Beruflich Dokumente
Kultur Dokumente
Diagnostic
Table of contents
FOREWORD
TECHNICAL INFORMATION FEEDBACK 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
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.
Dubuque, IA 52004-0538
USA
Publication Number:
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Name:
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THANK YOU!
Group 01 - Safety
Recognize Safety Information
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.
Safety Messages
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, contact your John Deere dealer.
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.
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.
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 contact 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.
large enough to operate machine functions. Verify the machine response to each control movement.
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. Contact your authorized John Deere dealer
for information on protective guarding.
Inspect Machine
Inspect Machine
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.
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.
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.
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. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
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: 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.
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).
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.)
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 130G Excavator Diagnostic
Section 9000 - GENERAL INFORMATION Group 01: Safety
Deere dealer.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and
free of debris.
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.
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact 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.
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 seat belt when operating machine . Remember 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
The complete seat belt assembly should be replaced every three years, regardless of appearance.
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.
Avoid contact 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 contact 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 unsupported 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 support machine. When working close to an excavation, position
travel motors away from the hole.
<- Go to Section TOC Section 9000 page 12 130G Excavator Diagnostic
Section 9000 - GENERAL INFORMATION 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.
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.
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.
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.
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.
Unloading Machine
Do Not Jump
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.
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.
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.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify 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.
Warn others of service work. Always park and prepare machine for service or repair properly.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
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.
Toxic Fumes
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
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.
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.
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.
4-Spool Solenoid Valve Unit (SG) Feedback Low Input Diagnostic Procedure ................................... 132
011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback ................................................... 134
011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input .................................................. 134
011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input ................................................... 134
011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback ................................................. 134
011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input ................................................ 134
011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input ................................................. 134
4-Spool Solenoid Valve Unit (SD) Abnormal Feedback Diagnostic Procedure ................................... 135
4-Spool Solenoid Valve Unit (SG) Feedback High Input Diagnostic Procedure .................................. 138
4-Spool Solenoid Valve Unit (SG) Feedback Low Input Diagnostic Procedure ................................... 141
011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback ............ 143
011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current ....... 143
011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current ........ 143
011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback ............ 143
011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current ....... 143
011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current ........ 143
011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal Feedback .................................. 143
011436.03 - Breaker Relief Proportional Solenoid Valve Feedback High Current ............................. 143
011436.04 - Breaker Relief Proportional Solenoid Valve Feedback 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 Feedback Diagnostic Procedure
................................................................................................................................................... 168
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic
Procedure .................................................................................................................................. 171
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic
Procedure .................................................................................................................................. 173
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure
................................................................................................................................................... 175
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic
Procedure .................................................................................................................................. 178
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback 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
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.)
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.
89 lb·in
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.)
Result:
Action:
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?
Result:
Action:
Pin B1 of engine control unit (ECU)-to-engine harness connector 2 (X15) and pin 28 of cab harness-to-main controller 31-
pin 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 31-
pin connector A (X31).
Is continuity indicated?
Result:
Action:
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:
Action:
Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014).
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:
Action:
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:
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.)
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Pin 2 of cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 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 1 and 2 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 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?
Result:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Is continuity indicated?
Result:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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?
Result:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Is continuity indicated?
Result:
Action:
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:
Action:
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?
Result:
Action:
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:
Action:
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:
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:
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:
NO:Go to CAN 0 Termination Resistor (R12) High and Low Side Continuity Check
( 22 ) CAN 0 Termination Resistor (R12) High and Low Side Continuity Check
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU) ,and modular telematics
gateway (MTG).
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.)
Action:
Check resistance between pin 2 and pin 3 on cab harness-to-main controller 30-pin connector D (X34).
Result:
( 24 ) Code Check
Action:
Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Result:
YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin 23 and pin 24 on monitor controller 28-pin connector A (X20).
Result:
( 26 ) Code Check
Action:
Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Result:
YES:Monitor controller (DSZ) malfunction.Replace (DSZ), see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin 2 and pin 3 on engine control unit (ECU)-to-engine harness connector 2 (X15).
Result:
( 28 ) Code Check
Action:
Connect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Result:
YES:Engine control unit (ECU) malfunction.Replace (ECU), see Engine Control Unit (ECU) Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin C and pin D on Service ADVISOR™ diagnostic connector (X1).
Result:
NO:Checks complete.
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.
89 lb·in
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.)
Result:
Action:
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:
Action:
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:
Action:
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:
Action:
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:
Action:
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
Pin 4 on cab harness-to-main controller 30-pin connector D (X34) and pins 1 and 2 on cab harness-to-main controller 24-
pin 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 24-
pin 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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
Is continuity indicated?
Result:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
Pin 4 of cab harness-to-main controller 30-pin connector D (X34) and pins 5 and 6 of cab harness-to-main controller 24-
pin 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 24-
pin 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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
Is continuity indicated?
Result:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
Is continuity indicated?
Result:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
Is continuity indicated?
Result:
Action:
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:
NO:Go to Data Converter CAN High and Low Side Continuity Check.
Action:
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:
Action:
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:
Action:
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:
Action:
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:
Action:
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:
Action:
Check resistance between pin 4 and pin 5 on cab harness-to-main controller 30-pin connector D (X34).
Result:
( 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).
Result:
YES:Main controller (MCZ) malfunction.Replace (MCZ), see Main Controller (MCZ) Remove and Install . (Group 9015-20.)
Action:
Result:
( 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).
Result:
YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin 25 and pin 26 on monitor controller 28-pin connector A (X20).
Result:
( 30 ) Code Check
Action:
Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).
Result:
YES:Monitor controller (DSZ) malfunction.Replace DSZ, see Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin 1 and pin 11 on machine controller 20-pin connector B (X11).
Result:
( 32 ) Code Check
Action:
Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).
Result:
YES:Machine controller (BCZ) malfunction.Replace BCZ, see Machine controller (BCZ) Remove and Install . (Group 9015-20.)
Action:
Result:
( 34 ) Code Check
Action:
Connect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio, and
air conditioner controller (ACF).
Result:
Action:
Check resistance between pin 10 and pin 11 on air conditioner controller (A7).
Result:
NO:Checks complete.
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.
89 lb·in
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.)
Result:
YES:Go to Data Converter and Service ADVISOR™ Diagnostic Connector Continuity Check.
Action:
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:
Action:
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.
Action:
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Is continuity indicated?
Result:
Action:
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.
Result:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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:
Action:
Disconnect all connectors to main controller (MCZ), data converter, monitor controller (DSZ), machine controller (BCZ), radio,
and air conditioner controller (ACF).
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:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
Is continuity indicated?
Result:
Action:
Disconnect all connectors to main controller (MCZ), monitor controller (DSZ), engine control unit (ECU), and modular telematics
gateway (MTG).
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).
Is continuity indicated?
Result:
Action:
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:
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:
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:
Action:
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:
Action:
Check resistance between pin 6 and pin 12 on data converter 17-pin connector ().
Result:
( 16 ) Code Check
Action:
Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).
Result:
YES:Data converter malfunction.Replace data converter, see Data Converter Remove and Install . (Group 9015-20.)
Action:
Check resistance between pin H and pin J on Service ADVISOR™ diagnostic connector (X1).
Result:
( 18 ) Code Check
Action:
Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).
Result:
Action:
Check resistance between pin G1 and pin G2 on modular telematics gateway 48-pin connector (X6014).
Result:
( 20 ) DTC Check
Action:
Connect all connectors to data converter connector, modular telematics gateway (MTG) connector, and interface CAN resistor 1
(R10).
Result:
YES:MTG malfunction.
NO:Checks complete.
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.
89 lb·in
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.)
Result:
Action:
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).
Result:
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.)
Action:
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.
Result:
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.)
Action:
Check for continuity between VGT pin 15 and VGT pin 14.
Check for continuity between VGT pin 16 and VGT pin 14.
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.)
Action:
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.
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.)
Action:
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.
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.)
Action:
Check for continuity between VGT pin 15 and VGT pin 13.
Check for continuity between VGT pin 16 and VGT pin 13.
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.)
Action:
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.
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
Action:
Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor
(R8).
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.)
( 10 ) Engine Control Unit (ECU) High and Low Side Continuity Check
Action:
Disconnect variable geometry turbocharger (VGT), engine control unit (ECU) connectors and engine CAN termination resistor
(R8).
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.)
Action:
Result:
Action:
Result:
YES:Checks complete.
NO:ECU malfunction. Repair or replace. See Engine Control Unit (ECU) Remove and Install . (9015-20.)
Action:
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.
Action:
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.)
Action:
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.
Action:
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.)
Action:
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.
Action:
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.)
Action:
Key switch: Off
If other sensor DTCs are present, diagnose all other DTCs before continuing.
Result:
YES:Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
→NOTE:
The main controller (MCZ) receives engine speed via the CAN 0 network from the engine control unit
(ECU).
Action:
For information on engine speeds, see Engine Speed Control System Operation . (Group 9010-05.)
Result:
YES:CAN 0 communication malfunction. See Controller Area Network 0 (CAN 0) Circuit 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.
89 lb·in
Action:
Cab harness-to-switch panel 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.)
Result:
( 2 ) Voltage Check
Action:
Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29).
Result:
Action:
Check between pin 16 of cab harness-to-main controller 30-pin connector D (X34) and machine ground for voltage.
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
Cab harness-to-switch panel 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.)
Result:
( 2 ) Voltage Check
Action:
Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29).
Result:
Action:
Pin 4 of cab harness-to-switch panel connector 3 (X29) and pin 25 of cab harness-to-main controller 26-pin connector F
(X36).
Pin 5 of cab harness-to-switch panel connector 3 (X29) and pin 16 of cab harness-to-main controller 30-pin connector D
(X34).
Is continuity indicated?
Result:
Action:
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37).
Operate machine.
Check for active MCZ diagnostic trouble code 011200.03—Pump 1 Delivery Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of pump 1 delivery pressure sensor (B35) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37).
Operate machine.
Check for active MCZ diagnostic trouble code 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of pump 1 delivery pressure sensor (B35) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
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?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
Pump 2 delivery pressure sensor (B37) 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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35).
Operate machine.
Check for active MCZ diagnostic trouble code 011202.03—Pump 2 Delivery Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of pump 2 delivery pressure sensor (B37) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
Pump 2 delivery pressure sensor (B37) 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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35).
Operate machine.
Check for active MCZ diagnostic trouble code 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input.
<- Go to Section TOC Section 9001 page 52 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor (B37) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
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?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38).
Operate machine.
Check for active MCZ diagnostic trouble code 011206.03—Pump 1 Flow Control Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of pump 1 control pressure sensor (B36) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 1 control pressure sensor (B36) connector to pump 2 control pressure sensor (B38).
Operate machine.
Check for active MCZ diagnostic trouble code 011206.04—Pump 1 Flow Control Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of pump 1 control pressure sensor (B36) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
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?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
Pump 2 control pressure sensor (B38) 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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36).
Operate machine.
Check for active MCZ diagnostic trouble code 011208.03—Pump 2 Flow Control Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of pump 2 control pressure sensor (B38) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
Pump 2 control pressure sensor (B38) 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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 control pressure sensor (B38) connector to pump 1 control pressure sensor (B36).
Operate machine.
Check for active MCZ diagnostic trouble code 011208.04—Pump 2 Flow Control Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor (B38) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
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?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect swing pressure sensor (B33) connector to travel pressure sensor (B34).
Operate machine.
Check for active MCZ diagnostic trouble code 011301.03—Swing Pilot Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of swing pressure sensor (B33) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect swing pressure sensor (B33) connector to travel pressure sensor (B34).
Operate machine.
Check for active MCZ diagnostic trouble code 011301.04—Swing Pilot Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of swing pressure sensor (B33) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch boom up pressure sensor (B30) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011302.03—Boom Up Pilot Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of boom up pressure sensor (B30) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch boom up pressure sensor (B30) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011302.04—Boom Up Pilot Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of boom up pressure sensor (B30) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch arm in pressure sensor (B31) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011303.03—Arm In Pilot Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of arm in pressure sensor (B31) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch arm in pressure sensor (B31) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011303.04—Arm In Pilot Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of arm in pressure sensor (B31) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect travel pressure sensor (B34) connector to swing pressure sensor (B33).
Operate machine.
Check for active MCZ diagnostic trouble code 011304.03—Travel Pilot Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of travel pressure sensor (B34) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect travel pressure sensor (B34) connector to swing pressure sensor (B33).
Operate machine.
Check for active MCZ diagnostic trouble code 011304.04—Travel Pilot Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of travel pressure sensor (B34) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011307.03—Front Attachment Pilot Pressure Sensor Circuit High Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check between pin 2 of front attachment pressure sensor (B32) connector and machine ground for voltage.
Is voltage indicated?
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Switch front attachment pressure sensor (B32) connector to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011307.04—Front Attachment Pilot Pressure Sensor Circuit Low Input.
Is code active?
Result:
( 3 ) Voltage Check
Action:
Check voltage between pin 1 and pin 3 of front attachment pressure sensor (B32) connector.
Is approximately 5 V indicated?
Result:
Action:
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?
Result:
Action:
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?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).
Operate machine.
Check for active MCZ diagnostic trouble code 011400.02—Pump 2 Flow Rate Limit Solenoid Feedback Abnormal.
Is code active?
<- Go to Section TOC Section 9001 page 90 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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:
Action:
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:
( 5 ) Harness Check
Action:
Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 6 ) Solenoid Check
Action:
Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
011400.03- Pump 2 Flow Rate Limit Solenoid Valve Feedback 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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).
Operate machine.
Check for active MCZ diagnostic trouble code 011400.03—Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current.
Is code active?
<- Go to Section TOC Section 9001 page 93 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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:
( 4 ) Harness Check
Action:
Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
011400.04- Pump 2 Flow Rate Limit Solenoid Valve Feedback 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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect pump 2 flow rate limit solenoid (Y20) connector to torque control solenoid (Y21).
Operate machine.
Check for active MCZ diagnostic trouble code 011400.04—Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current.
Is code active?
<- Go to Section TOC Section 9001 page 96 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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:
Action:
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:
( 5 ) Solenoid Check
Action:
Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).
Operate machine.
Check for active MCZ diagnostic trouble code 011401.02—Torque Control Solenoid Valve Abnormal Feedback.
Is code active?
<- Go to Section TOC Section 9001 page 99 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
<- Go to Section TOC Section 9001 page 100 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 6 ) Solenoid Check
Action:
Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 101 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).
Operate machine.
Check for active MCZ diagnostic trouble code 011401.03—Torque Control Solenoid Valve Feedback High Current.
Is code active?
<- Go to Section TOC Section 9001 page 102 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
<- Go to Section TOC Section 9001 page 103 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
9015-20.)
<- Go to Section TOC Section 9001 page 104 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect torque control solenoid (Y21) connector to pump 2 flow rate limit solenoid (Y20).
Operate machine.
Check for active MCZ diagnostic trouble code 011401.04—Torque Control Solenoid Valve Feedback Low Current.
Is code active?
<- Go to Section TOC Section 9001 page 105 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 106 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 107 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011402.02—3-Spool Solenoid Valve Unit (SF) Abnormal Feedback.
Is code active?
<- Go to Section TOC Section 9001 page 108 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
<- Go to Section TOC Section 9001 page 109 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 6 ) Solenoid Check
Action:
Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 110 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011402.03—3-Spool Solenoid Valve Unit (SF) Feedback High Input.
Is code active?
<- Go to Section TOC Section 9001 page 111 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
<- Go to Section TOC Section 9001 page 112 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
9015-20.)
<- Go to Section TOC Section 9001 page 113 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect dig regenerative solenoid (Y22) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011402.04—3-Spool Solenoid Valve Unit (SF) Feedback Low Input.
Is code active?
<- Go to Section TOC Section 9001 page 114 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 115 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 116 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).
Operate machine.
Check for active MCZ diagnostic trouble code 011403.02—3-Spool Solenoid Valve Unit (SC) Abnormal Feedback.
Is code active?
<- Go to Section TOC Section 9001 page 117 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
<- Go to Section TOC Section 9001 page 118 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 6 ) Solenoid Check
Action:
Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 119 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).
Operate machine.
Check for active MCZ diagnostic trouble code 011403.03—3-Spool Solenoid Valve Unit (SC) Feedback High Input.
Is code active?
<- Go to Section TOC Section 9001 page 120 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
<- Go to Section TOC Section 9001 page 121 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
9015-20.)
<- Go to Section TOC Section 9001 page 122 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm regenerative solenoid (Y23) connector to dig regenerative solenoid (Y22).
Operate machine.
Check for active MCZ diagnostic trouble code 011403.04—3-Spool Solenoid Valve Unit (SC) Feedback Low Input.
Is code active?
<- Go to Section TOC Section 9001 page 123 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 124 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 125 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011407.02—3-Spool Solenoid Valve Unit (SG) Abnormal Feedback.
Is code active?
<- Go to Section TOC Section 9001 page 126 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
<- Go to Section TOC Section 9001 page 127 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 6 ) Solenoid Check
Action:
Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 128 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011407.03—3-Spool Solenoid Valve Unit (SG) Feedback High Input.
Is code active?
<- Go to Section TOC Section 9001 page 129 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
<- Go to Section TOC Section 9001 page 130 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
9015-20.)
<- Go to Section TOC Section 9001 page 131 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect power dig solenoid (Y24) connector to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011407.04—3-Spool Solenoid Valve Unit (SG) Feedback Low Input.
Is code active?
<- Go to Section TOC Section 9001 page 132 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 133 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 134 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011428.02—4-Spool Solenoid Valve Unit (SD) Abnormal Feedback.
Is code active?
<- Go to Section TOC Section 9001 page 135 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
<- Go to Section TOC Section 9001 page 136 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 6 ) Solenoid Check
Action:
Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 137 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011428.03—4-Spool Solenoid Valve Unit (SG) Feedback High Input.
Is code active?
<- Go to Section TOC Section 9001 page 138 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
<- Go to Section TOC Section 9001 page 139 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
9015-20.)
<- Go to Section TOC Section 9001 page 140 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
→NOTE:
Connect arm 2 flow control solenoid (Y27) to arm regenerative solenoid (Y23).
Operate machine.
Check for active MCZ diagnostic trouble code 011428.04—4-Spool Solenoid Valve Unit (SD) Feedback Low Input.
Is code active?
<- Go to Section TOC Section 9001 page 141 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test arm 2 flow control solenoid (Y27) and compare to specification. See Proportional Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 142 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
011434.03- Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current
360
011434.04- Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current
360
011435.03- Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current
360
011435.04- Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current
360
<- Go to Section TOC Section 9001 page 143 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
→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 verify the DTC does not
reappear. If the machine has this solenoid, continue with 2-speed activation solenoid diagnostic
procedure.
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.)
Is continuity indicated?
Result:
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.)
Result:
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 Section 9001 page 144 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.)
Result:
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.)
Result:
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.)
Result:
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.
<- Go to Section TOC Section 9001 page 145 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.)
Result:
YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 146 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
→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 verify the DTC does not reappear. If the machine has this solenoid, continue with
selector valve solenoid valve diagnostic procedure.
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.)
Is continuity indicated?
Result:
NO:Replace fuse.
( 2 ) Solenoid Check
Action:
Disconnect connector from selector valve solenoid valve (Y40). See Attachment Harness (W17) Component Location . (Group
9015-10.)
Result:
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.)
<- Go to Section TOC Section 9001 page 147 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
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.)
Result:
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.)
Result:
YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 148 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Ignition OFF.
Remove fuse F18 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)
Is continuity indicated?
Result:
NO:Replace fuse.
( 2 ) Voltage Check
Action:
Ignition ON.
Result:
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.
Result:
<- Go to Section TOC Section 9001 page 149 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.)
Result:
YES:Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 150 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group
9015-20.)
Result:
( 3 ) Voltage Check
Action:
Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for more than 4.25 V.
Result:
( 4 ) Harness Check
Action:
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.
<- Go to Section TOC Section 9001 page 152 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks . (Group
9015-20.)
Result:
( 3 ) Voltage Check
Action:
Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for less than 0.1 V.
Result:
YES:Checks complete.
( 4 ) Harness Check
Action:
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.
<- Go to Section TOC Section 9001 page 154 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Voltage Check
Action:
Check between pin 3 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 0.0 V.
