spool Main Relief and Power Dig Valve Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit Blade Spool Blade Up Circuit Relief and Anticavitation Valve Blade Down Circuit Relief and Anticavitation Valve Blade Cylinder (2 used) Blade Control Valve Travel Flow Combiner Shuttle Valve Swing Parking Brake Shuttle Valve Blade Signal Selector Valve Blade Signal Shuttle Valve Blade Pilot Control Valve Blade Main Relief Valve Blade Pump Pilot Shutoff Valve Shuttle Valve High Pressure Oil Return Oil Pilot Oil Front Attachment Pressure Sensor Pilot Shutoff Solenoid

Blade pump (152) delivers pressure oil to blade main relief valve (151) and blade control valve (144). Return oil (604) from blade cylinders (143) is routed through blade control valve directly to return filter in hydraulic oil tank. Blade circuit is controlled by the blade pilot control valve (150). Pilot oil (609) is supplied to blade pilot control valve through pilot shutoff valve (153). Pilot oil is also supplied to blade signal selector valve (147) from solenoid valve manifold (37B). When blade function is activated, pilot oil from blade pilot control valve is routed to blade signal shuttle valve (148). From blade signal shuttle valve, pilot oil flows in four directions: To blade spool (140) inside blade control valve. To front attachment pressure sensor (B32) via swing parking brake shuttle valve (146). To blade signal selector valve. To by shuttle valve (93) from shuttle valve (155). Pilot oil to by shutoff valve causes the valve to shift and blocks pump 1 (15) flow to return. With blade signal selector valve shifted, pilot oil is routed through the travel flow combiner shuttle valve (145) to travel flow combiner valve (120) causing the valve to shift and allowing pump 1 pressure oil to combine with pump 2 (16) pressure oil. With blade spool shifted, combined oil flow from pump 1, pump 2, and blade pump travels to the blade cylinders.






When control lever is in neutral, high pressure oil from blade pump returns to the hydraulic oil tank through blade control valve.






Swing Reduction Gear Case Operation

Swing Gear Case Cross Section LEGEND: 1 2 3 4 5 6 7 8 9 10 52

Swing Motor Shaft First Stage Planetary Gear Ring Gear Second Stage Planetary Gear Swing Bearing Internal Gear Shaft Second Stage Carrier Second Stage Sun Gear First Stage Carrier First Stage Sun Gear Swing Motor

Swing gear case is a two-stage, planetary-type gear case. The ring gear (3) is attached to gear case housing. The swing motor shaft (1) rotates first stage sun gear (10). Power is transferred from the first stage sun gear to second stage sun gear (8) through first stage planetary gear (2) and first stage carrier (9). The second stage sun gear rotates shaft (6) through second stage planetary gear (4) and second stage carrier (7). The swing bearing internal gear (5) is mounted to the undercarriage. The shaft (6) is engaged in the internal gear and rotates the upperstructure.






Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation

Swing Motor LEGEND: 1 Spring 2 Brake Piston 3 Brake Plate 4 Piston 5 Shoe 6 Swash Plate 7 Shaft 8 Housing 9 Cylinder Block 10 Valve Plate 54 Swing Crossover Relief Valve Swing Motor— The swing motor is a fixed-displacement, axial-piston motor consisting of: a spring (1), brake piston (2), brake plate (3), swash plate (6), housing (8), cylinder block (9), and valve plate (10). Piston (4) is inserted into cylinder block which is splined to shaft (7). Piston is pushed by pressurized oil from pump. Shoe (5) slides over swash plate so that cylinder block rotates. Shaft is splined to the first stage sun gear of swing reduction gear case. Therefore, the rotation of shaft is transmitted to the swing reduction gear case. See Swing Reduction Gear Case Operation . (Group 9025-05.)






Swing Crossover Relief Valve and Make-Up Check Valve LEGEND: 11 53 54

Poppet (2 used) Swing Motor Make-Up Check Valve (2 used) Swing Crossover Relief Valve (2 used)

Swing Crossover Relief Valve—Neutral Position LEGEND: 12 13 14 15 54 600 604


Low Pressure Port (return circuit) High Pressure Port (swing circuit) Poppet Spring (2 used) Swing Crossover Relief Valve High Pressure Oil Return Oil





Swing Crossover Relief Valve—Relief Operation LEGEND: 12 Low Pressure Port (return circuit) 13 High Pressure Port (swing circuit) 14 Poppet 15 Spring (2 used) 54 Swing Crossover Relief Valve 601 Medium Pressure Oil 604 Return Oil Swing Motor Crossover Relief Valve— The swing crossover relief valve (54) prevents the occurrence of surge pressures and protects the circuit from being overloaded. Pressure in high pressure port (13) is applied to the poppet (14) until it reaches the spring set pressure. The poppet opens and allows pressure oil to flow into low pressure port (12). The pressure in the swing circuit decreases and the spring set force closes the poppet. Swing Motor Make-Up Check Valve— When the swing control lever is returned to the neutral position while the upperstructure is in motion, the weight of the upperstructure will continue to turn the swing motor which causes it to act like a pump. The flow caused by the pumping action of the swing motor cannot flow through the control valve, because the work ports are blocked by the valve spool. The high pressure oil is forced through the crossover relief valve. The swing motor makeup check valve (53) provides oil to the low pressure side of the swing motor to prevent cavitation.






Swing Motor Park Brake Release Circuit Operation

Swing Park Brake Release Circuit Operation (brake released) LEGEND: 1 Spring 2 Brake Piston 3 Brake Piston Chamber 4 Friction Plate (4 used) 5 Plate (4 used) 6 Rotor 51 Swing Device 57 Orifice 58 Check Valve 59 Flow Control Valve 604 Return Oil 609 Pilot Oil SH From Swing Park Brake Release Pilot Valve (port SH) Releasing Park Brake— When any dig or swing function is operated, the swing park brake release pilot valve is shifted, allowing pilot oil (609) through check valve (58) to move brake piston (2). As brake piston moves, plates (5) and friction plates (4) disengage, which releases the swing park brake.






Swing Park Brake Release Circuit Operation (brake applied) LEGEND: 1 Spring 2 Brake Piston 3 Brake Piston Chamber 4 Friction Plate (4 used) 5 Plate (4 used) 6 Rotor 51 Swing Device 57 Orifice 58 Check Valve 59 Flow Control Valve 604 Return Oil SH To Swing Park Brake Release Pilot Valve (port SH) Applying Park Brake— When the dig or swing pilot control lever is returned to neutral, the swing park brake release pilot valve stops the flow of pilot oil to the swing motor. The spring (1) pushes the brake piston down, forcing oil through orifice (57) into the swing motor case. The orifice prevents the brake piston from moving quickly and delays the application of the swing park brake until the upperstructure is stopped or nearly stopped. The spring force on the brake piston, which acts on the cylinder block, engages the friction plates (4) and plates (5), which acts on the inside of the swing motor housing, securing the upperstructure.






Center t Operation

Center t (forward travel; fast travel selected) LEGEND: 31A 37B 61 61A 61B 63 63A 63B 72 75A 75B 110A 110B 143 143A 143B 144A 144B 600 604 606 609

To Hydraulic Oil Tank From Solenoid Valve Manifold Right Travel Motor To Right Travel Motor From Right Travel Motor Left Travel Motor To Left Travel Motor From Left Travel Motor Center t To Right Travel Spool From Right Travel Spool To Left Travel Spool From Left Travel Spool Blade Cylinder (2 used) To Blade Cylinder (piston side) To Blade Cylinder (rod side) From Blade Control Valve (blade down) From Blade Control Valve (blade up) High Pressure Oil Return Oil Trapped Oil Pilot Oil

The center t (72) is a 360° rotary manifold. The center t allows oil to flow to and from the travel motors (61 and 63) and the blade cylinders (143) without twisting hoses when the upperstructure is rotated. The inner spindle is connected to the upperstructure and the housing is connected to the undercarriage. The housing rotates about the spindle during swing operation. Oil flows into and through the spindle to ages in the housing, and then out of the housing to the travel motors and the blade cylinders. Sealing rings stop oil from leaking between the spindle and housing into adjacent ages. <- Go to Section TOC





See Travel Hydraulic System Line Connection for line identification and connections. (Group 9025-15.)






Travel Motor and Park Brake Valve Operation

Travel Motor and Brake Valve Schematic LEGEND: 60 61 62 <- Go to Section TOC

Right Travel Device Right Travel Motor Left Travel Device Section 9025 page 138



63 64 65 66 66A 67 68 69 70 71 72 75A 75B 110A 110B 143A 143B 144A 144B 604 606


Left Travel Motor Travel Park Brake (2 used) Travel Speed Servo Piston (2 used) Travel Speed Change Valve (2 used) Travel Speed Solenoid (SI) Shuttle Valve (2 used) Travel Motor Crossover Relief Valve (4 used) Check Valve (4 used) Orifice (4 used) Counterbalance Valve (2 used) Center t Right Travel Spool Top Port—Forward Right Travel Spool Top Port—Reverse Left Spool Top Port—Forward Left Spool Top Port—Reverse Blade Cylinder (piston side) To Blade Cylinder (rod side) From Blade Control Valve (blade dn) Blade Cylinder (blade up) Return Oil Trapped Oil

Travel Motor and Brake Valve Components LEGEND: 1 2 3 <- Go to Section TOC

Drum Piston Housing Section 9025 page 139



4 5 6 7 8 64 65 66 67


Drive Shaft Valve Plate Brake Valve Housing Park Brake Piston Swash Plate Travel Park Brake Travel Speed Servo Piston Travel Speed Change Valve Shuttle Valve

Travel Motor and Brake Valve— The travel motor is a variable-displacement, swash plate, axial-piston type motor that includes the brake valve housing (6) and travel park brake (64). Brake valve housing consists of the following components: Travel Speed Change Valve (66) Shuttle Valve (67) Orifice (70) Counterbalance Valve (71) Travel Motor Crossover Relief Valve (68) (2 used) Check Valve (69) (2 used) Travel Park Brake— The travel park brake is a wet-type, multiple-disk brake. The brake is spring-applied and hydraulically released (negative type). The brake is released when travel function is actuated and high pressure oil is routed to the park brake piston by the counterbalance valve. The brake is applied when no functions or only the dig and swing functions are actuated. When travel function is released, the counterbalance valve returns to center position blocking the high pressure oil acting on park brake piston (7). The disk spring pushing against the park brake piston forces the oil to flow through the orifice (70) in the piston and into travel motor housing. The delay caused by oil flowing through the orifice is enough to slow engagement, to ensure park brake is only fully applied after the machine has stopped.






Travel Motor Slow Speed Operation LEGEND: 2 8 10 37 65 66 67 70 604

Piston Swash Plate Spring From Solenoid Valve Manifold—Power Dig Solenoid (marked SG) Travel Speed Servo Piston Travel Speed Change Valve Shuttle Valve Orifice Return Oil

Travel Motor Slow Speed— At slow speed (turtle), the oil acting on the travel speed change valve (66) is open to return through the solenoid valve manifold (37). Travel speed change valve is held up by the spring (10). For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.) The oil acting on the travel speed servo piston (65) is routed to return through the center of travel speed change valve. The travel speed change valve blocks the flow of high pressure oil to the servo piston. High pressure oil from the pressurized motor work port is routed to the valve by the shuttle valve (67). <- Go to Section TOC





The swash plate (8) is held at maximum displacement. At maximum displacement the motor turns at slow speed with high torque.

Travel Motor Fast Speed Operation LEGEND: 2 8 10 37 65 66 67 70 600 602 604

Piston Swash Plate Spring From Solenoid Valve Manifold—Power Dig Solenoid (marked SG) Travel Speed Servo Piston Travel Speed Change Valve Shuttle Valve Orifice High Pressure Oil Pilot Oil Return Oil

Travel Motor Fast Speed— At fast speed (rabbit), pilot oil (602) from the solenoid valve manifold (37) pushes the travel speed change valve (66) down. For more information, see Travel Motor Speed Circuit Operation . (Group 9025-05.)






High pressure oil (600) flows from the motor work port, through the shuttle valve (67), travel speed change valve, orifice (70), and to the travel speed servo piston (65). The piston then moves the swash plate (8) to its minimum angle. At minimum angle, the travel motors turn at fast speed with reduced torque. Orifice controls the flow of high pressure oil to the piston to modulate the change in speed.

Brake Valve Housing—Braking Operation LEGEND: 7 11 12 13 14 15 16 17 67 68 <- Go to Section TOC

To Park Brake Piston To Travel Motor Poppet Orifice Piston Spring (4 used) Spring (4 used) Restriction Shuttle Valve Travel Motor Crossover Relief Valve (2 used) Section 9025 page 143



69 70 71 75 600 601 602 604


Check Valve (2 used) Orifice Counterbalance Valve Right Travel Spool High Pressure Oil Medium Pressure Oil Low Pressure Oil Return Oil

Counterbalance Valve (71)— When the travel spools in the main control valve are in neutral, counterbalance spool is held in the center position by springs (16). Right travel spool (75) are open to return through the control valve return age. The check valves (69) and counterbalance valve traps the oil in each motor holding them stationary. When travel function is first actuated, high pressure oil pressure builds on one side of motor due to the motor′s resistance to turning and because the check valve and counterbalance valve blocks the flow of return oil from the motor. The increased pressure is sensed at the end of counterbalance valve through orifice (70) and begins to shift the counterbalance valve (71). As the valve shifts, a path is opened for return oil to flow to the control valve. High pressure oil (600) flows to the park brake piston (7) to release the travel park brake. High pressure oil flows around counterbalance valve and opens the check valve to supply the motor. When a machine is traveling down a hill, the weight can cause it to overrun the travel motors. Overrunning would cause faster travel than desired and cavitation in the motors. As pressure decreases in the work port of the motor, the spring begins to shift the valve toward the center position. A restriction (17) is created by restricting the flow of return oil (604) from the motor and keeps the motor from turning faster than desired. Travel Motor Crossover Relief Valves (68)— The crossover relief valves are direct acting relief valves with a shock reducing function. As oil flows through the orifice (13) and moves the piston (14), a pressure difference is created from one side of the poppet (12) to the other. The pressure difference allows the poppet to open below the set pressure to reduce pressure spikes. Once the piston reaches full stroke, the pressure difference is eliminated and the pressure in the travel circuit increases to the set pressure. Check Valves (69)— When travel control lever is returned to the neutral position while the machine is in motion, the inertia of machine continues to turn the travel motor, which causes it to act like a pump. High pressure is then created in the return side of motor and low pressure on the other. When pressure in the return side becomes higher than the low pressure side of motor, the check valve (69) is pushed open. Return oil from the return side flows to low pressure side preventing cavitation.






Travel Motor Speed Circuit Operation

Travel Motor Speed Circuit Fast Speed Operation LEGEND: 1 2 47 48 61 63 66 609 650 A3 B32 B34 B35 B36 B37 B38 S11 Y24

Fast (rabbit) Speed Slow (turtle) Speed Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) Right Travel Motor Left Travel Motor Travel Speed Change Valve (2 used) Pilot Oil Electrical Voltage Main Controller (MCZ) Front Attachment Pressure Sensor Travel Pressure Sensor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Travel Speed Switch Power Dig/Travel Speed Solenoid (marked SG)

Travel Motor Slow (Turtle) Speed— When the travel speed switch (S11) is in the slow (turtle) speed (2) position, the power dig/travel speed solenoid (Y24) is de-energized. Pilot oil (609) is open to return through the power dig/travel speed solenoid (Y24) and the travel motors are at slow speed. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.) Travel Motor Fast (Rabbit) Speed— When travel speed switch is in the fast (rabbit) speed (1) position, the power dig/travel <- Go to Section TOC





speed solenoid is energized. Pilot oil is routed to the travel speed change valves (66), and the travel motors are shifted to fast speed. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.) The power dig/travel speed solenoid is energized only when all of the following conditions are met: Travel speed switch is at fast (rabbit) speed position Pressure at travel pressure sensor (B34) No pressure at front attachment pressure sensor (B32) Both pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37) must indicate low pressure Both pump 1 control pressure sensor (B36) and pump 2 control pressure sensor (B38) must indicate high pressure. For electrical circuit information, see System Functional Schematic, Component Location, and Wiring Diagram Master Legend . (Group 9015-10.) Once the machine is operating in fast (rabbit) speed, a dig or swing function will not cause the travel speed to change to slow (turtle) speed, even though pressure is sensed at the front attachment pressure sensor (B32).






Power Dig/Travel Speed Solenoid Operation LEGEND: 1 2 3 4 5 <- Go to Section TOC





6 Pressure Equals Magnetic Force 29 From Pilot Filter and By Valve 31 To Hydraulic Oil Tank 37 Solenoid Valve Manifold 604 Return Oil 609 Pilot Oil 613 Reduced Pilot Oil Y22 Dig Regenerative Solenoid (marked SF) Y23 Arm Regenerative Solenoid (marked SC) Y24 Power Dig/Travel Speed Solenoid (marked SG) Y27 Arm 2 Flow Control Solenoid (marked SD) The power dig/travel speed solenoid (marked SG) (Y24) is a proportional-type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse width modulated signal. The solenoid coil (1) reacts to the “average” voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on verses on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (4), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port. When energized (5), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot filter and by valve (29) flows past the spool flange and out the valve function port as reduced pilot oil. Because the flange on the right is larger than the flange on the left, the spool is pushed to the right against the magnetic force as the oil pressure to the valve function increases. When the oil pressure becomes equal to or greater than the magnetic force, the spool is pushed to the right closing the age stopping the pressure increase. The oil pressure to the valve function is trapped. The spool is moving constantly to maintain the oil pressure in response to the voltage signal to the solenoid coil. See Control Valve Operation . (Group 9025-05.) and see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.)






Cylinder Operation

Cylinder Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Snap Ring Wiper Seal Backup Ring U-Cup Seal Buffer Ring Wear Ring Snap Ring Piston Buffer Ring (2 used) Wear Ring (2 used) Cap Seal Set Screw Nut Cushion Barrel Cylinder Rod Rod Guide Bucket Cylinder

Boom, Arm, and Bucket Cylinders The boom, arm, and bucket cylinders are similar in design. The bucket cylinder (18) is illustrated. The rod guide (17) is fastened to the cylinder barrel with cap screws and is fitted with a wear ring (6) held in place by a snap ring (7). A buffer ring (5), U-cup seal (4), backup ring (3), and wiper seal (2) are used in the rod guide. A snap ring (1) is used to help hold wiper seal in place. The U-cup seal (4) is protected against high pressure by the buffer ring (5) and stops the small amount of oil that may by the buffer ring. The piston (8) is a slip-fit on the cylinder rod (16) and is retained with a nut (13). A set screw (12) prevents loosening of the nut. The piston is fitted with a cap seal (11), wear rings (10), and buffer rings (9). Boom, bucket, and arm cylinders have a cushion (14) in front of the piston to provide cushioning action in cylinder extension. As the cylinder nears the end of its stroke, the cushion enters a bore in the rod guide. The remaining return oil ahead of the piston must flow through a small clearance between the cushion and rod guide. Only the arm cylinder is cushioned in <- Go to Section TOC





retraction. The end of the rod enters a bore in the head end of cylinder. The remaining return oil ahead of the piston and nut must flow through this small clearance as the cylinder bottoms out in this direction.






Return Filter Operation

Return Filter Operation LEGEND: 1 2 3 4 5 6

Return Filter By Operation Return Filter Normal Operation By Valve Filter Element Return Oil From Oil Cooler Return Oil From Control Valve

The filter element (4) is located in a chamber inside the hydraulic oil tank. O-rings are used at each end of the filter element to prevent leakage. A spring holds the filter element on its seat. Return oil from the oil cooler (5) and the control valve (6) flow through the filter element from the outside to the center. Filtered oil flows out the bottom of filter into the hydraulic oil tank. A by valve (3) is located at the top of the filter. The valve opens to protect the filter element against pressure surges in the return circuit and allows a path for return oil if the filter element becomes plugged. During by operation, oil flows into the chamber faster than it can flow through the filter element causing the pressure to increase. The higher pressure forces the by valve open allowing oil to flow down the center of the filter element and into the hydraulic oil tank. The by valve closes when the pressure decreases below the pressure setting of the by valve.

Auxiliary System Operation →NOTE: For auxiliary attachments to work properly multiple kits may be required.

The auxiliary system consist of a pilot control system to shift the auxiliary control valve spool. The shifted auxiliary control valve spool allows high pressure oil flow to work port of the auxiliary attachment depending on attachment and kits installed. <- Go to Section TOC





The following kits are available for auxiliary attachments: Auxiliary High Flow Line Kit, for more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.) Two Pump Combined Flow Kit, for more information, see Two Pump Combined Flow Kit Operation . (Group 9025-05.) Two Way Solenoid Kit Operation, for more information, see Two Way Solenoid Kit Operation . (Group 9025-05.) Two Way Foot Pedal Kit. One Way Foot Switch. For more information on attachment and required kits to operate go to info to go at www.dealernet.deere.com.






Auxiliary Pilot Control Valve Operation The auxiliary pilot control valve regulates the pilot oil pressure to actuate the pilot valve in the pilot signal manifold and to shift the auxiliary control valve spool to actuate the auxiliary functions. For pilot valve operation see Pilot Signal Manifold Operation . (Group 9025-05.) For control valve operation See Pilot Operation of Control Valve Operation . (Group 9025-05.)






Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)





LEGEND: 28 41 45 47 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 153 179 604 609 B60



Pilot Pump Pilot Signal Manifold Swing Park Brake Release Pilot Valve (port SH) Pump 2 Flow Rate Pilot Valve (port SB) To Swing Park Brake 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Pilot Shutoff Valve To Pump 2 Flow Rate Solenoid Valve Return Oil Pilot Oil Attachment Pressure Sensor





Auxiliary Pilot Control Valve LEGEND: 1 2 3 4 5 <- Go to Section TOC

Spool Washer Spring Guide Plunger Adjustment Screw Section 9025 page 156



6 7 8 9 10 11 12 15 604 609


Pedal Sleeve Balance Spring Return Spring To Pilot Shutoff Solenoid Valve Port T2 From Pilot Shutoff Solenoid Valve Port A3 Port 13 or 14 To Control Valve Pilot Cap Auxiliary Pilot Control Valve—Full Stroke Pilot Oil Return Oil

One pilot control valve is used to control the auxiliary functions. The pilot control valve contains two valve assemblies. The valves are controlled by movement of the pedals against the plunger (4). The ports (10, 11, and 12) in housing are identified by numbers and letters next to each port. In neutral, the spool is pushed up by the return spring (8) pushing the plunger up. The return springs hold the pedal in the neutral position. With the spool up, ports 13 and 14 to the control valve pilot cap (12) are open to pilot shutoff solenoid valve port T2 (10) through the age and holes in spool. Pilot oil from the pilot shutoff solenoid valve port A3 (11) is blocked by the spool. When the pedal is pushed to actuate an auxiliary function, the pedal pushes the plunger and spring guide down against the return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down and the holes move through the deadband area, the age from control valve pilot cap to the hydraulic oil tank is closed and then opened to the pilot oil from pilot shutoff solenoid valve. Pilot oil pressure increases until it is equal to the force applied by the balance spring, the spool moves up until the oil flowing through the holes is blocked in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the pedal is again actuated. When the pedal is pushed to full stroke, the plunger is pushed down farther by the balance spring opening the age through the spool to pilot oil pressure. When pressure to the control valve pilot cap is equal to the force applied by the balance spring, the spool moves up until it s the plunger. The plunger holds the spool down so the age through the spool remains open to pilot oil pressure. Oil pressure to the control valve pilot cap now approximately equals pilot oil pressure.






Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)





LEGEND: 28 41 45 47 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 153 172 173 179 604 609 B60


Pilot Pump Pilot Signal Manifold Swing Park Brake Release Pilot Valve (port SH) Pump 2 Flow Rate Pilot Valve (port SB) To Swing Park Brake 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Pilot Shutoff Valve Auxiliary Soleniod Valve Auxiliary Pressure Reducing Valve To Pump 2 Flow Rate Solenoid Valve Return Oil Pilot Oil Attachment Pressure Sensor

Auxiliary Solenoid Valve Operation LEGEND: 153 172 173 220 221 604 609

From Pilot Shutoff Valve Auxiliary Soleniod Valve Auxiliary Pressure Reducing Valve To Pilot Signal Manifold Port N To Pilot Signal Manifold Port M Return Oil Pilot Oil

Auxiliary Solenoid Valve Operation— When auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port M (221). Pilot signal manifold port 13 outputs pilot oil to the control valve auxiliary valve spool. Shifting control valve auxiliary spool and high-pressure oil is output to the auxiliary attachment.






Auxiliary Solenoid Valve Operation LEGEND: 153 172 173 220 221 604 609

From Pilot Shutoff Valve Auxiliary Soleniod Valve Auxiliary Pressure Reducing Valve To Pilot Signal Manifold Port N To Pilot Signal Manifold Port M Return Oil Pilot Oil

When auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port N (220). Pilot signal manifold port 14 outputs pilot oil to the control valve auxiliary valve spool. Shifting control valve auxiliary spool and high-pressure oil is output to the auxiliary attachment.






Flow Rate Select Solenoid Valve Operation

Flow Rate Select Solenoid Valve Schematic (2-speed solenoid energized) LEGEND: 29 93 108 118 177 SM SP Y43 Y44

From Pilot Filter and By Valve To By Shutoff Valve To Auxiliary Flow Rate Control Valve To Auxiliary Flow Combiner Valve Flow Rate Select Solenoid Valve From Pilot Signal Manifold Port SM To Pilot Signal Manifold Port SP 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve

The function of the flow rate select solenoid valve (177) is to allow for combined oil flow from pump 1 and pump 2, and to provide more or less priority to the functions under the following conditions: Two speed on (combined flow on) Pressure on attachment pressure sensor (B60) Combined with any of these inputs: Pressure on arm out pressure sensor (B61) Pressure on arm out pressure sensor (B61) and boom up pressure sensor (B30) Pressure on swing pressure sensor (B33) Pressure on travel pressure sensor (B34) For more information on sensors, see System Functional Schematic . (Group 9015-10.)






→NOTE: Two-Speed control will not work properly unless appropriate kits are installed on machine.

When energized, the 2-speed activation solenoid valve (Y43) sends pilot oil from pilot signal manifold port SM (SM), to pilot signal manifold port SP (SP), to by shutoff valve (93), and to auxiliary flow combiner valve (118). Pilot oil sent to auxiliary flow combiner valve allows for combined oil flow from pump 1 and pump 2 to operate the attachment. Pilot oil to pilot signal manifold port SP shifts the pump 1 flow rate pilot valve to send full control pressure to pump 1 and by shutoff valve allowing pump 1 pressure to increase. When de-energized, 2-speed activation solenoid valve spring tension shifts the valve allowing the circuit to drain to hydraulic oil tank. When energized, the flow rate adjustment solenoid valve (Y44) routes pilot oil from pilot filter and by valve (29) to auxiliary flow rate control valve (108). This adjusts the auxiliary flow rate control valve to provide more or less priority to the dig, swing, and travel functions over the attachment function. See Auxiliary Flow Rate Control Valve Circuit Operation . (Group 9025-05.) The main controller varies the signal to the flow rate adjustment solenoid valve to vary the pilot oil pressure at the auxiliary flow rate control valve. This allows for adjustment of the priority of the attachment function over arm out, arm out and boom up, swing, and travel using the monitor. For information on adjusting flow rate and priority level, see Attachment Control Circuit Theory of Operation (Group 9015-16.) and see Machine Setting . (Group 9015-16.) When de-energized, the flow rate adjustment solenoid valve spring tension shifts the valve allowing the circuit to drain to hydraulic oil tank.

Flow Rate Pressure Reducing Valve Operation

Flow Rate Pressure Reducing Valve Schematic LEGEND: 118 178 DP SN

To Auxiliary Flow Combiner Valve Flow Rate Pressure Reducing Valve To Solenoid Valve Manifold Port DP From Pilot Signal Manifold Port SN

The function of the flow rate pressure reducing valve (178) is to control the amount of pump 1 flow that is directed to the auxiliary spool when combining auxiliary with a pump 1 function. Pilot pressure is sent from pilot signal manifold port SN (SN) when a pump 1 function is activated. The pilot oil is then routed through the flow rate pressure reducing valve to auxiliary flow combiner valve (118). This shifts the auxiliary flow combiner valve to stop the flow of pump 1 high-pressure oil to the auxiliary spool, “de-combining” the flow. Flow rate reducing valve is adjustable, turn counterclockwise to give auxiliary priority flow over pump 1 functions or clockwise to give pump 1 functions priority over auxiliary. When pilot oil pressure to auxiliary flow combiner valve exceeds set pressure of flow rate reducing valve, the valve shifts <- Go to Section TOC





allowing pilot oil to flow to solenoid valve manifold port DP (DP) allowing the auxiliary flow combiner valve to shift combining pump 1 and pump 2 high-pressure oil flow. For more information, see Two Pump Combined Flow Kit Operation . (Group 9025-05.)

Selector Valve Solenoid Valve Operation

Selector Valve Solenoid Valve Schematic LEGEND: 29 175 176 Y40

From Pilot Filter and By Valve Selector Valve Solenoid Valve To Selector Valve Selector Valve Solenoid Valve

The function of the selector valve solenoid valve (175) is to shift the selector valve for attachment flow to return to the control valve or directly to hydraulic oil tank. →NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.

The selector valve solenoid valve is controlled by MPDr or Service ADVISOR ™ . See Attachment Control Circuit Theory of Operation . (Group 9015-15.) When the selector valve solenoid valve (Y40) is energized, pilot oil from pilot filter and by valve (29) is directed to selector valve (176). When the selector valve solenoid valve (Y40) is de-energized, spring tension shifts the spool and pilot oil to the selector will flow to hydraulic oil tank. For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)

Selector Valve Operation






Selector Valve Operation LEGEND: 107 174 175 176 DM

To or From Auxiliary Spool From Auxiliary Attachment From Selector Valve Solenoid Valve Selector Valve To Solenoid Valve Manifold Port DM

The function of the selector valve (176) is to allow the attachment to operate in one-way flow or two-way flow. →NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.

One-Way Flow Operation Pilot oil from selector valve solenoid valve (175) shifts selector valve allowing high-pressure oil from auxiliary attachment (174) to flow directly to hydraulic oil tank. Two-Way Flow Operation Without pilot oil from selector valve solenoid valve, spring tension shifts selector valve allowing high-pressure oil to or from auxiliary spool (107). High-pressure oil is directed to front attachment to operate two modes of use. For example, up-down, inout, left-right. Return oil then es through the auxiliary spool to control valve return age. For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)

Auxiliary Shuttle Valve Operation






Auxiliary Shuttle Valve Schematic

Auxiliary Shuttle Valve LEGEND: 93 118 155 170 177 SP

To By Shutoff Valve To Auxiliary Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve From Flow Rate Select Solenoid Valve To Pilot Signal Manifold Port SP

The auxiliary shuttle valve (170) allows pilot oil from flow rate select solenoid valve (177) or from shuttle valve (155) to shift by shutoff valve (93). Pilot oil from flow rate select solenoid valve port or from shuttle valve is sent to auxiliary shuttle <- Go to Section TOC





valve to prevent backfeeding between the circuits. For more information, see Control Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-05.)






Auxiliary High Flow Line Kit Operation






Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted)





LEGEND: 13 14 15 16 28 37 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 120 174 175 176 600 604 609 Y40


Auxiliary (pilot) Auxiliary (pilot) Pump 1 Pump 2 Pilot Pump Solenoid Valve Manifold 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Travel Flow Combiner Valve Auxiliary Attachment Selector Valve Solenoid Valve Selector Valve High-Pressure Oil Return Oil Pilot Oil Selector Valve Solenoid Valve

The function of the auxiliary high flow line kit is to operate auxiliary function in one-way flow operation or two-way flow operation. →NOTE: Auxiliary attachments will not work properly unless appropriate kits are installed on machine.

The selector valve solenoid valve (Y40) is controlled by settings in the monitor. For more information, see Attachment Control Circuit Theory of Operation . (Group 9015-15.)

Selector Valve Solenoid Valve De-Energized <- Go to Section TOC




LEGEND: 29 175 176 604 609 Y40


From Pilot Filter and By Valve Selector Valve Solenoid Valve From Selector Valve Return Oil Pilot Oil Selector Valve Solenoid Valve

Selector Valve Solenoid Valve De-Energized— For operation of selector valve solenoid valve (Y40), see Selector Valve Solenoid Valve Operation . (Group 9025-05.)

Selector Valve Solenoid Valve Energized LEGEND: 29 175 176 604 609 Y40

From Pilot Filter and By Valve Selector Valve Solenoid Valve To Selector Valve Return Oil Pilot Oil Selector Valve Solenoid Valve

Selector Valve Solenoid Valve Energized— For operation of selector valve solenoid valve (Y40), see Selector Valve Solenoid Valve Operation . (Group 9025-05.)






Selector Valve One-Way Operation LEGEND: 107 174 175 176 604 609 DM

To Auxiliary Spool From Auxiliary Attachment From Selector Valve Solenoid Valve Selector Valve Return Oil Pilot Oil To Solenoid Valve Manifold Port DM

Selector Valve One-Way Operation— For operation of the selector valve (176), see Selector Valve Operation . (Group 9025-05.)

Selector Valve Two-Way Operation LEGEND: 107 174 175 176 604 DM

To Auxiliary Spool From Auxiliary Attachment To Selector Valve Solenoid Valve Selector Valve Return Oil To Solenoid Valve Manifold Port DM

Selector Valve Two-Way Operation— For operation of the selector valve (176), see Selector Valve Operation . (Group 9025-05.)






Two Way Solenoid Kit Operation











LEGEND: 28 41 45 47 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 153 172 173 179 604 609 B60



→NOTE: Two way solenoid kit can be used on auxiliary high flow and auxiliary low flow.

The function of two way solenoid kit is to operate the auxiliary function from the left or right pilot control lever momentary and proportional switches. →NOTE: The right pilot control lever switches are standard from the factory, left pilot control lever switches are a field kit installation.

Pressure Reducing Valve— The auxiliary pressure reducing valve (173) reduces the pressure to the auxiliary solenoid valve (172) to limit the control valve auxiliary spool movement. The pressure reducing valve is adjustable, turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure.






Auxiliary Solenoid Valve Schematic LEGEND: 153 172 173 220 221 604 609

From Pilot Shutoff Valve Auxiliary Solenoid Valve Auxiliary Pressure Reducing Valve To Pilot Signal Manifold Port N To Pilot Signal Manifold Port M Return Oil Pilot Oil

Auxiliary Solenoid Valve— When the auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port M (221), pilot signal manifold port 13 outputs pilot oil to the control valve auxiliary valve spool. This shifts the control valve auxiliary valve spool and high-pressure oil is output to the auxiliary attachment.

Auxiliary Solenoid Valve Schematic LEGEND: 153 172 173 220 <- Go to Section TOC

From Pilot Shutoff Valve Auxiliary Solenoid Valve Auxiliary Pressure Reducing Valve To Pilot Signal Manifold Port N Section 9025 page 175



221 604 609


To Pilot Signal Manifold Port M Return Oil Pilot Oil

When the auxiliary solenoid valve (172) is shifted, pilot oil (609) is sent to pilot signal manifold port N (220), pilot signal manifold port 14 outputs pilot oil to the control valve auxiliary valve spool. This shifts the control valve auxiliary valve spool and high-pressure oil is output to the auxiliary attachment.






Two Pump Combined Flow Kit Operation






Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)





LEGEND: 15 16 28 41 45 47 48 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 119 120 155 170 177 178 179 180 600 604 609 B60 B61 DP DY Y43 Y44


Pump 1 Pump 2 Pilot Pump Pilot Signal Manifold Swing Park Brake Release Pilot Valve (port SH) Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) To Swing Park Brake 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve Flow Rate Select Solenoid Valve Flow Rate Select Reducing Valve To Pump 2 Flow Rate Solenoid Valve To Torque Control Solenoid Valve High-Pressure Oil Return Oil Pilot Oil Attachment Pressure Sensor Arm Out Pressure Sensor To Solenoid Valve Manifold Port DP To Solenoid Valve Manifold Port DY 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve

→NOTE: Two pump combined flow kit will not work properly unless appropriate kits are installed on machine.

The function of the two pump combined flow kit is to control auxiliary flow combiner valve (118) and auxiliary flow rate control valve (valve and poppet) (108) when multiple function are used with auxiliary attachments.






Auxiliary Shuttle Valve Schematic LEGEND: 93 118 155 170 177 SP

To By Shutoff Valve To Auxiliary Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve From Flow Rate Select Solenoid Valve To Pilot Signal Manifold Port SP

Auxiliary Shuttle Valve— For more information, see Auxiliary Shuttle Valve Operation . (Group 9025-05.)






Flow Rate Pressure Reducing Valve Operating Below Set Pressure LEGEND: 28 108 118 170 177 178 604 609 B60 DP SM SN SP Y43 Y44

Pilot Pump To Auxiliary Flow Rate Control Valve To Auxiliary Flow Combiner (2 used) To Auxiliary Shuttle Valve Flow Rate Select Solenoid Valve Flow Rate Select Reducing Valve Return Oil Pilot Oil Attachment Pressure Sensor To Solenoid Valve Manifold Port DP From Pilot Signal Manifold Port SM From Pilot Signal Manifold Port SN To Pilot Signal Manifold Port SP 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve

Flow Rate Pressure Reducing Valve Operating Below Set Pressure— For more information, see Flow Rate Pressure Reducing Valve Operation . (Group 9025-05.)






Flow Rate Pressure Reducing Valve Operating Above Set Pressure LEGEND: 28 108 118 170 177 178 604 609 B60 DP SM SN SP Y43 Y44

Pilot Pump To Auxiliary Flow Rate Control Valve From Auxiliary Flow Combiner (2 used) To Auxiliary Shuttle Valve Flow Rate Select Solenoid Valve Flow Rate Select Reducing Valve Return Oil Pilot Oil Attachment Pressure Sensor To Solenoid Valve Manifold Port DP From Pilot Signal Manifold Port SM From Pilot Signal Manifold Port SN To Pilot Signal Manifold Port SP 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve

Flow Rate Pressure Reducing Valve Above Set Pressure— For more information, see Flow Rate Pressure Reducing Valve Operation . (Group 9025-05.)






Flow Rate Select Solenoid Valve Energized LEGEND: 28 108 118 170 177 178 604 609 B60 DP SM SN SP Y43 Y44


Flow Rate Select Solenoid Valve Energized— For more information, see Flow Rate Select Solenoid Valve Operation . (Group 9025-05.)






Flow Rate Solenoid Valve De-Energized LEGEND: 28 108 118 170 177 178 604 609 B60 DP SM SN SP Y43 Y44


Flow Rate Solenoid Valve De-Energized— For more information, see Flow Rate Select Solenoid Valve Operation . (Group 9025-05.)






Group 15 - Diagnostic Information All Hydraulic Functions Slow 73

All Hydraulic Functions Slow Diagnostic Procedure ( 1 ) Low Hydraulic Oil Level

Action: Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.) Is hydraulic oil at proper level?

Result: YES:Go to Cold Hydraulic Oil. NO:Fill hydraulic tank to proper level. ( 2 ) Cold Hydraulic Oil

Action: Check hydraulic oil temperature. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Does hydraulic oil temperature meet specification?

Result: YES:Go to Oil Viscosity Too Heavy. NO:Perform hydraulic oil warm-up procedure. ( 3 ) Oil Viscosity Too Heavy

Action: Check hydraulic oil for proper viscosity. See Hydraulic Oil . (Operator’s Manual.) Is specified hydraulic oil used?

Result: YES:Go to Slow Engine Speed. NO:Use correct viscosity hydraulic oil for operating conditions. ( 4 ) Slow Engine Speed

Action: Check engine speed. See Engine Speed Control System Operation . (Group 9010-05.) Also see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) Does engine speed meet specification?

Result: YES:Go to Air Leak in Pump Suction Line. NO:Select correct engine speed. <- Go to Section TOC





( 5 ) Air Leak in Pump Suction Line

Action: Inspect pump suction line for leaks. See Hydraulic System Component Location . (Group 9025-15.) Is pump suction line free of leaks?

Result: YES:Go to Pump Control Pilot Pressure Signal Low. NO:Repair or replace pump suction line. ( 6 ) Pump Control Pilot Pressure Signal Low

Action: Perform Pump Control Pilot Pressure Signal Test . (Group 9025-25.) Does pump control pilot pressure meet specification?

Result: YES:Go to Pilot Circuit Malfunction. NO:Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) ( 7 ) Pilot Circuit Malfunction

Action: Check pilot circuit for malfunction. Is pilot circuit OK?

Result: YES:Go to Restricted Hydraulic Oil Tank Suction Screen. NO:Repair or replace pilot circuit. ( 8 ) Restricted Hydraulic Oil Tank Suction Screen

Action: Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.) Is hydraulic oil tank suction screen free of restriction?

Result: YES:Go to Pump 1 or Pump 2 Regulator Malfunction. NO:Clean or replace hydraulic oil tank suction screen. ( 9 ) Pump 1 or Pump 2 Regulator Malfunction

Action: Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.) <- Go to Section TOC





Does pump 1 or pump 2 regulator meet specification?

Result: YES:Go to Worn Pump. NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Disassemble and Assemble . (Group 3360.) ( 10 ) Worn Pump

Action: Slow travel cycle times may indicate a worn pump. Check travel cycle times. See Operational Checkout . (Group 9005-10.) If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.) Do travel cycle times and pump flow meet specification?

Result: YES:Go to Main Relief Valve Setting Too Low or Malfunctioning. NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.) ( 11 ) Main Relief Valve Setting Too Low or Malfunctioning

Action: Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.) Does main relief valve settings meet specification?

Result: YES:Go to Power Dig Solenoid Valve Setting Too Low or Malfunctioning. NO:Adjust or replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 12 ) Power Dig Solenoid Valve Setting Too Low or Malfunctioning

Action: See Power Dig Solenoid Valve Test and Adjustment . (Group 9025-25.) Does power dig solenoid valve setting meet specification?

Result: YES:Go to Low Pilot Oil Pressure. NO:Adjust or replace power dig solenoid valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 13 ) Low Pilot Oil Pressure

Action: Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.) Does pilot oil pressure meet specification?






Result: YES:Diagnostic checkout complete. NO:Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 3360.)






Hydraulic Oil Overheats 73

Hydraulic Oil Overheats Diagnostic Procedure ( 1 ) Low Hydraulic Oil Level


Result: YES:Go to Restricted Hydraulic Oil Cooler. NO:Fill hydraulic tank to proper level. ( 2 ) Restricted Hydraulic Oil Cooler

Action: Inspect hydraulic oil cooler. Is hydraulic oil cooler free of restriction?

Result: YES:Go to Oil Viscosity Too Light. NO:Clean, repair, or replace hydraulic oil cooler. ( 3 ) Oil Viscosity Too Light

Action: Check hydraulic oil for correct viscosity. See Hydraulic Oil . (Operator’s Manual.) Is specified hydraulic oil used?

Result: YES:Go to Fan Drive Malfunction. NO:Use correct viscosity hydraulic oil for operating conditions. ( 4 ) Fan Drive Malfunction

Action: Inspect fan drive. See Fan Speed Test and see Fan Drive Pump Flow Test . (Group 9025-25.) Does fan drive operate properly?

Result: YES:Go to Machine Lift Capacity Exceeded. NO:Repair or replace fan drive. See Fan Drive Motor Remove and Install . (Group 0510.) ( 5 ) Machine Lift Capacity Exceeded






Action: Check machine lift capacity. See Miscellaneous—Specifications . (Operator’s Manual.) Is amount of weight being lifted within machine lifting capacity?

Result: YES:Go to Restricted Hydraulic Oil Return Filter. NO:Reduce amount of weight being lifted. ( 6 ) Restricted Hydraulic Oil Return Filter

Action: Check hydraulic oil return filter for restriction. See Hydraulic System Component Location . (Group 9025-15.) Is hydraulic oil tank return filter restricted?

Result: YES:Replace hydraulic oil tank return filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.) NO:Go to Main Relief Valve Setting Too Low or Malfunctioning. ( 7 ) Main Relief Valve Setting Too Low or Malfunctioning

Action: Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.) Does main relief valve operate correctly?

Result: YES:Go to Power Dig Valve Setting Too Low or Malfunctioning. NO:Replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 8 ) Power Dig Valve Setting Too Low or Malfunctioning

Action: Perform main relief and power dig valve test. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.) Is power dig valve operating correctly?

Result: YES:Go to Oil Cooler By Valve Stuck Open. NO:Replace power dig valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.) ( 9 ) Oil Cooler By Valve Stuck Open

Action: Inspect oil cooler by valve. See Hydraulic Oil Cooler By Valve Remove and Install . (Group 3360.) Does oil cooler by valve operate correctly? <- Go to Section TOC





Result: YES:Go to Pump Stuck at Maximum Displacement. NO:Replace oil cooler by valve. ( 10 ) Pump Stuck at Maximum Displacement

Action: See Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.) Does pump control pilot pressure meet specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.) NO:Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)






No Hydraulic Functions 73

No Hydraulic Functions Diagnostic Procedure ( 1 ) Pilot Shutoff Lever in Locked (UP) Position

Action: Check position of pilot shutoff lever. Is pilot shutoff lever in unlocked (DOWN) position?

Result: YES:Go to Pilot Shutoff Solenoid Malfunction. NO:Place pilot shutoff lever in unlocked (DOWN) position. ( 2 ) Pilot Shutoff Solenoid Malfunction

Action: Check pilot shutoff solenoid. See Solenoid Test . (Group 9015-20.) Does pilot shutoff solenoid operate correctly?

Result: YES:Go to Low Hydraulic Oil Level. NO: See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) ( 3 ) Low Hydraulic Oil Level


Result: YES:Go to Pump Drive Failure. NO:Add proper hydraulic oil. See Hydraulic Oil . (Operator’s Manual.) ( 4 ) Pump Drive Failure

Action: Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install . (Group 0752.) Does damper drive (flex coupling) operate correctly?

Result: YES:Go to Restricted Hydraulic Oil Tank Suction Screen. NO:Repair or replace damper drive (flex coupling). ( 5 ) Restricted Hydraulic Oil Tank Suction Screen






Action: Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.) Is hydraulic oil tank suction screen free of restriction?

Result: YES:Diagnostic checkout complete. NO:Clean or replace hydraulic oil tank suction screen.






Poor Combined Operation 73

Poor Combined Operation Diagnostic Procedure ( 1 ) Front Attachment Pressure Sensor (B32) or Travel Pressure Sensor (B34) Malfunction

Action: Check front attachment pressure sensor (B32) or travel pressure sensor (B34). See Pressure Sensor Test . (Group 9015-20.) Do front attachment pressure sensor (B32) or travel pressure sensor (B34) operate correctly?

Result: YES:Go to Pilot Control Valve Malfunction. NO:Replace front attachment pressure sensor (B32) or travel pressure sensor (B34). ( 2 ) Pilot Control Valve Malfunction

Action: Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.) Does control valve spool actuating pressure meet specification?

Result: YES:Go to Check Valves or Pump 1 or Pump 2 Flow Rate Pilot Valve Stuck. NO:Inspect and repair or replace pilot control valve. See Pilot Shutoff Solenoid Valve Disassemble and Assemble . (Group 3360.) ( 3 ) Check Valves or Pump 1 or Pump 2 Flow Rate Pilot Valve Stuck

Action: Inspect check valves. See Control Valve Check Valves Identification and Operation . (Group 9025-05.) Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.) Do check valves or flow rate pilot valves operate correctly?

Result: YES:Diagnostic checkout complete. NO:Repair or replace check valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) NO:Repair or replace flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)






All Functions Cannot Be Operated 73

All Functions Cannot Be Operated Diagnostic Procedure ( 1 ) Pilot Shutoff Lever in Unlocked (DOWN) Position

Action: Check position of pilot shutoff lever. Is pilot shutoff lever in the unlocked (DOWN) position?

Result: YES:Go to Pilot Shutoff Solenoid Malfunction. NO:Place pilot shutoff lever in unlocked (DOWN) position. ( 2 ) Pilot Shutoff Solenoid Malfunction

Action: Check pilot shutoff solenoid. See Solenoid Test . (Group 9015-20.) Does pilot shutoff solenoid operate correctly?

Result: YES:Go to Low Pilot Oil Pressure. NO: See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) ( 3 ) Low Pilot Oil Pressure

Action: Check pilot oil pressure. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 9025-25.) Does pilot pressure meet specification?

Result: YES:Diagnostic checkout complete. NO:Adjust, repair, or replace pilot pressure valve. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 3360.) NO:Pilot pump worn. Inspect and repair or replace pilot pump. See Pilot Pump Remove and Install . (Group 3360.)






Function Does Not Stop When Control Lever Released 73

Function Does Not Stop When Control Lever Released Diagnostic Procedure ( 1 ) Control Valve Spool Stuck

Action: Inspect control valve spool. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) Do control valve spools move freely?

Result: YES:Go to Pilot Signal Manifold Malfunction. NO:Repair or replace control valve components. ( 2 ) Pilot Signal Manifold Malfunction

Action: Inspect pilot signal manifold for sticking spools. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) Do pilot signal manifold spools move freely?

Result: YES:Go to Left and Right Pilot Valve Malfunction. NO:Repair or replace pilot signal manifold. ( 3 ) Left and Right Pilot Valve Malfunction

Action: Inspect left and right pilot valve spools. See Pilot Valve (Left and Right) Disassemble and Assemble . (Group 3360.) Do left and right pilot valve spools move freely?

Result: YES:Diagnostic checkout complete. NO:Repair or replace left and right pilot valves.






Some Functions Cannot Be Operated, All Others Are Normal 73

Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure ( 1 ) Pilot Cap Loose

Action: Inspect pilot cap for leakage or damage. Check pilot cap screws for proper torque specification. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) Do control valve components meet specification?

Result: YES:Go to Pilot Control Valve or Hydraulic Line Malfunction. NO:Repair or replace control valve components. ( 2 ) Pilot Control Valve or Hydraulic Line Malfunction

Action: Inspect pilot control valve or hydraulic lines for function that can not be operated. Check for leaks or damage. See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern and see Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-15.) Are components free of leaks or damage?

Result: YES:Go to Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck. NO:Inspect and repair or replace leaking or damaged components. ( 3 ) Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck

Action: Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.) Do flow rate pilot spools move freely?

Result: YES:Go to Control Valve Spool Stuck. NO:Repair or replace pilot signal flow rate pilot spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) ( 4 ) Control Valve Spool Stuck

Action: Inspect control valve spools. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) Do control valve spools move freely?






Result: YES:Diagnostic checkout complete. NO:Repair or replace control valve components.






All Functions Slow 73

All Functions Slow Diagnostic Procedure ( 1 ) Restricted Pilot Filter

Action: Inspect pilot filter for restriction. See Hydraulic System Component Location . (Group 9025-15.) Is pilot filter free of restriction?

Result: YES:Go to Torque Control Solenoid Malfunction. NO:Replace pilot filter. See Replace Pilot Oil Filter . (Operator’s Manual.) ( 2 ) Torque Control Solenoid Malfunction

Action: Check torque control solenoid connection. Check torque control solenoid. See Proportional Solenoid Test . (Group 9015-20.) Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment . (Group 9025-25.) Is torque control solenoid and solenoid valve operate correctly?

Result: YES:Go to Low Pilot Oil Pressure. NO:Repair or replace torque control solenoid and solenoid valve. ( 3 ) Low Pilot Oil Pressure

Action: Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.) Does pilot pressure meet specification?

Result: YES:Go to Restricted Pilot Shutoff Solenoid Valve. NO:Adjust or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 3360.) NO:Pilot pump worn. See Pilot Pump Remove and Install . (Group 3360.) ( 4 ) Restricted Pilot Shutoff Solenoid Valve

Action: Inspect pilot shutoff solenoid valve for restriction. See Hydraulic System Component Location . (Group 9025-15.) Is pilot shutoff solenoid valve free of restriction?