Result:
( 3 ) Harness Check
Action:
Check for continuity between pin 3 of AFL connector (marked R_GRIP) (X536) to all pins on all option controller connectors.
<- Go to Section TOC Section 9001 page 155 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Auxiliary function lever (AFL) proportional control switch (S29) malfunction. Replace switch.
NO:Checks complete.
<- Go to Section TOC Section 9001 page 156 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Voltage Check
Action:
Check between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 5 V.
Result:
Action:
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 Section 9001 page 157 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground.
Is continuity indicated?
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 158 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011810.03—Electric Lever Operating Pressure Sensor 1 High Voltage.
Is code active?
Result:
NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor.
( 3 ) Voltage Check
Action:
<- Go to Section TOC Section 9001 page 159 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground for approximately 0.0 V.
Result:
( 4 ) Harness Check
Action:
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.
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 160 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor.
Operate machine.
Check for active MCZ diagnostic trouble code 011810.04—Electric Lever Operating Pressure Sensor 1 Low Voltage.
Is code active?
Result:
NO:AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor.
( 3 ) Voltage Check
Action:
<- Go to Section TOC Section 9001 page 161 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground for approximately 0.0 V.
Result:
Action:
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?
Result:
Action:
Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground.
Is continuity indicated?
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 162 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Continuity Check
Action:
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:
( 3 ) Solenoid Check
Action:
Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 163 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Checks complete.
NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.
<- Go to Section TOC Section 9001 page 164 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Switch connectors of secondary pilot shutoff solenoid (marked PiC) (Y66) with another solenoid.
Operate machine.
Check for active MCZ diagnostic trouble code 011813.02—OPT Electric Lever 1 Abnormal Operation.
Is code active?
Result:
NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.
( 3 ) Continuity Check
Action:
<- Go to Section TOC Section 9001 page 165 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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:
Action:
Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) to machine ground.
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 6 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector.
Result:
( 6 ) Solenoid Check
Action:
Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. See Solenoid Test . (Group 9015-20.)
<- Go to Section TOC Section 9001 page 166 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Result:
YES:Checks complete.
NO:Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid.
<- Go to Section TOC Section 9001 page 167 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).
Operate machine.
Check for active MCZ diagnostic trouble code 011816.02—OPT Solenoid 1 Feedback Abnormal.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 6 ) Solenoid Check
Action:
Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 170 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).
Operate machine.
Check for active MCZ diagnostic trouble code 011816.03—OPT Solenoid 1 Feedback Current High.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 172 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62).
Operate machine.
Check for active MCZ diagnostic trouble code 011816.04—OPT Solenoid 1 Feedback Current Low.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 174 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).
Operate machine.
Check for active MCZ diagnostic trouble code 011817.02—OPT Solenoid 2 Feedback Abnormal.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Harness Check
Action:
Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 6 ) Solenoid Check
Action:
Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 177 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).
Operate machine.
Check for active MCZ diagnostic trouble code 011817.03—OPT Solenoid 2 Feedback Current High.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
( 4 ) Harness Check
Action:
Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
Result:
( 5 ) Solenoid Check
Action:
Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 179 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
Action:
Result:
( 2 ) Component Check
Action:
Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61).
Operate machine.
Check for active MCZ diagnostic trouble code 011817.04—OPT Solenoid 2 Feedback Current Low.
Is code active?
Result:
( 3 ) Continuity Check
Action:
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?
Result:
Action:
Is continuity indicated?
Result:
( 5 ) Solenoid Check
Action:
Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Solenoid Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 181 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
Action:
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:
( 4 ) Voltage Check
Action:
Check pin 1 of hydraulic oil temperature sensor (B40) connector for voltage.
Is voltage indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 183 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
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.
89 lb·in
Action:
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.)
Result:
( 2 ) Component Check
Action:
Test hydraulic oil temperature sensor (B40) and compare to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
( 3 ) Voltage Check
Action:
Check between pin 1 and pin 2 on hydraulic oil temperature sensor (B40) connector for voltage.
Is voltage indicated?
Result:
Action:
Check for continuity between pin 1 of hydraulic oil temperature sensor (B40) and machine ground.
Is continuity indicated?
Result:
NO:Main controller (MCZ) malfunction.Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 185 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 10: Main Controller (MCZ) Diagnostic Trouble Codes
→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.
Action:
Result:
YES:Signal error.
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.)
<- Go to Section TOC Section 9001 page 186 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
→NOTE:
There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble
codes before continuing with procedure.
Action:
Result:
<- Go to Section TOC Section 9001 page 187 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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.)
<- Go to Section TOC Section 9001 page 188 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action:
Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.)
Result:
YES:Add coolant to surge tank and check cooling system for leaks.
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 3 ) Component Check
Action:
Result:
Action:
Check wire Y01 YEL for on engine coolant loss level sensor (S5001) connector pin 1 for continuity to ground.
<- Go to Section TOC Section 9001 page 189 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 190 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action:
Check coolant level in surge tank. See Check Engine Coolant Level . (Operator’s Manual.)
Result:
YES:Add coolant to surge tank and check cooling system for leaks.
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 3 ) Component Check
Action:
Result:
Action:
Check wire Y02 YEL on engine coolant service level sensor (S5002) connector pin 1 for continuity to ground.
<- Go to Section TOC Section 9001 page 191 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Result:
YES:Checks complete.
Action:
Ignition OFF.
Result:
YES:Checks complete.
( 2 ) Battery Charge
Action:
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 192 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Component Check
Action:
Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)
Result:
Action:
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.
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.
<- Go to Section TOC Section 9001 page 193 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
<- Go to Section TOC Section 9001 page 194 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Component Check
Action:
Disconnect and test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)
Result:
Action:
Check wire J01 TAN between variable speed fan solenoid connector pin 2 (Y5005) and machine ground.
Is continuity indicated?
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 195 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 1 ) Function Check
Action:
Result:
YES:Advise operator of reversing fan function or clean reversing fan switch (S15). See Reversing Fan Switch—If Equipped .
(Operator’s Manual.)
( 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.)
Check reversing fan switch (S15) for continuity between pins 6 and 9. See Reversing Fan Switch Harness (W23) Wiring Diagram
. (Group 9015-10.)
Is continuity indicated?
Result:
Action:
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 196 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
<- Go to Section TOC Section 9001 page 197 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
Action:
Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 198 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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.
89 lb.-in.
( 1 ) Code Check
Action:
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.)
Action:
Test CAN circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 199 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Code Check
Action:
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.)
( 3 ) Solenoid Check
Action:
Test variable speed fan solenoid (Y5005). See Proportional Solenoid Test . (Group 9015-20.)
Result:
( 4 ) Harness Check
Action:
Disconnect fan speed sensor (B53) and ECU-to-engine interface harness connector 3 (X16).
<- Go to Section TOC Section 9001 page 200 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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:
Action:
Result:
YES:Checks complete.
NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.)
<- Go to Section TOC Section 9001 page 201 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Voltage Check
Action:
Check wire P02 RED of fan speed sensor connector (B53) pin A for voltage.
Result:
Action:
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:
<- Go to Section TOC Section 9001 page 202 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action:
Result:
NO:Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation . (Group 9025-05.)
<- Go to Section TOC Section 9001 page 203 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Component Check
Action:
Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.)
Result:
Action:
Check wire J02 TAN for continuity between reversing fan solenoid (Y9) pin 2 and ECU-to-engine interface harness connector 3
(X16) pin 48.
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.
<- Go to Section TOC Section 9001 page 204 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
<- Go to Section TOC Section 9001 page 205 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
( 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.)
Result:
NO:Repair or replace connector or pins. See Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
( 2 ) Component Check
Action:
Disconnect and test reversing fan solenoid (Y9). See Proportional Solenoid Test . (Group 9015-20.)
Result:
Action:
Check wire J01 TAN between reversing fan solenoid connector (Y9) pin 2 and machine ground.
Is continuity indicated?
Result:
NO:Checks complete.
<- Go to Section TOC Section 9001 page 206 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
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.)
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics . (Group 9001-10.)
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics . (Group 9001-10.)
Action:
Result:
NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)
( 2 ) Screen Check
<- Go to Section TOC Section 9001 page 207 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Action:
Result:
NO:Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install . (Group 9015-20.)
Action:
Result:
YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 208 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
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.
89 lb.-in.
Action:
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.)
Result:
( 2 ) Resistance Check
Action:
Check resistance between pins 1 and 2 on fuel level sensor connector (B18).
3/4 26
1/2 33-43
1/4 53
<- Go to Section TOC Section 9001 page 209 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18).
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.)
<- Go to Section TOC Section 9001 page 210 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
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.
89 lb.-in.
Action:
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.)
Result:
( 2 ) Resistance Check
Action:
Check resistance between pins 1 and 2 on fuel level sensor connector (B18).
3/4 26
1/2 33-43
1/4 53
<- Go to Section TOC Section 9001 page 211 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Result:
( 3 ) Continuity Check
Action:
Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18).
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.)
Action:
Check for continuity between pin 18 on monitor controller 28-pin connector A (X20) and machine ground.
Is continuity indicated?
Result:
NO:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)
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.)
<- Go to Section TOC Section 9001 page 212 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Action:
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.)
Action:
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.)
Action:
Result:
YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 213 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Action:
Remove fuses (F6000—F6002). See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
Is continuity indicated?
Result:
( 2 ) Power Check
Action:
Disconnect satellite (SAT) module control unit 48-pin connector (X6015). See Satellite (SAT) Harness (W6003) Component
Location . (Group 9015-10.)
Check for voltage between pins M1 and M2 on satellite (SAT) module control unit 48-pin connector (X6015).
Result:
( 3 ) Harness Check
Action:
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?
<- Go to Section TOC Section 9001 page 214 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Result:
Action:
Result:
YES:Monitor controller malfunction.Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)
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 Section 9001 page 215 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
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 Section 9001 page 216 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
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.
89 lb.-in.
Action:
Replace hydraulic oil filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)
Result:
NO:Checks complete.
Action:
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:
( 3 ) Circuit Check
Action:
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:
<- Go to Section TOC Section 9001 page 217 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
NO:Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install . (Group
9015-20.)
<- Go to Section TOC Section 9001 page 218 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes
Action:
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.
Result:
( 2 ) Code Check
Action:
Result:
Action:
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:
Action:
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:
NO:Checks complete.
Diagnose diagnostic trouble code (DTC) 000094.17 of the engine control unit (ECU).
<- Go to Section TOC Section 9001 page 220 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
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.)
<- Go to Section TOC Section 9001 page 221 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 3 ) Voltage Check
Action:
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 4 ) Sensor Check
<- Go to Section TOC Section 9001 page 222 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 223 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 3 ) Voltage Check
Action:
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 4 ) Sensor Check
<- Go to Section TOC Section 9001 page 224 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 225 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
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.
89 lb.-in.
Action:
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.)
Result:
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:
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.
Result:
NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
( 3 ) Voltage Check
Action:
<- Go to Section TOC Section 9001 page 226 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Result:
YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
( 4 ) Sensor Check
Action:
Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 227 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
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.
89 lb.-in.
Action:
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.)
Result:
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:
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.
Result:
YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
( 3 ) Voltage Check
Action:
<- Go to Section TOC Section 9001 page 228 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Result:
YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
( 4 ) Sensor Check
Action:
Check resistance of sensor to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 229 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
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:
Disconnect air conditioner controller (A7) and solar sensor (B21) connectors.
Check wires between air conditioner controller (A7) and solar sensor (B21) connectors for continuity.
Result:
NO:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
( 3 ) Voltage Check
Action:
Result:
YES:Repair or replace wiring harness. See appropriate harness component location or wiring diagram.
<- Go to Section TOC Section 9001 page 231 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 3 ) Voltage Check
Action:
Check air conditioner freeze control switch (B41) circuit voltage to ground.
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 4 ) Switch Check
<- Go to Section TOC Section 9001 page 232 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 233 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
( 3 ) Voltage Check
Action:
Check air conditioner freeze control switch (B41) circuit voltage to ground.
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9001 page 234 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
( 4 ) Switch Check
Action:
Check resistance of switch to specification. See Temperature Sensor Test . (Group 9015-20.)
Result:
YES:Checks complete.
<- Go to Section TOC Section 9001 page 235 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
43- Abnormal Air Conditioner and Heater Blower Port Change Servomotor
188
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
Action:
Air conditioner and heater blower port change servomotor (M10) disconnected.
Check air conditioner and heater blower port change servomotor (M10) circuit voltage to ground.
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9001 page 236 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
Air conditioner and heater blower port change servomotor (M10) disconnected.
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.)
<- Go to Section TOC Section 9001 page 237 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
NO:Repair or replace connector or pins. See Heater and Air Conditioner Harness (W41) Wiring Diagram . (Group 9015-10.)
( 2 ) Harness Check
Action:
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.)
Result:
NO:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
Action:
Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground.
Result:
YES:Repair or replace wiring harness. See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9001 page 238 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
Check air conditioner and heater mixer servomotor (M11) circuit voltage to ground.
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.
<- Go to Section TOC Section 9001 page 239 130G Excavator Diagnostic
Section 9001 - DIAGNOSTICS Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Action:
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.)
Result:
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:
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.
Result:
NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.
<- Go to Section TOC Section 9001 page 240 130G Excavator Diagnostic
OPERATIONAL CHECKOUT PROCEDURE (g) by Belgreen v2.0
Action:
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.)
Result:
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:
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.
Result:
NO:Repair or replace wiring harness. See appropriate component location or wiring diagram.
<- Go to Section TOC Section 9005 page 241 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1
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).
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:
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.)
Action:
Horn Circuit
LEGEND:
1 Horn Button
sss:
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
LEGEND:
1 Hour Meter
2 Home Button
6 Fuel Gauge
Press and hold home button (2) until default screen appears.
sss:
sss:
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.
89 lb.-in.
Result:
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.)
Action:
LEGEND:
1 System Starting Screen
2 Default 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.
sss:
sss:
Does default screen with hour meter appear after system starting screen disappears?
Result:
NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.)
Action:
Default Screen
LEGEND:
1 Work Mode Indicator
2 Exhaust Filter Auto Cleaning Disabled Indicator
3 Power Mode Indicator
4 Hour Meter
5 Engine Coolant Temperature Gauge
6 Fuel Gauge
7 Travel Mode Indicator
8 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).
→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.
→NOTE:
If engine coolant temperature is below 30°C (86°F) engine temperature gauge needle may not move.
sss:
sss:
Does engine coolant temperature gauge (5) display correct engine coolant temperature?
sss:
sss:
sss:
Does work mode indicator (1) display correct work mode (dig or attachment)?
sss:
sss:
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.
89 lb.-in.
Result:
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.)
Action:
LEGEND:
5 Default Screen
Default Screen
LEGEND:
1 Main Menu Screen
LEGEND:
2 Monitor Dial
3 Back Button
4 Home Button
Switch Panel
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.
When the default screen (5) is displayed, press monitor dial (2) on the switch panel.
sss:
sss:
At settings menu, rotate monitor dial to highlight rear view camera monitor.
sss:
LEGEND:
6 Rear View Image
sss:
At rear view camera monitor menu, press monitor dial to turn camera OFF (disable).
sss:
Result:
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.)
Action:
LEGEND:
1 Forward
2 Rearward
Push both travel levers and pedals forward (1), then release.
Pull both travel levers and pedals rearward (2), then release.
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:
NO:Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Disassemble and Assemble . (Group 3360.)
Action:
Switch Panel
LEGEND:
3 Work Light Switch
sss:
Is monitor panel back light and base machine work light on?
sss:
sss:
Does base machine work light stay on and switch panel stay illuminated?
sss:
Does boom work light come on and monitor back panel light change to night mode?
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
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:
sss:
Does wiper operate intermittently, but faster than when in first position (5 second interval)?
sss:
Does wiper operate intermittently, but faster than when in second position (3 second interval)?
sss:
sss:
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
LEGEND:
4 Windshield Wiper and Washer Switch
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.
sss:
Press and hold windshield wiper and washer switch for 3 seconds.
sss:
sss:
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.
89 lb.-in.
Result:
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.)
Action:
LEGEND:
1 Lock Pin
2 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 contact with
the cab.
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 Panel
LEGEND:
4 Windshield Wiper and Washer Switch
sss:
sss:
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.
89 lb.-in.
Result:
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.)
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 Panel
LEGEND:
4 Windshield Wiper and Washer Switch
Press windshield wiper and washer switch (4) and hold for 3 seconds.
sss:
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.
89 lb.-in.
Result:
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.)
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.
→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.
Start engine.
sss:
sss:
sss:
Does engine coolant temperature gauge (3) display correct engine coolant temperature?
sss:
Result:
NO:Engine oil pressure alarm displayed. Immediately stop engine and check engine oil level. See Check Engine Oil Level .
(Operator’s Manual.)
NO:Other alarm indicators display on monitor. See Monitor Controller (DSZ) Circuit Theory of Operation . (Group 9015-15.)
Action:
LEGEND:
1 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.
sss:
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.
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
sss:
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Blower Speed Switch
9 Fan Reversing Switch
sss:
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:
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Mode Switch
4 Power Mode Button
sss:
sss:
Result:
NO:Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications . (Group 9015-10.)
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.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until PWR (power) mode is displayed on monitor.
Press power mode button until ECO (economy) mode is displayed on monitor.
sss:
Press power mode button until PWR (power) mode is displayed on monitor.
sss:
Result:
NO: See Engine Speed Control System Operation (Group 9010-05.) for additional information on engine speed and power
mode.
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until PWR (power) mode is displayed on monitor.
Press power mode button until H/P (high power) mode is displayed on monitor.
sss:
Result:
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 H/P (High Power) Function Does Not Operate, PWR (Power) Mode Is Normal . (Group 9025-15.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until H/P (high power) mode is displayed on monitor.
sss:
sss:
Result:
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.)
Action:
LEGEND:
A Pilot Shutoff Lever
B Travel Levers
C 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.
sss:
sss:
Result:
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.)
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:
Push travel pedals or levers and allow travel alarm to operate for a minimum of 12 seconds.
sss:
sss:
Result:
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.)
Action:
LEGEND:
1 Hydraulic Oil Tank Pressure Release Button
2 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.
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:
Action:
LEGEND:
1 Arm Out
2 Arm In
3 Swing Left
4 Swing Right
5 Boom Down
6 Boom Up
7 Bucket Load
8 Bucket Dump
CAUTION:
Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.
sss:
Result:
NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern . (Group 9025-15.)
Action:
LEGEND:
1 Arm Out
2 Arm In
3 Swing Left
4 Swing Right
5 Boom Down
6 Boom Up
7 Bucket Load
8 Bucket Dump
CAUTION:
Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.
sss:
Result:
NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern . (Group 9025-15.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
CAUTION:
Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket.
Machine must be on level ground.
Move arm to the extended position, bucket to the retracted position, and bucket-to-arm pivot pin at same level as boom-to-
frame pivot pin.
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?
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:
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.)
Action:
Machine Position
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 Section 9005 page 36 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
approximately 300 mm (1 ft) with the boom and then put a block under the track.
Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin.
→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:
sss:
Does upperstructure move only slightly when swing park brake is disengaged?
Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10
seconds.
sss:
sss:
Does upperstructure move only slightly when swing park brake is disengaged?
Result:
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.)
Action:
Machine Position
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
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.
Press power mode button (4) until H/P (high power) mode is displayed on monitor.
sss:
sss:
Result:
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.)
Action:
1650 lb.
Position bucket at maximum reach with bucket pivot pin at same height as boom pivot pin.
Stop engine.
0.39 in.
0.79 in.
0.59 in.
4.33 in.
0.20 in.
0.79 in.
sss:
Result:
NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.)
Action:
LEGEND:
1 Arm Tip Position Above Ground
Lower boom until arm tip is 1 m (40 in.) above ground (1).
Stop engine.
0.20 in.
0.59 in.
0.39 in.
3.94 in.
0.20 in.
0.79 in.
sss:
Result:
NO: See Load Drifts Down When Control Lever Is In Neutral Position . (Group 9025-15.)
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.
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
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 contact machine or ground.
Press power mode button (4) until PWR (power) mode is displayed on monitor.
Operate swing function and record time required for three complete revolutions.
Position machine as shown, arm extended, bucket curled, and upperstructure 90 degrees to tracks.