NO:Repair or replace pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install . (Group 3360.) Functions Move in Opposite Direction 73

Functions Move in Opposite Direction Diagnostic Procedure ( 1 ) Pilot Control Hoses Connected Incorrectly

Action: Check pilot control hose connections. See Control Lever Pattern Operation . (Operator′s Manual.) See Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-15.) Also see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern . (Group 9025-15.) Are pilot control hoses connected correctly?

Result: YES:Diagnostic checkout complete. NO:Correct pilot control hose connections.






All Dig Functions Slow or No Power 73

All Dig Functions Slow or No Power Diagnostic Procedure ( 1 ) Hydraulic System Malfunction

Action: Inspect hydraulic system for malfunctions. See All Hydraulic Functions Slow . (Group 9025-15.) Is hydraulic system operating correctly?

Result: YES:Go to Pilot Circuit Malfunction. NO:Repair or replace hydraulic system component causing malfunction. ( 2 ) Pilot Circuit Malfunction

Action: Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.) Is pilot circuit operating correctly?

Result: YES:Go to Pump 1 or Pump 2 Regulator Malfunction. NO:Repair or replace pilot circuit component causing malfunction. ( 3 ) Pump 1 or Pump 2 Regulator Malfunction

Action: Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.) Does pump 1 or pump 2 regulator meet specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.)






Some Dig Functions Slow (Not All) 73

Some Dig Functions Slow (Not All) Diagnostic Procedure ( 1 ) Pilot Circuit Malfunction

Action: Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.) Is pilot circuit operating correctly?

Result: YES:Go to Control Valve Leakage. NO:Repair or replace pilot circuit component causing malfunction. ( 2 ) Control Valve Leakage

Action: Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.) Is control valve free of leaks?

Result: YES:Go to Cylinder Leakage. NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 3 ) Cylinder Leakage

Action: Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group 9025-25.) Are cylinders free of leaks?

Result: YES:Go to Circuit Relief Valve Setting Too Low or Malfunctioning. NO:Repair or replace cylinder. See Boom Cylinder Remove and Install , see Arm Cylinder Remove and Install or see Bucket Cylinder Remove and Install . (Group 3360.) ( 4 ) Circuit Relief Valve Setting Too Low or Malfunctioning

Action: Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.) Do circuit relief valve settings meet specification?

Result: YES:Go to Control Valve Spool Stuck. NO:Adjust, repair, or replace circuit relief valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) <- Go to Section TOC





( 5 ) Control Valve Spool Stuck

Action: Inspect control valve for stuck spool. See Control Valve Operation . (Group 9025-05.) Do control valve spools move freely?

Result: YES:Go to Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck. NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 6 ) Pump 1 or Pump 2 Flow Rate Pilot Valve Spool Stuck

Action: Inspect pump 1 or pump 2 flow rate pilot valves? See Pilot Signal Manifold Operation . (Group 9025-05.) Do flow rate pilot valve spools move freely?

Result: YES:Diagnostic checkout complete. NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)






Load Drifts Down When Control Lever is in Neutral Position 73

Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure ( 1 ) Cylinder Leakage

Action: Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group 9025-25.) Are cylinders free of leaks?

Result: YES:Go to Circuit Relief Valve Setting Too Low or Malfunctioning. NO:Repair or replace cylinder. See Boom Cylinder Remove and Install , see Arm Cylinder Remove and Install and see Bucket Cylinder Remove and Install . (Group 3360.) ( 2 ) Circuit Relief Valve Setting Too Low or Malfunctioning

Action: Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.) Do circuit relief valve settings meet specification?

Result: YES:Go to Boom Manual Lower Screw Loose. NO:Adjust, repair, or replace circuit relief valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 3 ) Boom Manual Lower Screw Loose

Action: Inspect boom manual lower screw. See Lower Boom with Engine Stopped . (Operator’s Manual.) Is boom manual lower screw tightened to specification?

Result: YES:Go to Control Valve Leakage. NO:Tighten boom manual lower screw to specification. ( 4 ) Control Valve Leakage

Action: Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.) Is control valve free of leaks?

Result: YES:Diagnostic checkout complete.






NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle 73

Load Falls When Control Valve is Actuated To Raise Load With Engine Running at Slow Idle Diagnostic Procedure ( 1 ) Lift Check Valve Leakage

Action: Inspect control valve check valves for leakage. See Control Valve Check Valves Identification and Operation and see Control Valve Operation . (Group 9025-05.) Are check valves operating correctly?

Result: YES:Diagnostic checkout complete. NO:Repair or replace control valve components. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)






H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal 73


Measurement

Specification

Cab Harness-to-Machine Harness 100-Pin Connector (X3)

Torque

10 N·m 89 lb.-in.

H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure ( 1 ) Slow Engine Speed

Action: Check engine speed and power mode setting. See Engine Speed Control System Operation . (Group 9010-05.) Does engine speed meet specification?

Result: YES:Go to Pressure Sensor Malfunction. NO:Select correct engine speed and power mode setting. ( 2 ) Pressure Sensor Malfunction

Action: Check pressure readings of the following pressure sensors. Pump 1 Delivery Pressure Pump 2 Delivery Pressure Boom Up Pilot Pressure Arm In Pilot Pressure Pressure readings can be viewed using the monitor service menu. See Service Menu . (Group 9015-16.) Actuate arm in or boom up function to view reading. Compare pump 1 and pump 2 pressure readings to main relief and power dig valve specification. See Main Relief and Power Dig Valve Test and Adjustment and see Power Dig Solenoid Valve Test and Adjustment . (Group 9025-25.) Compare boom up and arm in pressure readings to control valve spool actuating pilot pressure specification. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.) Do pressure readings meet specification?

Result: YES:Go to Power Mode Button Malfunction. NO:Replace pressure sensors as required.For pump 1 and pump 2 pressure sensor locations, see Pump Harness (W8) Component Location . (Group 9015-10.) For boom up and arm in pressure sensor locations, see Machine Harness (W2) Component Location . (Group 9015-10.) NO:Check wiring harness for pump 1 and pump 2 pressure sensors. See Pump Harness (W8) Component Location . (Group 9015-10.) Check wiring harness for boom up and arm in pressure sensors. See Machine Harness (W2) Component Location . (Group 9015-10.) <- Go to Section TOC





( 3 ) Power Mode Button Malfunction

Action: Check power mode button using the monitor service menu. See Service Menu . (Group 9015-16.) Select power mode to display switch position. Press power mode button to ECO, PWR, and H/P positions. Monitor service display should correspond with switch position. Does monitor service menu correspond with switch position?

Result: YES:Diagnostic checkout complete. NO:Check wiring harness. See Machine Harness (W2) Component Location . (Group 9015-10.)






Swing Speed Slow in Both Directions 73

Swing Speed Slow in Both Directions Diagnostic Procedure ( 1 ) Slow Engine Speed

Action: Check engine speed. See Engine Speed Control System Operation . (Group 9010-05.) Also see Main Controller (MCZ) Circuit Theory of Operation . (Group 9015-15.) Does engine speed meet specification?

Result: YES:Go to Swing Motor Crossover Relief Valve Malfunction. NO:Select correct engine speed. ( 2 ) Swing Motor Crossover Relief Valve Malfunction

Action: Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) Does swing motor crossover relief valve meet specification?

Result: YES:Go to Control Valve Leakage. NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) ( 3 ) Control Valve Leakage

Action: Inspect swing valve spool in control valve for leakage. For component location, see Control Valve Operation . (Group 9025-05.) Is swing valve spool OK?

Result: YES:Go to Swing Motor Leakage. NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 4 ) Swing Motor Leakage

Action: Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.) Does swing motor meet specification?

Result: YES:Go to Swing Park Brake Not Fully Released. NO:Repair or replace swing motor. See Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake <- Go to Section TOC





Assemble . (Group 4360.) ( 5 ) Swing Park Brake Not Fully Released

Action: Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.) Do flow rate pilot valve spools move freely?

Result: YES:Go to Pump 2 Worn. NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) ( 6 ) Pump 2 Worn

Action: Slow travel cycle times may indicate worn pump. Check travel cycle times. See Cycle Times Check . (Group 9005-10.) If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.) Do travel cycle times and pump flow meet specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)






Swing Speed Slow or Does Not Operate in One Direction 73

Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure ( 1 ) Pilot Circuit Malfunction

Action: Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.) Is pilot circuit OK?

Result: YES:Go to Swing Motor Make-Up Check Valve Leakage. NO:Repair or replace pilot circuit malfunction. ( 2 ) Swing Motor Make-Up Check Valve Leakage

Action: Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation . (Group 9025-05.) Are swing motor make-up check valves OK?

Result: YES:Go to Swing Motor Crossover Relief Valve Malfunction. NO:Repair or replace swing motor make-up check valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) ( 3 ) Swing Motor Crossover Relief Valve Malfunction

Action: Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) Does swing motor crossover relief valve meet specification?

Result: YES:Go to Control Valve Sticking. NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) ( 4 ) Control Valve Sticking

Action: Inspect control valve for sticking spool. For component location, see Control Valve Operation . (Group 9025-05.) Does control valve spool move freely?






NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)






Upperstructure Drift with Swing Valve in Neutral 73

Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure ( 1 ) Park brake operation

Action: Inspect swing motor and park brake for proper application and release. See Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.) Does swing continue to drift after releasing controller for 10 seconds?

Result: YES:Go to Swing park brake not engaging. NO:Go to Drift direction. ( 2 ) Drift direction

Action: Operate machine and check for drift in both directions. Does swing drift occur in both directions?

Result: YES:Go to Case drain leakage. NO:Go to Swing motor make-up check valve leakage. ( 3 ) Case drain leakage

Action: Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.) Does observed leakage meet specification?

Result: YES:Go to Damper valve spool sticking. NO:Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install , see Swing Motor and Park Brake Disassemble , and see Swing Motor and Park Brake Assemble . (Group 4360.) ( 4 ) Damper valve spool sticking

Action: Inspect park brake valve for sticking damper valve spool. See Swing Motor Park Brake Release Circuit Operation (Group 9025-05) for component identification. Does damper valve spool move freely?

Result: YES:Diagnostic checkout complete. NO:Repair or replace damper valve spool. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group <- Go to Section TOC





4360.) ( 5 ) Swing motor make-up check valve leakage

Action: Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation . (Group 9025-05.) Are swing motor make-up check valves OK?

Result: YES:Go to Swing motor crossover relief valve malfunction. NO:Repair or replace swing motor make-up check valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) ( 6 ) Swing motor crossover relief valve malfunction

Action: Remove crossover relief valves and install in opposite ports in park brake housing. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) Does swing drift change directions?

Result: YES:Repair or replace crossover relief valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.) NO:Diagnostic checkout complete. ( 7 ) Swing park brake not engaging

Action: Inspect swing motor and park brake. See Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.) See Swing Motor and Park Brake Inspection . (Group 4360.) Is swing motor and park brake OK?

Result: YES:Diagnostic checkout complete. NO:Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install , see Swing Motor and Park Brake Disassemble , and see Swing Motor and Park Brake Assemble . (Group 4360.)






Swing Function Does Not Operate 73

Swing Function Does Not Operate Diagnostic Procedure ( 1 ) Pilot Circuit Malfunction


Result: YES:Go to Swing Park Brake Malfunction. NO:Repair or replace pilot circuit malfunction. ( 2 ) Swing Park Brake Malfunction

Action: Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.) Do flow rate pilot valve spools move freely?

Result: YES:Go to Control Valve Stuck. NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) ( 3 ) Control Valve Stuck

Action: Inspect for stuck swing valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.) Does swing valve spool move freely?

Result: YES:Go to Mechanical Failure of Swing Motor or Gear Case. NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 4 ) Mechanical Failure of Swing Motor or Gear Case

Action: Inspect swing motor and gear case. Are swing motor and gear case OK?

Result: YES:Diagnostic checkout complete. NO:Repair or replace swing motor and gear case. See Swing Gear Case Disassemble and Assemble . (Group 4350.) Also see Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake Assemble . (Group 4360.) <- Go to Section TOC





Travel Park Brakes Do Not Apply 73

Travel Park Brakes Do Not Apply Diagnostic Procedure ( 1 ) Counterbalance Valve Spool Stuck, Oil Not Releasing From Piston Cavity

Action: Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)

Result: YES:Go to Mechanical Failure of Travel Motor and Gear Case. NO:Repair or replace counterbalance valve. ( 2 ) Mechanical Failure of Travel Motor and Gear Case

Action: Inspect travel motor and gear case for mechanical failure. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) Also see Travel Gear Case Disassemble and Assemble . (Group 0250.) Is travel motor and gear case OK?

Result: YES:Diagnostic checkout complete. NO:Repair or replace travel motor or gear case.






Track Will Not Move in One Direction 73

Track Will Not Move in One Direction Diagnostic Procedure ( 1 ) Pilot Circuit Malfunction


Result: YES:Go to Travel Motor Crossover Relief Valve Malfunction. NO:Repair or replace pilot circuit malfunction. ( 2 ) Travel Motor Crossover Relief Valve Malfunction

Action: Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) Is travel motor crossover relief valve OK?

Result: YES:Go to Control Valve Stuck. NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 3 ) Control Valve Stuck

Action: Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.) Does travel valve spool move freely?

Result: YES:Go to Counterbalance Valve Spool Stuck. NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 4 ) Counterbalance Valve Spool Stuck

Action: Inspect counterbalance valve. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.) Does counterbalance valve spool move freely?

Result: YES:Go to Center t Leakage. NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 5 ) Center t Leakage <- Go to Section TOC





Action: Inspect center t for leakage. See Center t Air Test . (Group 4360.) Is center t OK?

Result: YES:Diagnostic checkout complete. NO:Repair or replace center t. See Center t Disassemble and Assemble . (Group 4360.)






Track Will Not Move in Either Direction 73

Track Will Not Move in Either Direction Diagnostic Procedure ( 1 ) Pilot Circuit Malfunction


Result: YES:Go to Travel Motor Crossover Relief Valve Malfunction. NO:Repair or replace pilot circuit malfunction. ( 2 ) Travel Motor Crossover Relief Valve Malfunction


Result: YES:Go to Control Valve Stuck. NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 3 ) Control Valve Stuck

Action: Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.) Does travel valve spool move freely?

Result: YES:Go to Counterbalance Valve Spool Stuck. NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) ( 4 ) Counterbalance Valve Spool Stuck

Action: Inspect counterbalance valve. Does counterbalance valve spool move freely?

Result: YES:Go to Mechanical Failure of Travel Motor or Gear Case. NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 5 ) Mechanical Failure of Travel Motor or Gear Case <- Go to Section TOC






Result: YES:Go to Center t Leakage. NO:Repair or replace travel motor or gear case. ( 6 ) Center t Leakage


Result: YES:Diagnostic checkout complete. NO:Repair or replace center t. See Center t Remove and Install . (Group 4360.)






Machine Mistracks at All Speeds in Both Directions 73

Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure ( 1 ) Incorrect Track Sag Adjustment


Result: YES:Go to Pilot Control Valve Malfunction. NO:Adjust track sag. ( 2 ) Pilot Control Valve Malfunction

Action: Check control valve spool actuating pilot pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.) Does control valve spool actuating pilot pressure meet specification?

Result: YES:Go to Travel Motor Crossover Relief Valve. NO:Inspect and repair or replace pilot control valve. See Pilot Valve (Left and Right) Disassemble and Assemble and see Travel Pilot Valve Disassemble and Assemble . (Group 3360.) ( 3 ) Travel Motor Crossover Relief Valve

Action: Inspect travel motor crossover relief valves. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) Are travel motor crossover relief valves OK?

Result: YES:Go to Servo Piston Shuttle Valve Leakage. NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 4 ) Servo Piston Shuttle Valve Leakage

Action: Inspect servo piston shuttle valve. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) Does shuttle valve operate correctly?

Result: YES:Go to Travel Motor Leakage. NO:Repair or replace servo piston shuttle valve. <- Go to Section TOC





( 5 ) Travel Motor Leakage

Action: Check tracking while descending a hill. If tracking is within specification when descending a hill, but not when on the level or going up hill, travel motor leakage is indicated. See Travel System Tracking Check . (Group 9005-10.) If tracking does not meet specification, check travel motor leakage. See Travel Motor Leakage Test . (Group 9025-25.) Does tracking and motor leakage meet specification?

Result: YES:Go to Center t Leakage. NO:If travel motor leakage does not meet specification, repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) ( 6 ) Center t Leakage


Result: YES:Go to Pump 1 or Pump 2 Regulator Malfunction. NO:Repair or replace center t. See Center t Disassemble and Assemble . (Group 0260.) ( 7 ) Pump 1 or Pump 2 Regulator Malfunction

Action: Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.) Does pump 1 or pump 2 regulator meet specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Disassemble and Assemble . (Group 3360.)






Slow Travel Speed or Low Power 73

Slow Travel Speed or Low Power Diagnostic Procedure ( 1 ) Incorrect Track Sag Adjustment


Result: YES:Go to Travel Motor Crossover Relief Valve Malfunction. NO:Adjust track sag. ( 2 ) Travel Motor Crossover Relief Valve Malfunction


Result: YES:Go to Travel Park Brake Not Releasing. NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) ( 3 ) Travel Park Brake Not Releasing

Action: Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) Is travel park brake OK?

Result: YES:Go to Travel Motor Leakage. NO:Repair or replace travel park brake. ( 4 ) Travel Motor Leakage

Action: Inspect travel motor for leakage. See Travel Motor Leakage Test . (Group 9025-25.) Does travel motor meet specification?

Result: YES:Go to Center t Leakage. NO:Repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) ( 5 ) Center t Leakage







Result: YES:Go to Worn Pump. NO:Repair or replace center t. See Center t Disassemble and Assemble . (Group 0260.) ( 6 ) Worn Pump

Action: Slow travel cycle times may indicate worn pump. Check travel cycle times. See Cycle Times Check . (Group 9005-10.) If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.) Do travel cycle times and pump flow meet specification?

Result: YES:Go to Engine Performance Low. NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.) ( 7 ) Engine Performance Low

Action: Check engine speed and power mode setting. See Engine Speed Control System Operation . (Group 9010-05.) Does engine speed meet specification?

Result: YES:Diagnostic checkout complete. NO:Select desired engine speed and power mode.






Combined Travel and Dig Functions Slow or No Power 73

Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure ( 1 ) Travel Flow Combiner Valve Circuit Malfunction

Action: Inspect travel flow combiner pilot valve (SL) in pilot signal manifold for stuck spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.) Inspect travel flow combiner valve. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.) Is travel flow combiner valve circuit OK?

Result: YES:Go to Control Valve Stuck. NO:Repair or replace travel flow combiner valve circuit components. ( 2 ) Control Valve Stuck

Action: Inspect for stuck travel and boom valve spools in control valve. For component location, see Control Valve Operation . (Group 9025-05.) Does travel and boom valve spools move freely?

Result: YES:Diagnostic procedure complete. NO:Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)






Travel is “Jerky” 73

Travel is “Jerky” Diagnostic Procedure ( 1 ) Incorrect Track Sag Adjustment


Result: YES:Go to Roller Malfunction. NO:Adjust track sag. ( 2 ) Roller Malfunction

Action: Inspect rollers. Is oil level to specification?

Result: YES:Go to Travel Park Brake Leakage. NO:Add oil as required. ( 3 ) Travel Park Brake Leakage

Action: Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.) Is travel park brake OK?

Result: YES:Go to Mechanical Failure of Travel Motor or Gear Case. NO:Repair or replace travel park brake. ( 4 ) Mechanical Failure of Travel Motor or Gear Case


Result: YES:Go to Undercarriage Components Worn. NO:Repair or replace travel motor or gear case. ( 5 ) Undercarriage Components Worn <- Go to Section TOC





Action: Inspect undercarriage components. See SP326VOL1 Undercarriage Appraisal Manual for 130G specifications. Do undercarriage components meet specification?

Result: YES:Diagnostic checkout complete. NO:Repair or replace undercarriage components. Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline 73

Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure ( 1 ) Counterbalance Valve Spool Stuck

Action: Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) Does counterbalance valve spool move freely?

Result: YES:Diagnostic checkout complete. NO:Repair or replace counterbalance valve. Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs 73

Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure ( 1 ) Counterbalance Valve Spool Stuck

Action: Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.) Does counterbalance valve spool move freely?

Result: YES:Diagnostic checkout complete. NO:Repair or replace counterbalance valve.






Pump 1, Pump 2, and Pilot Pump Line Identification

Pump 1, Pump 2, and Pilot Pump Line Identification LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 15

Pilot Pump Suction Pilot Signal Manifold (port SB)-to-Pump 2 Regulator Pump 2-to-Control Valve (5 spool) Pilot Signal Manifold (port SA)-to-Pump 1 Regulator Pump 1-to-Control Valve (4 spool) Pilot Filter-to-Return Manifold Pilot Filter-to-Solenoid Valve Manifold (port PD) Pump 1 Attenuator Pump 1, Pump 2 Suction Pilot Pump-to-Pilot Filter Pilot Filter-to-Pump 2 Regulator Pump 2 Attenuator Pump 1 (4-spool)





16 17 28 29


Pump 2 (5-spool) Regulator Drain Hose to Hydraulic Oil Tank Pilot Pump Pilot Filter and By Valve






Control Valve Line Identification

Control Valve Line Identification—5-Spool Side LEGEND: 2 4 6 7 10 12 31 36 43 51 52A 52B 63A <- Go to Section TOC

Boom Down (pilot) Arm In (pilot) Swing Right (pilot) Bucket Curl (pilot) Left Travel Reverse (pilot) Right Travel Reverse (pilot) To Hydraulic Oil Tank To Hydraulic Oil Cooler From Arm In Flow Rate Pilot Valve (port SE) From Swing Device To Swing Motor (swing left) To Swing Motor (swing right) To Center t (left travel forward) Section 9025 page 229



63B 73 74 127A 127B 144 155 157 B31 DE DN DY SC SG


To Center t (left travel reverse) 4-Spool Control Valve 5-Spool Control Valve To Arm Cylinder (rod end) To Arm Cylinder (head end) To Blade Control Valve To Shuttle Valve Auxiliary Function (2 used) Arm In Pressure Sensor To Solenoid Valve Manifold Port DE To Solenoid Valve Manifold Port DN To Solenoid Valve Manifold Port DY (2 used) To Solenoid Valve Manifold Port SC To Solenoid Valve Manifold Port SG

Control Valve Line Identification—4-Spool Side LEGEND: 1 <- Go to Section TOC

Boom Up (pilot) Section 9025 page 230



3 5 8 9 11 15 16 31 46 61A 61B 73 74 83 87 125A 125B 126A 126B 145 155 B30 DD DK DN DZ SF SI



Arm Out (pilot) Swing Left (pilot) Bucket Dump (pilot) Left Travel Forward (pilot) Right Travel Forward (pilot) From Hydraulic Pump 1 From Hydraulic Pump 2 To Hydraulic Oil Tank From Bucket Flow Rate Pilot Valve (port SK) To Center t (right travel forward) To Center t (right travel reverse) 4-Spool Control Valve 5-Spool Control Valve To Boom Flow Rate Control Valve From Boom Lower Meter-In Cut Valve To Boom Cylinder (head end) To Boom Cylinder (rod end) To Bucket Cylinder (head end) To Bucket Cylinder (rod end) From Travel Flow Combiner Shuttle Valve From Shuttle Valve Boom Up Pressure Sensor To Solenoid Valve Manifold Port DD To Solenoid Valve Manifold Port DK To Solenoid Valve Manifold Port DN To Solenoid Valve Manifold Port DZ To Solenoid Valve Manifold Port SF To Solenoid Valve Manifold Port SI





Swing Motor Line Identification

Swing Motor Line Identification LEGEND: 1 2 3 4 5 6 B32


From Control Valve Swing Left From Control Valve Swing Right To Hydraulic Oil Tank Return Manifold To Control Valve From Pilot Signal Manifold (port SH) Case Drain Line Front Attachment Pressure Sensor





Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern





LEGEND: 1 2 3 4 5 6 39 40 41 A A1 A2 A3 A4 B C D E F G H P PI T T1 T2 T3


Port 1 Port 2 Port 3 Port 4 Pilot Control Shutoff Valve From Solenoid Valve Manifold (port PE) Left Pilot Control Valve Right Pilot Control Valve Pilot Signal Manifold Port A To Travel Pilot Controller Port A2 Port A3 Port A4 Port B Port C Port D Port E Port F Port G Port H Port P Port PI Port T From Travel Pilot Controller Port T2 Port T3

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern Excavator Pattern

Right Pilot Lever

Left Pilot Lever

Functions

Pilot Control Valve Ports

Bucket Dump

Pilot Signal Manifold Ports Pilot Control Valve Side

Control Valve Side

1

H

8

Boom Down

2

B

2

Bucket Curl

3

G

7

Boom Up

4

A

1

P

Pilot Shutoff Valve A2

T

Pilot Shutoff Valve T2

Swing Right

1

F

6

Arm Out

2

C

3

Swing Left

3

E

5

Arm In

4

D

4

P


T


NOTE: Letters and numbers are located on housings next to ports.






Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern





LEGEND: 1 2 3 4 5 6 39 40 41 A A1 A2 A3 A4 B C D E F G H P PI T T1 T2 T3


Port 1 Port 2 Port 3 Port 4 Pilot Control Shutoff Valve From Solenoid Valve Manifold (port PE) Left Pilot Control Valve Right Pilot Control Valve Pilot Signal Manifold Port A To Travel Pilot Controller Port A2 Port A3 Port A4 Port B Port C Port D Port E Port F Port G Port H Port P Port PI Port T From Travel Pilot Controller Port T2 Port T3

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern Backhoe Pattern

Right Pilot Lever

Left Pilot Lever

Functions

Pilot Control Valve Ports

Bucket Dump

Pilot Signal Manifold Ports Pilot Control Valve Side

Control Valve Side

1

H

8

Arm Out

2

C

3

Bucket Curl

3

G

7

Arm In

4

D

4

P


T


Swing Right

1

F

6

Boom Down

2

B

2

Swing Left

3

E

5

Boom Up

4

A

1

P


T


NOTE: Letters and numbers are located on housings next to ports.






Pilot Signal Manifold-to-Control Valve Line Connection

Pilot Signal Manifold-to-Control Valve Line Connection—Top LEGEND: 2 4 6 <- Go to Section TOC

Port 2 to Boom Down Pilot Cap Port 4 to Arm In Pilot Cap Port 6 to Swing Right Pilot Cap Section 9025 page 237



7 10 12 41 73 74


Port 7 to Bucket Curl Pilot Cap Port 10 to Left Travel Reverse Pilot Cap Port 12 to Right Travel Reverse Pilot Cap Pilot Signal Manifold Front Control Valve (4-spool) Rear Control Valve (5-spool)

Pilot Signal Manifold-to-Control Valve Line Connection—Bottom <- Go to Section TOC




LEGEND: 1 3 5 8 9 11 41 73 74 B33 B34



Port 1 to Boom Up Pilot Cap Port 3 to Arm Out Pilot Cap Port 5 to Swing Left Pilot Cap Port 8 to Bucket Dump Pilot Cap Port 9 to Left Travel Forward Pilot Cap Port 11 to Right Travel Forward Pilot Cap Pilot Signal Manifold Front Control Valve (4-spool) Rear Control Valve (5-spool) Swing Pressure Sensor Travel Pressure Sensor





Travel System Component Location

Travel System Component Location LEGEND: 15 16 28 31 38 41 <- Go to Section TOC

Pump 1 (4-spool) Pump 2 (5-spool) Pilot Pump Hydraulic Oil Tank Travel Pilot Control Valve Pilot Signal Manifold Section 9025 page 240



60 62 72 75 110 Y10



Right Travel Device Left Travel Device Center t Right Travel Spool Left Travel Spool Pilot Shutoff Solenoid





Travel Hydraulic System Line Connection

Travel Hydraulic System Line Connection





LEGEND: 9 10 11 12 37 38 41 60 62 72 73 74 75 110 160 161 162 163 164 I J K L PI Y10 Y24



Left Travel Forward Port (pilot side) Left Travel Reverse Port (pilot side) Right Travel Forward Port (pilot side) Right Travel Reverse Port (pilot side) Solenoid Valve Manifold Travel Pilot Control Valve Pilot Signal Manifold Right Travel Device Left Travel Device Center t Right Control Valve (4-spool) Left Control Valve (5-spool) Right Travel Spool (4-spool) Left Travel Spool (5-spool) Left Travel Forward Right Travel Forward Left Travel Reverse Right Travel Reverse Return Line to Hydraulic Oil Tank Left Travel Forward Port (control side) Left Travel Reverse Port (control side) Right Travel Forward Port (control side) Right Travel Reverse Port (control side) Pilot Shutoff Solenoid Valve Port Pilot Shutoff Solenoid Valve Power Dig Solenoid Valve (port SG)





Blade Hydraulic System Component Location

Blade Hydraulic System Component Location





LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 28 31 37 40 41 52 72 74 132 143 144 146 148 150 151 152 153


Center t-to-Blade Cylinder Rod End Hose (2 used) Center t-to-Blade Cylinder Head End Hose (2 used) Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose Blade Control Valve-to-Control Valve (5 spool) Hose Blade Control Valve-to-Blade Signal Shuttle Valve Hose Blade Control Valve-to-Blade Signal Shuttle Valve Hose Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose Blade Control Valve-to-Center t Hose Blade Control Valve-to-Blade Main Relief Valve Hose Blade Control Valve-to-Center t Hose Blade Signal Shuttle Valve-to-Pilot Signal Manifold Hose Blade Control Valve-to-Swing Parking Brake Shuttle Valve Hose Solenoid Valve Manifold-to-Pilot Shutoff Valve Hose Pump 1 Regulator Valve-to-Pilot Signal Manifold Hose Hydraulic Oil Return-to-Hydraulic Oil Tank Hose Swing Parking Brake Shuttle Valve-to-Swing Park Brake Hose Pilot Pump-to-Solenoid Valve Manifold Hose Blade Pump-to-Blade Main Relief Valve Hose Blade Main Relief Valve-to-Control Valve Hose Pilot Pump Hydraulic Oil Tank Solenoid Valve Manifold Blade Pump Supply Hose Pilot Signal Manifold Swing Motor Center t Control Valve (5 spool) Fan Drive Pump Blade Cylinder (2 used) Blade Control Valve Swing Parking Brake Shuttle Valve Blade Signal Shuttle Valve Blade Pilot Control Valve Blade Main Relief Valve Blade Pump Pilot Shutoff Valve






Auxiliary Attachment Schematic






Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)





LEGEND: 28 41 45 47 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 153 179 604 609 B60



Pilot Pump Pilot Signal Manifold Swing Park Brake Release Pilot Valve (port SH) Pump 2 Flow Rate Pilot Valve (port SB) To Swing Park Brake 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Pilot Shutoff Valve To Pump 2 Flow Rate Solenoid Valve Return Oil Pilot Oil Attachment Pressure Sensor










LEGEND: 28 41 45 47 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 153 172 173 179 604 609 B60








Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted)





LEGEND: 13 14 15 16 28 37 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 120 174 175 176 600 604 609 Y40



Auxiliary (pilot) Auxiliary (pilot) Pump 1 Pump 2 Pilot Pump Solenoid Valve Manifold 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxiliary Flow Combiner Valve Travel Flow Combiner Valve Auxiliary Attachment Selector Valve Solenoid Valve Selector Valve High-Pressure Oil Return Oil Pilot Oil Selector Valve Solenoid Valve





Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)





LEGEND: 15 16 28 41 45 47 48 56 73 74 75 76 81 90 93 95 97 104 107 108 110 117 118 119 120 155 170 177 178 179 180 600 604 609 B60 B61 DP DY Y43 Y44



Pump 1 Pump 2 Pilot Pump Pilot Signal Manifold Swing Park Brake Release Pilot Valve (port SH) Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) To Swing Park Brake 4-Spool Control Valve 5-Spool Control Valve Right Travel Spool Bucket Spool Boom 1 Spool Arm 2 Spool By Shutoff Valve Swing Spool Arm 1 Spool Boom 2 Spool Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Left Travel Spool Main Relief and Power Dig Valve Auxilairy Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve From Shuttle Valve Auxiliary Shuttle Valve Flow Rate Select Solenoid Valve Flow Rate Select Reducing Valve To Pump 2 Flow Rate Solenoid Valve To Torque Control Solenoid Valve High-Pressure Oil Return Oil Pilot Oil Attachment Pressure Sensor Arm Out Pressure Sensor To Solenoid Valve Manifold Port DP To Solenoid Valve Manifold Port DY 2-Speed Activation Solenoid Valve Flow Rate Adjustment Solenoid Valve





Auxiliary System Line Connections






High Flow Line Connections





LEGEND: 28 29 31 37 73 74 174 175 176 Y40



Pilot Pump Pilot Filter and By Valve Hydraulic Oil Tank Solenoid Valve Manifold 4-Spool Control Valve 5-Spool Control Valve Auxiliary Attachment Selector Valve Solenoid Valve Selector Valve Selector Valve Solenoid Valve





Two Pump Combined Flow Kit Line Connections





LEGEND: 28 29 31 37 41 73 74 155 170 177 178



Pilot Pump Pilot Filter and By Valve Hydraulic Oil Tank Solenoid Valve Manifold Pilot Signal Manifold 4-Spool Control Valve 5-Spool Control Valve Shuttle Valve Auxiliary Shuttle Valve Flow Rate Select Solenoid Valve Flow Rate Select Reducing Valve





Hydraulic System Schematic






Pilot Signal Manifold—Excavator Pattern





LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 17 18 28 29 30 37 38 39 40 41 42 43 44 45 46 47 48 49 50 56 77 83 84 91 93 94 98 108 118 120 129 145 146 147 148 150 153 155 200 201 202 203 204 604 609 B32 B33 B34 Y10 Y22 Y23 Y24 Y27


Boom Up (pilot) Boom Down (pilot) Arm Out (pilot) Arm In (pilot) Swing Left (pilot) (5-spool) Swing Right (pilot) (5-spool) Bucket Curl (pilot) Bucket Dump (pilot) Left Travel Forward (pilot) Left Travel Reverse (pilot) Right Travel Forward (pilot) Right Travel Reverse (pilot) To Pump 1 Regulator To Pump 2 Regulator Pilot Pump Pilot Filter and By Valve Pilot Pressure Regulating Valve Solenoid Valve Manifold Travel Pilot Control Valve Left Pilot Control Valve Right Pilot Control Valve Pilot Signal Manifold Boom Down Shockless Valve Arm 1 Flow Rate Pilot Valve (port SE) Travel Flow Combiner Pilot Valve (port SL) Swing Park Brake Release Pilot Valve (port SH) Bucket Flow Rate Pilot Valve (port SK) Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) Filter Screen (17 used) Shuttle Valve (17 used) From Swing Park Brake To Bucket Flow Rate Control Valve (valve and poppet) From Boom Flow Rate Control Valve (valve and poppet) From Dig Regenerative Valve (2 used) From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used) To By Shutoff Valve From Arm Regenerative Cut Valve To Arm 1 Flow Rate Control Valve (valve and poppet) From Auxiliary Flow Rate Control Valve (valve and poppet) From Auxiliary Function Flow Combiner Valve To Travel Flow Combiner Valve Orifice Travel Flow Combiner Shuttle Valve Swing Parking Brake Shuttle Valve Blade Signal Selector Valve Blade Signal Shuttle Valve Blade Pilot Control Valve Pilot Shutoff Valve Shuttle Valve From Main Relief and Power Dig Valve and Center t To Pump 1 Control Pressure Sensor and Pump 1 Regulator Blade Down (pilot) Blade Up (pilot) From Boom Lower Meter-In Cut Valve and Arm 1 Spool Return Oil Pilot Oil Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pilot Shutoff Solenoid Dig Regenerative Solenoid (SF) Arm Regenerative Solenoid (SC) Power Dig Solenoid (SG) Arm 2 Flow Control Solenoid (SI)






Pilot Signal Manifold—Backhoe Pattern





LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 17 18 28 29 30 37 38 39 40 41 42 43 44 45 46 47 48 49 50 56 77 83 84 91 93 94 98 108 118 120 129 145 146 147 148 150 153 155 200 201 202 203 204 604 609 B32 B33 B34 Y10 Y22 Y23 Y24 Y27


Boom Up (pilot) Boom Down (pilot) Arm Out (pilot) Arm In (pilot) Swing Left (pilot) (5-spool) Swing Right (pilot) (5-spool) Bucket Curl (pilot) Bucket Dump (pilot) Left Travel Forward (pilot) Left Travel Reverse (pilot) Right Travel Forward (pilot) Right Travel Reverse (pilot) To Pump 1 Regulator To Pump 2 Regulator Pilot Pump Pilot Filter and By Valve Pilot Pressure Regulating Valve Solenoid Valve Manifold Travel Pilot Control Valve Left Pilot Control Valve Right Pilot Control Valve Pilot Signal Manifold Boom Down Shockless Valve Arm 1 Flow Rate Pilot Valve (port SE) Travel Flow Combiner Pilot Valve (port SL) Swing Park Brake Release Pilot Valve (port SH) Bucket Flow Rate Pilot Valve (port SK) Pump 2 Flow Rate Pilot Valve (port SB) Pump 1 Flow Rate Pilot Valve (port SA) Filter Screen (17 used) Shuttle Valve (17 used) From Swing Park Brake To Bucket Flow Rate Control Valve (valve and poppet) From Boom Flow Rate Control Valve (valve and poppet) From Dig Regenerative Valve (2 used) From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used) To By Shutoff Valve From Arm Regenerative Cut Valve To Arm 1 Flow Rate Control Valve (valve and poppet) From Auxiliary Flow Rate Control Valve (valve and poppet) From Auxiliary Function Flow Combiner Valve To Travel Flow Combiner Valve Orifice Travel Flow Combiner Shuttle Valve Swing Parking Brake Shuttle Valve Blade Signal Selector Valve Blade Signal Shuttle Valve Blade Pilot Control Valve Pilot Shutoff Valve Shuttle Valve From Main Relief and Power Dig Valve and Center t To Pump 1 Control Pressure Sensor and Pump 1 Regulator Blade Down (pilot) Blade Up (pilot) From Boom Lower Meter-In Cut Valve and Arm 1 Spool Return Oil Pilot Oil Front Attachment Pressure Sensor Swing Pressure Sensor Travel Pressure Sensor Pilot Shutoff Solenoid Dig Regenerative Solenoid (SF) Arm Regenerative Solenoid (SC) Power Dig Solenoid (SG) Arm 2 Flow Control Solenoid (SI)






Control Valve Schematic (S.N. —040159)







Boom Up (pilot) Boom Down (pilot) Arm Out (pilot) Arm In (pilot) Swing Left (pilot) (5-spool) Swing Right (pilot) (5-spool) Bucket Curl (pilot) Bucket Dump (pilot) Left Travel Forward (pilot) Left Travel Reverse (pilot) Right Travel Forward (pilot) Right Travel Reverse (pilot) Plug—Auxiliary (pilot) Plug—Auxiliary (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Arm 1 Flow Rate Pilot Valve (port SE) Bucket Flow Rate Pilot Valve (port SK) From Swing Device Swing Motor Right Travel Motor Left Travel Motor From Center t Right Control Valve (4-spool) Left Control Valve (5-spool) Right Travel Spool Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Dump Circuit Relief and Anticavitation Valve Bucket Curl Circuit Relief and Anticavitation Valve Boom 1 Spool Boom Regeneration Valve Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve (valve and check valve) Orifice Boom Lower Meter-In Cut Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Arm Regenerative Valve Swing Spool Check Valve (lift check)—Swing Neutral age Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Check Valve (lift check)—Boom 2 Power Circuit Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Plug (2 used) Left Travel Spool Check Valve (lift check)—Left Travel Neutral age Check Valve (lift check)—Left Travel Power age Orifice—Left Travel Power age Orifice—Air Bleed (9 used) Main Relief Valve Isolation Check Valve—5-Spool Main Relief Valve Isolation Check Valve—4-Spool Section 9025 page 266



117 118 119 120 121 122 123 124 125 126 127 128 140 141 142 143 144 145 149 151 152 155A 155B 166 202 203 600 604 606 B30 B31 DD DE DK DN DY DZ SC SF SG SI



Main Relief and Power Dig Valve Auxiliary Function Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit Check Valve (lift check)—Bucket Orifice—Bucket Power Circuit Oil Cooler By Valve Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder Check Valve Blade Spool Blade Up Circuit Relief and Anticavitation Valve Blade Down Circuit Relief and Anticavitation Valve Blade Cylinder (2 used) Blade Control Valve From Travel Flow Combiner Shuttle Valve Arm Regenerative Cut Valve Blade Main Relief Valve Blade Pump From Shuttle Valve To Shuttle Valve Bucket Regenerative Cut Valve Blade Down (pilot) Blade Up (pilot) High Pressure Oil Return Oil Trapped Oil Boom Up Pressure Sensor Arm In Pressure Sensor To Solenoid Valve Manifold Port DD To Solenoid Valve Manifold Port DE To Solenoid Valve Manifold Port DK To Solenoid Valve Manifold Port DN To Solenoid Valve Manifold Port DY To Solenoid Valve Manifold Port DZ To Solenoid Valve Manifold Port SC To Solenoid Valve Manifold Port SF To Solenoid Valve Manifold Port SG To Solenoid Valve Manifold Port SI





Control Valve Schematic (S.N. 040160—)







Boom Up (pilot) Boom Down (pilot) Arm Out (pilot) Arm In (pilot) Swing Left (pilot) (5-spool) Swing Right (pilot) (5-spool) Bucket Curl (pilot) Bucket Dump (pilot) Left Travel Forward (pilot) Left Travel Reverse (pilot) Right Travel Forward (pilot) Right Travel Reverse (pilot) Plug—Auxiliary (pilot) Plug—Auxiliary (pilot) Pump 1 (4-spool) Pump 2 (5-spool) Hydraulic Oil Cooler Arm 1 Flow Rate Pilot Valve (port SE) Bucket Flow Rate Pilot Valve (port SK) From Swing Device Swing Motor Right Travel Motor Left Travel Motor From Center t Right Control Valve (4-spool) Left Control Valve (5-spool) Right Travel Spool Bucket Spool Bucket Flow Rate Control Valve (valve and poppet) Bucket Regenerative Valve Bucket Dump Circuit Relief and Anticavitation Valve Bucket Curl Circuit Relief and Anticavitation Valve Boom 1 Spool Boom Regeneration Valve Boom Flow Rate Control Valve (valve and poppet) Dig Regenerative Valve Boom Reduced Leakage Valve (valve and check valve) Orifice Boom Lower Meter-In Cut Valve Boom Up Circuit Relief and Anticavitation Valve Boom Down Circuit Relief and Anticavitation Valve Arm 2 Spool Arm 2 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Arm 2 Neutral age By Shutoff Valve Arm Regenerative Valve Swing Spool Check Valve (lift check)—Swing Neutral age Arm 1 Spool Arm 1 Flow Rate Control Valve (valve and poppet) Check Valve (lift check)—Dig Regenerative Circuit Arm Reduced Leakage Valve (valve and poppet) Arm In Circuit Relief and Anticavitation Valve Arm Out Circuit Relief and Anticavitation Valve Boom 2 Spool Check Valve (lift check)—Boom 2 Power Circuit Auxiliary Spool Auxiliary Flow Rate Control Valve (valve and poppet) Plug (2 used) Left Travel Spool Check Valve (lift check)—Left Travel Neutral age Check Valve (lift check)—Left Travel Power age Orifice—Left Travel Power age Orifice—Air Bleed (9 used) Main Relief Valve Isolation Check Valve—5-Spool Main Relief Valve Isolation Check Valve—4-Spool Section 9025 page 269



117 118 119 120 121 122 123 124 125 126 127 128 140 141 142 143 144 145 149 151 152 155A 155B 166 202 203 600 604 606 B30 B31 DD DE DK DN DY DZ SC SF SG SI



Main Relief and Power Dig Valve Auxiliary Function Flow Combiner Valve Check Valve—Flow Combiner Valve Circuit Travel Flow Combiner Valve Check Valve—Travel Flow Combiner Valve Circuit Check Valve (lift check)—Bucket Orifice—Bucket Power Circuit Oil Cooler By Valve Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder Check Valve Blade Spool Blade Up Circuit Relief and Anticavitation Valve Blade Down Circuit Relief and Anticavitation Valve Blade Cylinder (2 used) Blade Control Valve From Travel Flow Combiner Shuttle Valve Arm Regenerative Cut Valve Blade Main Relief Valve Blade Pump From Shuttle Valve To Shuttle Valve Bucket Regenerative Cut Valve Blade Down (pilot) Blade Up (pilot) High Pressure Oil Return Oil Trapped Oil Boom Up Pressure Sensor Arm In Pressure Sensor To Solenoid Valve Manifold Port DD To Solenoid Valve Manifold Port DE To Solenoid Valve Manifold Port DK To Solenoid Valve Manifold Port DN To Solenoid Valve Manifold Port DY To Solenoid Valve Manifold Port DZ To Solenoid Valve Manifold Port SC To Solenoid Valve Manifold Port SF To Solenoid Valve Manifold Port SG To Solenoid Valve Manifold Port SI





Swing Motor Schematic LEGEND: 51 52 53 54 55 56 57 58 59 73 95A 95B 205 604

Swing Device Swing Motor Swing Motor Make-Up Check Valve (2 used) Swing Crossover Relief Valve (2 used) Swing Damper Valve Swing Park Brake Orifice Check Valve Flow Control Valve To Right Control Valve Return age From Swing Spool—Right Swing From Swing Spool—Left Swing To Swing Parking Brake Shuttle Valve and Swing Park Brake Release Pilot Valve (port SH) Return Oil






Travel Motor Schematic LEGEND: 60 61 62 63 64 65 66 67 68 69 70 71 72 75A 75B

Right Travel Device Right Travel Motor Left Travel Device Left Travel Motor Travel Park Brake (2 used) Travel Speed Servo Piston (2 used) Travel Speed Change Valve (2 used) Shuttle Valve (2 used) Travel Motor Crossover Relief Valve (4 used) Check Valve (4 used) Orifice (4 used) Counterbalance Valve (2 used) Center t From Right Travel Spool—Forward From Right Travel Spool—Reverse





110A 110B 143 144A 144B 207 604 606


From Left Travel Spool—Reverse From Left Travel Spool—Forward Blade Cylinder (2 used) From Blade Control Valve (blade down) From Blade Control Valve (blade up) From Travel Speed Solenoid (SI) and Main Relief and Power Dig Valve (P1, P2) Trapped Oil Return Oil






Hydraulic Pumps and Regulators





LEGEND: 15 16 17 18 27 28 29 30 31 32 34 35 36 37A 37B 41 47 52 72 73A 73B 73C 74A 74B 124 128 132 133 144A 144B 151 152 153 206 208 600 604 609 B35 B36 B37 B38 Y20 Y21


Pump 1 (4-spool) Pump 2 (5-spool) Pump 1 Regulator Pump 2 Regulator Attenuator Hose (2 used) Pilot Pump Pilot Filter and By Valve Pilot Pressure Regulating Valve Hydraulic Oil Tank Return Filter Filter By Suction Screen Hydraulic Oil Cooler To Solenoid Valve Manifold From Solenoid Valve Manifold From Pilot Signal Manifold From Pump 2 Flow Rate Pilot Valve (port SB) From Swing Motor From Center t To Right Control Valve (4-spool) From Right Control Valve (4-spool) From Right Control Valve (4-spool To Left Control Valve (5-spool) From Left Control Valve (5-spool) Oil Cooler By Valve Check Valve Fan Drive Pump To Fan Drive Motor From Blade Control Valve From Blade Control Valve From Blade Main Relief Valve Blade Pump From Pilot Shutoff Valve To Blade Main Relief Valve and Blade Control Valve From Pump 1 Flow Rate Pilot Valve (port SA) High Pressure Oil Return Oil Pilot Oil Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor Pump 2 Flow Rate Limit Solenoid (SB) Torque Control Solenoid (ST)

For more information on fan drive, See Fan Drive Hydraulic System Schematic . (Group 9025-15.)






Hydraulic System Component Location

Hydraulic System Component Location LEGEND: 15 16 28 29 30 31 36 37 38 39 40 41 51 <- Go to Section TOC

Pump 1 (4-spool) Pump 2 (5-spool) Pilot Pump Pilot Filter and By Valve Pilot Pressure Regulating Valve Hydraulic Oil Tank Hydraulic Oil Cooler Solenoid Valve Manifold Travel Pilot Control Valve Left Pilot Control Valve Right Pilot Control Valve Pilot Signal Manifold Swing Device Section 9025 page 276



60 62 72 73 74 125 126 127 Y10



Right Travel Device Left Travel Device Center t Front Control Valve (4-spool) Rear Control Valve (5-spool) Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder Pilot Shutoff Solenoid





Hydraulic System Line Connections

Hydraulic System Line Connections





LEGEND: 15 16 28 29 30 31 36 41 51 72 73 74 125 126 127 SA SB SH



Pump 1 (4-spool) Pump 2 (5-spool) Pilot Pump Pilot Filter and By Valve Pilot Pressure Regulating Valve Hydraulic Oil Tank Hydraulic Oil Cooler Pilot Signal Manifold Swing Device Center t Right Control Valve (4-spool) Left Control Valve (5-spool) Boom Cylinder (2 used) Bucket Cylinder Arm Cylinder Pump 1 Flow Rate Pilot Valve Port Pump 2 Flow Rate Pilot Valve Port Swing Park Brake Release Port





Fan Drive System Component Location

Fan Drive Hydraulic System Component Location





LEGEND: 1 2 3 4 5 6 31 132 133 B53 Y9 Y5005



Case Drain Line (fan drive motor to hydraulic oil tank) Supply Line (hydraulic oil tank to fan drive pump) Supply Line (fan drive pump to fan drive motor) Return Line (fan drive motor to hydraulic oil return manifold) Hydraulic Oil Return Manifold Return Line (hydraulic oil cooler to hydraulic oil return manifold) Hydraulic Oil Tank Fan Drive Pump Fan Drive Motor Fan Speed Sensor Reversing Fan Solenoid (if equipped) Variable Speed Fan Solenoid





Fan Drive Hydraulic System Schematic

Fan Drive Hydraulic System Schematic LEGEND: 31 32 34 35 132 133 134 600 604 Y5005


Hydraulic Oil Tank Return Filter Filter By Suction Screen Fan Drive Pump Fan Drive Motor Fan Speed Control Valve High Pressure Oil Return Oil Variable Speed Fan Solenoid




Group 25: Tests

Fan Drive Hydraulic System Schematic—Reversing (if equipped) LEGEND: 31 32 34 35 132 133 135 600 604 Y9 Y5005


Hydraulic Oil Tank Return Filter Filter By Suction Screen Fan Drive Pump Fan Drive Motor Fan Speed and Reversing Control Valve (if equipped) High Pressure Oil Return Oil Reversing Fan Solenoid Variable Speed Fan Solenoid




Group 25: Tests

Group 25 - Tests JT05800 Digital Thermometer Installation LEGEND: A Temperature Probe B Cable C JT05800 Digital Thermometer

JT05800 Digital Thermometer Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer

[1] - Fasten temperature probe (A) to a bare metal hydraulic line using a tie band. Digital Thermometer JT05800 To measure the temperature of hydraulic oil. [2] - Wrap temperature probe and line with a shop towel.