Press power mode button (4) until PWR (power) mode is displayed on monitor.
Raise boom high enough so bucket does not contact 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:
sss:
Result:
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.)
Action:
LEGEND:
1 Engine Speed Dial
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.)
( 20 ) Boom Up, Arm In, and Bucket Combined Function Operation Check
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until PWR (power) mode is displayed on monitor.
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:
NO:If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve (5-Spool) Disassemble and
Assemble . (Group 3360.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until PWR (power) mode is displayed on monitor.
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:
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 (5-
Spool) Disassemble and Assemble . (Group 3360.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
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.
sss:
Does the arm move smoothly through the complete cycle and not hesitate when it goes through the vertical position?
Result:
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.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
<- Go to Section TOC Section 9005 page 48 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
Press power mode button (4) until PWR (power) mode is displayed on monitor.
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:
NO:Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation . (Group 9025-05.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
sss:
sss:
Does machine travel speed decrease and then increase as dig function is actuated and then released?
sss:
Result:
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.)
Action:
CAUTION:
Prevent possible injury from unexpected machine movement. Clear all persons from the area before
operating machine.
Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
Machine Position
LEGEND:
9 Bucket Height
Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
Press power mode button (4) until PWR (power) mode is displayed on monitor.
Tracking Check
LEGEND:
5 Distance of Mistrack
6 Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)
7 Test Line (distance): 20 m (66 ft.)
8 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 Section 9005 page 52 130G Excavator Diagnostic
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
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.
sss:
Result:
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.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
→NOTE:
After machine is moving, actuate arm out from neutral to full actuation and extend the arm.
sss:
Result:
YES: See Combined Travel And Dig Functions Slow Or No Power . (Group 9025-15.)
Action:
Switch Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
sss:
Does each track slow down in response to pedal or lever movement in order to turn?
sss:
Does each track slow down in response to pedal or lever movement in order to turn?
Result:
NO: See Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline . (Group
9025-15.)
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 Panel
LEGEND:
1 Engine Speed Dial
2 Auto-Idle Switch
3 Travel Speed Switch
4 Power Mode Button
5 Monitor Dial
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
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:
Result:
NO: See All Hydraulic Functions Slow or see Some Dig Functions Slow (Not All) . (Group 9025-15.)
Action:
Switch Panel
LEGEND:
5 Temperature Control/Mode Switch
6 Blower Speed Switch
sss:
sss:
sss:
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.
89 lb.-in.
Result:
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.)
Action:
Switch Panel
LEGEND:
5 Temperature Control/Mode Switch
6 Blower Speed Switch
7 Fan Speed
8 AUTO Display
9 Vent Position
10 Temperature Setting
sss:
sss:
sss:
Does monitor display vent position (9), fan speed (7), and temperature setting (10)?
sss:
sss:
sss:
sss:
sss:
sss:
sss:
Does air conditioner compressor clutch solenoid “click”? (air conditioner and heater are ON in manual mode.)
sss:
sss:
sss:
sss:
sss:
sss:
sss:
sss:
sss:
sss:
Are air conditioner and heater OFF? (press blower speed switch to start air conditioner and heater).
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.
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.)
John Deere excavators are available in different machine configurations based on the various markets into which they are sold.
Different supporting 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 supporting manual for your machine.
LEGEND:
1 PIN Plate
2 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.
LEGEND:
3 Engine Serial Number Plate
4 9 Character Engine Model Number
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.
The 9 character engine model number corresponds to a specific engine emissions level.
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
th
17 Character PIN (11 character) Engine Emissions Level
→NOTE:
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.)
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 130G Excavator Diagnostic
Section 9010 - ENGINE Group 05: Theory of Operation
LEGEND:
1 Radiator
2 Radiator-to-Coolant Pump Hose
3 Radiator-to-Thermostat Housing Hose
4 Surge Tank
5 Surge Tank Overflow Hose
6 Surge Tank-to-Radiator Hose
7 Surge Tank-to-Thermostat Housing Hose
8 Surge Tank-to-Coolant Pump Hose
9 Coolant Pump-to-Heater Hose
10 Engine-to-Heater Hose
11 Coolant Pump
LEGEND:
2 Ether Canister
Y19 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:
For more information, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)
SPECIFICATIONS
Engine Speeds
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)
Auto Warm-Up
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
Switch Panel
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:
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.
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:
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.
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 will increase up to 100 rpm over the engine speed dial setting for increased pump flow when the following
conditions are met:
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:
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.
When auto-idle is deactivated, the engine rpm increases to the setting of the engine speed dial.
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 user-selected idle speed.
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.
→NOTE:
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.)
Group 20 - Adjustments
John Deere Engine
→NOTE:
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.)
Group 25 - Tests
John Deere Engine
→NOTE:
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.)
SPECIFICATIONS
4—7°C
Top to Bottom of Radiator Temperature Differential (typical)
7.2—12.6°F
→NOTE:
LEGEND:
1 Top Test Position
2 Bottom Test Position
[2] -
→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.)
[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-Contact 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.
JT07253
Measure Temperature
7.2—12.6°F
[7] -
→NOTE:
SPECIFICATIONS
105 kPa
Turbocharger Boost Pressure 1.05 bar
15.2 psi
Other Material
OTHER MATERIAL
→NOTE:
Boost specifications are based on use of No. 2 fuel. If using No. 1 fuel, reduce boost specifications by 7%.
[1] -
LEGEND:
1 Adapter
3 Hose
4 Pressure Gauge
Remove plug from intake manifold and install adapter (1). Install hose (3) and pressure gauge (4) from JT07248 Turbo Boost
Test Kit.
JT07248
[2] - Warm engine and hydraulic oil to normal operating temperature. Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
[5] - Slowly actuate arm in function over relief and hold until engine rpm stabilizes at highest reading. Repeat this step at least
six times.
[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.
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.
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 Section 9010 page 19 130G Excavator Diagnostic
ELECTRICAL SYSTEM (g) by Belgreen v2.0
[9] - Apply PM37418 Thread Lock and Sealer (medium strength) to plug. Tighten plug.
→NOTE:
All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in
the OFF position.
LEGEND:
1 Continuity Chart
2 Power Wires
3 Routing Location Information
4 Wire Identification
5 Ground Wires
<- Go to Section TOC Section 9015 page 2 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 05: System Information
7 Section Number
8 Component Name
9 Component Identification Number
10 Component Schematic Symbol
11 Connector Identification Number
12 Connector
13 Connector Pin Information
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
K19 Battery Relay
S1 Key Switch
W5 Battery To Frame Ground
W6 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
LEGEND:
1 Wire Number
2 Wire End #1 Termination Location
3 Wire Color
4 Wire End #2 Termination Location
5 Wiring Diagram Wire Legend
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
LEGEND:
1 Component Identification Number
2 Connector
3 Connector End View
4 Wire Harness
5 Wire Number
6 Wire Splice
7 Wire End #1 Termination Location
8 Wire Number
9 Wire Color
10 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.
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.
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.
LEGEND:
1 Battery
2 Wire Splice
3 Fuse
4 Circuit Breaker
5 Power Outlet
6 Alternator
7 Air Conditioner Compressor
8 Compressor
9 Liquid Pump
10 Antenna
11 Diode
12 Zener Diode
13 Capacitor
14 Magnet
15 Flasher
16 Buzzer
17 Horn
18 Alarm
19 Clock
20 Internal Ground
21 Single Point Ground
22 External Ground
23 Sensor
24 Sensor with Normally Open Switch
25 Speed Sensor
26 Rotary Sensor
27 Single Element Bulb
28 Dual Element Bulb
29 Solenoid Operated Hydraulic Valve With Suppression Diode
30 Solenoid Normally Open
31 Solenoid Normally Closed
32 Starter Motor
33 Starter Motor
34 DC Motor
35 DC Stepping Motor
36 Wiper Motor
37 Blower Motor
38 Servo Motor
39 Speedometer
40 Tachometer
41 Temperature Gauge
42 Liquid Level Gauge
43 Gauge
44 Hourmeter
45 Resistor
46 Variable Resistor
47 Manually Adjusted Variable Resistor
48 Multi-Pin Connector
49 Single Pin Connector
50 Connector
51 4 Pin Relay
52 5 Pin Relay
53 5 Pin Relay With Internal Suppression Diode
54 5 Pin Relay With Internal Suppression Resistor
55 Key Switch
56 Temperature Switch Normally Open
57 Temperature Switch Normally Closed
58 Pressure Switch Normally Open
59 Pressure Switch Normally Closed
60 Liquid Level Switch Normally Open
61 Liquid Level Switch Normally Closed
62 Momentary Switch Normally Open
63 Momentary Switch Normally Closed
64 Toggle Switch Normally Open
65 Toggle Switch Normally Closed
66 2 Way Toggle Switch Normally Open
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.
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
LEGEND:
1 Relay Block
2 Fuse Block 1
3 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 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
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 Start Aid 20 A Fuse (marked START AID)
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
Fuse Block 2
LEGEND:
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 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 3 5 A Fuse (marked AUX. 3)
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 Not Used
F36 Not Used
F37 Not Used
F38 Not Used
F39 Not Used
F40 Not Used
Relay Block
Relay Block
LEGEND:
K1 Load Dump Relay
K2 Pilot Shutoff Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K14 (not used)
K19—Battery Relay
K34—Starter Relay
LEGEND:
1 Relay Block
2 Fuse Block 1
3 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
Fuse Block 2
LEGEND:
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
Relay Block
Relay Block
LEGEND:
K1 Load Dump Relay
K2 Pilot Shutoff Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19—Battery Relay
K34—Starter Relay
K35—Starter Protection Relay
LEGEND:
F4 Solenoid 20 A Fuse (marked SOLENOID)
F7 Start Position Signal 5 A Fuse (marked START)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X175 Machine Harness-to-Starter Harness Connector
Y10 Pilot Shutoff Solenoid
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E7 Switch Panel Back Light 3
E8 Switch Panel Back Light 4
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
H2 Security Alarm
H3 Monitor Warning Alarm
K3 Security Alarm Relay
S10 Work Light Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
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
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X64 Machine Harness-to-Rear Camera Harness Connector
X76 Cab Harness Connector 1 (not used)
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
H4 Travel Alarm
R15 Engine Speed Dial
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X29 Cab Harness-to-Switch Panel Connector 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
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
B82 Ambient Air Temperature Sensor 2
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
R12 CAN 0 Termination Resistor
S7 Power Dig Switch
X1 Service ADVISOR ™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
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
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)
LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
S15 Reversing Fan Switch
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid
LEGEND:
A6 Radio
A8 12-Volt Power Converter
B25 Right Speaker
B26 Left Speaker
E1 Work Light
E2 Boom Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F6 12-Volt Power Outlet 10 A Fuse (marked OPT. 2 ALT)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F15 Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F62 Wiper Motor Assembly Circuit Breaker
G5 12-Volt Power Outlet
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
R9 Lighter
S28 Window Switch
V6 Auxiliary Power Connector Diode
W60 Radio Antenna
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X44 Optional Light Connector
X73 Cab Harness-to-Speakers Connector
X77 Radio Auxiliary Connector
LEGEND:
A5 Data Converter
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway (MTG) Controller (if equipped)
A6001 GPS/Cellular Antenna
A6002 Satellite (SAT) Module Control Unit (if equipped)
A6003 Satellite (SAT) Antenna
E3 Cab Dome Light
E9 Key Switch Light
E10 Switch Panel Back Light 5
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
S2 Cab Dome Light Switch
S9 Windshield Wiper and Washer Switch
S14 Door Switch
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X27 Cab Harness-to-Switch Panel Connector 1
X6007 JDLink™ Harness Ground 1
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 Engine Interface Harness-to-Satellite (SAT) Harness
X6019 Modular Telematics Gateway (MTG) Connector
LEGEND:
A7 Air Conditioner Controller (ACF)
B20 Air Conditioner High/Low Pressure Switch
B21 Solar Sensor
B22 Ambient Air Temperature Sensor
B23 High Note Horn
B24 Low Note Horn
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F19 Horn 10 A Fuse (marked HORN)
K10 Horn Relay
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
S5 Horn Switch
V8 Air Conditioner Clutch Diode
X52 Air Conditioner 10-Pin Connector
Y11 Air Conditioner Compressor Clutch
LEGEND:
B80 Seat Temperature Switch 1
B81 Seat Temperature Switch 2
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 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 3 5 A Fuse (marked AUX. 3)
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)
K20 Seat Heater Relay
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
M12 Seat Air Compressor Motor
R18 Seat Heater (marked SEAT HEATER)
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked A)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked A)
S34 Right Enable Switch
S35 Left Enable Switch
S61 Seat Compressor Switch
S62 Seat Heater Switch
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
X26 Optional Connector
X44 Optional Light 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)
X59 Satellite Communication Connector (marked IMOBI)
X60 12-Volt Power Supply Connector (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)
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y35 Left Solenoid (marked SL/H)
LEGEND:
F4 Solenoid 20 A Fuse (marked SOLENOID)
F7 Start Position Signal 5 A Fuse (marked START)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X175 Machine Harness-to-Starter Harness Connector
Y10 Pilot Shutoff Solenoid
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E7 Switch Panel Back Light 3
E8 Switch Panel Back Light 4
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
H2 Security Alarm
H3 Monitor Warning Alarm
K3 Security Alarm Relay
S10 Work Light Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
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
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X64 Machine Harness-to-Rear Camera Harness Connector
X76 Cab Harness Connector 1 (not used)
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
H4 Travel Alarm
R15 Engine Speed Dial
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
V43 2-Speed Activation Solenoid Valve Diode
X29 Cab Harness-to-Switch Panel Connector 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
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
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
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)
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
B82 Ambient Air Temperature Sensor 2
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
R12 CAN 0 Termination Resistor
S7 Power Dig Switch
X1 Service ADVISOR ™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
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
X574 Auxiliary Function Lever (AFL) Connector 1
X575 Auxiliary Function Lever (AFL) Connector 2
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)
LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU)
S15 Reversing Fan Switch
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid
LEGEND:
A6 Radio
A8 12-Volt Power Converter
B25 Right Speaker
B26 Left Speaker
E1 Work Light
E2 Boom Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F13 Lighter 10 A Fuse (marked LIGHTER)
F15 Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F62 Wiper Motor Assembly Circuit Breaker
G5 12-Volt Power Outlet
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
R9 Lighter
S28 Window Switch
V6 Auxiliary Power Connector Diode
W60 Radio Antenna
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X73 Cab Harness-to-Speakers Connector
X77 Radio Auxiliary Connector
LEGEND:
A5 Data Converter
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway (MTG) Controller (if equipped)
A6001 GPS/Cellular Antenna
A6002 Satellite (SAT) Module Control Unit (if equipped)
A6003 Satellite (SAT) Antenna
E3 Cab Dome Light
E9 Key Switch Light
E10 Switch Panel Back Light 5
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
S2 Cab Dome Light Switch
S9 Windshield Wiper and Washer Switch
S14 Door Switch
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X27 Cab Harness-to-Switch Panel Connector 1
X6007 JDLink™ Harness Ground 1
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 Engine Interface Harness-to-Satellite (SAT) Harness
X6019 Modular Telematics Gateway (MTG) Connector
LEGEND:
A7 Air Conditioner Controller (ACF)
B20 Air Conditioner High/Low Pressure Switch
B21 Solar Sensor
B22 Ambient Air Temperature Sensor
B23 High Note Horn
B24 Low Note Horn
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
F3 Air Conditioner and Heater 20 A Fuse (marked HEATER)
F19 Horn 10 A Fuse (marked HORN)
K10 Horn Relay
K15 Air Conditioner Blower Motor Relay
K17 Max-Hi Relay
K18 Air Conditioner Compressor Clutch Relay
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servo Motor
M10 Air Conditioner and Heater Blower Port Change Servo Motor
M11 Air Conditioner and Heater Mixer Servo Motor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
S5 Horn Switch
V8 Air Conditioner Clutch Diode
X52 Air Conditioner 10-Pin Connector
Y11 Air Conditioner Compressor Clutch
LEGEND:
B80 Seat Temperature Switch 1
B81 Seat Temperature Switch 2
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 IMMOBI 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)
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)
K20 Seat Heater Relay
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
M12 Seat Air Compressor Motor
R18 Seat Heater (marked SEAT HEATER)
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked C)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked C)
S34 Right Enable Switch
S35 Left Enable Switch
S61 Seat Compressor Switch
S62 Seat Heater Switch
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
X26 Optional Connector
X44 Optional Light 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)
X59 Satellite Communication Connector (marked IMOBI)
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)
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y35 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)
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.
89 lb.-in.
LEGEND:
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A8 12-Volt Power Converter
A11 Machine Controller (BCZ)
E3 Cab Dome Light
F50 Fuse Box
F51 Auxiliary Fuse Box
G5 12-Volt Power Outlet
H2 Security Alarm
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
R9 Lighter
R10 Interface CAN Resistor 1
R15 Engine Speed Dial
S1 Key Switch
S5 Horn Switch
S7 Power Dig Switch
S8 Auto-Idle Switch
S9 Windshield Wiper and Washer Switch
S10 Work Light Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
S14 Door Switch
S15 Reversing Fan Switch
S16 Exhaust Filter Parked Cleaning Switch
S18 Service ADVISOR ™ Remote (SAR) Switch
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S34 Right Enable Switch
S60 Keypad
S62 Seat Heater Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V6 Auxiliary Power Connector Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
LEGEND:
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A8 12-Volt Power Converter
A11 Machine Controller (BCZ)
E3 Cab Dome Light
F50 Fuse Box
F51 Fuse Box 2
G5 12-Volt Power Outlet
H2 Security Alarm
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
R9 Lighter
R10 Interface CAN Resistor 1
R15 Engine Speed Dial
S1 Key Switch
S5 Horn Switch
S7 Power Dig Switch
S8 Auto-Idle Switch
S9 Windshield Wiper and Washer Switch
S10 Work Light Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
S14 Door Switch
S15 Reversing Fan Switch
S16 Exhaust Filter Parked Cleaning Switch
S18 Service ADVISOR™ Remote (SAR) Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S34 Right Enable Switch
S60 Keypad
S62 Seat Heater Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V6 Auxiliary Power Connector Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W1 Cab Harness
W3 Monitor Harness
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.
89 lb.-in.
LEGEND:
1 Continued on Sheet 2
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
S7 Power Dig Switch
V1 Battery Relay Diode
V4 Security Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V10 Starter Protection Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W35 Cab Harness Ground 1
W36 Cab Harness Ground 2
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Monitor Harness Connector
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 Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel 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
X76 Cab Harness Connector (not used)
X78 Optional Switch
LEGEND:
1 Continued on Sheet 1
2 Continued on Sheet 3
A5 Data Converter
E3 Cab Dome Light
H2 Security Alarm
K15 Air Conditioner Blower Motor Relay
K17 Max Hi Relay
K18 Air Conditioner Compressor Clutch Relay
R10 Interface CAN Resistor 1
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V5 Starter Cut Relay Diode
V9 Pilot Shutoff Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
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
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X73 Cab Harness-to-Speakers Connector
X99 Cab Ground Splice
LEGEND:
2 Continued on Sheet 2
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 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
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 Start Aid 20 A Fuse (marked START AID)
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)
F50 Fuse Box
G5 12-Volt Power Outlet
R9 Lighter
S5 Horn Switch
S14 Door Switch
V6 Auxiliary Power Connector Diode
W37 Cab Harness Ground 3
X2 MPDr 6-Pin Connector
X25 Cab Harness Auxiliary Power Connector 1
X26 Optional Connector
X39 Cab Harness-to-Window Switch Connector
X43 Optional Fuse Connector
X44 Optional Light Connector
X45 Option 2 12-Pin Connector (not used)
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
X77 Radio Auxiliary Connector
X83 Cab Harness-to-Reversing Fan Switch Harness Connector
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)
LEGEND:
1 Continued on sheet 2
2 Continued on sheet 4
A5 Information Controller (ICF)
E3 Cab Dome Light
H2 Security Alarm
R10 Interface CAN Resistor 1
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V5 Starter Cut Relay Diode
V9 Pilot Shutoff Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
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
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X73 Cab Harness-to-Speakers Connector
X99 Cab Ground Splice
X573 Exhaust Solenoid Harness Connector (not used)
LEGEND:
2 Continued on sheet 3
3 Continued on sheet 5
K1 Load Dump Relay
K2 Pilot Shutoff Solenoid Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K5 Security Relay
K6 Windshield Wiper Relay
K7 Work Light Relay
K8 Boom Light Relay
K9 Windshield Washer Relay
K10 Horn Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
V1 Battery Relay Diode
V4 Security Diode
V7 Start Relay Diode
V8 Air Conditioner Clutch Diode
V10 Starter Protection Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
W36 Cab Harness Ground 2
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X17 Cab Harness-to-Monitor Harness Connector
X42 CAN 1 Connector
X78 Optional Switch
X574 Auxiliary Function Lever (AFL) Connector 1
X575 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 Panel Connector 1
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel 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)
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.
89 lb.-in.
LEGEND:
B18 Fuel Level Sensor
B20 Air Conditioner High/Low Pressure Switch
<- Go to Section TOC Section 9015 page 95 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B18 Fuel Level Sensor
B20 Air Conditioner High/Low Pressure Switch
B22 Ambient Air Temperature Sensor
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G3 Alternator
K34 Starter Relay
M1 Starter Motor
M6 Windshield Washer Motor
R13 Alternator Resistor
W2 Machine Harness
<- Go to Section TOC Section 9015 page 97 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 100 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
1 Continued on Sheet 2
B18 Fuel Level Sensor
B23 High Note Horn
B24 Low Note Horn
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
E1 Work Light
E2 Boom Light
X46 Attachment Connector
X67 Machine Harness Auxiliary Power Connector
X90 Machine Harness-to-Hydraulic Oil Temperature Switch Connector
X98 Machine Harness Splice Connector
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
<- Go to Section TOC Section 9015 page 101 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 102 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
1 Continued on Sheet 1
B20 Air Conditioner High/Low Pressure Switch
B22 Ambient Air Temperature Sensor
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G3 Alternator
K19 Battery Relay
M6 Windshield Washer Motor
R13 Alternator Resistor
X1 Service ADVISOR ™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X40 Pump Harness-to-Machine Harness Connector
X64 Machine Harness-to-Rear Camera Harness Connector
X86 Machine Harness-to-Travel Alarm Harness
X175 Machine Harness-to-Starter Harness Connector
X6022 Cab Harness-to-Exhaust Filter Solenoid Harness (not used)
Y11 Air Conditioner Compressor Clutch
<- Go to Section TOC Section 9015 page 103 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
B21 Solar Sensor
H3 Monitor Warning Alarm
W1 Cab Harness
W3 Monitor Harness
X17 Cab Harness-to-Monitor Harness
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
X23 Monitor Controller 12-Pin Connector C
X24 Monitor Controller 2-Pin Connector G
<- Go to Section TOC Section 9015 page 104 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B21 Solar Sensor
H3 Monitor Warning Alarm
X17 Cab Harness-to-Monitor Harness
<- Go to Section TOC Section 9015 page 105 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 106 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A1 Engine Control Unit (ECU)
B5206 Manifold Air Temperature (MAT) Sensor
M1 Starter Motor
<- Go to Section TOC Section 9015 page 107 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 108 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
<- Go to Section TOC Section 9015 page 109 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 110 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 111 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 112 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
1 Continued on Sheet 2
M1 Starter Motor
R12 CAN 0 Termination Resistor
W30 Static Ground
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X174 Engine Harness-to-Engine Interface Harness Connector
X240 G01 BLK Splice 1
X241 G04 BLK Splice 2
X242 P99 RED Splice 1
X243 P01 RED Splice 2
X244 R02 BLK Splice 3
X245 M13 GRN Splice 1
X246 M12 YEL Splice 1
X247 R92 BLK Splice 4
X248 5446 LT BLU Splice
<- Go to Section TOC Section 9015 page 113 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 114 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
1 Continued on Sheet 1
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
M13 High Pressure Fuel Pump
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector
<- Go to Section TOC Section 9015 page 115 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor 2
B5107 Inlet Fuel Pressure Sensor
B5600 Water-in-Fuel Sensor
F6000 JDLink ™ Unswitched Power 7.5 A Fuse
F6001 JDLink™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R11 Interface CAN Resistor 2 (later models)
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
W5 Engine Interface Harness
W43 Engine Interface Harness Ground
<- Go to Section TOC Section 9015 page 116 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 117 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 118 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 119 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor 2
B5107 Inlet Fuel Pressure Sensor
B5600 Water-in-Fuel Sensor
F6000 JDLink™ Unswitched Power 7.5 A Fuse
F6001 JDLink ™ Ground 7.5 A Fuse
F6002 JDLink™ Switched Power 7.5 A Fuse
R11 Interface CAN Resistor 2 (later models)
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X6 Machine Harness-to-Engine Interface Harness 1-Pin Connector
X7 Machine Harness-to-Engine Interface Harness 8-Pin Connector 2
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X160 1356 YEL Splice
X161 1357 GRN Splice
X174 Engine Harness-to-Engine Interface Harness Connector
X200 M12A YEL Splice
X201 M13A GRN Splice
X202 R02A BLK Splice 1
X203 P01A RED Splice 1
X204 G01A BLK Splice 2
X205 P01B RED Splice 2
X206 P307 RED Splice 3
X207 G01B BLK Splice 3
X208 R99A BLK Splice 4
X6016 Engine Interface Harness-to-Satellite (SAT) Connector
X6019 Modular Telematics Gateway (MTG) Connector
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 Variable Speed Fan Solenoid
<- Go to Section TOC Section 9015 page 120 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B36 Pump 1 Control Pressure Sensor
B38 Pump 2 Control Pressure Sensor
W8 Pump Harness
<- Go to Section TOC Section 9015 page 121 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B35 Pump 1 Delivery Pressure Sensor
<- Go to Section TOC Section 9015 page 122 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 123 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
<- Go to Section TOC Section 9015 page 124 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 125 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S18 Service Advisor™ Remote (SAR) Switch
X74 Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness
<- Go to Section TOC Section 9015 page 126 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V20 Pilot Shutoff Switch Diode
W11 Pilot Shutoff Switch Harness
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
<- Go to Section TOC Section 9015 page 127 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 128 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V20 Pilot Shutoff Switch Diode
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X135 Pilot Shutoff Harness Splice 1
X136 Pilot Shutoff Harness Splice 2
X137 Machine Harness-to-Starter Harness Connector
Auxiliary Fuse Box Harness (W13) Component Location
See Cab Harness (W1) Component Location . (Group 9015.)
<- Go to Section TOC Section 9015 page 129 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 130 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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)
<- Go to Section TOC Section 9015 page 131 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
K20 Seat Heater Relay
M12 Seat Air Compressor
R18 Seat Heater (marked SEAT HEATER)
<- Go to Section TOC Section 9015 page 132 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 133 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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)
<- Go to Section TOC Section 9015 page 134 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
<- Go to Section TOC Section 9015 page 135 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 136 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 137 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
K30 Right Solenoid Relay B
K31 Right Solenoid Relay A
K32 Left Solenoid Relay B
K33 Left Solenoid Relay A
S30 Right Pilot Control Lever Switch B (marked B)
S31 Right Pilot Control Lever Switch A (marked A)
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked A)
X26 Optional Connector
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X82 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X534 Right Auxiliary Solenoid (marked SR/H) Connector
X535 Left Auxiliary Solenoid (marked SL/H) Connector
Travel Alarm Cancel Switch Harness (W16) Component Location
See Cab Harness (W1) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9015 page 138 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S13 Travel Alarm Cancel Switch
X50 Cab Harness-to-Travel Alarm Cancel Switch Harness Connector
<- Go to Section TOC Section 9015 page 139 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
V40 Selector Valve Solenoid Valve Diode
<- Go to Section TOC Section 9015 page 140 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 141 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 142 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B60 Attachment Pressure Sensor
V40 Selector Valve Solenoid Valve Diode
V41 Secondary Relief Solenoid Valve Diode
X46 Attachment Connector
X87 Attachment Harness-to-Two Speed Harness Connector
Y40 Selector Valve Solenoid Valve
Y41 Secondary Relief Solenoid Valve
<- Go to Section TOC Section 9015 page 143 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A12 Rear Camera
W19 Camera Harness
X64 Machine Harness-to-Rear Camera Harness Connector
<- Go to Section TOC Section 9015 page 144 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A12 Rear Camera
X64 Machine Harness-to-Rear Camera Harness Connector
<- Go to Section TOC Section 9015 page 145 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
W21 Pilot Shutoff Valve Harness
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10 Pilot Shutoff Solenoid
<- Go to Section TOC Section 9015 page 146 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
X75 Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10 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.)
<- Go to Section TOC Section 9015 page 147 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S34 Right Enable Switch
S35 Left Enable Switch
X81 Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
X82 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.)
<- Go to Section TOC Section 9015 page 148 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S15 Reversing Fan Switch
X83 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.)
<- Go to Section TOC Section 9015 page 149 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S62 Seat Heater Switch
X53 Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)
<- Go to Section TOC Section 9015 page 150 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
H4 Travel Alarm
W2 Machine Harness
W26 Travel Alarm Harness
X86 Machine Harness-to-Travel Alarm Harness
<- Go to Section TOC Section 9015 page 151 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
H4 Travel Alarm
X86 Machine Harness-to-Travel Alarm Harness
<- Go to Section TOC Section 9015 page 152 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
F45 Starter In-Line 30 A Fuse
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
V44 Starter Relay Diode
W27 Starter Harness
X175 Machine Harness-to-Starter Harness Connector
<- Go to Section TOC Section 9015 page 153 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
F45 Starter In-Line 30 A Fuse
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
<- Go to Section TOC Section 9015 page 154 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 155 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
S1 Key Switch
X47 Cab Harness-to-Key Switch Harness Connector
2-Speed Harness (W32) Component Location
See Attachment Harness (W17) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9015 page 156 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B61 Arm Out Pressure Sensor
V43 2-Speed Activation Solenoid Valve Diode
X87 Attachment Harness-to-Two Speed Harness Connector
<- Go to Section TOC Section 9015 page 157 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 158 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
X209 5491 BLK Splice 1
X210 5496 BLK Splice 2
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector
<- Go to Section TOC Section 9015 page 159 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 160 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A7 Air Conditioner Controller (ACF)
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
W41 Heater and Air Conditioner Harness
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
<- Go to Section TOC Section 9015 page 161 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
<- Go to Section TOC Section 9015 page 162 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
A7 Air Conditioner Controller (ACF)
B41 Air Conditioner Freeze Control Switch
B55 Air Recirculation Sensor
M7 Air Conditioner and Heater Blower Motor
M9 Air Conditioner and Heater Internal and External Servomotor
M10 Air Conditioner and Heater Blower Port Change Servomotor
M11 Air Conditioner and Heater Mixer Servomotor
R16 Blower Motor Transistor
R17 Blower Motor Resistor
X51 Air Conditioner 4-Pin Connector
X52 Air Conditioner 10-Pin Connector
X418 978 BLK Splice
X419 BLK/RED Splice
X420 BLK/YEL Splice
X421 979 RED Splice
X422 RED/BLK Splice
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
V33 Left Solenoid Diode A
W15 Multi-Function Pilot Control Lever Harness
W61 Auxiliary Solenoid Harness
W75 Auxiliary Function Lever (AFL) Harness
X534 Right Auxiliary Solenoid Connector (marked SR/H)
X535 Left Auxiliary Solenoid Connector (marked SL/H)
Y34 Right Solenoid (marked SR/H)
Y34A Right Solenoid Connector A (marked SR/H)
Y34B Right Solenoid Connector B (marked SR/H)
Y35 Left Solenoid (marked SR/H)
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
V30 Right Solenoid Diode B
V31 Right Solenoid Diode A
V32 Left Solenoid Diode B
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
K31 Right Solenoid Relay A (marked RSW1)
K32 Left Solenoid Relay B (marked LSW1)
K33 Left Solenoid Relay A (marked LSW3)
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
S5 Horn Switch
S7 Power Dig Switch
S29 Auxiliary Function Lever (AFL) Proportional Control Switch
S31 Right Pilot Control Lever Switch
S32 Left Pilot Control Lever Switch B (marked B)
S33 Left Pilot Control Lever Switch A (marked C)
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
W75 Auxiliary Function Lever (AFL) Harness
X26 Optional Connector (2 used)
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
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
B68 Secondary Hydraulic Oil Temperature Sensor
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
B85 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
W75 Auxiliary Function Lever (AFL) Harness
W76 Auxiliary Function Lever (AFL) Solenoid Harness
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)
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
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Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
LEGEND:
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 Modular Telematics Gateway (MTG) Connector
Satellite (SAT) Harness (W6003) Component Location
See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
X6015 Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 JDLink ™ Harness-to-Satellite (SAT) Harness
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. —040754)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway Controller (MTG)
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2 (later models)
R12 CAN 0 Termination Resistor
X1 Service ADVISOR™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X52 Air Conditioner 10-Pin Connector
X174 Engine Harness-to-Engine Interface Harness Connector
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 Modular Telematics Gateway (MTG) Connector
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. 040755— )
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
A6000 Modular Telematics Gateway Controller (MTG)
R10 Interface CAN Resistor 1
R11 Interface CAN Resistor 2
R12 CAN 0 Termination Resistor
X1 Service ADVISOR™ Diagnostic Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X5 Machine Harness-to-Engine Interface Harness 8-Pin Connector 1
X8 Machine Harness-to-Engine Interface Harness 8-Pin Connector 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X52 Air Conditioner 10-Pin Connector
X174 Engine Harness-to-Engine Interface Harness Connector
X6014 Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6019 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:
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 utilizes two terminating resistors; CAN 0 termination resistor (R12) and one located inside monitor controller (DSZ) (A4),
which is not accessible.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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:
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:
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K11 Idle Stop Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
W37 Cab Harness Ground 3
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 Machine Harness-to-Starter Harness Connector
Y19 Ether Start Aid
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 contacts 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 contacts of key cut relay, power is passed 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 pass
through to pin B of starter motor (M1) and pin 3 of starter relay (K34). Power is also passed 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 contacts of starter cut relay, power is passed 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 contacts are opened, removing power from starter pin S, stopping the starter motor
from turning.
Utilizing the normally closed contacts of the starter cut relay (K4), power is passed to pin 3 of the starter protection relay (K35).
Applied power is then transferred through the normally closed contacts 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.
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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 contacts 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.
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.)
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.)
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).
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A5 Data Converter
A6 Radio
A7 Air Conditioner Controller (ACF)
A11 Machine Controller (BCZ)
F7 Start Position Signal 5 A Fuse (marked START)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F14 Monitor 5 A Fuse (marked MONITOR)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
H2 Security Alarm
H3 Monitor Warning Alarm
K1 Load Dump Relay
K3 Security Alarm Relay
K4 Starter Cut Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R13 Alternator Resistor
S1 Key Switch
V1 Battery Relay Diode
V2 Alternator Excitation Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V11 Accessory Cut Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X11 Machine Controller 20-Pin Connector B
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X52 Air Conditioner 10-Pin Connector
X175 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 contacts of accessory cut relay, current flows through accessory cut diode (V11), through monitor
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 contacts 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.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A12 Rear Camera
B18 Fuel Level Sensor
B27 Hydraulic Oil Filter Restriction Switch (if equipped)
E5 Switch Panel Back Light 1
E6 Switch Panel Back Light 2
E8 Switch Panel Back Light 4
S20 Seat Belt Switch
S21 Blower Motor Speed Switch
S22 Temperature Control/Mode Switch
S23 Radio Volume and Power Switch
S24 Radio Tuning Switch
S25 Monitor Dial
S26 Back Button
S27 Home Button
S40 Hydraulic Oil Temperature Switch (if equipped)
S50 0 Key
S51 1 Key
S52 2 Key
S53 3 Key
S54 4 Key
S55 5 Key
S56 6 Key
S57 7 Key
S58 8 Key
S59 9 Key
S60 Keypad
X2 MPDr 6-Pin Connector
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X18 Monitor 12-Pin Connector C
X19 Monitor 2-Pin Connector G
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
X28 Cab Harness-to-Switch Panel Connector 2
X29 Cab Harness-to-Switch Panel Connector 3
X30 Cab Harness-to-Switch Panel Connector 4
X65 Cab Harness-to-Pilot Shutoff Switch Harness Connector
X90 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.
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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Hydraulic Oil Filter Restriction Indicator— Ground is passed 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.
Back Button (S26)— The back button (S26) grounds pin B25 of monitor controller (DSZ), returning the monitor to the
previous menu.
Home Button (S27)— The home button (S27) grounds pin B26 of monitor controller (DSZ), returning the monitor to the
default screen.
Keypad (S60)— Keypad (S60) contains numerical keys 0—9 (S50—S59, respectively). Keypad also contains switch panel back
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
The keypad is used to input the anti-theft security code and other various parameters into the monitor controller (DSZ).
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A6000 Modular Telematics Gateway (MTG) Controller
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R12 CAN 0 Termination Resistor
S1 Key Switch
S15 Reversing Fan Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X1 Service ADVISOR™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X36 Cab Harness-to-Main Controller 30-Pin Connector D
X175 Machine Harness-to-Starter Harness Connector
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
A6000 Modular Telematics Gateway (MTG) Controller
F6 Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT)
F8 Engine Control Unit (ECU) 20 A Fuse (marked ECU P1)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F20 Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
R12 CAN 0 Termination Resistor
S1 Key Switch
S15 Reversing Fan Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
W37 Cab Harness Ground 3
X1 Service ADVISOR™ Diagnostic Connector
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X34 Cab Harness-to-Main Controller 30-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 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.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 downloading 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 contacts of the key cut relay, current is passed 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 contacts 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 de-
energized, 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 contacts of the key cut relay, current is passed 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 contacts 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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 de-
energized, 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:
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 passed 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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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:
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 passed 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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
B16 Air Filter Restriction Switch
B53 Fan Speed Sensor
B82 Ambient Air Temperature Sensor
B5100 Fuel Rail Pressure Sensor
B5101 Engine Oil Pressure Sensor
B5107 Inlet Fuel Pressure Sensor
B5206 Manifold Air Temperature (MAT) Sensor
B5208 Engine Coolant Temperature Sensor
B5209 Fuel Temperature Sensor
B5301 Crankshaft Position Sensor
B5302 Camshaft Position Sensor
B5600 Water-in-Fuel Sensor
M13 High Pressure Fuel Pump
S5001 Engine Coolant Loss Level Sensor
S5002 Engine Coolant Service Level Sensor
X14 Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X5000 Engine Harness-to-Fuel Injector Harness 8-Pin Connector
Y1 Electronic Injector 1 (cylinder 1)
Y2 Electronic Injector 2 (cylinder 2)
Y3 Electronic Injector 3 (cylinder 3)
Y4 Electronic Injector 4 (cylinder 4)
Y9 Reversing Fan Solenoid
Y19 Ether Start Aid
Y5005 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 Section 9015 page 207 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 passes 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.)
<- Go to Section TOC Section 9015 page 208 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 Section 9015 page 209 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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)-to-
engine 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 passing 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 Section 9015 page 210 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 Section 9015 page 211 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Fan Speed Temperature Thresholds
*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 Section 9015 page 212 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.)
<- Go to Section TOC Section 9015 page 213 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
<- Go to Section TOC Section 9015 page 215 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Motor Diode
W37 Cab Harness Ground 3
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
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
X175 Machine Harness-to-Starter Harness Connector
<- Go to Section TOC Section 9015 page 216 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
<- Go to Section TOC Section 9015 page 217 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
H4 Travel Alarm
R15 Engine Speed Dial
S7 Power Dig Switch
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
X29 Cab Harness-to-Switch Panel Connector 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
X35 Cab Harness-to-Main Controller 24-Pin Connector D
X36 Cab Harness-to-Main Controller 26-Pin Connector E
X40 Pump Harness-to-Machine Harness Connector
X90 Not Used
X91 Not Used
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
Y22 Dig Regenerative Solenoid (marked SF)
Y23 Arm Regenerative Solenoid (marked SC)
Y24 Power Dig Solenoid (marked SG)
Y27 Arm 2 Flow Control Solenoid (marked SD)
Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine:
Main Controller Power Up (Power and Ground)— Unswitched battery power is available at pins 3 and 4 of the main
<- Go to Section TOC Section 9015 page 218 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 contacts of the key cut relay, current is passed 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.