Group 25: Tests

JT02156A Digital Pressure and Temperature Analyzer Kit Installation

JT02156A Digital Pressure and Temperature Analyzer Kit LEGEND: A Digital Pressure and Temperature Analyzer B 3400 kPa (35 bar) (500 psi) Transducer 34 000 kPa (350 bar) (5000 psi) Transducer 70 000 kPa (700 bar) (10 000 psi) Transducer Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Kit JT02158 Digital Pressure and Temperature Analyzer JT02159 6 m (20 ft.) Cable with Couplers JT02161 3400 kPa (35 bar) (500 psi) Transducer JT02162 34 000 kPa (350 bar) (5000 psi) Transducer JT05969 Thermo-Coupler 312883 Carry Case JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)

Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a separate temperature reader. Digital Pressure and Temperature Analyzer Kit JT02156A Kit contains the analyzer, cable, two transducers, thermo-coupler, and a carry case. Digital Pressure and Temperature Analyzer JT02158 To display digital readings for temperature and single, multiple, or differential hydraulic oil pressure. Also reads vacuum when used with 500 psi transducer. 6 m (20 ft.) Cable with Couplers JT02159 To connect tranducers to digital pressure and temperature analyzer. 3400 kPa (35 bar) (500 psi) Transducer JT02161 <- Go to Section TOC




Group 25: Tests

To measure hydraulic oil pressure and vacuum. 34 000 kPa (350 bar) (5000 psi) Transducer JT02162 To measure hydraulic oil pressure. Thermo-Coupler JT05969 To measure hydraulic oil temperature. Carry Case 312883 Storage for analyzer and components. 70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately) JT02160 To measure hydraulic oil pressure. Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no pressure applied, push sensor zero button for one second to set the true zero point. When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are inaccurate if proper range for transducer is not used.





Group 25: Tests

Hydraulic Oil Cleanup Procedure Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JDG10712 Super Caddy One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends One Discharge Hose 4.6 m (15 ft) x 19 mm (0.75 in.) I.D. 100R1 Hose with 0.75 in. M NPT Ends 3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip) 3 Foot Discharge Wand 19 mm (0.75 in.) O.D.

This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter procedure must be done prior to starting machine after a component has been repaired or replaced. IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils. Avoid oil contamination. Oil contamination could result if Super Caddy is used in dusty or wet conditions. Instrument cleanliness and clean work practices are critical when filtering or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results. Super Caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.

[1] LEGEND: 1 Pressure Release Button 2 Cap Screw (6 used) 3 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Pressure Relief Cover Filter oil at 27°C (80°F) or above for best JDG10712 Super Caddy performance. Reduce flow rate to filter oil below 27°C (80°F). [2] - Clean surrounding area of hydraulic oil tank cover (3) to prevent hydraulic system contamination. [3] - Press pressure release button (1) to relief pressure from hydraulic oil tank. [4] - Remove cap screws (2) and cover. [5] -





Group 25: Tests

→NOTE: Ensure maximum oil movement during cleanup procedure. Orient submerged ends of suction and discharge wands as far away from each other as possible.

Insert suction and discharge wands from Super Caddy into hydraulic oil tank opening. Super Caddy JDG10712 Remove particle contamination and moisture from oil. One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends Use with Super Caddy to transfer and clean hydraulic oil. 3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip) Use with Super Caddy to transfer and clean hydraulic oil. 3 Foot Discharge Wand 19 mm (0.75 in.) O.D. Use with Super Caddy to transfer and clean hydraulic oil. [6] →NOTE: Ensure suction and discharge wands maintain position in hydraulic reservoir.

Seal suction and discharge wands in opening of hydraulic oil tank to prevent contamination. [7] - Use Super Caddy to remove oil contaminants. Refer to operator′s manual included with Super Caddy or see Super Caddy in Service ADVISOR ™ for operating procedure. [8] - Install new hydraulic system oil filters for cleanup procedure. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter . (Operator’s Manual.) [9] - Install hydraulic oil tank cover and cap screws. [10] CAUTION:

Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.

CAUTION:

Avoid entanglement and possible electrocution from Super Caddy power cord. DO NOT operate machine while Super Caddy is connected to machine.





Group 25: Tests

Make sure area is clear and large enough to operate all functions of machine. [11] - Fill hydraulic oil tank to operating level. See Drain and Refill Hydraulic Tank Oil . (Operator’s Manual.) [12] IMPORTANT: Avoid hydraulic system damage or further oil contamination. DO NOT force hydraulic system over system relief or over return filter by.

Run machine at slow idle. Operate each circuit a minimum of 3—5 minutes in each direction to flush any remaining contaminants. [13] - Stop machine and install suction and discharge wands. [14] - Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operation manual. [15] - When oil reaches acceptable value of cleanliness, remove suction and discharge wands. [16] - Install new hydraulic system oil filters. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter . (Operator’s Manual.) [17] - See Check Hydraulic Tank Oil Level . (Operator’s Manual.) [18] - Return machine to service. [19] →NOTE: Some hydraulic systems may not be able to maintain correct specification without additional filtration equipment. Additional filtration equipment is recommended for machines in extreme environments. By filtration systems are available.

Check and record oil particle counts. After 100 hours of operation check hydraulic oil to confirm system is within specification according to Super Caddy operation manual. Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also increase chances for contaminants to enter hydraulic system. Use care when connecting and removing components to prevent system contamination. Quick couplers must not be connected until they have been cleaned and capped when not in use.

Hydraulic Oil Tank Pressure Release Procedure





Group 25: Tests

Park Machine [1] - Park machine on level surface. [2] - Position machine with arm cylinder fully retracted and bucket cylinder fully extended. [3] - Lower boom until bucket is resting on ground. [4] - Shut engine off. [5] LEGEND: 1 Pressure Release Button 2 Hydraulic Oil Tank Cover

Hydraulic Oil Tank Cover Press pressure release button (1) to relieve hydraulic oil tank pressure.





Group 25: Tests

Hydraulic Oil Warm-Up Procedure Specifications SPECIFICATIONS Engine Speed

1300—1500 rpm if below -18°C (0°F) 1750—1850 rpm if above -18°C (0°F)


ECO (economy) Mode if below -18°C (0°F) H/P (high power) Mode if above -18°C (0°F)


Dig Mode


OFF

Travel Speed Switch Position

Slow (turtle)


45—55°C 110—130°F

IMPORTANT: If machine temperature is below -18°C (0°F), start procedure in the ECO (economy) mode. Failure to do this could cause pump cavitation. Once oil temperature is above -18°C (0°F), the power mode can be switched to H/P (high power) mode.

Below -18°C (0°F) an extended warm-up period may be necessary. Hydraulic functions will move slowly and lubrication of parts may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic functions move at or close to normal cycle times. Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed. Operate a function by moving it a short distance in each direction. Continue operating the function increasing the distance traveled in each cycle until full stroke is reached. For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity oil to minimize warm-up period. See Hydraulic Oil . (Operator′s Manual.) [1] - Connect one of the following test equipment to monitor the coolant temperature, hydraulic oil temperature and actual engine speed. Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items from monitoring list: Coolant Temperature Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items from the menu: Coolant Temperature Hydraulic Oil Temperature Actual Engine Speed MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items from the monitor display: Coolant Temperature Hydraulic Oil Temperature Actual Engine Speed [2] CAUTION:

Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all bystanders before doing the warm-up procedure. <- Go to Section TOC




Group 25: Tests

Clear the area of all bystanders to allow for machine movement. [3] - Run machine at specification for approximately 5 minutes before operating any functions. Item

Measurement

Specification

Engine

Speed

1300—1500 rpm if below -18°C (0°F) 1750—1850 rpm if above -18°C (0°F)

Power Mode Button

Position

ECO (economy) Mode if below -18°C (0°F) H/P (high power) Mode if above -18°C (0°F)

Work Mode Switch

Position

Dig Mode

Auto-Idle Switch

Position

OFF

Travel Speed Switch

Position

Slow (turtle)

[4] - Slowly turn upperstructure so boom is to the side. [5] CAUTION:

Avoid possible serious injury from machine sliding backwards. Keep angle between boom and arm at 90—110°.

Keeping the angle between boom and arm at 90—110°, lower boom to raise track off the ground. [6] - Operate travel function (side with track off ground) for approximately 5 minutes. [7] - When oil temperature is above -18°C (0°F), increase engine speed to 1750—1850 rpm and press power mode button to H/P (high power). [8] IMPORTANT: Holding a function over relief for more than 10 seconds can cause damage due to hot spots in the control valve.

Operate the travel function (side with track off the ground). Also operate the bucket curl function over relief for 10 seconds and then stop for 5 seconds. Repeat the cycle until oil is heated to specifications. [9] - Stop periodically and operate all hydraulic functions to distribute the heated oil. [10] - Continue procedure until oil temperature is within specifications. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F





Group 25: Tests

Pilot Pressure Regulating Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle and Slow Idle


Dig Mode


PWR (power) Mode


OFF

Pilot System Pressure (slow idle)

3.8—4.8 MPa 3805—4805 kPa 39.0—49.0 bar 552—697 psi

Pilot System Pressure (fast idle)

3.5—5.0 MPa 3509—5012 kPa 36.0—51.0 bar 509—727 psi

Pilot Pressure Regulating Valve Shim [approximate per 0.25 mm (0.010 in.) shim]

0.078 MPa 78 kPa 0.78 bar 11.3 psi


0.157 MPa 157 kPa 1.57 bar 22.8 psi


0.304 MPa 304 kPa 3.04 bar 44.1 psi

Plug-to-Pilot Pressure Regulating Valve Housing Torque

25 N˙m 220 lb.-in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)

The purpose of this test is to check and, if necessary, adjust the pressure setting of the pilot pressure regulating valve. Pilot pressure is controlled by this valve. This test is to ensure there is enough pilot pressure to operate all pilot system functions and to adjust pressure as needed. The pilot pressure regulating valve is used to regulate pilot system pressure. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] -





Group 25: Tests

LEGEND: 1 Test Port 2 Adapter 3 JT02162 Transducer 4 Oil Sample Port (if equipped) 30 Pilot Pressure Regulating Valve

Pilot Pressure Regulating Valve and Test Port Remove plug from test port (1). Adapter 1/4 M BSPP ORB x 7/16-20 M 37° To connect a gauge or transducer to pilot pressure regulating valve Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Gauge 7000 kPa (70 bar) (1000 psi) Used to measure hydraulic pressure. [3] - Install adapter (2). [4] - Connect JT02162 Transducer (3) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter. →NOTE: The monitor can be used to make a quick check of the pilot system pressure using arm in function. Monitor arm in pilot pressure with engine at fast idle and then actuate arm in function over relief. The pressure reading displayed is from arm in pressure sensor located on control valve. Before making any adjustments, check the pilot pressure at the test port using a pressure gauge. For pilot filter and pressure regulating valve location, see Hydraulic System Component Location . (Group 9025-15.) <- Go to Section TOC




Group 25: Tests

Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed [5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [6] - Run machine at specification: Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed


Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[7] - Compare pressure readings to specifications. Make adjustments as necessary. Item

Measurement

Specification

Pilot System Pressure (slow idle)

Pressure

3.8—4.8 MPa 3805—4805 39.0—49.0 bar 552—697 psi

Pilot System Pressure (fast idle)

Pressure

3.5—5.0 MPa 3509—5012 kPa 36.0—51.0 bar 509—727 psi

[8] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [9] -





Group 25: Tests

LEGEND: 1 Test Port 2 Adapter 3 JT02162 Transducer 4 Oil Sample Port (if equipped) 30 Pilot Pressure Regulating Valve

Pilot Pressure Regulating Valve and Test Port Remove pilot pressure regulating valve (30). Add shims to increase pressure. Remove shims to decrease pressure. Item

Measurement


Pressure Change 0.078 MPa

Specification

78 kPa 0.78 bar 11.3 psi Pilot Pressure Regulating Valve Shim [approximate per 0.50 mm (0.020 in.) shim]

Pressure Change 0.157 MPa 157 kPa 1.57 bar 22.8 psi


Pressure

0.304 MPa 304 kPa 3.04 bar 44.1 psi

[10] - Tighten pilot pressure regulating valve plug to specification. Item

Measurement

Specification

Plug-to-Pilot Pressure Regulating Valve Housing

Torque

25 N˙m 220 lb.-in.

[11] - Check pressure settings again.





Group 25: Tests

Control Valve Spool Actuating Pilot Pressure Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed



Dig Mode


PWR (power) Mode


OFF


Fast (rabbit)

Control Valve Spool Actuating Pressure

3.4—4.0 MPa 3432—4021 kPa 34.3—40.2 bar 495—583 psi

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Adaptor Tee (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°) Gauge 7000 kPa (70 bar) (1000 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer

Purpose of test is to ensure pilot pressure to the valve spools is adequate to completely shift the spools. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] →NOTE: Spool actuating pressure can be checked for each function by installing a tee and gauge in pilot line and then actuating that function.

LEGEND: 1 2

Adaptor Tee JT02162 Transducer

Control Valve Spool Actuating Pilot Pressure Test <- Go to Section TOC




Group 25: Tests

Install adaptor tee in pilot line for function being tested. Adaptor Tee 9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37° To connect a gauge or transducer to pilot line. Gauge 7000 kPa (70 bar) (1000 psi) Used to measure hydraulic pressure. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. [3] - Install JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge. [4] →NOTE: Spool actuating pressure for boom up, arm in, left and right swing, and all travel functions can also be measured with the monitor.

Connect one of the following test equipment to monitor pressure reading, hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Roll-In Pilot Pressure Hydraulic Oil Temperature Actual Engine Speed [5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [6] - Run machine at specifications. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode





Group 25: Tests

Item

Measurement

Specification

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

Travel Speed Switch

Position

Fast (rabbit)

[7] - Actuate the function to be checked to full stroke. Record pressure. [8] - Compare pressure to specifications. Item

Measurement

Specification

Control Valve Spool Actuating

Pressure

3.4—4.0 MPa 3432—4021 kPa 34.3—40.2 bar 495—583 psi

If valve spool actuating pressure is not to specification, check pilot system pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.) If pilot system pressure is to specification, check pressure at the solenoid valve manifold, pilot control shutoff solenoid valve, pilot controllers, and pilot signal manifold.





Group 25: Tests

Dig Regenerative Solenoid Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Dig Regenerative Solenoid (port SF) Pressure

Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)

0.111 MPa 111 kPa 1.11 bar 16.1 psi

End of Adjusting Screw-to-Nut Length (maximum)

4 mm 0.157 in.

Adjusting Screw-to-Nut Torque

5.0 N˙m 45 lb.-in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check the output pressure for the dig regenerative solenoid (Y22) is within specification. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] -

Solenoid Valve Manifold Location





Group 25: Tests

Solenoid Valve Manifold Detail LEGEND: 1 Power Dig Solenoid Fitting 2 Dig Regenerative Solenoid Fitting 3 Arm Regenerative Solenoid Fitting 4 Arm 2 Flow Control Solenoid Fitting 37 Solenoid Valve Manifold Y22 Dig Regenerative Solenoid (port SF) Y23 Arm Regenerative Solenoid (port SC) Y24 Power Dig Solenoid (port SG) Y27 Arm 2 Flow Control Solenoid (port SI) Remove dig regenerative solenoid fitting (2) from dig regenerative solenoid (Y22). [3] (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) Adaptor Tee Used to connect test gauges. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. Gauge 7000 kPa (70 bar) (1000 psi) <- Go to Section TOC




Group 25: Tests

Used to measure hydraulic pressure. Install adaptor tee where elbow was. Connect line to adaptor tee. [4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee. [5] - Connect one of the following test equipment to monitor the dig regenerative solenoid reading, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Digging Regen P/S O/P Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Digging Regen P/S O/P Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Digging Regen P/S O/P Hydraulic Oil Temperature Actual Engine Speed [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[8] →NOTE: Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller (MCZ). The reading does not change when solenoid adjustment is made.

Operate boom up and arm in over relief. Record monitor and gauge pressure readings. [9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. [10] - that the actual reading from gauge is within the calculated pressure range from monitor.

Item


Dig Regenerative Solenoid (port SF)

Pressure

Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi




Section 9025 - HYDRAULIC SYSTEM Item

Group 25: Tests Measurement Specification Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance

→NOTE: An example of monitor reading is given in the chart below for the dig regenerative solenoid.

Example of Monitor Calculated Reading Example of Calculated Reading From Monitor

Example Monitor Reading

Actuated

Non Actuated

3.19 MPa 3190 kPa 31.9 bar 463 psi

0.03 MPa 30 kPa 0.3 bar 4 psi

[11] LEGEND: 4 5 6

Solenoid Nut Adjusting Screw

Solenoid Adjustment Adjust solenoid (4) being tested as necessary. IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. Loosen nut (5). b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The length from end of adjusting screw to nut must not exceed 4 mm (0.157 in.). Item

Measurement

Specification

Solenoid Adjusting Screw

Pressure Change (approximate per 1/4 turn)

0.111 MPa 111 kPa 1.11 bar 16.1 psi

End of Adjusting Screw-to-Nut

Length (maximum)

4 mm 0.157 in.

c. Hold adjusting screw and tighten nut to specification. Item

Measurement

Specification

Adjusting Screw-to-Nut

Torque

5.0 N˙m 45 lb.-in.





Group 25: Tests

[12] - Check pressure setting again.





Group 25: Tests

Arm Regenerative Solenoid Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Arm Regenerative Solenoid (port SC) Pressure



0.111 MPa 111 kPa 1.11 bar 16.1 psi


4 mm 0.157 in.


5.0 N˙m 45 lb.-in.


Purpose of this test is to check the output pressure for the arm regenerative solenoid (Y23) is within specification. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] -






Group 25: Tests

Solenoid Valve Manifold Detail LEGEND: 1 Power Dig Solenoid Fitting 2 Dig Regenerative Solenoid Fitting 3 Arm Regenerative Solenoid Fitting 4 Arm 2 Flow Control Solenoid Fitting 37 Solenoid Valve Manifold Y22 Dig Regenerative Solenoid (port SF) Y23 Arm Regenerative Solenoid (port SC) Y24 Power Dig Solenoid (port SG) Y27 Arm 2 Flow Control Solenoid (port SI) Remove arm regenerative solenoid fitting (3) from arm regenerative solenoid (Y23). [3] (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) Adaptor Tee Used to connect test gauges. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. Gauge 7000 kPa (70 bar) (1000 psi) <- Go to Section TOC




Group 25: Tests

Used to measure hydraulic pressure. Install adaptor tee where elbow was. Connect line to adaptor tee. [4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee. [5] - Connect one of the following test equipment to monitor the arm regenerative solenoid reading, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Arm Regen P/S Output Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Regen P/S Output Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Arm Regen P/S Output Hydraulic Oil Temperature Actual Engine Speed [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[8] CAUTION:

To avoid personal injury, clear area of all bystanders before doing test. Slowly swing through one complete revolution to ensure that the area is clear of objects before testing.

→NOTE: Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller (MCZ). The reading does not change when solenoid adjustment is made.

Combined operation of swing and arm in functions. Record monitor and gauge pressure readings. [9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.





Group 25: Tests

[10] - that the actual reading from gauge is within the calculated pressure range from monitor.

Item


Arm Regenerative Solenoid (port SC)

Pressure


→NOTE: An example of monitor reading is given in the chart below for the arm regenerative solenoid.



Actuated

Non Actuated

3.19 MPa 3190 kPa 31.9 bar 463 psi


[11] LEGEND: 4 5 6



Measurement

Specification



0.111 MPa 111 kPa 1.11 bar 16.1 psi


Length (maximum)

4 mm 0.157 in.





Group 25: Tests


Measurement

Specification


Torque

5.0 N˙m 45 lb.-in.






Group 25: Tests

Power Dig Solenoid Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Power Dig Solenoid (port SG) Pressure



0.111 MPa 111 kPa 1.11 bar 16.1 psi


4 mm 0.157 in.


5.0 N˙m 45 lb.-in.


Purpose of this test is to check the output pressure for the power dig solenoid (Y24) is within specification. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] -






Group 25: Tests

Solenoid Valve Manifold Detail LEGEND: 1 Power Dig Solenoid Fitting 2 Dig Regenerative Solenoid Fitting 3 Arm Regenerative Solenoid Fitting 4 Arm 2 Flow Control Solenoid Fitting 37 Solenoid Valve Manifold Y22 Dig Regenerative Solenoid (port SF) Y23 Arm Regenerative Solenoid (port SC) Y24 Power Dig Solenoid (port SG) Y27 Arm 2 Flow Control Solenoid (port SI) Remove power dig solenoid fitting (1) from power dig solenoid (Y24). [3] (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) Adaptor Tee Used to connect test gauges. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. Gauge 7000 kPa (70 bar) (1000 psi) <- Go to Section TOC




Group 25: Tests

Used to measure hydraulic pressure. Install adaptor tee where elbow was. Connect line to adaptor tee. [4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee. [5] - Connect one of the following test equipment to monitor the power dig solenoid reading, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pressure Boost P/S Output Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pressure Boost P/S Output Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pressure Boost P/S Output Hydraulic Oil Temperature Actual Engine Speed [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF


Press power dig switch to turn function on. Record monitor and gauge pressure readings. [9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. [10] - actual pressure reading at gauge is within the calculated pressure range from monitor.

Item


Power Dig Solenoid (port SG)

Pressure







→NOTE: An example of monitor reading is given in the chart below for the power dig solenoid.



Actuated

Non Actuated

3.19 MPa 3190 kPa 31.9 bar 463 psi


[11] LEGEND: 4 5 6



Measurement

Specification



0.111 MPa 111 kPa 1.11 bar 16.1 psi


Length (maximum)

4 mm 0.157 in.


Measurement

Specification


Torque

5.0 N˙m 45 lb.-in.





Group 25: Tests






Group 25: Tests

Arm 2 Flow Control Solenoid Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Arm 2 Flow Control Solenoid (port SI) Pressure



0.111 MPa 111 kPa 1.11 bar 16.1 psi


4 mm 0.157 in.


5.0 N˙m 45 lb.-in.


Purpose of this test is to check output pressure for the arm 2 flow control solenoid (Y27) is within specification. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] -






Group 25: Tests

Solenoid Valve Manifold Detail LEGEND: 1 Power Dig Solenoid Fitting 2 Dig Regenerative Solenoid Fitting 3 Arm Regenerative Solenoid Fitting 4 Arm 2 Flow Control Solenoid Fitting 37 Solenoid Valve Manifold Y22 Dig Regenerative Solenoid (port SF) Y23 Arm Regenerative Solenoid (port SC) Y24 Power Dig Solenoid (port SG) Y27 Arm 2 Flow Control Solenoid (port SI) Remove arm 2 flow control solenoid fitting (4) from arm 2 flow control solenoid (Y27). [3] (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) Adaptor Tee Used to connect test gauges. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. Gauge 7000 kPa (70 bar) (1000 psi) <- Go to Section TOC




Group 25: Tests

Used to measure hydraulic pressure. Install adaptor tee where elbow was. Connect line to adaptor tee. [4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee. [5] - Connect one of the following test equipment to monitor the dig regenerative solenoid reading, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Arm 2 Flw Cont P/S Output Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Arm 2 Flw Cont P/S Output Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Arm 2 Flw Cont P/S Output Hydraulic Oil Temperature Actual Engine Speed [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF


Combined operation of boom up and arm in. Record monitor and gauge pressure readings. [9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. [10] - that the actual reading from gauge is within the calculated pressure range from monitor.

Item


Arm 2 Flow Control Solenoid (port SI)

Pressure







→NOTE: An example of monitor reading is given in the chart below for the arm 2 flow control solenoid.



Actuated

Non Actuated

3.19 MPa 3190 kPa 31.9 bar 463 psi


[11] LEGEND: 4 5 6



Measurement

Specification



0.111 MPa 111 kPa 1.11 bar 16.1 psi


Length (maximum)

4 mm 0.157 in.


Measurement

Specification


Torque

5.0 N˙m 45 lb.-in.





Group 25: Tests






Group 25: Tests

Torque Control Solenoid Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Torque Control Solenoid Valve Pressure


Adjusting Screw Pressure Change (approximate per 1/4 turn)

0.111 MPa 111 kPa 1.11 bar 16.1 psi


4 mm 0.157 in.

Adjusting Screw-to-Housing Nut Torque

5.0 N˙m 45 lb.-in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)

Purpose of this test is to check that the output pressure from the torque control solenoid valve (4) is within specification. [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] LEGEND: 1 Pump 1 Regulator 2 Test Port 3 Pump 2 Regulator 4 Torque Control Solenoid Valve

Torque Control Test Port <- Go to Section TOC




Group 25: Tests

Remove plug from torque control solenoid valve test port (2) in pump 1 regulator (1). [3] Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) To connect to the test port of pump 1 and pump 2. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A Used to measure hydraulic pressure and temperature. Gauge 7000 kPa (70 bar) (1000 psi) To measure hydraulic pressure. Install adapter. [4] - Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter. [5] - Connect one of the following test equipment to monitor the pump torque proportional valve pressure reading, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pumps 1&2 Torque P/S O/P Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pumps 1&2 Torque P/S O/P Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pumps 1&2 Torque P/S O/P Hydraulic Oil Temperature Actual Engine Speed [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF





Group 25: Tests

[8] →NOTE: Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller (MCZ). The reading does not change when valve adjustment is made.

Place all pilot control levers and pedals in the neutral position. Record the pressure readings from monitor and gauge. [9] - Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. [10] - actual reading from gauge is within the calculated pressure range from monitor.

Item


Torque Control Solenoid Valve

Pressure


→NOTE: An example of monitor reading is given in chart below for the torque control solenoid valve. When a function is actuated, readings start to decrease. The reading will vary depending on the load on the function.