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 warm-
up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F).
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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:
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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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:
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:
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
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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:
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Line 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K1 Load Dump Relay
K4 Starter Cut Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V7 Start Relay Diode
V10 Starter Protection Diode
V44 Starter Motor Diode
W37 Cab Harness Ground 3
X15 Engine Control Unit (ECU)-to-Engine Harness Connector 2
X20 Monitor Controller 28-Pin Connector A
X22 Monitor Controller 16-Pin Connector D
X31 Cab Harness-to-Main Controller 31-Pin Connector A
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
X175 Machine Harness-to-Starter Harness Connector
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
B40 Hydraulic Oil Temperature Sensor
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
H4 Travel Alarm
R15 Engine Speed Dial
S7 Power Dig Switch
S8 Auto-Idle Switch
S11 Travel Speed Switch
S12 Power Mode Button
S13 Travel Alarm Cancel Switch
X29 Cab Harness-to-Switch Panel Connector 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
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
X40 Pump Harness-to-Machine Harness Connector
X97 Pump Harness Splice Connector
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
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)
Main Controller (MCZ) (A3)— The main controller (MCZ) uses inputs from the following sensors on the machine:
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,
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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 contacts of the key cut relay current is passed 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.
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 warm-
up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F).
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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:
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
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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:
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:
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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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:
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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:
After the MCZ processes received input signals, output signals are sent to the solenoids to control hydraulic speed and volume
with the following components:
→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).
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A11 Machine Controller (BCZ)
E1 Work Light
E10 Switch Panel Back Light 5
F1 Lights 20 A Fuse
F2 Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F17 Power On 5 A Fuse (marked POWER ON)
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
F62 Wiper Motor Assembly Circuit Breaker
G1 Battery
G2 Battery
K6 Windshield Wiper Relay
K7 Work Light Relay
K9 Windshield Washer Relay
K13 Key Cut Relay
K19 Battery Relay
M5 Windshield Wiper Motor
M6 Windshield Washer Motor
S1 Key Switch
S9 Windshield Wiper and Washer Switch
S28 Window Switch
V3 Load Dump Relay Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X18 Monitor 12-Pin Connector C
X20 Monitor Controller 28-Pin Connector A
X23 Monitor Controller 12-Pin Connector C
X27 Cab Harness-to-Switch Panel Connector 1
X30 Cab Harness-to-Switch Panel Connector 4
X39 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:
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:
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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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:
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A4 Monitor Controller (DSZ)
A10 Monitor
A11 Machine Controller (BCZ)
E1 Work Light
E2 Boom Light
E3 Cab Dome Light
E9 Key Switch Light
F1 Work and Boom Lights 20 A Fuse (marked LAMP)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F12 Radio and Dome 5 A Fuse (marked RADIO)
F17 Power On 5 A Fuse (marked POWER ON)
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
K7 Work Light Relay
K8 Boom Light Relay
K12 Accessory Cut Relay
K13 Key Cut Relay
K19 Battery Relay
S1 Key Switch
S2 Cab Dome Light Switch
S10 Work Light Switch
S14 Door Switch
V3 Load Dump Relay Diode
V11 Accessory Cut Diode
V12 Starter Cut Diode
V13 Work Light 1 Diode
V14 Work Light 2 Diode
X3 Cab Harness-to-Machine Harness 100-Pin Connector
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
X18 Monitor 12-Pin Connector C
X20 Monitor Controller 28-Pin Connector A
X23 Monitor Controller 12-Pin Connector C
X27 Cab Harness-to-Switch Panel Connector 1
X29 Cab Harness-to-Switch Panel 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 8-
pin 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 passed to pin 3 of key cut relay (K13).
Utilizing the normally closed contacts of key cut relay, power is passed 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 passed to pin 3 of key cut relay (K13).
Utilizing the normally closed contacts of key cut relay, power is passed 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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B34 Travel Pressure Sensor
F5 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
H4 Travel Alarm
S13 Travel Alarm Cancel Switch
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X35 Cab Harness-to-Main Controller 24-Pin Connector E
X36 Cab Harness-to-Main Controller 26-Pin Connector F
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B34 Travel Pressure Sensor
F11 Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
H4 Travel Alarm
S13 Travel Alarm Cancel Switch
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A1 Engine Control Unit (ECU)
A3 Main Controller (MCZ)
A4 Monitor Controller (DSZ)
F4 Solenoid 20 A Fuse (marked SOLENOID)
F18 Idle Stop 5 A Fuse (marked IDLE STOP)
F45 Starter In-Lne 30 A Fuse
F60 Alternator 65 A Fuse
F61 Battery 45 A Fuse
G1 Battery
G2 Battery
G3 Alternator
K2 Pilot Shutoff Solenoid Relay
K4 Starter Cut Relay
K5 Security Relay
K13 Key Cut Relay
K19 Battery Relay
K34 Starter Relay
K35 Starter Protection Relay
M1 Starter Motor
S1 Key Switch
S3 Pilot Shutoff Switch 1
S4 Pilot Shutoff Switch 2
V1 Battery Relay Diode
V3 Load Dump Relay Diode
V4 Security Diode
V5 Starter Cut Relay Diode
V7 Start Relay Diode
V9 Pilot Shutoff Diode
V10 Starter Protection Diode
V44 Starter Relay Diode
V20 Pilot Shutoff Switch Diode
X21 Monitor Controller 36-Pin Connector B
X22 Monitor Controller 16-Pin Connector D
X32 Cab Harness-to-Main Controller 24-Pin Connector B
X33 Cab Harness-to-Main Controller 17-Pin Connector C
X175 Machine Harness-to-Starter Harness Connector
Y10 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 contacts of key cut relay, power is passed 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 pass through alternator 65 A fuse (F60) providing power
to pin B of alternator (G3). Power from pin B of alternator passes 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 passes 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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
A3 Main Controller (MCZ)
B32 Front Attachment Pressure Sensor (marked FRT)
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
F5 Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT.)
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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.)
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:
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
8 ATT 1 Type (attachment 1)
Attachment Type
Each attachment also has a dynamic number that is user 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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
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
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.
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
LEGEND:
12 ATT 1 Selector Valve Setting
→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, bypassing 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
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Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
deactivated.
LEGEND:
13 ATT 1 Auxiliary Flow Combiner Valve Setting
→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 bypass 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.
<- Go to Section TOC Section 9015 page 254 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
LEGEND:
11 ATT 1 Relief Valve Setting
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.
<- Go to Section TOC Section 9015 page 255 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
[1] -
LEGEND:
1 Key Pad
2 Key Switch
3 BACK Button
4 HOME Button
5 Monitor Dial
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. Troubleshooting
2. Monitoring
3. Controller Version
4. Issued Warning Record
5. Operation
6. Machine Setting
7. 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.
Engine
<- Go to Section TOC Section 9015 page 256 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
Main
Monitor
Information
Air Conditioner
[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)
<- Go to Section TOC Section 9015 page 257 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
Monitoring
→NOTE:
Items listed in the monitoring section may not be in the same order as the monitor on the machine.
[2] - Rotate monitor dial to highlight monitoring. Press monitor dial to enter the monitoring menu.
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.
Engine Oil Pressure kPa Input signal from oil pressure sensor
Coolant Temp (Meter) °C Input signal from coolant temperature sensor (coolant temperature gauge)
Hydraulic Oil Temperature °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 Command signal to maximum pump 2 flow rate limit control solenoid valve
3
Tgt Pump 1 Displacement cm Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor
3
Tgt Pump 2 Displacement cm Calculation signal from engine speed and input signal from pump 2 delivery pressure sensor
Pump 1 Load Factor % Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor
Pump 2 Load Factor % Calculation signal from engine speed and input signal from pump 2 delivery pressure sensor
<- Go to Section TOC Section 9015 page 258 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
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)
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
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
Auxil Flw Cont P/S Output MPa Control signal to auxiliary flow rate control solenoid valve
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 Feedback from pump 1 and 2 torque control solenoid valve output
Pump 2 Flw Limit P/S O/P FB mA Feedback from maximum pump 2 flow rate limit control solenoid valve output
Arm Regen P/S Output FB mA Feedback from four spool solenoid valve unit (SC) output
Digging Regen P/S O/P FB mA Feedback from four spool solenoid valve unit (SF) output
Pump 1 Flw Limit P/S O/P FB mA Feedback 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 Feedback from auxiliary flow rate control solenoid valve output
Engine Oil Level Switch OFF/ON Engine oil level switch ON/OFF status
<- Go to Section TOC Section 9015 page 259 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
2-speed Combined Flow* OFF/ON Two Speed combined flow control valve ON/OFF status
→NOTE:
*: Optional
<- Go to Section TOC Section 9015 page 260 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
[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.
[4] - Use the BACK button to return to the 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.)
<- Go to Section TOC Section 9015 page 261 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
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.
Hour Meters
Hour Meters
[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)
<- Go to Section TOC Section 9015 page 262 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
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.
ATT Speed Deceleration Waiting Time ms The time when the increased engine speed is held at attachment operation speed increased control.
Kinds of attachments:
0: Unset
1: Breaker
2: Pulverizer
ATT 1 Type 0—7 3: Crusher
4: Vibrating Hammer
5: Others
6: Grapple
7: Clamshell
<- Go to Section TOC Section 9015 page 263 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
ATT1 Pump 1 Maximum Flow Rate L/min Adjustment of maximum pump 1 flow rate when using attachment.
ATT1 Pump 2 Maximum Flow Rate L/min Adjustment of maximum pump 2 flow rate when using attachment.
ATT1 Pump 3 Maximum Flow Rate L/min Adjustment of maximum pump 3 flow rate when using attachment.
-1
ATT1 Engine Speed min Adjustment of engine speed when using attachment.
Selection of breaker relief solenoid valve, auxiliary overload relief solenoid valve.
0: Both are disabled
ATT1 Relief Valve (OPT) 0—2
1: ATT relief is enabled
2: Breaker relief is enabled
<- Go to Section TOC Section 9015 page 264 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
<- Go to Section TOC Section 9015 page 265 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
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.
0: System Starting
1: HITACHI
Start Up Screen Image 2: John Deere - 1
3: System Starting (Fixed)
4: REC
0: Auto-control: OFF
Startup Screen Control - 1
1: Auto-control: ON
0: Void
Work Mode With or without function 1
1: Exist
0: Void
Setting Menu With or without function 1
1: Exist
0: Void
Date and Time With or without function 1
1: Exist
0: Void
Attachment Adjust With or without function 1
1: Exist
0: Void
Attachment Name Input With or without function 1
1: Exist
0: Void
Breaker Alarm With or without function 1
1: Exist
0: Void
Auto Shut-down With or without function 1
1: Exist
0: Void
Sub Meter Selection With or without function 1
1: Exist
0: Void
Rear View Camera Monitor With or without function 0
1: Exist
0: Void
Display Item Selection With or without function 1
1: Exist
0: Void
Brightness Adjustment With or without function 1
1: Exist
0: Void
Language With or without function 1
1: Exist
0: Void
Unit Selection With or without function 1
1: Exist
0: Void
Main Menu Sequence Change With or without function 1
1: Exist
0: Void
Information Menu With or without function 1
1: Exist
0: Void
Operation With or without function 1
1: Exist
0: Void
Maintenance With or without function 1
1: Exist
0: Inhibited
Operation Permission - 1
1: Permission
0: Un-displayed
Engine Oil Display 1
1:0 Permission
0: Un-displayed
Engine Oil Filter Display 1
1:0 Permission
0: Un-displayed
Hydraulic Oil Display 1
1:0 Permission
<- Go to Section TOC Section 9015 page 266 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
0: Un-displayed
Pilot Hydraulic Oil Filter Display 1
1:0 Permission
0: Un-displayed
Hydraulic Oil Full-Flow Filter Display 1
1:0 Permission
0: Un-displayed
Pump Transmission Oil Display 1
1:0 Permission
0: Un-displayed
Travel Reduction Gear Oil Display 1
1:0 Permission
0: Un-displayed
Swing Reduction Gear Oil Display 1
1:0 Permission
0: Un-displayed
Swing Motor Drain Filter Display 1
1:0 Permission
0: Un-displayed
Swing Bearing Grease Display 1
1:0 Permission
0: Un-displayed
Air Cleaner Element Display 1
1:0 Permission
0: Un-displayed
Fuel Filter Display 1
1:0 Permission
0: Un-displayed
Air Conditioner Filter Display 1
1:0 Permission
0: Un-displayed
Line Filter Display 1
1:0 Permission
0: Un-displayed
User Setting 1 Display 1
1:0 Permission
0: Un-displayed
User setting 2 Display 1
1:0 Permission
0: Void
Troubleshooting With or without function 1
1: Exist
0: Void
Monitoring With or without function 1
1: Exist
[4] - Use the BACK button to return to the service menu. See Service Menu . (Group 9015-16.)
<- Go to Section TOC Section 9015 page 267 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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:
[5] - Use the BACK button to return to the troubleshooting screen and select another system.
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 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
<- Go to Section TOC Section 9015 page 268 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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
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:
[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.
[7] - Refer to Service ADVISOR ™ system instructions to log into 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] -
<- Go to Section TOC Section 9015 page 269 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Diagnostic Connector
2 Service Laptop
3 PDM-to-Service Laptop Cable
4 PDM
5 PDM-to-Machine Cable
[5] - Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include:
[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.
[8] - Refer to Service ADVISOR ™ system instructions to log into service laptop and connect to machine.
See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
<- Go to Section TOC Section 9015 page 270 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Diagnostics Shortcut Bar
2 Connected Diagnostic Trouble Codes Folder
3 Readings Tab
4 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.)
[4] - From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).
[6] -
<- Go to Section TOC Section 9015 page 271 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.
[7] -
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:
[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).
[10] - After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab
(4) display.
<- Go to Section TOC Section 9015 page 272 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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.
<- Go to Section TOC Section 9015 page 273 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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
[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
Connect service laptop (3) to MPDr connector (2) using TH3100010 MPDr Cable (4), 4668565 RS232C Cable (5), and USB-to-
serial adapter cable (6) if needed.
MPDr Cable
<- Go to Section TOC Section 9015 page 274 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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
<- Go to Section TOC Section 9015 page 275 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Fuse Test
Fuse Test (S.N. —040754)
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 Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
F6 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
F7 Start Position Signal 5 A Fuse (marked START)
F8 Engine Control Unit (ECU) 30 A Fuse (marked ECU)
F9 Radio Backup 10 A Fuse (marked BACK UP)
F10 Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 Not Used
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 One 10 A Fuse (marked AUX)
F16 Start Aid 20 A Fuse (marked START AID)
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)
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.
<- Go to Section TOC Section 9015 page 276 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Fuse Test
Fuse Test
F4—Solenoid 20 A Fuse (marked SOLENOID) If hydraulic system functions normally, fuse is OK. Travel and stick functions 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.
F15—Cab Auxiliary Power Connector One 10 A Fuse (marked Cab auxiliary power connector will not
Check with multimeter.
AUX) operate.
F16—Start Aid (marked SA) If start aid works, fuse is OK. Start aid will not operate.
F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Check with multimeter. Optional equipment will not operate.
<- Go to Section TOC Section 9015 page 277 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Fuse Block 2
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)
F28 Not Used
F29 Not Used
F30 Not Used
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 Not Used
F36 Not Used
F37 Not Used
F38 Not Used
F39 Not Used
F40 Not Used
Fuse Test
Fuse Test
F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) Check with multimeter. Optional equipment will not operate.
F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) Check with multimeter. Optional equipment will not operate.
F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) Check with multimeter. Optional equipment will not operate.
F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) Check with multimeter. Optional equipment will not operate.
F25—IMOBI 5 A Fuse (marked IMOBI) Check with multimeter. Optional equipment will not operate.
F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) Check with multimeter. Optional equipment will not operate.
<- Go to Section TOC Section 9015 page 278 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
F27—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) Check with multimeter. Optional equipment will not operate.
F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) Check with multimeter. Optional equipment will not operate.
F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) Check with multimeter. Optional equipment will not operate.
F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) Check with multimeter. Optional equipment will not operate.
F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) Check with multimeter. Optional equipment will not operate.
Fuse Test
Fuse Test
F60—Alternator 65 A Fuse Check with multimeter. Alternator will not charge electrical system.
F5002—Fuel Transfer Pump 15 A Fuse Check with multimeter. Engine will run out of fuel.
F6000— JDLink ™ Unswitched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.
F6001—JDLink™ Ground 7.5 A Fuse Check with multimeter. JDLink will not operate.
F6002—JDLink™ Switched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.
(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 Section 9015 page 279 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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
F4—Solenoid 20 A Fuse (marked SOLENOID) If hydraulic system functions normally, fuse is OK. Travel and stick functions will not operate.
F16—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) Check with multimeter. 12-Volt Power Outlet will not operate.
F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) Check with multimeter. Optional equipment will not operate.
<- Go to Section TOC Section 9015 page 280 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Fuse Block 2
LEGEND:
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
Fuse Test
Fuse Test
F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) Check with multimeter. Optional equipment will not operate.
F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) Check with multimeter. Optional equipment will not operate.
F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) Check with multimeter. Optional equipment will not operate.
F24—IMOBI 5 A Fuse (marked IMOBI) Check with multimeter. Optional equipment will not operate.
F25—Quick Hitch 5 A Fuse (marked QUICK HITCH) Check with multimeter. Optional equipment will not operate.
F26—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) Check with multimeter. Optional equipment will not operate.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) Check with multimeter. Optional equipment will not operate.
F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) Check with multimeter. Optional equipment will not operate.
F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) Check with multimeter. Optional equipment will not operate.
F34—Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) Check with multimeter. Optional equipment will not operate.
F35—Service Advisor Diagnostic Connector 5 A Fuse (marked DIAG) Check with multimeter. Service ADVISOR ™ will not connect to machine.
Fuse Test
Fuse Test
F60—Alternator 65 A Fuse Check with multimeter. Alternator will not charge electrical system.
F5002—Fuel Transfer Pump 15 A Fuse Check with multimeter. Engine will run out of fuel.
F6000— JDLink ™ Unswitched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.
F6001—JDLink™ Ground 7.5 A Fuse Check with multimeter. JDLink will not operate.
F6002—JDLink™ Switched Power 7.5 A Fuse Check with multimeter. JDLink will not operate.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Relay Test
Relay Test
[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.
[6] - Connect multimeter to terminals 3 and 5. Multimeter must read less than 0.4 ohms. If not, relay has malfunctioned.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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.
[3] - To check a pressure sensor using a multimeter, remove it from the machine.
Multimeter
[4] -
→NOTE:
Resistance values for pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37)
may vary widely.
To verify 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.
Pump 2 Control Pressure Sensor (B38) Resistance 5—15 kilo-ohms (Pins 1—2)
Front Attachment Pressure Sensor (B32) Resistance 5—15 kilo-ohms (Pins 1—2)
For location of pressure sensors, see Machine Harness (W2) Component Location and see Pump Harness (W8) Component
Location . (Group 9015-10.)
[1] - No voltage at pressure sensors will generate diagnostic trouble codes. Disconnect harness connector from a pressure
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
sensor.
[2] - With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector.
Multimeter
To measure voltage
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.
89 lb.-in.
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.
[4] - Measure resistance as indicated. Resistance may vary from one solenoid to another.
Excavator Solenoids
Pilot Shut-Off Solenoid (Y10) Resistance 42—58 ohms
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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.
[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.
Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20) 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
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[1] - To check a temperature sensor using a JDG1478 Digital Multimeter, remove sensor from machine.
Digital Multimeter
JDG1478
[2] - Measure resistance as indicated. Resistance may vary from one sensor to another.
Resistance Temperature
0°C
9900 ohms
32°F
40°C
1600 ohms
104°F
Resistance Temperature
-20°C
13 840—16 330 ohms
-4°F
0°C
5740 ohms
32°F
20°C
2320—2590 ohms
68°F
40°C
1150 ohms
104°F
60°C
584 ohms
140°F
80°C
310—326 ohms
176°F
Resistance Temperature
0°C
9900 ohms
32°F
40°C
1600 ohms
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Alternator Test
LEGEND:
1 Battery
2 Alternator
3 Key Switch
4 To Accessories
5 ACC
6 Alternator Excitation Diode
7 Excitation Terminal (marked D+)
8 B+
9 Exciter Diodes
10 Positive Diodes
11 Negative Diodes
12 Stator
13 Excitation Winding (field)
14 Regulator
15 AC Terminal (marked W)
16 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. ]
.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[ 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 .
[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. ]
.
[ 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 .
[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.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Component Checks
( 1 ) Key Switch Check
Action:
LEGEND:
1 B Terminal
2 G1 Terminal
3 G2 Terminal
4 ACC Terminal
5 M Terminal
6 ST Terminal
Remove starter switch harness (W29) from key switch (S1). See Starter Switch Harness (W29) Component Location . (Group
9015-10.)
Multimeter
To read continuity.
sss:
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.
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Action:
Disconnect machine harness (W2) from battery relay (K19). See Machine Harness (W2) Component Location . (Group 9015-10.)
sss:
Multimeter
To read continuity.
sss:
Is continuity measured?
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.
89 lb.-in.
Result:
YES:Battery relay is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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:
Result:
NO:Batteries are undercharged. Charge batteries. See Using Battery Charger . (Operator′s Manual.)
Action:
LEGEND:
1 Locking Tab
2 Lift Direction
Multimeter
To read continuity.
sss:
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.
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
Multimeter
To test diode.
sss:
sss:
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.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Action:
Multimeter
Disconnect travel alarm harness (W26) from travel alarm (H4). See Travel Alarm Harness (W26) Component Location . (Group
9015-10.)
sss:
sss:
Is continuity measured?
sss:
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.
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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.)
Action:
Disconnect monitor harness (W3) from monitor warning alarm (H3). See Monitor Harness (W3) Component Location . (Group
9015-10.)
sss:
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.)
Action:
Multimeter
To read continuity.
sss:
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Result:
Action:
LEGEND:
1 Terminal 1
2 Terminal 2
Alternator Resistor
Multimeter
To read continuity.
sss:
Result:
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Battery (2 used)
2 Wing Nut (4 used)
3 Washer (8 used)
4 Cover (2 used)
5 Spacer (4 used)
6 Nut (4 used)
7 Clamp
8 Bracket (2 used)
9 Bolt (4 used)
10 Positive Cable
11 Jumper Cable
12 Negative Cable
13 Cap Screw
[6] - Check cables and clamps for wear or corrosion. Verify 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.
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Plug (2 used)
2 Cap Screw (3 used)
3 Right Cover
4 Cap Screw
5 Cap Screw
6 Left Cover
7 Plug (2 used)
8 Cap Screw (2 used)
9 Upper Rear Cover
10 Cap Screw (2 used)
11 Washer (2 used)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.)
[5] - Tag and disconnect lighter (R9) and 12 volt power outlet (G5) from cab harness and remove left cover (6).
[8] - Remove plugs (12) and cap screws and washers (10, 11 and 13).
[12] - Install cap screws and washers (10, 11 and 13) and plugs (12).
[15] - Connect lighter (R9) and 12 volt power outlet (G5) to cab harness and install left cover (6).
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)
[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.
[11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
(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
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)
[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.
[11] - Connect electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)
[13] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
[4] -
LEGEND:
1 Screw (4 used)
2 Screw (4 used)
3 Bracket
A7 Air Conditioner Controller (ACF)
Disconnect air conditioner controller (ACF) connector (A7). See Heater and Air Conditioner Harness (W41) Component Location
. (Group 9015-10.)
[7] -
LEGEND:
4 Screw (2 used)
A11 Machine Controller (BCZ)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[8] -
LEGEND:
A11 Machine Controller (BCZ)
X10 Machine Controller 8-Pin Connector A
X11 Machine Controller 20-Pin Connector B
Disconnect electrical connectors; machine controller 8-pin connector A (X10) and machine controller 20-pin connector B (X11).
[11] - Connect electrical connectors and install machine controller and screws.
[15] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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
Tag and disconnect engine control unit (ECU) electrical connectors (X14 and X15) from ECU (A1). See Engine Harness (W4)
Component Location . (Group 9015-10.)
[7] - Connect ECU electrical connectors. See Engine Harness (W4) Component Location . (Group 9015-10.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Screw (3 used)
A5 Data Converter
Data Converter
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)
[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
[8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.
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
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)
[3] - Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
[4] - Disconnect electrical connectors (X20—X24) from monitor controller (DSZ) (A4).
[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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9001-01.)
[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.)
[8] - Install rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.)
[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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Cap Screw (2 used)
2 Armrest
3 Storage Compartment
4 Cap Screw (3 used)
5 Rear Switch Console
6 Cap Screw (2 used)
7 Pilot Control Lever Bezel
8 Cap Screw (2 used)
9 Right Switch Console
10 Right Switch Console Bezel
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
[5] - Disconnect cab harness (W1) electrical connectors from rear switch console (5). See Cab Harness (W1) Component
Location . (Group 9015-10.)
[7] - Pull pilot control lever boot up and remove cap screws (6).
[10] - Disconnect cab harness (W1) electrical connectors from right switch console (9). See Cab Harness (W1) Component
Location . (Group 9015-10.)
[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.)
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Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
1 Cap Screw (2 used)
2 Washer (2 used)
3 Armrest
4 Cap Screw (3 used)
5 Left Switch Console
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.)
[4] - Pull pilot control lever boot up and remove cap screws (4).
[6] - Tag and disconnect cab harness (W1) electrical connectors. See Cab Harness (W1) Component Location . (Group
9015-10.)
<- Go to Section TOC Section 9015 page 314 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[8] - Connect cab harness electrical connectors. See Cab Harness (W1) Component Location . (Group 9015-10.)
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.)
<- Go to Section TOC Section 9015 page 315 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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
[2] - While holding tab in, grasp other half of connector and pull connector halves apart.
<- Go to Section TOC Section 9015 page 316 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.
<- Go to Section TOC Section 9015 page 317 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[1] - Select correct size extractor tool for size of wire to be removed:
[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:
Slide extractor tool along wire into connector body until it is positioned over terminal contact.
[6] -
IMPORTANT:
<- Go to Section TOC Section 9015 page 318 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Push Contact
Push contact straight into connector body until positive stop is felt.
<- Go to Section TOC Section 9015 page 319 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
→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 Connector
2 Locking Wedge
Pull connector (1) apart. Inspect and clean connector seal and contacts.
[2] - Remove locking wedge (2) from connector using hook on JDG1383 service tool.
JDG1383
[3] -
LEGEND:
3 Primary Locking Latches
<- Go to Section TOC Section 9015 page 320 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Removing Wire
Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool.
[5] - Replace connector contact as necessary. See Install DEUTSCH™ Contact . (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.
<- Go to Section TOC Section 9015 page 321 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Crimper
[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:
Adjusting Screw
Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).
[6] -
IMPORTANT:
<- Go to Section TOC Section 9015 page 322 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Crimp
[8] -
IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.
→NOTE:
<- Go to Section TOC Section 9015 page 323 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Terminal Contact
IMPORTANT:
[2] - Insert JDG364 Extraction Tool over terminal contact 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
contact from connector.
[4] -
IMPORTANT:
→NOTE:
Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment.
<- Go to Section TOC Section 9015 page 324 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
<- Go to Section TOC Section 9015 page 325 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Strip Insulation
→NOTE:
[2] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
[3] -
→NOTE:
Contacts 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 contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.
[4] -
<- Go to Section TOC Section 9015 page 326 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
IMPORTANT:
Proper contact installation for "sleeve" (A) and "pin” (B) is shown.
<- Go to Section TOC Section 9015 page 327 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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
Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.
Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body
socket.
<- Go to Section TOC Section 9015 page 328 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
→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.
Disconnect the Metri-Pack ™ connector. Remove the tie bands and tape.
Remove the connector lock (A), and mark wire colors for identification.
→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.
<- Go to Section TOC Section 9015 page 329 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[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
[4] -
<- Go to Section TOC Section 9015 page 330 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Removing Terminals
Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will
release the primary contact locking tab.
<- Go to Section TOC Section 9015 page 331 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
LEGEND:
A Top of Tool
B Contact Support
C Locator
D Wire
E Micro Timer Slot
F Junior Timer Slot
G Contact
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
[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 contact.
Position the contact so that the mating end of the contact (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 Section 9015 page 332 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
[3] - Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in
position. Do NOT deform wire and insulation tabs (I and J).
[4] - Insert stripped wire into contact 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 contact.
<- Go to Section TOC Section 9015 page 333 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Cinch ™ Connector
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.
[4] -
<- Go to Section TOC Section 9015 page 334 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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 20 Gauge Holes
B 16 & 18 Gauge Holes
C Holes
D Terminal Hole
E Terminal
Connector Holes
<- Go to Section TOC Section 9015 page 335 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
JDG1744
JDG1744
[7] -
LEGEND:
A CINCH™ Terminal Crimping Tool
B Terminal Receptacle
C Terminal
D Wire
Crimp terminal
<- Go to Section TOC Section 9015 page 336 130G Excavator Diagnostic
Section 9015 - ELECTRICAL SYSTEM Group 20: References
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.
[14] - Hold wire stationary and squeeze tool together until ratchet releases.
[16] - Terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position.
<- Go to Section TOC Section 9015 page 337 130G Excavator Diagnostic
POWER TRAIN (g) by Belgreen v2.0
[19] - Install connector to controller and close connector body locking cam.
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.
<- Go to Section TOC Section 9020 page 338 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1
LEGEND:
1 Grease Fitting
2 Valve
3 Grease Relief Passage
4 Cylinder
5 Yoke
6 Front Idler
7 Piston
8 Recoil Spring
9 Grease
The track adjuster and recoil spring is supported 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).
Increasing track sag is accomplished by loosening the valve (2) to release grease from the cylinder through the grease relief
passage (3). When releasing grease from the cylinder, only loosen the valve (2).
LEGEND:
1 Ring Gear
2 Second Stage Carrier
3 Second Stage Sun Gear
4 First Stage Carrier
5 First Stage Sun Gear (input shaft)
6 First Stage Planetary Gear
7 Second Stage Planetary Gear
8 Bearing Nut
9 Sprocket
10 Drum
11 Travel Motor Housing
12 Bearing Cone and Cup (2 used)
13 Travel Motor Valve Housing
14 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.
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
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.)
Result:
YES:Go to Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve.
( 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.)
Result:
Action:
Result:
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
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.)
Result:
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.
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.)
Action:
Measure grouser height specification for rebuilding or replacing track shoes. See 130G Three Bar Grouser Height . (SP326VOL1
Undercarriage Appraisal Manual.)
Result:
NO:Repair or replace track shoes. See Track Shoe Remove and Install . (Group 0130.)
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.)
Result:
Action:
Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch Panel . (Operator′s
Manual.)
Result:
“Popping” of Track
81
Action:
High travel speeds in reverse can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize travel loads in
reverse.
Result:
Action:
Result:
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
Action:
Result:
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
Action:
Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode. See Switch Panel . (Operator′s
Manual.)
Result:
Action:
Are the narrowest possible shoes for required flotation being used?
Result:
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
Action:
Are the narrowest possible shoes for required flotation being used?
Result:
Action:
Check track chain pitch specifications. See 130G Track Chain Pitch . (SP326VOL1 Undercarriage Appraisal Manual.)
Result:
NO:Repair or replace track chain as necessary. See Track Chain Remove and Install . (Group 0130.)
Action:
Measure components to determine if they can be rebuilt using weld. See Component Rebuild . (SP326VOL1 Undercarriage
Appraisal Manual.)
Result:
SPECIFICATIONS
Swing Bearing
0.2—1.00 mm normal
Swing Bearing Play
0.008—0.039 in. normal
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.
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.)
[4] -
→NOTE:
Readings vary depending on the location of dial indicator base with respect to the swing bearing support
tower. To obtain an accurate reading, the base for dial indicator must be attached to the support tower
or as close to it as possible.
Install dial indicator with needle point contacting bottom face of bearing outer race and base attached to the swing bearing
support tower or as close to it as possible.
Dial Indicator
[5] - Move boom and arm to the position shown with bucket off the ground. Bucket must be empty.
[7] - Lower the boom to raise front idlers off the ground approximately 500 mm (20 in.).
Swing Bearing
Swing Bearing Play 0.2—1.00 mm normal
If play is more than specified, check for wear to balls, spacers, and bearing race. See Swing Bearing Remove and Install .
(Group 4350.)
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 (5-
spool). 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 passages in control valve by the valve spools. From the return
passages, 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 passage 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 bypass 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 bypass 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.)
LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
134 Fan Speed Control Valve
600 High Pressure Oil
604 Return Oil
Y5005 Variable Speed Fan Solenoid
LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
135 Fan Speed and Reversing Control Valve (if equipped)
600 High Pressure Oil
604 Return Oil
Y9 Reversing Fan Solenoid
Y5005 Variable Speed Fan Solenoid
A hydraulic-powered cooling fan is used to provide air flow for the machine′s cooling package. The fan drive system consists of:
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 bypass 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.
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.
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 bypass valve, and pilot pressure regulating valve.
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.
LEGEND:
2 Driven Gear
3 From Hydraulic Pump Suction Line
4 Drive Gear
5 Port PE-to-Pump 1 and 2 Servo Pistons and Regulators
6 Port TA-to-Hydraulic Return Manifold
7 Plug (port PC)
8 Plug (port PG)
10 Regulated Pilot Oil (marked PD)-to-Solenoid Valve Manifold
11 Test Port (marked PF)
12 From Pilot Pump Outlet (marked PA)
13 Pilot Filter Element
14 Pilot Pressure Regulating Valve Spool
15 Spring
16 Shim (as required)
28 Pilot Pump
30 Pilot Pressure Regulating Valve
Pilot filter element (13), bypass valve, and pilot pressure regulating valve (30) are incorporated into one assembly.
Pilot filter bypass valve senses differential pressure between inlet side and outlet side of filter element. During normal
operation, bypass 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 bypass valve open.
Pilot oil now bypasses 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.)
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.)
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 de-
energized. 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.
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.
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.
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 contacts the spool, pushing it down until the plunger contacts 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 passage to the control valve pilot cap is open to
port T and pilot oil from port P is blocked.
LEGEND:
1 Spool
2 Washer
3 Spring Guide
4 Plunger
5 Adjustment Screw
6 Cam and Pedal
7 Sleeve
8 Balance Spring
9 Return Spring
10 Port T to Hydraulic Oil Tank
11 Port P From Pilot Shutoff Solenoid Valve
12 Port 1, 2, 3, or 4-to-Control Valve Pilot Cap
13 Travel Pilot Control Valve—Full Stroke
604 Return Oil
609 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 passage 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 passage 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
passage 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 contacts the plunger. The plunger holds the spool down so the passage 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 Travel Pedal
15 Spring Pin
16 Damper
17 Support
18 Bracket
19 Gear 2
20 Gear 1
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 support (17) connected to the bracket with a spring pin (15). Gear 1 (20) is connected to the support.
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.
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:
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:
→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 bypass shutoff valve
(93) and to front attachment pressure sensor (B32) inside swing parking brake shuttle valve (146).
LEGEND:
1, A Boom Up
2, B Boom Down
3, C Arm Out
4, D Arm In
5, E Swing Left
6, F Swing Right
7, G Bucket Curl
8, H Bucket Dump
9, I Left Travel Forward
10, J Left Travel Reverse
11, K Right Travel Forward
12, L Right Travel Reverse
13, M Plug (auxiliary)
14, N Plug (auxiliary)
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
42 Boom Down Shockless Valve
43 Arm 1 (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)
70 Orifice
→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.
LEGEND:
1 To Bottom Pilot Cap
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
42 Boom Down Shockless Valve
50 Shuttle Valve
<- Go to Section TOC Section 9025 page 20 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
138 Spring A
139 Passage 1
140 Tapered Land
141 Orifice
142 Spring B
143 Passage 3
144 Oil Chamber
145 Passage 2
A From Pilot Control Valve—Boom Up
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 passage 2
(145), and out port 1 to the control valve pilot cap. Pilot oil also flows through passage 3 (143) into spring B (142) cavity and
passage 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 passage 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 passage 1 to spring A
cavity and through passage 2, through the orifice, and into the oil chamber. From the oil chamber, return oil flows through
passage 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.
LEGEND:
41A Control Valve Side of Pilot Signal Manifold
41B Pilot Control Valve Side of Pilot Signal Manifold
47 Pump 2 Flow Rate Pilot Valve Spool (port SB)
48 Pump 1 Flow Rate Pilot Valve Spool (port SA)
50 Shuttle Valve
146 To Hydraulic Oil Tank by Port DF
147 Pilot Oil From Actuated Pilot Control Valves
148 Pilot Oil From Actuated Pilot Control Valves
149 Pilot Oil From Port PI
150 Spring Chamber
151 Passage A
SA Port SA to Pump 1 Regulator
SB 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 passage 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.
LEGEND:
152 Pilot Oil Pressure
153 To Hydraulic Oil Tank
154 To Bucket Flow Rate Valve
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.
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.)
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
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.)
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.
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).
Boom Up, A X X X
Boom Down, B X X
Arm In, D X X X X X
Arm Out, C X X X
Bucket Curl, G X X
Bucket Dump, H X X
Right Swing, F X X
Left Swing, E X X
Right Travel, L, K X X
Left Travel, I, J X
Auxiliary, N, M X X
There are six outputs of the pilot signal manifold other than providing passages for pilot oil to shift control valve spools.
LEGEND:
7 Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons
11 Damper Drive (flex coupling)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
28 Pilot Pump
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 Torque Control Solenoid (marked ST)
LEGEND:
7 Pilot Pressure Regulating Valve Port PC-to-Maximum Displacement Servo Pistons
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
<- Go to Section TOC Section 9025 page 30 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
25 Feedback Lever
26 Feedback Link
27 Swash Plate
28 Pilot Pump
29 Minimum Displacement Servo Piston (2 used)
30 Maximum Displacement Servo Piston (2 used)
Y20 Pump 2 Flow Rate Limit Solenoid (marked SB)
Y21 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 feedback lever (25) and feedback link (26), providing a
feedback 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.)
LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
5 Remote Control Spool
6 Piston
7 Minimum Flow Adjusting Screw
8 Load Adjusting Screw (inner spring)
9 Load Adjusting Cartridge (outer spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback 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
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 feedback 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.)
LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
<- Go to Section TOC Section 9025 page 33 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Pilot oil (609) from pilot pump is constantly supplied through drilled passages 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 passages 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 passages 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.
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 passage 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
feedback link (16). Sleeves move left until passages 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.
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
contacts maximum flow adjusting screw (2). Movement of spool opens the passage 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 feedback link (16). Sleeves move left until passage 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 Section 9025 page 34 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passage 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 contacts 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 feedback
link (16). Sleeves move right until passage 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.
LEGEND:
1 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
5 Remote Control Spool
6 Piston
8 Load Adjusting Cartridge (outer spring)
9 Load Adjusting Screw (inner spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback Link
17 Servo Piston
18 To Large End of Servo Piston
19 Return to Pump Housing
20 Pump 1 Pressure Inlet
21 Pump 2 Pressure Inlet
22 Torque Control Port
23 From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 Pilot Oil Inlet
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
611 Charge Oil
613 Reduced Pilot Oil
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
passage 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 feedback 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 passage 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 feedback 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 Flow Adjusting Cartridge (track cycle time)
2 Maximum Flow Adjusting Screw
3 Spring
4 Remote Control Sleeve
5 Remote Control Spool
6 Piston
8 Load Adjusting Cartridge (outer spring)
9 Load Adjusting Screw (inner spring)
10 Inner Spring
11 Outer Spring
12 Load Sleeve
13 Load Spool
14 Load Piston 2
15 Load Piston 1
16 Feedback Link
17 Servo Piston
18 To Large End of Servo Piston
19 Return to Pump Housing
20 Pump 1 Pressure Inlet
21 Pump 2 Pressure Inlet
22 Torque Control Port
23 From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 Pilot Oil Inlet
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
<- Go to Section TOC Section 9025 page 37 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
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.)