Neutral (Non Actuated)

Actuated

3.79 MPa 3850 kPa 38.5 bar 558 psi

0.33 MPa 330 kPa 3.3 bar 48 psi

[11] - Adjust torque control solenoid valve as needed. LEGEND: 4 Torque Control Solenoid Valve 5 Nut 6 Adjusting Screw





Group 25: Tests

Solenoid Valve Adjustment

IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. Loosen nut (5). b. Turn adjusting screw (6) in to increase pressure setting or turn adjusting screw out to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification. Item

Measurement

Specification

Adjusting Screw


0.111 MPa 111 kPa 1.11 bar 16.1 psi


Length (maximum)

4 mm 0.157 in.

c. Hold adjusting screw. Tighten nut to specification. Item

Measurement

Specification

Adjusting Screw-to-Housing Nut

Torque

5.0 N˙m 45 lb.-in.






Group 25: Tests

Pump Control Pilot Pressure Signal Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure (approximate)

1.03 MPa 1030 kPa 10.3 bar 149 psi

Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate)

3.70 MPa 3700 kPa 37.0 bar 537 psi

The function of the pump 1 and pump 2 flow rate pilot valves (port SA and SB), is to send a regulated pilot control pressure signal to its respective pump regulator to change pump flow in response to the actuation of pilot control valves to shift the control valve spools. Purpose of this test is to check regulated pump control pilot pressure signal from flow rate pilot valves to remote control spool in pump 1 and pump 2 regulators. Pressure increases as a function is actuated and decreases when function is returned to neutral. The pressure signals are checked by monitoring the pump 1 and pump 2 control pressure sensors. For the flow rate pilot valves, see Pilot Signal Manifold Operation . (Group 9025-05.) For the remote control spools, see Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.) [1] - Connect one of the following test equipment to monitor pump 1 and pump 2 control pressure, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pump 1 Pump Control Pressure Pump 2 Pump Control Pressure Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Pump Control Pressure Pump 2 Pump Control Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Pump Control Pressure Pump 2 Pump Control Pressure Hydraulic Oil Temperature Actual Engine Speed

[2] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [3] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C





Group 25: Tests Measurement

Specification 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[4] - Return all control levers and pedals to neutral position. Place pilot shutoff lever in the unlock (DOWN) position. [5] - Record pressure readings from monitor. Item

Measurement

Specification

Pump 1 and Pump 2 Pump Control Pressure in Neutral

Pressure (approximate)

1.03 MPa 1030 kPa 10.3 bar 149 psi

[6] CAUTION:

Prevent possible injury from machine movement. Ensure that area is clear of bystanders and large enough to operate all machine functions.

Slowly actuate control lever for boom up to full stroke while observing the monitor. The pressures must increase smoothly and evenly as function is actuated to full stroke. [7] - Hold control lever at full stroke. Record pressure readings from monitor. Item

Measurement

Specification

Pump 1 and Pump 2 Pump Control Pressure at Full Actuation


3.70 MPa 3700 kPa 37.0 bar 537 psi

[8] - Check the following if the pressure signal does not increase smoothly and evenly or is not to specification. Check hoses from pilot signal manifold to pump 1 and pump 2 regulators for damage. Check pump 1 and pump 2 control pressure sensors, Perform Pressure Sensor Test . (Group 9015-20.) To remove and inspect pump 1 and pump 2 flow rate pilot valves, See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)





Group 25: Tests

Main Relief and Power Dig Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Main Relief Valve Pressure

34.0—36.5 MPa 34 000—36 500 kPa 340—365 bar 4931—5294 psi

Power Dig Valve Pressure

35.3—38.3 MPa 35 300—38 300 kPa 353—383 bar 5120—5555 psi

First Adjusting Plug Pressure Change (approximate per 1/4 turn)

2.95 MPa 2950 kPa 29.5 bar 427 psi

24 mm Nut Torque

49—55 N·m 36—41 lb.-ft.

Second Adjusting Plug Pressure Change (approximate per 1/4 turn)

2.95 MPa 2950 kPa 29.5 bar 427 psi

27 mm Nut Torque

59—69 N·m 44—50 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Pump 2 Adapter (-8 ORFS) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi) Combination Wrenches 24 and 27 mm

Purpose of main relief valve is to limit the maximum hydraulic system pressure. Power dig is a temporary increase of the system pressure. The valve is checked and adjusted to protect components from damage caused by excessive pressures. [1] -





Group 25: Tests

Pump 1 and Pump 2 Test Ports

Pump 1 and Pump 2 Test Ports LEGEND: 1 Pump 1 Test Port 2 Pump 1 Adapter 3 Pump 2 Test Port 4 Pump 2 Adapter 5 JT02160 Transducer Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure <- Go to Section TOC




Group 25: Tests

Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Pump 1 Adapter 1/4 M BSPP ORB x 7/16-20 M 37° To connect to the test port of pump 1 Pump 2 Adapter -8 ORFS To connect to the test port of pump 2. Gauge 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Transducer 70 000 kPa (700 bar) (10 000 psi) JT02160 To measure hydraulic pressure. [2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] - Remove plug from pump 1 test port (1) or pump 2 test port (3). [4] - Install pump 1 adapter (2) or pump 2 adaptor (4). [5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter. [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C






Specification 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[8] - Actuate arm in function over relief. Record main relief pressure reading. [9] - Actuate arm in function over relief while pressing power dig switch. Record power dig pressure reading. [10] - Adjust main relief and power dig valve (117) pressure as needed. LEGEND: 6 7 8 9 10 73 74 117

First Adjusting Plug 24 mm Nut Second Adjusting Plug 27 mm Nut Piston Right Control Valve (4-spool) Left Control Valve (5-spool) Main Relief and Power Dig Valve

Main Relief and Power Dig Valve Location





Group 25: Tests

Main Relief and Power Dig Valve

→NOTE: If pressure setting cannot be raised by adjusting main relief and power dig valve, arm in circuit relief valve pressure setting may be low. Before continuing, see Circuit Relief Valve Test and Adjustment . (Group 9025-25.)

Item

Measurement

Specification

Main Relief Valve

Pressure

34.0—36.5 MPa 34 000—36 500 kPa 340—365 bar 4931—5294 psi

Power Dig Valve

Pressure

35.3—38.3 MPa 35 300—38 300 kPa 353—383 bar 5120—5555 psi

[11] - Loosen 24 mm nut (7). 24 and 27mm Combination Wrenches To loosen and tighten adjusting plugs and nuts. [12] - Turn first adjusting plug (6) in until piston (10) is against bottom of bore in second adjusting plug (8). Tighten nut finger tight. <- Go to Section TOC




Group 25: Tests

[13] - Loosen 27 mm nut (9). [14] - Start engine. [15] - Actuate arm in function over relief. [16] - Turn second adjusting plug (8) IN to increase power dig relief pressure or turn adjusting plug OUT to decrease pressure. Item

Measurement

Specification

Second Adjusting Plug


2.95 MPa 2950 kPa 29.5 bar 427 psi

[17] - Hold second adjusting plug (8). Tighten 27 mm nut (9) to specification. Item

Measurement

Specification

27 mm Nut

Torque

59—69 N·m 44—51 lb.-ft.

[18] - Loosen 24 mm nut (7). [19] - Actuate arm in function over relief. [20] - Turn first adjusting plug (6) OUT to decrease pressure within specified pressure for main relief valve. Item

Measurement

Specification

First Adjusting Plug


2.95 MPa 2950 kPa 29.5 bar 427 psi

[21] - Hold first adjusting plug (6). Tighten 24 mm nut (7) to specification. Item

Measurement

Specification

24 mm Nut

Torque

49—55 N·m 36—41 lb.-ft.

[22] - Repeat test procedure and compare pressures to specification.





Group 25: Tests

Circuit Relief Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed (approximate)

1300 rpm


Dig Mode


PWR (power) Mode


OFF

Bucket Curl Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

Bucket Dump Pressure

39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Arm In Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

Arm Out Pressure

39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Boom Up Pressure

39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Boom Down Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

Circuit Relief Valve Pressure Change (approximate per 1/4 turn)

2.65 MPa 2650 kPa 26.5 bar 385 psi

Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque

20 N·m 177 lb.-in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Pump 2 Adapter (-8 ORFS) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to the front attachment circuit relief valve pressures are within specification. Circuit relief valves limit high pressure spikes caused by external forces when functions are in neutral. Valves are checked and adjusted to specification to protect components from damage. [1] -





Group 25: Tests


Pump 1 and Pump 2 Test Ports LEGEND: 1 Pump 1 Test Port 2 Pump 1 Adapter 3 Pump 2 Test Port 4 Pump 2 Adapter 5 JT02160 Transducer Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed. Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure <- Go to Section TOC




Group 25: Tests

Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) To connect to the test port of pump 1 and pump 2. Pump 2 Adapter (-8 ORFS) To connect to the test port of pump 2. Gauge 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Transducer 70 000 kPa (700 bar) (10 000 psi) JT02160 To measure hydraulic pressure. [2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] - Remove plug from pump 1 test port (1) and pump 2 test port (3). [4] - Install pump 1 adapter (2) and pump 2 adapter (4). [5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter. [6] - Turn second adjusting plug of main relief and power dig valve in 1/2 turn to increase pressure setting. See Main Relief and Power Dig Valve Test and Adjustment for adjustment procedure. (Group 9025-25.) [7] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)





Group 25: Tests

[8] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed (approximate)

1300 rpm

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[9] -

Control Valve (top view)





Group 25: Tests

Control Valve (bottom view) LEGEND: 73 Front Control Valve (4-spool) 74 Rear Control Valve (5-spool) 79 Bucket Dump Circuit Relief and Anticavitation Valve 80 Bucket Curl Circuit Relief and Anticavitation Valve 88 Boom Up Circuit Relief and Anticavitation Valve 89 Boom Down Circuit Relief and Anticavitation Valve 102 Arm In Circuit Relief and Anticavitation Valve 103 Arm Out Circuit Relief and Anticavitation Valve 117 Main Relief and Power Dig Valve Actuate the function over relief for circuit relief valve (79, 80, 88, 89, 102, and 103) being checked. Record pressure reading. Item

Measurement

Specification

Bucket Curl

Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

Bucket Dump

Pressure

39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Arm In

Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

Arm Out

Pressure

39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Boom Up <- Go to Section TOC

Pressure

39.2—40.2 MPa




Measurement

Group 25: Tests Specification 39 200—40 200 kPa 392—402 bar 5685—5831 psi

Boom Down

Pressure

37.3—38.3 MPa 37 300—38 300 kPa 373—383 bar 5410—5555 psi

[10] - Adjust the circuit relief valve as needed. Turn adjusting screw in to increase pressure setting; turn adjusting screw out to decrease pressure setting. Hold screw and tighten nut to specification. Item

Measurement

Specification

Circuit Relief Valve


2.65 MPa 2650 kPa 26.5 bar 385 psi

Circuit Relief Valve Adjusting Screw-to-Plug Nut

Torque

20 N·m 177 lb.-in.

[11] - Check pressures again. [12] - Turn second adjusting plug of main relief and power dig valve out to its original setting. Check main pressure setting. See Main Relief and Power Dig Valve Test and Adjustment for adjustment procedure. (Group 9025-25.)





Group 25: Tests

Blade Main Relief Valve Test and Adjustment IMPORTANT: Relief pressure setting is higher when operating blade down function. The blade down circuit relief and anticavitation valve is set higher than blade up circuit relief and anticavitation valve. The difference is noticed when checking both blade up and blade down circuits over relief.

Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed Dial Position

1650—1750 rpm

Work Mode Switch Preload

Dig Mode

Power Mode Switch Position

PWR (power) Mode


OFF

Blade Up Relief Valve (approximate)

27.5 MPa 27 500 kPa 275 bar 3989 psi

Blade Down Relief Valve (approximate)

39.2 MPa 39 200 kPa 392 bar 5685 psi

Blade Main Relief Valve Pressure Change (approximate per 1/4 turn)

3.8 MPa 3378 kPa 34 bar 490 psi

24 mm Lock Nut Torque

9.82 N·m 7.2 lb·ft

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Adapter Tee (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37°) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer, 70 000 kPa (700 bar) (10 000 psi) Combination Wrench 24 mm

The purpose of blade main relief valve is to limit the maximum hydraulic system pressure in the blade circuit. The valve is checked and adjusted, to protect components from damage caused by excessive pressures. [1] CAUTION:

Avoid injury from escaping fluid under pressure. The hydraulic oil tank is pressurized. Stop engine and relieve pressure in the system before disconnecting hydraulic lines.

Stop engine and release hydraulic oil tank pressure, by pushing pressure release valve at top of hydraulic oil tank. [2] -





Group 25: Tests

Blade Pump Pressure Test LEGEND: 1 Test Port 2 Adapter Tee 3 JT02160 Transducer 132 Fan Drive/Blade Pump Disconnect delivery line from fan drive/blade pump (132). For blade and line connection location, see Blade Hydraulic System Component Location . (Group 9025-15.) [3] - Install adapter tee (2) and connect delivery line to test port (1). [4] - Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer or 70 000 kPa (700 bar) (10 000 psi) gauge. Adapter Tee 9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37° To connect gauge or transducer in blade pump delivery line. Gauge 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A <- Go to Section TOC




Group 25: Tests

To display hydraulic pressure readings. Transducer, 70 000 kPa (700 bar) (10 000 psi) Transducer, 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. [5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [6] - Run machine at following specifications: Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

1650—1750 rpm

Work Mode Switch

Position

Dig Mode

Power Mode Switch

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[7] - Slowly operate blade function over relief. Record blade main relief valve pressure reading. [8] →NOTE: If blade circuit main relief valve does not meet specification, adjustment can be made.

Adjust blade main relief valve pressure as needed. Item

Measurement

Specification

Blade Up Relief Valve


20.6 MPa 20 600 kPa 206 bar 2990 psi

Blade Down Relief Valve


39.2 MPa 39 200 kPa 392 bar 5685 psi

[9] -





Group 25: Tests

LEGEND: 1 2 136

24 mm Lock Nut Adjusting Screw Blade Main Relief Valve

Blade Main Relief Valve Loosen 24 mm lock nut (1). Combination Wrench 24 mm To loosen and tighten adjusting lock nut. [10] - Turn adjusting screw (2) to change blade main relief valve setting. Turn clockwise to increase pressure; turn counter clockwise to decrease pressure. Item

Measurement

Specification

Blade Main Relief Valve


3.8 MPa 3378 kPa 34 bar 490 psi

[11] - Hold adjusting screw. Tighten 24 mm lock nut to specification. Item

Measurement

Specification

24 mm Nut

Torque

9.82 N·m 7.2 lb·ft

[12] - Check pressure again. [13] →NOTE: Adjustments to circuit relief valves should not be attempted. Replace circuit relief valves as necessary.





Group 25: Tests

LEGEND: 137 Blade Control Valve 141 Blade Up Circuit Relief and Anticavitation Valve 142 Blade Down Circuit Relief and Anticavitation Valve

Blade Control Valve Circuit Relief and Anticavitation Valves If pressure specification cannot be achieved by adjusting blade main relief valve replace circuit relief and anticavitation valves (141 and 142). [14] - Check pressure again.





Group 25: Tests

Swing Motor Crossover Relief Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F


1300 rpm


Dig Mode


PWR (power) Mode


OFF

Swing Motor Crossover Relief Valve Pressure

33.0—35.5 MPa 33 000—35 500 kPa 330—355 bar 4787—5150 psi

Swing Motor Crossover Relief Adjusting Screw Pressure Change (approximate per 1/4 turn)

1.0 MPa 1000 kPa 10 bar 142 psi

Swing Motor Crossover Relief Valve Lock Nut

49 N·m 36 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Pump 2 Adapter (-8 ORFS) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to the swing motor crossover relief valve pressures are within specification. Swing motor crossover relief valves limit system pressure in the swing circuit. They protect swing components from high stresses generated during the starting and stopping of the upperstructure. They also protect components against pressure spikes from external forces when the control valve is in neutral. [1] -





Group 25: Tests


Pump 1 and Pump 2 Test Ports LEGEND: 1 Pump 1 Test Port 2 Pump 1 Adapter 3 Pump 2 Test Port 4 Pump 2 Adapter 5 JT02160 Transducer Connect one of the following test equipment to monitor pump 2 delivery pressure, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure <- Go to Section TOC




Group 25: Tests

Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, See MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Adapter 1/4 M BSPP ORB x 7/16-20 M 37° To connect to the test port of pump 1 and pump 2. Pump 2 Adapter -8 ORFS To connect to the test port of pump 2. Gauge 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Transducer 70 000 kPa (700 bar) (10 000 psi) JT02160 To measure hydraulic pressure. [2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] - Remove plug from pump 2 test port (3). [4] - Install adapter (4). [5] - Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter. [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] - Run machine at specification.





Group 25: Tests

Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C

Engine

Speed (approximate)

1300 rpm

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

110—130°F

[8] - Actuate swing function over relief. Record pressure reading. Repeat for opposite direction. Compare recorded pressures to specification. Item

Measurement

Specification

Swing Motor Crossover Relief Valve

Pressure

33.0—35.5 MPa 33 000—35 500 kPa 330—355 bar 4787—5150 psi

[9] -

Swing Motor Crossover Relief Valve Location





Group 25: Tests

Swing Motor Crossover Relief Valve LEGEND: 6 Poppet 7 Spring 8 Lock Nut 9 Adjusting Screw 52 Swing Motor 54 Swing Crossover Relief Valve (2 used) 59 Swing Gear Case Stop machine before making adjustments. Loosen lock nut (8). Turn adjusting screw (9) IN to increase pressure; OUT to decrease pressure. Item

Measurement

Specification

Swing Motor Crossover Relief Adjusting Screw Pressure Change

Pressure Change (approximate per 1/4 turn) 1.00 MPa 1000 kPa 10 bar 142 psi

[10] - Tighten lock nut to specification. Item

Measurement

Specification

Swing Motor Crossover Relief Valve lock nut

Torque

49 N·m 36 lb.-ft.

[11] - Actuate swing function over relief to check adjustment.





Group 25: Tests

Travel Motor Crossover Relief Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F


1300 rpm


Dig Mode


PWR (power) Mode


OFF

Travel Motor Crossover Relief Valve Pressure

34.0—36.5 MPa 34 000—36 500 kPa 344—3650 bar 4931—5294 psi

Crossover Relief Valve Shim Pressure Change [per 0.5 mm (0.02 in.)]

0.9 MPa 900 kPa 9 bar 130 psi

Crossover Relief Valve Torque

310 N˙m 230 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Pump 1 Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Pump 2 Adapter (-8 ORFS) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi) 76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used)

Purpose of test is to check that the travel motor crossover relief valve pressure is within specification. [1] -





Group 25: Tests


Pump 1 and Pump 2 Test Ports LEGEND: 1 Pump 1 Test Port 2 Pump 1 Adapter 3 Pump 2 Test Port 4 Pump 2 Adapter 5 JT02160 Transducer Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure <- Go to Section TOC




Group 25: Tests

Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Application . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) To connect to the test port of pump 1 and pump 2. Pump 2 Adapter -8 ORFS To connect to the test port of pump 2. Gauge 70 000 kPa (700 bar) (10 000 psi) To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Transducer 70 000 kPa (700 bar) (10 000 psi) JT02160 To measure hydraulic pressure. [2] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] - Remove the plug from pump 1 and pump 2 test port (1 and 3). [4] - Install adapters (2 and 4). [5] - Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (5) or 70 000 kPa (700 bar) (10 000 psi) gauge. [6] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [7] -





Group 25: Tests

LEGEND: 6

76.2 mm (3 in.) OD Pin

Travel Motor Stalled Using Pin Install 76.2 mm (3 in.) OD pin (6) or round bar stock between sprocket and track frame to stall travel motor. 76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used) To put between sprocket and track frame to stall travel motor. [8] - Run machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed (approximate)

1300 rpm

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[9] LEGEND: 68 Travel Motor Crossover Relief Valve (2 used)

Travel Motor Crossover Relief Valve Location <- Go to Section TOC




Group 25: Tests

Hold power dig switch. Slowly actuate the travel function for the crossover relief valve (68) being checked. Record pressure reading. Make adjustments as necessary. Item

Measurement

Specification

Travel Motor Crossover Relief Valve

Pressure

34.0—36.5 MPa 34 000—36 500 kPa 340—365 bar 4931—5294 psi

[10] - Stop engine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. [11] -

Travel Motor Crossover Relief Valve Shims LEGEND: 22 Poppet 23 Spring Seat 24 Shim 25 Spring Remove crossover relief valve. Add or remove shims (24) to adjust pressure. Item

Measurement

Specification

Crossover Relief Valve Shim

Pressure Change [per 0.5 mm (0.02 in.)]

0.9 MPa 900 kPa 9 bar 130 psi

[12] - Install crossover relief valve. Tighten to specification. Item

Measurement

Specification

Crossover Relief Valve

Torque

310 N˙m






Specification 230 lb.-ft.

[13] - Hold power dig switch. Actuate travel function at stall to check adjustment.





Group 25: Tests

Pump Regulator Test and Adjustment—Minimum Flow Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF


Slow (turtle)

One Revolution of Raised Track Cycle Time (with pump regulator pilot line disconnected)

24.4—26.4 seconds

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Plug 7/16-20 M 37° Stop Watch Combination Wrench 17 mm Flat Blade Screwdriver

Purpose of this test is to check and adjust the minimum flow rate of pump 1 and 2 using the cycle time for travel as an indicator of pump flow rate. [1] - Check and adjust track sag. See Check and Adjust Track Sag . (Operator′s Manual.) [2] - Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed [3] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[4] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [5] -





Group 25: Tests

LEGEND: 1 Hydraulic Pump 1 Pilot Line 2 Hydraulic Pump 2 Pilot Line 17 Hydraulic Pump 1 Regulator 18 Hydraulic Pump 2 Regulator

Hydraulic Pump Regulator Pilot Lines Disconnect pump regulator pilot lines (1 and 2) from pump 1 and 2 regulators (17 and 18). Install plugs in pilot lines. Plug 7/16-20 M 37° To plug pump control valve pilot lines. Leave fittings on regulator open. Lay a shop towel over the fittings. [6] - Raise right track off ground for pump 1 testing or left track for pump 2. [7] - Run machine at specifications: Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

Travel Speed Switch

Position

Slow (turtle)

[8] - Actuate travel function to full speed. Record cycle time for one revolution. Stop Watch To time test. [9] -





Group 25: Tests

LEGEND: 5 Minimum Flow Adjusting Screw 6 17 mm Nut

Minimum Flow Adjusting Screw Adjust minimum flow adjusting screw (5) as needed to obtain specified cycle time. Turn screw in to decrease cycle time (flow rate increases); turn screw out to increase cycle time (flow rate decreases). Hold screw and tighten 17 mm nut (6). Combination Wrench 17 mm To loosen and tighten nut Flat Blade Screwdriver To turn adjusting screw Item

Measurement

Specification

One Revolution of Raised Track (with pump regulator pilot line disconnected)

Cycle Time

24.4—26.4 seconds

[10] - Repeat procedure for other pump. Adjust regulators so cycle times are approximately the same for each track.





Group 25: Tests

Pump Regulator Test and Adjustment—Maximum Flow Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

End of Maximum Flow Adjusting Screw to 13 mm Nut Distance

3 mm 0.125 in. (1/8 in.)

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF


Slow (turtle)

Track Raised—3 Revolutions

23.4—27.4 sec.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Combination Wrench 13 mm Flat Blade Screwdriver Stop Watch Combination Wrench 30 mm

Purpose of this test is to check and adjust the maximum flow rate of pump 1 and 2 using the cycle times for travel. Travel times for each side need to be the same. Maximum flow rate cannot be significantly increased by turning out the flow adjusting cartridge. [1] - Check and adjust track sag. See Check and Adjust Track Sag . (Operator′s Manual.) [2] - Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed [3] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[4] -





Group 25: Tests

LEGEND: 1 Distance 2 Maximum Flow Adjusting Screw 3 13 mm Nut 4 Flow Adjusting Cartridge (track cycle time) 5 30 mm Nut

Flow Adjusting Cartridge and Maximum Flow Adjusting Screw Check distance from end of maximum flow adjusting screw (2) to 13 mm nut (3) for both pump 1 and pump 2 regulators. Adjust screw to specification as needed. Combination Wrench 13 mm To loosen and tighten nut and adjust cartridge. Flat Blade Screwdriver To turn adjusting screw. Item

Measurement

Specification

End of Maximum Flow Adjusting Screw to 13 mm Nut

Distance

3 mm 0.125 in. (1/8 in.)

[5] - Run machine at specifications. Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

Travel Speed Switch

Position

Slow (turtle)

[6] - Raise the right track off ground to test pump 1 or left track for pump 2. [7] - Actuate travel function to full speed with raised track. Record track cycle time for three revolutions. <- Go to Section TOC




Group 25: Tests

Repeat procedure for the other pump. Stop Watch To time test. [8] - Adjust flow adjusting cartridge (track cycle time) (4) on pump 1 and pump 2 regulators so track cycle times are within specification and approximately the same. Item

Measurement

Specification

Track Raised—3 Revolutions

Cycle Time

23.4—27.4 sec.

Loosen 30 mm nut (5). Turn flow adjusting cartridge in for a slower track cycle time (decrease flow rate), turn flow adjusting cartridge out for a faster track cycle time (increase flow rate). Tighten 30 mm nut after adjustment. Combination Wrench 30 mm To loosen and tighten nut.





Group 25: Tests

Pump Flow Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Pump 1 or Pump 2 Flow Rate

59—67 L/min. at 27 MPa 59—67 L/min. at 27 000 kPa 59—67 L/min. at 270 bar 15.5—17.7 gpm at 3930 psi

Pump 1 or Pump 2 Flow Rate

100—106 L/min. at 14.7 MPa 100—106 L/min. at 14 700 kPa 100—106 L/min. at 147 bar 26.4—28.0 gpm at 2130 psi

Specifications SPECIFICATIONS (continued)

Minimum Flow Adjusting Screw Turn

1/4 turn clockwise increases minimum pump flow rate approximately 6.2 L/min. 1/4 turn clockwise increases minimum pump flow rate approximately 1.7 gpm

Minimum Flow Rate Adjusting Screw 17 mm Nut Torque

20 N·m 180 lb.-in.

Maximum Flow Adjusting Screw Turn

1/4 turn clockwise decreases maximum pump flow rate approximately 5.2 L/min. 1/4 turn clockwise decreases maximum pump flow rate approximately 1.4 gpm

Maximum Flow Rate Adjusting Screw 13 mm Nut Torque

10 N·m 89 lb.-in.

Flow Adjusting Cartridge (track cycle time) Turn

1/4 turn clockwise decreases flow rate approximately 10.4 L/min. 1/4 turn clockwise decreases flow rate approximately 2.8 gpm

Flow Adjusting Cartridge (track cycle time) 30 mm Nut Torque

30 N·m 22 lb.-ft.

Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Turn

1/4 turn clockwise increases flow rate approximately 10.4 L/min. 1/4 turn clockwise increases flow rate approximately 2.8 gpm

Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Torque

30 N·m 22 lb.-ft.

Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) Turn


Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) Torque

10 N·m 89 lb.-in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Vacuum Pump JT03452 Split Flange Connector Plate Kit Flowmeter T107068 Flange Fitting Split Clamp Half (Code 62) 1020 mm (40 in.) x 1 in. Hose with 90° flange fitting end (Code 62) Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)

Purpose of this test is to determine pump condition, and should be performed only if a comparison of actual machine cycle <- Go to Section TOC




Group 25: Tests

times to specified cycle times indicates low pump flow. Do the following appropriate procedures before continuing test: See Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.) See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.) See Pump 1 and Pump 2 Regulator Operation for information on pump control pressure operation. (Group 9025-05.) See Torque Control Solenoid Valve Test and Adjustment . (Group 9025-25.) See Pump Control Pilot Pressure Signal Test . (Group 9025-25.) [1] -

Pump Flow Test LEGEND: 1 2 3 73 74 <- Go to Section TOC

Pump 1 Delivery Port Pump 2 Delivery Port Pump 1 and Pump 2 Regulator Front Control Valve (4-spool) Rear Control Valve (5-spool) Section 9025 page 361



Group 25: Tests

Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] - Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank . (Group 3360.) See Drain and Refill Hydraulic Tank Oil . (Operator’s Manual.) Vacuum Pump To minimize oil loss. [3] - Disconnect pump-to-control valve line from pump 1 delivery port (1) and/or pump 2 delivery port (2). For instruction, see DFT1218 Split Flange Hose Cap . (Group 9900.) Split Flange Hose Cap DFT1218 Close split flange style hose ends. [4] →NOTE: Both pumps can be connected as shown, but only one pump at a time can be checked when only one return line is used. An alternate method is to connect pump-to-control valve lines to outlet of flowmeters. Return oil then flows through the control valve and hydraulic oil cooler to the hydraulic oil tank.

Connect flowmeter. If available, connect flowmeters to both pumps as shown. Elbow Fitting (-16 M BSPP ORB x -16 M ORFS) To connect return hose from flowmeter to return manifold. Flowmeter To measure pump flow. Flange Fitting Split Clamp Half (Code 62) T107068 Hold hose with flange fittings in place. 1020 mm (40 in.) x 1 in. hose with 90° flange fitting end (Code 62) Connect flowmeter to pump. [5] -





Group 25: Tests

LEGEND: 6 41

Arm In Pilot Line Pilot Signal Manifold

Arm In Pilot Line Disconnect arm in pilot line (6). Install cap on pilot signal manifold (41) and tighten. Install plug in pilot line loose and cover with shop towel to avoid contamination. →NOTE: Pilot line is disconnected so arm in function can be used to put pump 1 and pump 2 into stroke and not move arm.

[6] - Remove vacuum. [7] - Open flowmeter loading valve completely. [8] - Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Pump 1 Delivery Pressure Pump 2 Delivery Pressure Hydraulic Oil Temperature Actual Engine Speed Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) To connect to the test port of pump 1 and pump 2. Gauge 70 000 kPa (700 bar) (10 000 psi) <- Go to Section TOC




Group 25: Tests

To measure hydraulic pressure. Digital Pressure/Temperature Analyzer JT02156A To display hydraulic pressure readings. Transducer, 70 000 kPa (700 bar) (10 000 psi) JT02160 To measure hydraulic pressure. [9] - Warm hydraulic oil to specification by closing flowmeter loading valve to increase pressure. [10] - Operate machine at specification. Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[11] - Actuate arm in for pump 1 and pump 2 to full actuation and hold throughout test. [12] - Slowly close loading valve on flowmeter to obtain specified pressures. Record flow rate at each pressure. [13] - Open loading valve. Stop engine. [14] - Compare flow rates to specifications. Item

Measurement

Specification

Flow Rate

59—67 L/min. at 27 MPa

Pump 1 or Pump 2 Pump 1 or Pump 2

59—67 L/min. at 27 000 kPa 59—67 L/min. at 270 bar 15.5—17.7 gpm at 3930 psi Pump 1 or Pump 2

Flow Rate

100—106 L/min. at 14.7 MPa 100—106 L/min. at 14 700 kPa 100—106 L/min. at 147 bar 26.4—28.0 gpm at 2130 psi

[15] - Pump flow rate can be increased by adjusting pump 1 and/or pump 2 regulators. IMPORTANT: Avoid possible pump damage. Do not turn minimum flow adjusting screw more than two turns.





Group 25: Tests

Pump 1 and Pump 2 Regulator Adjustment LEGEND: 8 17 mm Nut 9 Minimum Flow Adjusting Screw 10 13 mm Nut 11 Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) 12 Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) 13 30 mm Nut 14 13 mm Nut 15 Maximum Flow Adjusting Screw 16 Flow Adjusting Cartridge (track cycle time) 17 30 mm Nut 18 Hydraulic Oil Pressure 19 Hydraulic Oil Flow Rate Minimum flow rate: a. Loosen 17 mm nut (8). b. Turn minimum flow adjusting screw (9) clockwise 1/4 turn to increase minimum pump flow. Item


Minimum Flow Adjusting Screw

Turn

1/4 turn clockwise increases minimum pump flow rate approximately 6.2 L/min. 1/4 turn clockwise increases minimum pump flow rate approximately 1.7 gpm

c. Hold minimum flow adjusting screw. Tighten 17 mm nut to specification. Item

Measurement

Specification

Minimum Flow Rate Adjusting Screw 17 mm Nut

Torque

20 N·m 180 lb.-in.

[16] -





Group 25: Tests

IMPORTANT: Avoid possible pump damage. Do not increase the maximum pump flow rate over maximum flow specifications. Do not turn maximum flow adjusting screw more than two turns.

Maximum flow rate: a. Loosen 13 mm nut (14). b. Turn maximum flow adjusting screw (15) clockwise 1/4 turn to decrease maximum pump flow. Item


Maximum Flow Adjusting Screw

Turn

1/4 turn clockwise decreases maximum pump flow rate approximately 5.2 L/min. 1/4 turn clockwise decreases maximum pump flow rate approximately 1.4 gpm

c. Hold maximum flow adjusting screw. Tighten 13 mm nut to specification. Item

Measurement

Specification

Maximum Flow Rate Adjusting Screw 13 mm Nut

Torque

10 N·m 89 lb.-in.

[17] IMPORTANT: Avoid possible pump damage. Do not turn flow adjusting cartridge more than one turn.

Flow adjusting cartridge (track cycle time): a. Loosen 30 mm nut (17). b. Turn flow adjusting cartridge (16) clockwise 1/4 turn to decrease flow rate. Item


Flow Adjusting Cartridge (track cycle time)

Turn

1/4 turn clockwise decreases flow rate approximately 10.4 L/min. 1/4 turn clockwise decreases flow rate approximately 2.8 gpm

c. When flow adjusting cartridge (16) is turned clockwise, the maximum flow rate also decreases. To maintain the maximum flow rate unchanged, turn adjusting screw (15) counterclockwise twice as much as adjusting cartridge was turned clockwise. d. Hold flow adjusting cartridge. Tighten 30 mm nut to specification. Item

Measurement

Specification

Flow Adjusting Cartridge (track cycle time) 30 mm Nut

Torque

30 N·m 22 lb.-ft.

[18] IMPORTANT: Avoid possible pump damage. Do not turn load adjusting cartridge more than one turn.

Load adjusting cartridge (outer spring) (pressure to flow control-torque adjustment): a. Loosen 30 mm nut (13). <- Go to Section TOC




Group 25: Tests

b. Turn load adjusting cartridge (12) clockwise 1/4 turn to increase flow rate. Item


Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment)

Turn


c. Hold load adjusting cartridge. Tighten 30 mm nut to specification. Item


Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment)

Torque

30 N·m 22 lb.-ft.

[19] IMPORTANT: Avoid possible pump damage. Do not turn load adjusting screw more than one turn.

Load adjusting screw (inner spring) (pressure to flow control-torque adjustment): a. Loosen 13 mm nut (10). b. Turn load adjusting screw (11) clockwise 1/4 turn to increase flow rate. Item


Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment)

Turn


c. Hold load adjusting screw. Tighten 13 mm nut to specification. Item

Measurement

Specification

Load adjusting screw (inner spring) (pressure to flow control-torque adjustment)

Torque

10 N·m 89 lb.-in.





Group 25: Tests

Swing Motor Leakage Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Swing Motor Swinging Leakage

0.4 L/min. or less 0.11 gpm of less 0.6 L/min. (maximum allowable) 0.16 gpm (maximum allowable)

Swing Motor Stalled Leakage

1.6 L/min. or less 0.42 gpm or less 2.0 L/min. (maximum allowable) 0.53 gpm (maximum allowable)

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Cap (9/16-18 F 37°) Calibrated Container

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[2] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] LEGEND: Return Line (swing motor to hydraulic oil tank return 1 manifold) 2 Hydraulic Oil Tank Return Manifold 3 Calibrated Container

Return Line Disconnect return line (1) from hydraulic oil tank return manifold (2). Place return line in calibrated container (3). Install cap on return manifold fitting. <- Go to Section TOC




Group 25: Tests

Cap 9/16-18 F 37° Cap elbow while return line is disconnected. Calibrated Container To measure amount of fluid leakage. [4] - Run machine at specification. Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[5] CAUTION:

To avoid personal injury, clear area of all bystanders before doing test. Slowly swing through one complete revolution to ensure that the area is clear of objects before testing.

Raise and lower boom to pressurize hydraulic oil tank. [6] - Operate swing function for 1 minute. Record amount of leakage. Repeat procedure in opposite swing direction. Record amount of leakage. Compare amount of leakage for each direction to specification. Item

Measurement

Specification

Swing Motor Swinging

Leakage

0.4 L/min. or less 0.11 gpm of less 0.6 L/min. (maximum allowable) 0.16 gpm (maximum allowable)

[7] - Stall swing function for 1 minute. Record the amount of leakage. Repeat procedure by stalling the motor in several different positions. Record the amount of leakage for each position. Repeat procedure in opposite direction. Take an average of the readings. Compare amount of leakage to specification. Item

Measurement

Specification

Swing Motor Stalled

Leakage

1.6 L/min. or less 0.42 gpm or less 2.0 L/min. (maximum allowable) 0.53 gpm (maximum allowable)

[8] - Remove cap and connect return line to hydraulic oil tank return manifold. [9] - Swing motor leakage over specified allowable amount can be caused by a malfunction in the swing motor crossover relief <- Go to Section TOC




Group 25: Tests

valves. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) [10] - Repair or replace swing motor if the leakage is over specified amount and crossover relief valves are OK. See Swing Motor and Park Brake Remove and Install . (Group 4360.)





Group 25: Tests

Travel Motor Leakage Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode

Auto-Idle Position

OFF


Fast (rabbit)

Travel Motor with Track Raised Leakage

0.3—1.2 L/min 0.08—0.32 gpm 1.8 L/min (maximum allowable) 0.48 gpm (maximum allowable)

Travel Motor Stalled Leakage


Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Cap (3/4-16 F 37°) Calibrated Container 76.2 mm (3 in.) Outside Diameter Pin or Round Bar Stock Plug (3/4-16 M 37°)

[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[2] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [3] LEGEND: Return Line (center t to hydraulic oil tank return 1 manifold) 2 Hydraulic Oil Tank Return Manifold 3 Calibrated Container

Center t Return Line <- Go to Section TOC




Group 25: Tests

Disconnect return line (1) from hydraulic oil tank return manifold (2). Place return line in a calibrated container (3). Install cap on hydraulic oil tank return manifold fitting. Cap 3/4-16 F 37° To cap fitting after disconnecting return line. Calibrated Container To measure fluid leakage. [4] - Raise track off the ground for side being tested. [5] - Run machine at specification. Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle

Position

OFF

Travel Speed Switch

Position

Fast (rabbit)

[6] - For travel motor being tested, actuate travel forward function at full speed for 1 minute. Record amount of fluid leakage. Repeat procedure for reverse travel. Compare leakage to specification. Repair or replace travel motor as necessary. See Travel Motor and Park Brake Remove and Install . (Group 0260.) Item

Measurement

Specification

Travel Motor with Track Raised

Leakage


[7] LEGEND: 4 76.2 mm (3 in.) Outside Diameter Pin

Travel Motor Stalled Using Pin





Group 25: Tests

To test travel motor for leakage at stall, install pin (4) or round bar stock between the sprocket and track frame on the side being tested. 76.2 mm (3 in.) Outside Diameter Pin or Round Bar Stock Put between sprocket and track frame to stall travel motor. [8] - Actuate the forward travel function being tested to full stroke for 1 minute. Record the amount of fluid leakage. Repeat procedure by stalling the motor in several different positions and then take an average of readings. Repeat procedure for reverse travel. Item

Measurement

Specification

Travel Motor Stalled

Leakage


[9] - Remove cap and connect return line to hydraulic oil tank return manifold. [10] -

Travel Motor Drain Line LEGEND: 6 Travel Motor Drain Line 7 Test Hose 8 Calibrated Container For leakage that is substantially more in one direction than the other, a seal in the center t may be leaking. To isolate leakage in travel motor or center t, check leakage at the travel motor. [11] - Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [12] - Disconnect travel motor drain line (6) at travel motor. Install plug in the line. Connect a test hose (7) to fitting on travel motor. Put line in a calibrated container (8). Plug 3/4-16 M 37° <- Go to Section TOC




Group 25: Tests

To close drain line after disconnected at travel motor. [13] - Repeat test procedure. Record and compare results. [14] - Remove test hose and plug. Connect travel motor drain line to travel motor. [15] - Travel motor leakage over specified allowable amount can be caused by a malfunction in travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.) [16] - Repair or replace travel motor if leakage is over specified amount and the crossover relief valves are OK. See Travel Motor and Park Brake Remove and Install . (Group 0260.)





Group 25: Tests

Cylinder Drift Test—Boom, Arm, and Bucket Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Bucket Load Weight (approximate)

750 kg 1654 lb.

Boom Cylinder Drift (maximum allowable for 5 minutes)

10 mm 0.39 in.

Arm Cylinder Drift (maximum allowable for 5 minutes)

20 mm 0.79 in.

Bucket Cylinder Drift (maximum allowable for 5 minutes)

15 mm 0.59 in.

Bottom of Bucket-to-Ground Drift (maximum allowable for 5 minutes)

110 mm 4.33 in.

Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)

5 mm 0.20 in.

Arm Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)

15 mm 0.59 in.

Bucket Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)

10 mm 0.39 in.

Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes)

100 mm 3.94 in.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Tape Measure

Procedure is used to check leakage past the cylinder piston seals, control valve spools, circuit relief valves, boom reduced leakage valve, and arm reduced leakage valve. Drift Test—Bucket Filled [1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[2] - Fill bucket with material to specification. Item

Measurement

Specification

Loaded Bucket

Weight (approximate)

750 kg 1654 lb.

[3] -





Group 25: Tests

Machine Position—Bucket Loaded Position arm cylinder so rod is extended approximately 50 mm (2 in.) from retracted position. [4] - Position bucket cylinder so rod is retracted 50 mm (2 in.) from extended position. [5] - Position boom cylinders so bucket pivot pin is at the same height as the boom-to-main frame pin. [6] - After 5 minutes, measure amount of movement for boom, arm, and bucket cylinders and bottom of bucket to the ground. Item

Measurement

Specification

Boom Cylinder

Drift (maximum allowable for 5 minutes) 10 mm

Arm Cylinder


0.39 in.

0.79 in. Bucket Cylinder

Drift (maximum allowable for 5 minutes) 15 mm 0.59 in.

Bottom of Bucket-to-Ground Drift (maximum allowable for 5 minutes) 110 mm 4.33 in.

Tape Measure Used to measure drift.





Group 25: Tests

Machine Position—Bucket Empty LEGEND: 1 Arm Tip Position Above Ground Drift Test—Bucket Empty [1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) [2] - Empty bucket of material. [3] - Position arm and bucket so rod is fully extended. [4] - Lower boom until arm tip position above ground (1) is 1 m (40 in.). [5] - Position bucket cylinder so rod is retracted 50 mm (2 in.) from extended position. [6] - After 5 minutes, measure amount of movement for boom, arm, and bucket cylinders and arm tip to ground. Item

Measurement

Boom Cylinder—Bucket Empty


Specification

0.20 in. Arm Cylinder—Bucket Empty


Bucket Cylinder—Bucket Empty


Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes) 100 mm 3.94 in.





Group 25: Tests

Fan Drive Pump Flow Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

45—55°C 110—130°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

New, Typical Flow Rate

47 L/min. 12.4 gpm

Used, Minimum Flow Rate

40 L/min. 10.6 gpm

Fan Drive Circuit Pressure

24.8—25.2 MPa 24 800—25 200 kPa 248—252 bar 3600—3650 psi

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT05984 Flowmeter Female End Test Hose -10 ORFS

Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation . (Group 9025-05.) [1] - Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure . (Group 9025-25.) [2] - Remove cooling package guard from under the machine. [3] LEGEND: 1 Pressure Line (fan drive pump to fan drive motor) 133 Fan Drive Motor Y5005 Variable Speed Fan Solenoid

Fan Drive Motor Disconnect pressure line (1) coming from fan drive pump and connect JT05984 Flowmeter in-line using hose containing -10 ORFS female ends. Flowmeter JT05984





Group 25: Tests

Used to determine fan drive pump flow Test Hose -10 ORFS Female Ends Connect Flow Meter-to-Fan Drive Motor [4] - Connect one of the following test equipment to display hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate the service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed [5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

45—55°C 110—130°F

[6] →NOTE: When the variable speed fan solenoid is disconnected, all hydraulic oil is forced through fan drive motor (133) with the exception of a small portion is sent over circuit relief to tank. This non adjustable circuit relief valve is built into the variable speed fan solenoid.

Disconnect variable speed fan solenoid (Y5005). See Engine Interface Harness (W5) Component Location . (Group 9015-10.) Be aware that the hydraulic oil temperature will cool rapidly due to high fan speed, so it is important to have this test done quickly and with proper hydraulic oil temperatures. [7] - Run engine at specification. Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[8] - Record fan drive pump flow and compare to specification. Item

Measurement

Specification

New, Typical

Flow Rate

47 L/min.

Used, Minimum

Flow Rate

12.4 gpm 40 L/min. 10.6 gpm Fan Drive Circuit

Pressure

24.8—25.2 MPa 24 800—25 200 kPa






Specification 248—252 bar 3600—3650 psi

[9] - If fan drive circuit testing pressure is not to specification, change variable speed fan solenoid which contains a built in relief valve. If pump flow is below minimum specification, replace cooling fan drive pump. See Fan Drive Pump Remove and Install . (Group 3360.) If pump flow is within specification and overheating persists, perform the following: Check hydraulic lines to and from fan drive motor. Check variable speed fan solenoid. See Proportional Solenoid Test . (Group 9015-20.) Replace fan drive motor. See Fan Drive Motor Remove and Install . (Group 3360.) [10] - Connect variable speed fan solenoid. See Engine Interface Harness (W5) Component Location . (Group 9015-10.) [11] - Install cooling package guard.





Group 25: Tests

Fan Speed Test Specifications SPECIFICATIONS Hydraulic Oil Temperature

50—60°C 122—140°F

Engine Speed

Fast Idle


Dig Mode


PWR (power) Mode


OFF

Cooling Fan Speed

1300—1500 rpm

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT05709 Reflective Tape JT05719 Handheld Digital Tachometer

Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation . (Group 9025-05.) [1] LEGEND: 1 2 133 Y5005

Fan Blade JT05709 Reflective Tape Fan Drive Motor Variable Speed Fan Solenoid

Fan Drive Motor Remove cooling package guard from under the machine. [2] - Install JT05709 Reflective Tape (2) on one fan blade (1). Reflective Tape JT05709 Mark Fan Blade Handheld Digital Tachometer JT05719 Measuring Fan Speed




HEATING AND AIR CONDITIONING


[3] - Use one of the following to display hydraulic oil temperature and actual engine speed. Monitor application. For instruction to actuate service menu on monitor in cab, see Service Menu . (Group 9015-16.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed Service ADVISOR ™ application. For instruction, see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed MPDr application. For instruction, see MPDr Connection Procedure . (Group 9015-20.) Select the following items to display: Hydraulic Oil Temperature Actual Engine Speed [4] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.) Item

Measurement

Specification

Hydraulic Oil

Temperature

50—60°C 122—140°F

[5] - Disconnect engine coolant temperature sensor (B5208). See Engine Harness (W4) Component Location . (Group 9015-10.) This will allow maximum oil flow allowed by engine control unit (ECU) through fan drive motor (133). [6] - Operate engine at specification. Item

Measurement

Specification

Engine

Speed

Fast Idle

Work Mode Switch

Position

Dig Mode

Power Mode Button

Position

PWR (power) Mode

Auto-Idle Switch

Position

OFF

[7] - Measure fan speed with JT05719 Handheld Digital Tachometer. Record result. [8] - Compare reading to specification. Item

Measurement

Specification

Cooling Fan

Speed

1300—1500 rpm

[9] - If fan speed is below specification, test fan drive pump. See Fan Drive Pump Flow Test . (Group 9025-25.) If fan drive pump flow is in specification, check variable speed fan solenoid. See Proportional Solenoid Test . (Group 9015-20.) [10] - Connect engine coolant temperature sensor (B5208). See Engine Harness (W4) Component Location . (Group 9015-10.) [11] - Install cooling package guard.






Section 9031 - HEATING AND AIR CONDITIONING Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Air Conditioning System Cycle of Operation ......................................................................................... 1 Group 15 - Diagnostic Information ........................................................................................................ 3 Air Conditioning System Does Not Operate Diagnostic Procedure ....................................................... 3 Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure .................................................. 5 Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure ....................................................... 7 Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure .................................. 9 Heater System Does Not Operate Diagnostic Procedure .................................................................... 11 Heater Does Not Warm Interior of Cab Diagnostic Procedure ............................................................ 16 Interior Windows Continue to Fog Using Heater Diagnostic Procedure .............................................. 18 Heater and Air Conditioner Diagnostic Trouble Code Check ............................................................... 19 Heater and Air Conditioner Component Location ............................................................................... 20 Group 25 - Tests ..................................................................................................................................... 22 Refrigerant Cautions and Proper Handling ......................................................................................... 22 Visual Inspection of Components ....................................................................................................... 23 Air Conditioner Compressor Clutch Test ............................................................................................. 25 Refrigerant Leak Test ......................................................................................................................... 26 Refrigerant Hoses and Tubing Inspection ........................................................................................... 26 Air Conditioner Compressor Belt Check and Adjustment .................................................................... 26 R134a Air Conditioning System Test .................................................................................................. 27 Operating Pressure Diagnostic Chart .................................................................................................. 30



Section 9031 - HEATING AND AIR CONDITIONING


Group 05 - Theory of Operation Air Conditioning System Cycle of Operation

Refrigerant System Cycle of Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11

Evaporator Compressor Condenser Circulation Blower Motor Expansion Valve Receiver-Dryer High Pressure Liquid High Pressure Gas Low Pressure Liquid Low Pressure Gas Air Flow

The compressor (2) is belt driven and engaged by an electromagnetic clutch. The air conditioner circuit automatically controls compressor engagement or disengagement when system is in operation. The compressor draws low pressure gas (10) from evaporator (1) and compresses it into high pressure gas (8). High pressure gas causes temperature of refrigerant to rise higher than outside air temperature. High pressure gas leaves compressor and flows through condenser (3). Inside condenser, heat is removed and transferred to outside air that is drawn through condenser core by the fan. Cooling refrigerant causes it to condense, and refrigerant leaves condenser as high pressure liquid (7). <- Go to Section TOC

Section 9031 page 1




High pressure liquid flows into receiver-dryer (6), where moisture and contaminants (acid, solids, etc.) are removed. The receiver-dryer contains a color moisture indicator. (Blue) indicates no moisture is present. (Pink) indicates moisture is present. Should moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are corrosive to metal surfaces, and leakage will eventually develop. The receiver-dryer also stores refrigerant, allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls. Refrigerant flows from receiver-dryer through expansion valve (5) to the evaporator. The expansion valve senses refrigerant temperature and pressure to modulate refrigerant flow, which then changes refrigerant to low pressure liquid (9) entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from evaporator by compressor and cycle is repeated. A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the evaporator from becoming cold enough to freeze moisture that condenses on the evaporator coil. Condensed moisture is drained away through drain tubes connected to a drain pan under evaporator. System pressure is monitored by a high/low pressure switch, located on high pressure side of expansion valve. If pressure becomes too high or too low, the switch opens and stops the compressor, interrupting the cycle. The engine cooling fan increases to 1200 rpm for increased flow across the condenser when ambient air is over 15°C (60°F) and air conditioner is on. For location of machine heater and air conditioner components, see Heater and Air Conditioner Component Location . (Group 9031-15.)


Section 9031 page 2




Group 15 - Diagnostic Information Air Conditioning System Does Not Operate 188

Air Conditioning System Does Not Operate Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check

Action: Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display . (Group 9015-20.) Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?

Result: YES:Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes . (Group 9001-40.) NO:Go to Monitor Settings Check. ( 2 ) Monitor Settings Check

Action: Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.) Is the correct setting selected?

Result: YES:Go to Fuse Check. NO:Select the correct setting. ( 3 ) Fuse Check

Action: Remove air conditioner and heater 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.) Check continuity of air conditioner and heater 20 amp fuse (F3). See Fuse Test . (Group 9015-20.) Is continuity indicated?

Result: YES:Go to Air Conditioner Compressor Belt Check. NO:Replace air conditioner and heater 20 amp fuse (F3) (marked HEATER). ( 4 ) Air Conditioner Compressor Belt Check

Action: Check air conditioner compressor belt for proper pulley alignment and damage. See Inspect Serpentine Belt . (Operator′s Manual.) Is the belt properly aligned and in good condition?


Section 9031 page 3




Result: YES:Go to Vent Air Flow Check. NO:Replace belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 5 ) Vent Air Flow Check

Action: Turn key switch to ON position. Turn fan speed switch to maximum speed. Is cool air coming from vents?

Result: YES:Checks complete. NO: See Air Conditioning Does Not Cool Interior of Cab . (Group 9031-15.)


Section 9031 page 4




Air Conditioning Does Not Cool Interior of Cab 188

Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure ( 1 ) Cab Fresh Air Filter Restriction Check

Action: Check cab fresh air filter for debris or air flow restrictions. Is cab fresh air filter dirty or clogged with debris?

Result: YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Cab Recirculating Air Filter Restriction Check. ( 2 ) Cab Recirculating Air Filter Restriction Check

Action: Check cab recirculating air filter for debris or air flow restrictions. Is cab recirculating air filter dirty or clogged with debris?

Result: YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Cab Seals Check. ( 3 ) Cab Seals Check

Action: Check windows and doors to make sure seals are in good condition. Are seals on all windows and doors in good condition?

Result: YES:Go to Refrigerant Hose Restriction Check. NO:Repair or replace damaged or malfunctioning seals. ( 4 ) Refrigerant Hose Restriction Check

Action: Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection . (Group 9031-25.) Are any hoses kinked, pinched or collapsed?

Result: YES:Reroute or re-index hoses. Replace kinked or collapsed hoses. See Heater and Air Conditioner Component Location . (Group 9031-15.) NO:Go to Condenser Air Flow Restriction Check. ( 5 ) Condenser Air Flow Restriction Check <- Go to Section TOC

Section 9031 page 5




Action: Check condenser fins for air flow restrictions. Are condenser fins clogged with debris?

Result: YES:Clean condenser fins. NO:Go to Evaporator Core Air Flow Restriction Check. ( 6 ) Evaporator Core Air Flow Restriction Check

Action: Check evaporator core fins for restrictions. Are the evaporator core fins clogged with debris?

Result: YES:Clean evaporator fins. NO:Go to Evaporator Core Fins Check. ( 7 ) Evaporator Core Fins Check

Action: Check evaporator core fins for frosting or freezing. Is there any ice or frost on evaporator core fins?

Result: YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control switch. NO:Go to System Operating Pressures Check. ( 8 ) System Operating Pressures Check

Action: Check air conditioner system operating pressures. See R134a Air Conditioning System Test . (Group 9031-25.) Are air conditioner system operating pressures within range?

Result: YES:Checks complete. NO:Check conditions. See Operating Pressure Diagnostic Chart . (Group 9031-25.)


Section 9031 page 6




Air Conditioning Runs Constantly, Too Cold 188

Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure ( 1 ) Air Conditioning System Check

Action: Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.) Is the air conditioning system operating correctly?

Result: YES:Go to Evaporator Core Component Check. NO: Go to Air Conditioning System Does Not Operate . (Group 9031-15.) ( 2 ) Evaporator Core Component Check

Action: Check evaporator core fins for frosting or freezing. Is there any ice or frost on evaporator core fins?

Result: YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control switch. NO:Go to Air Conditioner Compressor Clutch Relay Check. ( 3 ) Air Conditioner Compressor Clutch Relay Check

Action: Remove air conditioner compressor clutch relay (K18). See Cab Harness (W1) Component Location . (Group 9015-10.) Test air conditioner compressor clutch relay (K18). See Relay Test . (Group 9015-20.) Does air conditioner compressor clutch relay test good?

Result: YES:Go to Wiring Harness Check. NO:Replace air conditioner compressor clutch relay (K18). ( 4 ) Wiring Harness Check

Action: Check heater and air conditioner harness (W41) for open and short circuits. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Is heater and air conditioner harness in good condition?

Result: YES:Checks complete. <- Go to Section TOC

Section 9031 page 7




NO:Repair or replace heater and air conditioner harness (W41).


Section 9031 page 8




Interior Windows Continue to Fog Using Air Conditioner 188

Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure ( 1 ) Air Conditioning System Check

Action: Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.) Is the air conditioning system operating correctly?

Result: YES:Go to Cab Fresh Air Filter Restriction Check. NO: Go to Air Conditioning System Does Not Operate . (Group 9031-15.) ( 2 ) Cab Fresh Air Filter Restriction Check




Result: YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Check Air Conditioner Drain Hoses. ( 4 ) Check Air Conditioner Drain Hoses

Action: See Heater and Air Conditioner Component Location . (Group 9031-15.) Are the hoses plugged or pinched?

Result: YES:Unplug or replace hoses. NO:Go to Heater Core Check.


Section 9031 page 9




( 5 ) Heater Core Check

Action: Check to see if heater core is leaking engine coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.) Is heater core leaking engine coolant?

Result: YES:Replace heater core. NO:Checks complete.






Heater System Does Not Operate 188

Heater System Does Not Operate Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check

Action: Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display . (Group 9015-20.) Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?

Result: YES:Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes . (Group 9001-30.) NO:Go to Monitor Settings Check. ( 2 ) Monitor Settings Check

Action: Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.) Is the correct setting selected?

Result: YES:Go to Fuse Check. NO:Select the correct setting. ( 3 ) Fuse Check

Action: Remove heater and air conditioner 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications . (Group 9015-10.) Check continuity of heater and air conditioner 20 amp fuse (F3). See Fuse Test . (Group 9015-20.) Is continuity indicated?

Result: YES:Go to Cab Fresh Air Filter Restriction Check. NO:Replace heater and air conditioner 20 amp fuse (F3). ( 4 ) Cab Fresh Air Filter Restriction Check


Result: YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) <- Go to Section TOC





NO:Go to Cab Recirculating Air Filter Restriction Check. ( 5 ) Cab Recirculating Air Filter Restriction Check


Result: YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Air Conditioner and Heater Blower Motor Operation Check. ( 6 ) Air Conditioner and Heater Blower Motor Operation Check

Action: Operate the blower speed switch in low, medium, and high speed modes. See Switch Functions . (Operator’s Manual.) Does the air conditioner and heater blower motor work at any speed?

Result: YES:Go to Air Conditioner and Heater Blower Motor Low Speed Check. NO: Go to Air Conditioner and Heater Blower Motor Check . ( 7 ) Air Conditioner and Heater Blower Motor Low Speed Check

Action: Operate air conditioner and heater blower motor at low speed. Does air conditioner and heater blower motor operate?

Result: YES:Go to Air Conditioner and Heater Blower Motor Medium Speed Check. NO:Replace blower motor resistor (R17). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 8 ) Air Conditioner and Heater Blower Motor Medium Speed Check

Action: Operate air conditioner and heater blower motor at medium speed. Does air conditioner and heater blower motor speed increase?

Result: YES:Go to Air Conditioner and Heater Blower Motor High Speed Check. NO:Replace blower motor transistor (R16). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 9 ) Air Conditioner and Heater Blower Motor High Speed Check <- Go to Section TOC





Action: Operate air conditioner and heater blower motor at high speed. Does air conditioner and heater blower motor speed increase?

Result: YES:Checks complete. NO:Replace max hi relay (K17). See Cab Harness (W1) Component Location . (Group 9015-10.) ( 10 ) Air Conditioner and Heater Blower Motor Check

Action: Disconnect air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Supply 24 volts and ground to air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Does air conditioner and heater blower motor run?

Result: YES:Go to Air Conditioner and Heater Blower Motor Circuit Check. NO:Replace air conditioner and heater blower motor. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) ( 11 ) Air Conditioner and Heater Blower Motor Circuit Check

Action: Disconnect air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Turn key switch to ON position, check for voltage between terminal 2 and ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is 24 volts present?

Result: YES:Go to Blower Motor Resistor (R17) Ground Circuit Check. NO: Go to Air Conditioner Blower Motor Relay Check . ( 12 ) Blower Motor Resistor (R17) Ground Circuit Check

Action: Disconnect blower motor resistor (R17). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Disconnect air conditioner 4-pin connector (X51). Check for continuity between blower motor resistor (R17) connector pin 4 and air conditioner 4-pin connector (X51) pin 1. Is continuity indicated?






Result: YES:Go to Air Conditioner Controller (ACF) Ground Circuit Check. NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness. ( 13 ) Air Conditioner Controller (ACF) Ground Circuit Check

Action: Disconnect air conditioner controller (A7) connector. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Disconnect air conditioner 4-pin connector (X51). Check for continuity between air conditioner controller (A7) connector pins 4 and 9 and air conditioner 4-pin connector (X51) pin 1. Is continuity indicated at both pins?

Result: YES:Go to Cab Harness (W1) Ground Circuit Check. NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness. ( 14 ) Cab Harness (W1) Ground Circuit Check

Action: Check for continuity between air conditioner 4-pin connector (X51) pin 1 and ground. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.) Is continuity indicated?

Result: YES:Go to Air Conditioner Blower Motor Relay Check. NO:Open in cab harness (W1) ground circuit. Repair or replace harness. See Cab Harness (W1) Component Location . (Group 9015-10.) ( 15 ) Air Conditioner Blower Motor Relay Check

Action: Remove air conditioner blower motor relay (K15). See Cab Harness (W1) Component Location . (Group 9015-10.) Test air conditioner blower motor relay. See Relay Test . (Group 9015-20.) Does air conditioner blower motor relay test OK?

Result: YES:Go to Power Check. NO:Replace air conditioner blower motor relay. ( 16 ) Power Check






Action: Disconnect air conditioner blower motor relay (K15). Disconnect air conditioner controller (ACF) connector. Check for voltage between air conditioner blower motor relay (K15) connector pin 1 and ground, and between air conditioner controller (ACF) connector pin 7 and ground. See Cab Harness (W1) Component Location and see Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.) Is 24 volts present at both locations?

Result: YES:Go to Air Conditioner Controller (ACF) Signal Check. NO:Repair or replace cab harness (W1) or heater and air conditioner harness (W41). ( 17 ) Air Conditioner Controller (ACF) Signal Check

Action: Turn key switch to ON position. Set blower speed switch to maximum speed. See Switch Functions . (Operator’s Manual.) Check for continuity between air conditioner 10-pin connector (X52) pins 1 and 2 and ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.) Is continuity indicated at both pins?

Result: YES:Checks complete. NO:Replace air conditioner controller (ACF). See Air Conditioner Controller (ACF) Remove and Install . (Group 9015-20.)






Heater Does Not Warm Interior of Cab 188

Heater Does Not Warm Interior of Cab Diagnostic Procedure ( 1 ) Heater Check

Action: Check heater system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.) Is the heater system operating correctly?

Result: YES:Go to Coolant Check. NO: Go to Heater System Does Not Operate . (Group 9031-15.) ( 2 ) Coolant Check

Action: Check engine coolant level. See Check Engine Coolant Level . (Operator’s Manual.) Is engine coolant full?

Result: YES:Go to Cab Fresh Air Filter Restriction Check. NO:Fill with proper coolant to specification. See Check Engine Coolant Level . (Operator’s Manual.) ( 3 ) Cab Fresh Air Filter Restriction Check




Result: YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Heater Hose Restriction Check. ( 5 ) Heater Hose Restriction Check






Action: Check heater hoses. See Heater and Air Conditioner Component Location . (Group 9031-15.) Are any hoses kinked, pinched or collapsed?

Result: YES:Reroute or re-index hoses. Replace kinked or collapsed hoses. NO:Go to Heater Door Servo Motor Check. ( 6 ) Heater Door Servo Motor Check

Action: Inspect heater servo motor and door. Is the servo motor and door working correctly?

Result: YES:Go to Heater Core Air Flow Restriction Check. NO:Repair or replace servo motor or door. ( 7 ) Heater Core Air Flow Restriction Check

Action: Check heater core fins for debris. Are the heater core fins clogged with debris?

Result: YES:Clean heater core fins. NO:Checks complete.






Interior Windows Continue to Fog Using Heater 188

Interior Windows Continue to Fog Using Heater Diagnostic Procedure ( 1 ) Cab Fresh Air Filter Restriction Check


Result: YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) NO:Go to Heater Core Leak Check. ( 2 ) Heater Core Leak Check

Action: Check to see if the heater core is leaking coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.) Is the heater core leaking coolant?

Result: YES:Replace heater core. NO:Go to Cab Seals Check. ( 3 ) Cab Seals Check

Action: Check windows and doors to make sure seals are good. Are seals on all windows and doors functioning properly?

Result: YES:Go to Air Conditioner Check. NO:Repair or replace malfunctioning seals. ( 4 ) Air Conditioner Check

Action: Check to see if the air conditioner is working properly. Is air conditioner working properly?

Result: YES:Go to Door Servo Motor Check. NO:Correct air conditioner problem. See Air Conditioning System Does Not Operate . (Group 9031-15.) ( 5 ) Door Servo Motor Check






Action: Check to make sure the servo motor(s) are opening doors correctly. Are the servo motor(s) operating correctly?

Result: YES:Checks complete. NO:Repair or replace servo motor(s).

Heater and Air Conditioner Diagnostic Trouble Code Check Air conditioner controller (ACF) diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR ™ , or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) See MPDr Application . (Group 9015-20.)






Heater and Air Conditioner Component Location

Heater and Air Conditioner Component Location LEGEND: 1 2 3 <- Go to Section TOC

Heater and Air Conditioner Unit Heater Return Line Heater Supply Line Section 9031 page 20



4 5 6 7 8 9 A7 B20 M7 Y11


Group 25: Tests

Evaporator-to-Compressor Low Pressure Line Condenser Receiver-Dryer Condenser-to-Receiver-Dryer High Pressure Line Compressor-to-Condenser Line Evaporator-to-Receiver-Dryer Line Air Conditioner Controller (ACF) Air Conditioner High/Low Pressure Switch Air Conditioner and Heater Blower Motor Air Conditioner Compressor Clutch




Group 25: Tests

Group 25 - Tests Refrigerant Cautions and Proper Handling Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02167A Prism Pro Refrigerant Identification Instrument

CAUTION:

DO NOT allow liquid refrigerant to eyes or skin. Liquid refrigerant will freeze eyes or skin on . Wear goggles, gloves and protective clothing. If liquid refrigerant s eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

IMPORTANT: To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils. Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is performed.

Prism Pro Refrigerant Identification Instrument JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.





Group 25: Tests

Heater and Air Conditioner Operational Checks Visual Inspection of Components ( 1 ) Lines and Hoses Check

Action: Inspect all lines and hoses. sss: Are all lines and hoses straight and in good condition, not kinked, worn from rubbing, or weather checked? sss: Are hose and line connections clean and not showing signs of leakage, such as dirt, oil, or refrigerant dye? sss: Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to prevent damage to hoses or lines?

Result: YES:Go to Air Conditioner Compressor Check. NO:Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that will require replacement. ( 2 ) Air Conditioner Compressor Check

Action: Inspect air conditioner compressor. sss: Is belt in good condition, not frayed, worn, or glazed? sss: Is belt properly tensioned? sss: Is belt tensioner in good condition, not worn or damaged? sss: Is compressor pulley in good condition and properly aligned with belt drive pulley on engine? sss: Are compressor mounting brackets in good condition, and is mounting hardware properly tightened? sss: Are electrical connections to compressor clean and tight? Is wiring in good condition?

Result: YES:Go to Condenser Check. NO:Repair or replace components as necessary. <- Go to Section TOC




Group 25: Tests

( 3 ) Condenser Check

Action: Inspect condenser core. sss: Is core free of dirt and debris? sss: Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye? sss: Are fins of core straight, not bent or damaged?

Result: YES:Go to Engine Fan Check. NO:Clean and straighten fins if necessary. Repair or replace components as necessary. ( 4 ) Engine Fan Check

Action: Inspect engine fan. sss: Are fan blades in good condition, not worn, bent, broken, or missing? sss: Is fan securely installed?

Result: YES:Go to Heater/Evaporator Core Check. NO:Repair or replace components as necessary. ( 5 ) Heater/Evaporator Core Check

Action: Inspect heater/evaporator core. sss: Is core free of dirt and debris? sss: Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye? sss: Are fins of core straight, not bent or damaged? sss: <- Go to Section TOC




Group 25: Tests

Is condensation drain hose attached and in good condition, not kinked, damaged, or clogged?

Result: YES:Go to Cab Air Filter Check. NO:Clean and straighten fins if necessary. Repair or replace components as necessary. ( 6 ) Cab Air Filter Check

Action: Inspect cab air filter. sss: Is cab air filter clean and free of debris?

Result: YES:Go to Cab Door and Windows Check. NO:Replace cab air filter. ( 7 ) Cab Door and Windows Check

Action: Open and close cab door and windows. Inspect seals. sss: Are seals present, properly installed, and in good condition? sss: Do door and windows seals evenly?

Result: YES:Checks complete. NO:Adjust door and windows if necessary. Repair or replace components as necessary.

Air Conditioner Compressor Clutch Test [1] - Disconnect machine harness (W2) from air conditioner compressor clutch (Y11). See Machine Harness (W2) Component Location . (Group 9015-10.) [2] - Connect battery voltage to air conditioner compressor clutch (Y11). [3] - Clutch solenoid will engage and click will be heard. [4] - If clutch solenoid does not engage, replace air conditioner compressor clutch. See Air Conditioner Compressor Remove and Install . (Group 1830.) [5] - If clutch solenoid engages but the air conditioning system does not cool, see Air Conditioning System Does Not Operate . (Group 9031-15.) <- Go to Section TOC




Group 25: Tests

Refrigerant Leak Test Specifications SPECIFICATIONS 25 mm per second 1 in. per second

Leak Detector Probe Speed

[1] - Inspect all lines, fittings, and components for oily or dusty conditions. When refrigerant leaks from the system, a small amount of oil is carried out with it. [2] - A soap and water solution can be applied on components in the system, this forms bubbles at the source of a leak. [3] - If a leak detector is used, move leak detector probe under hoses and around connections at a rate of 25 mm (1 in.) per second. Item

Measurement

Specification

Leak Detector Probe Speed

Speed

25 mm per second 1 in. per second

[4] - Some refrigerant manufacturers add dye to refrigerant to aid in leak detection. [5] - Repair or replace components as necessary to correct identified leaks.

Refrigerant Hoses and Tubing Inspection IMPORTANT: Prevent refrigerant gas leakage. Do not use hydraulic hoses as replacement hoses in the air conditioning system. Only use certified hoses meeting SAE J2064 Type C requirements. Hoses used for air conditioning systems contain special barriers in their walls to prevent migration of refrigerant gas.

When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. IMPORTANT: Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. The use of these solvents will cause deterioration of hoses.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. To assist in making leak proof ts, use a small amount of clean correct viscosity refrigerant oil on all hose and tube connections. Dip O-rings in correct viscosity oil before assembling.

Air Conditioner Compressor Belt Check and Adjustment Inspect condition and tension of air conditioner belt. See Inspect Serpentine Belt . (Operator′s Manual.)





Group 25: Tests

R134a Air Conditioning System Test Specifications SPECIFICATIONS Engine Speed Dial

Fast Idle

Auto-Idle Switch

A/I OFF

Power Mode Button

PWR (power) Mode

Temperature Control/Mode Switch

Maximum Cooling

Blower Motor Speed Switch

High Speed

Service Equipment And Tools SERVICE EQUIPMENT AND TOOLS JT02045 R134a Deluxe Recovery/Recycling and Charging Station JT02167A Prism Pro Refrigerant Identification Instrument Thermometer

CAUTION:

Liquid refrigerant will freeze eyes or skin on . Wear goggles, gloves, and protective clothing. See Refrigerant Cautions and Proper Handling . (Group 9031-25.) IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils to avoid air conditioning system contamination. Identify refrigerant before recovering, recycling, and charging system.

[1] - Prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01). [2] - Clean the cooling package compartment access door, and fins of hydraulic oil cooler, radiator, condenser, and evaporator to ensure proper air flow. [3] - Clean and inspect cab fresh air filter. Replace if necessary. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.) [4] - Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument. Prism Pro Refrigerant Identification Instrument JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems. [5] →NOTE: Follow manufacturer′s instructions when operating refrigerant recovery, recycling, and charging station.

Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging <- Go to Section TOC




Group 25: Tests

Station Installation Procedure . (Group 1830.) [6] - Open both low and high pressure valves on refrigerant recovery, recycling, and charging station. [7] - Open cab door and windows. [8] - Start engine and run at specification. Item

Measurement

Specification

Engine Speed Dial

Position

Fast Idle

Auto-Idle Switch

Position

A/I OFF

Power Mode Button

Setting

PWR (power) Mode

R134a Air Conditioning System Test

[9] - Press the blower motor speed switch to turn the air conditioner ON. See Cab Heater and Air Conditioner . (Operator′s Manual.) [10] - Turn the temperature control/mode switch to maximum cooling position. [11] - Turn blower motor speed switch to high. [12] - Run machine for at least 5 minutes. [13] - Measure and record air temperature at condenser air inlet and at air ducts in cab. Thermometer Used to measure air temperature at condenser air inlet and air ducts in air conditioning unit. [14] - Observe low side pressure and high side pressure on gauges. [15] - Compare pressures and air duct temperature readings to specifications shown. Low And High Pressures At Various Temperatures Ambient Air Temperature

Expected Air Duct Temperature

Low Side Pressure

High Side Pressure

18—21°C 65—70°F

9—15°C 48—59°F

140—169 kPa 1.40—1.69 bar 20—25 psi

595—721 kPa 5.95—7.21 bar 86—104 psi

22—24°C 72—76°F

9—15°C 48—59°F

131—158 kPa 1.31—1.58 bar 19—23 psi

689—835 kPa 6.89—8.35 bar 100—121 psi

25—26°C 77—79°F

10—16°C 50—61°F

122—148 kPa 1.22—1.48 bar 18—21 psi

766—927 kPa 7.66—9.27 bar 111—134 psi

27—29°C 81—85°F

10—16°C 50—61°F

111—134 kPa 1.11—1.34 bar 16—19 psi

843—1020 kPa 8.43—10.20 bar 122—148 psi

30—32°C 86—90°F

10—16°C 50—61°F

94—113 kPa 0.94—1.13 bar 14—16 psi

975—1181 kPa 9.75—11.81 bar 141—171 psi

33—35°C 92—95°F

10—16°C 50—61°F

77—93 kPa 0.77—0.93 bar 11—14 psi

1125—1361 kPa 11.25—13.61 bar 163—197 psi





Group 25: Tests

Ambient Air Temperature

Expected Air Duct Temperature

Low Side Pressure

High Side Pressure

36—38°C 97—101°F

10—16°C 50—61°F

72—87 kPa 0.72—0.87 bar 10—13 psi

1265—1531 kPa 12.65—15.31 bar 183—222 psi

39—40°C 103—104°F

11—17°C 52—63°F

79—96 kPa 0.79—0.96 bar 11—14 psi

1360—1646 kPa 13.60—16.46 bar 197—239 psi

41—43°C 106—110°F

13—20°C 55—68°F

91—110 kPa 0.91—1.10 bar 13—16 psi

1495—1810 kPa 14.95—18.10 bar 217—262 psi

44—47°C 112—117°F

16—23°C 61—73°F

108—131 kPa 1.08—1.31 bar 16—19 psi

1669—2020 kPa 16.69—20.20 bar 242—293 psi

48—51°C 119—124°F

16—23°C 61—73°F

108—131 kPa 1.08—1.31 bar 16—19 psi

1669—2020 kPa 16.69—20.20 bar 242—293 psi

[16] - If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart . (Group 9031-25.)




DEALER FABRICATED TOOLS


Operating Pressure Diagnostic Chart Pressure Diagnostic Chart

Condition

Low Side kPa (bar) (psi)

High Side kPa (bar) (psi)

Suction Line

Receiver-Dryer

Liquid Line

Discharge Line

Discharge Air

Lack of Refrigerant

Very Low

Very Low

Slightly Cool

Slightly Warm

Slightly Warm

Slightly Warm

Warm

Loss of Refrigerant

Low

Low

Cool

Warm to Hot

Warm

Warm to Hot

Slightly Cool

Cool, Sweating, or Frosting

Hot to Point of Restriction

Slightly Cool

High Side Restriction

Low

Low

Cool

Cool, Sweating, or Frosting

Expansion Valve Closed

Low

Low

Cold, Sweating, or Frosting Heavily at Valve Outlet

Warm

Warm

Hot

Slightly Cool

Loose Belt or Compressor Malfunction

High

Low

Cool

Warm

Warm

Warm

Slightly Cool

Condenser Malfunction

High

High

Slightly Cool to Warm

Hot

Hot

Hot

Warm

Refrigerant Contaminated and Air in System

High

High

Warm to Hot

Warm

Warm

Hot

Warm

Expansion Valve Open

High

High

Cold, Sweating, or Frosting Heavily

Warm

Warm

Hot

Slightly Cool

Plugged Condenser, Overcharge of Refrigerant

Normal

High

Cool

Warm

Warm

Hot

Slightly Cool

Moisture in System

Normal (may drop)

Normal (may drop)

Cool

Warm

Warm

Hot

Cool to Warm

Heater Valve Stuck Open

Normal

Normal

Cool

Warm

Warm

Hot

Warm

Lack of Refrigerant and Air in System

Normal (no drop)

Normal

Warm to Hot

Warm

Warm

Warm

Slightly Cool






Section 9900 - DEALER FABRICATED TOOLS Table of contents Group 99 - Dealer Fabricated Tools ...................................................................................................... 1 DFT1218 Split Flange Hose Cap ........................................................................................................... 1



Section 9900 - DEALER FABRICATED TOOLS

Group 99: Dealer Fabricated Tools

Group 99 - Dealer Fabricated Tools DFT1218 Split Flange Hose Cap

Split Flange Hose Cap Split Flange Hose Cap is used with split clamp halves to close 1 in. split flange. Material required is 9.5 mm (3/8 in.) steel plate.



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