LEGEND:
1 Spring
2 Spool Return Spring
3 Inlet Port
4 Sleeve
5 Outlet Port to Load Piston
6 Spool
7 Return Port to Pump Case
17 Pump 1 Regulator
18 Pump 2 Regulator
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
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.)
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.
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
87 Boom Lower Meter-In Cut Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
95 Swing Spool
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
79 Bucket Dump Circuit Relief and Anticavitation Valve
<- Go to Section TOC Section 9025 page 42 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passages 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.
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.)
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
<- Go to Section TOC Section 9025 page 44 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passages for
each valve spool section and then into return oil (604) the return passage. Neutral and power passages 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 passages 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 passage to supply the auxiliary spool (107).
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
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 passages so oil is not trapped
between the travel valve spools and the counterbalance valves in the travel motors. The circuit is open to return passage 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 passage, through the left travel neutral passage 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 passage, through the travel power
passage 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 passage, 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 passage.
For additional information, See Travel Flow Combiner Valve Operation . (Group 9025-05.)
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 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 passage, 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 passage.
In combined operation with right propel valve, pump 1 high pressure oil also flows from the right control valve neutral passage,
through the power passage, 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 Section 9025 page 47 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passage, through the
power passage, 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 passage. High pressure
oil from pump 1 can be combined with high pressure oil from pump 2 by using the bypass shutoff valve and auxiliary flow
combiner valve to operate an auxiliary functions. The pilot lines to the auxiliary flow combiner valve and bypass shutoff valve
are connected to the hydraulic oil tank.
For additional information, See Auxiliary Flow Rate Control Valve Circuit Operation . (Group 9025-05.)
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
115 Main Relief Valve Isolation Check Valve (P1)
116 Main Relief Valve Isolation Check Valve (P2)
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 Bypass Shut-Off Valve Operation (Group 9025-05.)
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
89 Boom Down Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
156 Manual Boom Lower Screw
B30 Boom Up Pressure Sensor
<- Go to Section TOC Section 9025 page 49 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.)
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
88 Boom Up Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
94 Arm Regenerative Valve
97 Arm 1 Spool
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 Bypass Shutoff Valve Cross Section (from rear)
LEGEND:
73 4-Spool Control Valve
74 5-Spool Control Valve
93 Bypass Shutoff Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
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 passage (96). (Group
9025-05.)
Bypass shutoff valve (93) is used when optional attachments are installed on the machine. See Auxiliary Flow Combiner Valve
and Bypass Shut-Off Valve Operation . (Group 9025-05.)
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Function Flow Combiner Valve
119 Check Valve—Auxiliary Function Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
122 Check Valve (lift check)—Bucket
123 Orifice—Bucket Power Circuit
124 Hydraulic Oil Cooler Bypass Valve
128 Check Valve
149 Arm 1 Regenerative Cut Valve
166 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 passages.
Check Valves (105 and 112): Check valves function as lift checks in the power passages.
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 Section 9025 page 54 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Orifice—Left Travel Power Passage (113): Restricts the flow of high pressure oil from pump 2 (16) through the power
passage 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 passage 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 passage oil flow pressure for the 4-
spool 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 bypass shutoff valve (93). Check valve closes if high pressure oil in the left control valve (74) power
passage becomes higher than high pressure oil pressure in the right control valve (73) neutral passage.
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 Bypass 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 bypass valve is higher than the restriction valve.
Operational Check: Hydraulic oil continues to run hot. Check for an open bypass valve.
LEGEND:
1 Main Poppet
2 Orifice A
3 Orifice B
4 Seat
5 Passage A
6 Spring B
7 Piston
8 Pilot Poppet
9 Spring Chamber
10 Spring A
11 Sleeve
12 Normal Operation
13 Relief Operation
<- Go to Section TOC Section 9025 page 56 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passage 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.
LEGEND:
1 Main Poppet
2 Orifice A
3 Orifice B
4 Seat
5 Passage A
6 Spring B
7 Piston
8 Pilot Poppet
9 Spring Chamber
10 Spring A
11 Sleeve
117 Main Relief and Power Dig Valve
200 From Main Circuit
201 To Return
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
SG 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.)
LEGEND:
1 Adjusting Screw
2 Pilot Poppet Spring
3 Pilot Poppet
4 Main Poppet
5 Main Poppet Spring
6 Orifice
7 Anticavitation Valve Poppet
8 Anticavitation Valve Spring
9 Conical Face
10 From Work Circuit
11 Return Passage
12 Drain Passage
13 Closed Relief Valve
14 Relief Operation
15 Anticavitation Operation
600 High Pressure Oil
601 Low Pressure Oil
604 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 passage (12) to the return
passage (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 passage. 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 passage.
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 passage into the work circuit preventing cavitation. The main poppet bottoms against
a shoulder and does not follow the anticavitation valve poppet.
LEGEND:
4 Arm In (pilot)
9 Left Travel Forward (pilot)
11 Right Travel Forward (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
61 Right Travel Motor
63 Left Travel Motor
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
117 Main Relief and Power Dig Valve
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Circuit
124 Oil Cooler Bypass Valve
127 Arm Cylinder
144 To Blade Control Valve
145 From Travel Flow Combiner Shuttle Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B31 Arm In Pressure Sensor
LEGEND:
15 From Pump 1
110 To Left Travel Spool
120 Travel Flow Combiner Valve
145 From Travel Flow Combiner Shuttle Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
When only travel functions are actuated, high pressure oil (600) from pump 2 (16) flows through the neutral passage 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 passages 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.
LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
73 4-Spool Control Valve
74 5-Spool Left Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
174 Auxiliary Attachment
177 From Flow Rate Select Solenoid Valve
178 To Flow Rate Select Reducing Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
→NOTE:
Auxiliary flow combiner valve and bypass shutoff valve will not wok properly unless appropriate kits are
installed on machine.
The combined functions of auxiliary flow combiner valve (118) and bypass 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).
LEGEND:
15 From Pump 1
107 To Auxiliary Spool
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
177 From Flow Rate Select Solenoid Valve
178 To Flow Rate Select Reducing Valve
600 High-Pressure Oil
604 Return Oil
609 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 bypass shutoff valve. When the bypass shutoff valve is shifted, pump 1 high-pressure oil in neutral
passage flow to return passage 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 Section 9025 page 70 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
neutral position and block flow of pump 1 oil to the auxiliary spool.
LEGEND:
15 From Pump 1
31 To Hydraulic Oil Tank
93 Bypass Shutoff Valve
170 From Auxiliary Shuttle Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
When an auxiliary or blade function is actuated, pilot pressure is applied to bypass shutoff valve, causing the valve to shift.
When the bypass shutoff valve is shifted, pump 1 high-pressure oil in neutral passage flow to return passage 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.
LEGEND:
2 Boom Down (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
128 Check Valve
154 To Shuttle Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regeneration Oil
LEGEND:
2 Boom Down (pilot)
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.)
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Hole A
15 From Pump 1
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Meter-In Cut Valve
87A From Boom Meter-In Cut Valve
104 From Boom 2 Spool
125 Boom Cylinder (2 used)
125A From Boom Cylinders (head end)
125B To Boom Cylinders (rod end)
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
610 Regeneration Oil
DD 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 Section 9025 page 76 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
to the return passage. 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.
LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
73 4-Spool Control Valve
74 5-Spool Rear Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
128 Check Valve
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regenerative Oil
650 Voltage Signal
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
DZ To Solenoid Valve Manifold Port DZ
Y22 Dig Regenerative Solenoid (marked SF)
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)
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.
LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 83 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 bypass
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 passage 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 Schematic (arm in and swing left actuated)
LEGEND:
1 Boom Up (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot)
6 Swing Right (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 From Arm 1 Flow Rate Pilot Valve (port SK)
52 Swing Motor
73 4-Spool Control Valve
74 5-Spool Control Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
124 Oil Cooler Bypass Valve
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High-Pressure Oil
602 Low-Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regenerative Oil
650 Voltage Signal
A3 Main Controller (MCZ)
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
B33 Swing Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
DE To Solenoid Valve Manifold Port DE
Y23 Arm Regenerative Solenoid (SC)
LEGEND:
3 Arm Out (pilot)
4 Arm In (pilot)
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
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)
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).
LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 90 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 bypass
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 passage 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.)
LEGEND:
1 Hole A
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
15 From Pump 1
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
126 Bucket Cylinder
126A To Bucket Cylinder Head End
126B From Bucket Cylinder Rod End
166 Bucket Regeneration Cut Valve
166A To Bucket Regeneration Cut Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
610 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 passage. 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
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.
→NOTE:
The operation of boom reduced leakage valve and arm reduced leakage valve is similar. Boom reduced
leakage valve operation is depicted.
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Spring A
4 Spring B
5 Orifice
15 From Pump 1
81 Boom 1 Spool
81A To Boom 1 Spool
85 Boom Reduced Leakage Valve (valve and check valve)
125 Boom Cylinder (2 used)
125A From Boom Cylinder Head Ends
200 Valve
201 Check Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
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.)
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Spring A
4 Spring B
5 Orifice
15 From Pump 1
81 Boom 1 Spool
81A To Boom 1 Spool
85 Boom Reduced Leakage Valve (valve and check valve)
125 Boom Cylinder (2 used)
125A From Boom Cylinder Head Ends
200 Valve
201 Check Valve
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
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 passage 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.
LEGEND:
4 Arm In (pilot)
5 Swing Left (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 From Arm 1 Flow Rate Pilot Valve (port SE)
52 Swing Motor
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 2 Flow Rate Control Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B31 Arm In Pressure Sensor
DE 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.
<- Go to Section TOC Section 9025 page 100 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
16 From Pump 2
43 From Arm 1 Flow Rate Pilot Valve (port SE)
97 To Arm 1 Spool
98 Arm 1 Flow Rate Control Valve
200 Check Valve
201 Poppet
202 Switch Valve
600 High Pressure Oil
604 Return Oil
DE 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.
<- Go to Section TOC Section 9025 page 101 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
16 From Pump 2
43 From Arm 1 Flow Rate Pilot Valve (port SE)
97 To Arm 1 Spool
98 Arm 1 Flow Rate Control 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
DE 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.
<- Go to Section TOC Section 9025 page 102 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 103 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 104 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Coolet Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
SI 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.)
<- Go to Section TOC Section 9025 page 105 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 106 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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
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.
<- Go to Section TOC Section 9025 page 107 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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.)
<- Go to Section TOC Section 9025 page 108 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 109 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 110 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Boom Up (pilot)
4 Arm In (pilot)
7 Bucket Curl (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
46 From Bucket Flow Rate Pilot Valve (port SK)
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
94 Arm Regenerative Valve
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
117 Main Relief and Power Dig Valve
124 Oil Coolet Bypass Valve
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
149 Arm 1 Regenerative Cut Valve
166 Bucket Regenerative Cut Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
B30 Boom Up Pressure Sensor
B31 Arm In Pressure Sensor
DD To Solenoid Valve Manifold Port DD
DK To Solenoid Valve Manifold Port DK
SI 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.
<- Go to Section TOC Section 9025 page 111 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 112 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.)
<- Go to Section TOC Section 9025 page 113 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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.)
<- Go to Section TOC Section 9025 page 114 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 116 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
2 Boom Down (pilot)
3 Arm Out (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
81 Boom 1 Spool
82 Boom Regenerative Valve
83 Boom Flow Rate Control Valve (valve and poppet)
85 Boom Reduced Leakage Valve (valve and check valve)
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
97 Arm 1 Spool
98 Arm 1Flow Rate Control Valve (valve and poppet)
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
117 Main Relief and Power Dig Valve
124 Oil Cooler Bypass Valve
125 Boom Cylinder (2 used)
127 Arm Cylinder
128 Check Valve
149 Arm 1 Regenerative Cut Valve
154 To Shuttle Valve
600 High Pressure Oil
602 Low Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
610 Regeneration Oil
DD 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.)
<- Go to Section TOC Section 9025 page 117 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 118 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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).
<- Go to Section TOC Section 9025 page 119 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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 Section 9025 page 120 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 122 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
5 Swing Left (pilot)
6 Swing Right (pilot)
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
52 Swing Motor
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
174 Auxiliary Attachment
177 From Flow Rate Select Solenoid Valve (2 used)
178 To Flow Rate Select Reducing 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
→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:
For more information on sensors, see System Functional Schematic . (Group 9015-10.)
<- Go to Section TOC Section 9025 page 123 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 124 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 high-
pressure oil flows through the poppet to auxiliary spool. For auxiliary flow rate control valve circuit location information, see
Control Valve Operation . (Group 9025-05.)
<- Go to Section TOC Section 9025 page 125 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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.
<- Go to Section TOC Section 9025 page 126 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 127 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
15 Pump 1
16 Pump 2
37A From Solenoid Valve Manifold
37B From Solenoid Valve Manifold
73 Right Control Valve
74 Left Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
117 Main Relief and Power Dig Valve
120 Travel Flow Combiner Valve
121 Check Valve—Travel Flow Combiner Valve Circuit
140 Blade Spool
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve
143 Blade Cylinder (2 used)
144 Blade Control Valve
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
151 Blade Main Relief Valve
152 Blade Pump
153 Pilot Shutoff Valve
155 Shuttle Valve
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
Y10 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:
Pilot oil to bypass 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.
<- Go to Section TOC Section 9025 page 128 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
When control lever is in neutral, high pressure oil from blade pump returns to the hydraulic oil tank through blade control
valve.
<- Go to Section TOC Section 9025 page 129 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Swing Motor Shaft
2 First Stage Planetary Gear
3 Ring Gear
4 Second Stage Planetary Gear
5 Swing Bearing Internal Gear
6 Shaft
7 Second Stage Carrier
8 Second Stage Sun Gear
9 First Stage Carrier
10 First Stage Sun Gear
52 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.
<- Go to Section TOC Section 9025 page 130 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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.)
<- Go to Section TOC Section 9025 page 131 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
11 Poppet (2 used)
53 Swing Motor Make-Up Check Valve (2 used)
54 Swing Crossover Relief Valve (2 used)
LEGEND:
12 Low Pressure Port (return circuit)
13 High Pressure Port (swing circuit)
14 Poppet
15 Spring (2 used)
54 Swing Crossover Relief Valve
600 High Pressure Oil
604 Return Oil
<- Go to Section TOC Section 9025 page 132 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of 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 make-
up check valve (53) provides oil to the low pressure side of the swing motor to prevent cavitation.
<- Go to Section TOC Section 9025 page 133 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
<- Go to Section TOC Section 9025 page 134 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
<- Go to Section TOC Section 9025 page 135 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
31A To Hydraulic Oil Tank
37B From Solenoid Valve Manifold
61 Right Travel Motor
61A To Right Travel Motor
61B From Right Travel Motor
63 Left Travel Motor
63A To Left Travel Motor
63B From Left Travel Motor
72 Center Joint
75A To Right Travel Spool
75B From Right Travel Spool
110A To Left Travel Spool
110B From Left Travel Spool
143 Blade Cylinder (2 used)
143A To Blade Cylinder (piston side)
143B To Blade Cylinder (rod side)
144A From Blade Control Valve (blade down)
144B From Blade Control Valve (blade up)
600 High Pressure Oil
604 Return Oil
606 Trapped Oil
609 Pilot Oil
The center joint (72) is a 360° rotary manifold. The center joint 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 passages 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 passages.
<- Go to Section TOC Section 9025 page 136 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
See Travel Hydraulic System Line Connection for line identification and connections. (Group 9025-15.)
<- Go to Section TOC Section 9025 page 137 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
60 Right Travel Device
61 Right Travel Motor
62 Left Travel Device
<- Go to Section TOC Section 9025 page 138 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Drum
2 Piston
3 Housing
<- Go to Section TOC Section 9025 page 139 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
4 Drive Shaft
5 Valve Plate
6 Brake Valve Housing
7 Park Brake Piston
8 Swash Plate
64 Travel Park Brake
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 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 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.
<- Go to Section TOC Section 9025 page 140 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
2 Piston
8 Swash Plate
10 Spring
37 From Solenoid Valve Manifold—Power Dig Solenoid (marked SG)
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 Shuttle Valve
70 Orifice
604 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 Section 9025 page 141 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
The swash plate (8) is held at maximum displacement. At maximum displacement the motor turns at slow speed with high
torque.
LEGEND:
2 Piston
8 Swash Plate
10 Spring
37 From Solenoid Valve Manifold—Power Dig Solenoid (marked SG)
65 Travel Speed Servo Piston
66 Travel Speed Change Valve
67 Shuttle Valve
70 Orifice
600 High Pressure Oil
602 Pilot Oil
604 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.)
<- Go to Section TOC Section 9025 page 142 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
LEGEND:
7 To Park Brake Piston
11 To Travel Motor
12 Poppet
13 Orifice
14 Piston
15 Spring (4 used)
16 Spring (4 used)
17 Restriction
67 Shuttle Valve
68 Travel Motor Crossover Relief Valve (2 used)
<- Go to Section TOC Section 9025 page 143 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 passage. 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.
<- Go to Section TOC Section 9025 page 144 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Fast (rabbit) Speed
2 Slow (turtle) Speed
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
61 Right Travel Motor
63 Left Travel Motor
66 Travel Speed Change Valve (2 used)
609 Pilot Oil
650 Electrical Voltage
A3 Main Controller (MCZ)
B32 Front Attachment Pressure Sensor
B34 Travel Pressure Sensor
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
S11 Travel Speed Switch
Y24 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 Section 9025 page 145 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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:
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).
<- Go to Section TOC Section 9025 page 146 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Solenoid Coil
2 Spool
3 To Valve Function
4 De-Energized
5 Energized
<- Go to Section TOC Section 9025 page 147 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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 bypass
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 passage 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.)
<- Go to Section TOC Section 9025 page 148 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Cylinder Operation
Cylinder Operation
LEGEND:
1 Snap Ring
2 Wiper Seal
3 Backup Ring
4 U-Cup Seal
5 Buffer Ring
6 Wear Ring
7 Snap Ring
8 Piston
9 Buffer Ring (2 used)
10 Wear Ring (2 used)
11 Cap Seal
12 Set Screw
13 Nut
14 Cushion
15 Barrel
16 Cylinder Rod
17 Rod Guide
18 Bucket Cylinder
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
pass 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 Section 9025 page 149 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
<- Go to Section TOC Section 9025 page 150 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Return Filter Bypass Operation
2 Return Filter Normal Operation
3 Bypass Valve
4 Filter Element
5 Return Oil From Oil Cooler
6 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 bypass 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 bypass 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
bypass valve open allowing oil to flow down the center of the filter element and into the hydraulic oil tank. The bypass valve
closes when the pressure decreases below the pressure setting of the bypass valve.
→NOTE:
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 Section 9025 page 151 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
<- Go to Section TOC Section 9025 page 152 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.)
<- Go to Section TOC Section 9025 page 153 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 154 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
<- Go to Section TOC Section 9025 page 155 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
1 Spool
2 Washer
3 Spring Guide
4 Plunger
5 Adjustment Screw
<- Go to Section TOC Section 9025 page 156 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
6 Pedal
7 Sleeve
8 Balance Spring
9 Return Spring
10 To Pilot Shutoff Solenoid Valve Port T2
11 From Pilot Shutoff Solenoid Valve Port A3
12 Port 13 or 14 To Control Valve Pilot Cap
15 Auxiliary Pilot Control Valve—Full Stroke
604 Pilot Oil
609 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 passage 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 passage 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 passage 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 contacts the plunger. The plunger holds the spool down so the passage through the spool remains
open to pilot oil pressure. Oil pressure to the control valve pilot cap now approximately equals pilot oil pressure.
<- Go to Section TOC Section 9025 page 157 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
<- Go to Section TOC Section 9025 page 158 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 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.
<- Go to Section TOC Section 9025 page 159 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 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.
<- Go to Section TOC Section 9025 page 160 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
29 From Pilot Filter and Bypass Valve
93 To Bypass Shutoff Valve
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner Valve
177 Flow Rate Select Solenoid Valve
SM From Pilot Signal Manifold Port SM
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 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:
For more information on sensors, see System Functional Schematic . (Group 9015-10.)
<- Go to Section TOC Section 9025 page 161 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
→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 bypass 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 bypass 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 bypass 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.
LEGEND:
118 To Auxiliary Flow Combiner Valve
178 Flow Rate Pressure Reducing Valve
DP To Solenoid Valve Manifold Port DP
SN 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 Section 9025 page 162 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.)
LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 To Selector Valve
Y40 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 bypass 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.)
<- Go to Section TOC Section 9025 page 163 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
107 To or From Auxiliary Spool
174 From Auxiliary Attachment
175 From Selector Valve Solenoid Valve
176 Selector Valve
DM 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.
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.
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, in-
out, left-right. Return oil then passes through the auxiliary spool to control valve return passage.
For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)
<- Go to Section TOC Section 9025 page 164 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
93 To Bypass Shutoff Valve
118 To Auxiliary Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 From Flow Rate Select Solenoid Valve
SP 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
bypass 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 Section 9025 page 165 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
For more information, see Control Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-05.)
<- Go to Section TOC Section 9025 page 166 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 167 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 168 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1
16 Pump 2
28 Pilot Pump
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
120 Travel Flow Combiner Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
Y40 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.)
<- Go to Section TOC Section 9025 page 169 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 From Selector Valve
604 Return Oil
609 Pilot Oil
Y40 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.)
LEGEND:
29 From Pilot Filter and Bypass Valve
175 Selector Valve Solenoid Valve
176 To Selector Valve
604 Return Oil
609 Pilot Oil
Y40 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.)
<- Go to Section TOC Section 9025 page 170 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
107 To Auxiliary Spool
174 From Auxiliary Attachment
175 From Selector Valve Solenoid Valve
176 Selector Valve
604 Return Oil
609 Pilot Oil
DM 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.)
LEGEND:
107 To Auxiliary Spool
174 From Auxiliary Attachment
175 To Selector Valve Solenoid Valve
176 Selector Valve
604 Return Oil
DM 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.)
<- Go to Section TOC Section 9025 page 171 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 172 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
<- Go to Section TOC Section 9025 page 173 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
→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.
<- Go to Section TOC Section 9025 page 174 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Solenoid Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
221 To Pilot Signal Manifold Port M
604 Return Oil
609 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.
LEGEND:
153 From Pilot Shutoff Valve
172 Auxiliary Solenoid Valve
173 Auxiliary Pressure Reducing Valve
220 To Pilot Signal Manifold Port N
<- Go to Section TOC Section 9025 page 175 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
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.
<- Go to Section TOC Section 9025 page 176 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
<- Go to Section TOC Section 9025 page 177 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)
<- Go to Section TOC Section 9025 page 178 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
15 Pump 1
16 Pump 2
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
180 To Torque Control Solenoid Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
DP To Solenoid Valve Manifold Port DP
DY To Solenoid Valve Manifold Port DY
Y43 2-Speed Activation Solenoid Valve
Y44 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.
<- Go to Section TOC Section 9025 page 179 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
93 To Bypass Shutoff Valve
118 To Auxiliary Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 From Flow Rate Select Solenoid Valve
SP To Pilot Signal Manifold Port SP
Auxiliary Shuttle Valve— For more information, see Auxiliary Shuttle Valve Operation . (Group 9025-05.)
<- Go to Section TOC Section 9025 page 180 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 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.)
<- Go to Section TOC Section 9025 page 181 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 From Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 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.)
<- Go to Section TOC Section 9025 page 182 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation
LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve
Flow Rate Select Solenoid Valve Energized— For more information, see Flow Rate Select Solenoid Valve Operation .
(Group 9025-05.)
<- Go to Section TOC Section 9025 page 183 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
28 Pilot Pump
108 To Auxiliary Flow Rate Control Valve
118 To Auxiliary Flow Combiner (2 used)
170 To Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
DP To Solenoid Valve Manifold Port DP
SM From Pilot Signal Manifold Port SM
SN From Pilot Signal Manifold Port SN
SP To Pilot Signal Manifold Port SP
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve
Flow Rate Solenoid Valve De-Energized— For more information, see Flow Rate Select Solenoid Valve Operation . (Group
9025-05.)
<- Go to Section TOC Section 9025 page 184 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)
Result:
Action:
Check hydraulic oil temperature. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
Result:
Action:
Check hydraulic oil for proper viscosity. See Hydraulic Oil . (Operator’s Manual.)
Result:
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.)
Result:
<- Go to Section TOC Section 9025 page 185 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pump suction line for leaks. See Hydraulic System Component Location . (Group 9025-15.)
Result:
Action:
Result:
NO:Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)
Action:
Result:
Action:
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)
Result:
Action:
Check pump 1 or pump 2 regulator. See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)
<- Go to Section TOC Section 9025 page 186 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Result:
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.)
Result:
NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)
Action:
Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Adjust or replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)
Action:
See Power Dig Solenoid Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Adjust or replace power dig solenoid valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)
Action:
Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)
<- Go to Section TOC Section 9025 page 187 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Result:
NO:Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install .
(Group 3360.)
<- Go to Section TOC Section 9025 page 188 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)
Result:
Action:
Result:
Action:
Check hydraulic oil for correct viscosity. See Hydraulic Oil . (Operator’s Manual.)
Result:
Action:
Inspect fan drive. See Fan Speed Test and see Fan Drive Pump Flow Test . (Group 9025-25.)
Result:
NO:Repair or replace fan drive. See Fan Drive Motor Remove and Install . (Group 0510.)
<- Go to Section TOC Section 9025 page 189 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Result:
Action:
Check hydraulic oil return filter for restriction. See Hydraulic System Component Location . (Group 9025-15.)
Result:
YES:Replace hydraulic oil tank return filter. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)
Action:
Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)
Action:
Perform main relief and power dig valve test. See Main Relief and Power Dig Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Replace power dig valve. See Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)
Action:
Inspect oil cooler bypass valve. See Hydraulic Oil Cooler Bypass Valve Remove and Install . (Group 3360.)
<- Go to Section TOC Section 9025 page 190 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Result:
Action:
Result:
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.)
<- Go to Section TOC Section 9025 page 191 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
No Hydraulic Functions
73
Action:
Result:
Action:
Result:
Action:
Check hydraulic oil level. See Check Hydraulic Tank Oil Level . (Operator’s Manual.)
Result:
Action:
Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install . (Group 0752.)
Result:
<- Go to Section TOC Section 9025 page 192 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter . (Operator’s Manual.)
Result:
<- Go to Section TOC Section 9025 page 193 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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:
NO:Replace front attachment pressure sensor (B32) or travel pressure sensor (B34).
Action:
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.)
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.)
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.)
Result:
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.)
<- Go to Section TOC Section 9025 page 194 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Result:
Action:
Result:
Action:
Check pilot oil pressure. See Pilot Pressure Regulating Valve and Filter Remove and Install . (Group 9025-25.)
Result:
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.)
<- Go to Section TOC Section 9025 page 195 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect control valve spool. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)
Result:
Action:
Inspect pilot signal manifold for sticking spools. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)
Result:
Action:
Inspect left and right pilot valve spools. See Pilot Valve (Left and Right) Disassemble and Assemble . (Group 3360.)
Result:
<- Go to Section TOC Section 9025 page 196 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
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.)
Result:
Action:
Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)
Result:
NO:Repair or replace pilot signal flow rate pilot spool. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)
Action:
Inspect control valve spools. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)
<- Go to Section TOC Section 9025 page 197 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Result:
<- Go to Section TOC Section 9025 page 198 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot filter for restriction. See Hydraulic System Component Location . (Group 9025-15.)
Result:
NO:Replace pilot filter. See Replace Pilot Oil Filter . (Operator’s Manual.)
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.)
Result:
Action:
Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)
Result:
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.)
Action:
Inspect pilot shutoff solenoid valve for restriction. See Hydraulic System Component Location . (Group 9025-15.)
Result:
<- Go to Section TOC Section 9025 page 199 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
NO:Repair or replace pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install . (Group 3360.)
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.)
Result:
<- Go to Section TOC Section 9025 page 200 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect hydraulic system for malfunctions. See All Hydraulic Functions Slow . (Group 9025-15.)
Result:
Action:
Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.)
Result:
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.)
Result:
NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.)
<- Go to Section TOC Section 9025 page 201 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated . (Group 9025-15.)
Result:
Action:
Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.)
Result:
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.)
Result:
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.)
Action:
Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
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 Section 9025 page 202 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect control valve for stuck spool. See Control Valve Operation . (Group 9025-05.)
Result:
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.)
Action:
Inspect pump 1 or pump 2 flow rate pilot valves? See Pilot Signal Manifold Operation . (Group 9025-05.)
Result:
NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
<- Go to Section TOC Section 9025 page 203 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group 9025-25.)
Result:
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.)
Action:
Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
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.)
Action:
Inspect boom manual lower screw. See Lower Boom with Engine Stopped . (Operator’s Manual.)
Result:
Action:
Inspect control valve for leakage. See Travel System Component Location . (Group 9025-15.)
Result:
<- Go to Section TOC Section 9025 page 204 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
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.)
<- Go to Section TOC Section 9025 page 205 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal
73
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.
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.)
Result:
Action:
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.)
Result:
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 Section 9025 page 206 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.
Result:
NO:Check wiring harness. See Machine Harness (W2) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9025 page 207 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
Action:
Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)
Action:
Inspect swing valve spool in control valve for leakage. For component location, see Control Valve Operation . (Group 9025-05.)
Result:
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.)
Action:
Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.)
Result:
NO:Repair or replace swing motor. See Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake
<- Go to Section TOC Section 9025 page 208 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)
Result:
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.)
Result:
NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)
<- Go to Section TOC Section 9025 page 209 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)
Result:
Action:
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .
(Group 9025-05.)
Result:
NO:Repair or replace swing motor make-up check valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)
Action:
Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)
Action:
Inspect control valve for sticking spool. For component location, see Control Valve Operation . (Group 9025-05.)
Result:
<- Go to Section TOC Section 9025 page 210 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
<- Go to Section TOC Section 9025 page 211 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect swing motor and park brake for proper application and release. See Swing Motor Park Brake Release Circuit Operation .
(Group 9025-05.)
Result:
( 2 ) Drift direction
Action:
Result:
Action:
Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.)
Result:
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.)
Action:
Inspect park brake valve for sticking damper valve spool. See Swing Motor Park Brake Release Circuit Operation (Group
9025-05) for component identification.
Result:
NO:Repair or replace damper valve spool. See Crossover Relief Valve and Make-Up Check Valve Remove and Install . (Group
<- Go to Section TOC Section 9025 page 212 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
4360.)
Action:
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation .
(Group 9025-05.)
Result:
NO:Repair or replace swing motor make-up check valves. See Crossover Relief Valve and Make-Up Check Valve Remove and
Install . (Group 4360.)
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.)
Result:
YES:Repair or replace crossover relief valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install .
(Group 4360.)
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.)
Result:
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.)
<- Go to Section TOC Section 9025 page 213 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)
Result:
Action:
Inspect pump 1 or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation . (Group 9025-05.)
Result:
NO:Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
Action:
Inspect for stuck swing valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)
Result:
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.)
Action:
Result:
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 Section 9025 page 214 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
Result:
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.)
Result:
<- Go to Section TOC Section 9025 page 215 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)
Result:
Action:
Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
Action:
Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)
Result:
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.)
Action:
Inspect counterbalance valve. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.)
Result:
NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
<- Go to Section TOC Section 9025 page 216 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 4360.)
Result:
NO:Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 4360.)
<- Go to Section TOC Section 9025 page 217 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect pilot circuit for malfunction. See Pilot System Operation . (Group 9025-05.)
Result:
Action:
Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
Action:
Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation . (Group 9025-05.)
Result:
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.)
Action:
Result:
NO:Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
<- Go to Section TOC Section 9025 page 218 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)
Result:
NO:Repair or replace center joint. See Center Joint Remove and Install . (Group 4360.)
<- Go to Section TOC Section 9025 page 219 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
Action:
Check control valve spool actuating pilot pressure. See Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-25.)
Result:
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.)
Action:
Inspect travel motor crossover relief valves. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
Action:
Inspect servo piston shuttle valve. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)
Result:
<- Go to Section TOC Section 9025 page 220 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
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.)
Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)
Result:
NO:Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 0260.)
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.)
Result:
NO:Repair or replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Disassemble and Assemble . (Group 3360.)
<- Go to Section TOC Section 9025 page 221 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
Action:
Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
NO:Repair or replace travel motor crossover relief valve. See Park Brake Valve Disassemble and Assemble . (Group 0260.)
Action:
Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)
Result:
Action:
Inspect travel motor for leakage. See Travel Motor Leakage Test . (Group 9025-25.)
Result:
NO:Repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)
<- Go to Section TOC Section 9025 page 222 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 0260.)
Result:
NO:Repair or replace center joint. See Center Joint 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.)
Result:
NO:Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)
Action:
Check engine speed and power mode setting. See Engine Speed Control System Operation . (Group 9010-05.)
Result:
<- Go to Section TOC Section 9025 page 223 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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.)
Result:
Action:
Inspect for stuck travel and boom valve spools in control valve. For component location, see Control Valve Operation . (Group
9025-05.)
Result:
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.)
<- Go to Section TOC Section 9025 page 224 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Travel is “Jerky”
73
Action:
Check track sag. See Check and Adjust Track Sag . (Operator′s Manual.)
Result:
( 2 ) Roller Malfunction
Action:
Inspect rollers.
Result:
Action:
Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble . (Group 0260.)
Result:
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.)
Result:
<- Go to Section TOC Section 9025 page 225 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Action:
Inspect undercarriage components. See SP326VOL1 Undercarriage Appraisal Manual for 130G specifications.
Result:
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.)
Result:
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.)
Result:
<- Go to Section TOC Section 9025 page 226 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Pilot Pump Suction
2 Pilot Signal Manifold (port SB)-to-Pump 2 Regulator
3 Pump 2-to-Control Valve (5 spool)
4 Pilot Signal Manifold (port SA)-to-Pump 1 Regulator
5 Pump 1-to-Control Valve (4 spool)
6 Pilot Filter-to-Return Manifold
7 Pilot Filter-to-Solenoid Valve Manifold (port PD)
8 Pump 1 Attenuator
9 Pump 1, Pump 2 Suction
10 Pilot Pump-to-Pilot Filter
11 Pilot Filter-to-Pump 2 Regulator
12 Pump 2 Attenuator
15 Pump 1 (4-spool)
<- Go to Section TOC Section 9025 page 227 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
16 Pump 2 (5-spool)
17 Regulator Drain Hose to Hydraulic Oil Tank
28 Pilot Pump
29 Pilot Filter and Bypass Valve
<- Go to Section TOC Section 9025 page 228 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
2 Boom Down (pilot)
4 Arm In (pilot)
6 Swing Right (pilot)
7 Bucket Curl (pilot)
10 Left Travel Reverse (pilot)
12 Right Travel Reverse (pilot)
31 To Hydraulic Oil Tank
36 To Hydraulic Oil Cooler
43 From Arm In Flow Rate Pilot Valve (port SE)
51 From Swing Device
52A To Swing Motor (swing left)
52B To Swing Motor (swing right)
63A To Center Joint (left travel forward)
<- Go to Section TOC Section 9025 page 229 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Boom Up (pilot)
<- Go to Section TOC Section 9025 page 230 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 231 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 From Control Valve Swing Left
2 From Control Valve Swing Right
3 To Hydraulic Oil Tank Return Manifold
4 To Control Valve
5 From Pilot Signal Manifold (port SH)
6 Case Drain Line
B32 Front Attachment Pressure Sensor
<- Go to Section TOC Section 9025 page 232 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 233 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Port 1
2 Port 2
3 Port 3
4 Port 4
5 Pilot Control Shutoff Valve
6 From Solenoid Valve Manifold (port PE)
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
A Port A
A1 To Travel Pilot Controller
A2 Port A2
A3 Port A3
A4 Port A4
B Port B
C Port C
D Port D
E Port E
F Port F
G Port G
H Port H
P Port P
PI Port PI
T Port T
T1 From Travel Pilot Controller
T2 Port T2
T3 Port T3
Excavator Pattern
Bucket Dump 1 H 8
Boom Down 2 B 2
Right Pilot Lever
Bucket Curl 3 G 7
Boom Up 4 A 1
Swing Right 1 F 6
Arm Out 2 C 3
Swing Left 3 E 5
Left Pilot Lever
Arm In 4 D 4
<- Go to Section TOC Section 9025 page 234 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 235 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Port 1
2 Port 2
3 Port 3
4 Port 4
5 Pilot Control Shutoff Valve
6 From Solenoid Valve Manifold (port PE)
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
A Port A
A1 To Travel Pilot Controller
A2 Port A2
A3 Port A3
A4 Port A4
B Port B
C Port C
D Port D
E Port E
F Port F
G Port G
H Port H
P Port P
PI Port PI
T Port T
T1 From Travel Pilot Controller
T2 Port T2
T3 Port T3
Backhoe Pattern
Bucket Dump 1 H 8
Arm Out 2 C 3
Right Pilot Lever
Bucket Curl 3 G 7
Arm In 4 D 4
Swing Right 1 F 6
Boom Down 2 B 2
Swing Left 3 E 5
Left Pilot Lever
Boom Up 4 A 1
<- Go to Section TOC Section 9025 page 236 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
2 Port 2 to Boom Down Pilot Cap
4 Port 4 to Arm In Pilot Cap
6 Port 6 to Swing Right Pilot Cap
<- Go to Section TOC Section 9025 page 237 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 238 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Port 1 to Boom Up Pilot Cap
3 Port 3 to Arm Out Pilot Cap
5 Port 5 to Swing Left Pilot Cap
8 Port 8 to Bucket Dump Pilot Cap
9 Port 9 to Left Travel Forward Pilot Cap
11 Port 11 to Right Travel Forward Pilot Cap
41 Pilot Signal Manifold
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
<- Go to Section TOC Section 9025 page 239 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
31 Hydraulic Oil Tank
38 Travel Pilot Control Valve
41 Pilot Signal Manifold
<- Go to Section TOC Section 9025 page 240 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 241 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 242 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
9 Left Travel Forward Port (pilot side)
10 Left Travel Reverse Port (pilot side)
11 Right Travel Forward Port (pilot side)
12 Right Travel Reverse Port (pilot side)
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
41 Pilot Signal Manifold
60 Right Travel Device
62 Left Travel Device
72 Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool (4-spool)
110 Left Travel Spool (5-spool)
160 Left Travel Forward
161 Right Travel Forward
162 Left Travel Reverse
163 Right Travel Reverse
164 Return Line to Hydraulic Oil Tank
I Left Travel Forward Port (control side)
J Left Travel Reverse Port (control side)
K Right Travel Forward Port (control side)
L Right Travel Reverse Port (control side)
PI Pilot Shutoff Solenoid Valve Port
Y10 Pilot Shutoff Solenoid Valve
Y24 Power Dig Solenoid Valve (port SG)
<- Go to Section TOC Section 9025 page 243 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 244 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Center Joint-to-Blade Cylinder Rod End Hose (2 used)
2 Center Joint-to-Blade Cylinder Head End Hose (2 used)
3 Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose
4 Blade Pilot Control Valve-to-Blade Signal Shuttle Valve Hose
5 Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose
6 Blade Pilot Control Valve-to-Pilot Shutoff Valve Hose
7 Blade Control Valve-to-Control Valve (5 spool) Hose
8 Blade Control Valve-to-Blade Signal Shuttle Valve Hose
9 Blade Control Valve-to-Blade Signal Shuttle Valve Hose
10 Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose
11 Blade Control Valve-to-Hydraulic Oil Tank Return Manifold Hose
12 Blade Control Valve-to-Center Joint Hose
13 Blade Control Valve-to-Blade Main Relief Valve Hose
14 Blade Control Valve-to-Center Joint Hose
15 Blade Signal Shuttle Valve-to-Pilot Signal Manifold Hose
16 Blade Control Valve-to-Swing Parking Brake Shuttle Valve Hose
17 Solenoid Valve Manifold-to-Pilot Shutoff Valve Hose
18 Pump 1 Regulator Valve-to-Pilot Signal Manifold Hose
19 Hydraulic Oil Return-to-Hydraulic Oil Tank Hose
20 Swing Parking Brake Shuttle Valve-to-Swing Park Brake Hose
21 Pilot Pump-to-Solenoid Valve Manifold Hose
22 Blade Pump-to-Blade Main Relief Valve Hose
23 Blade Main Relief Valve-to-Control Valve Hose
28 Pilot Pump
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
40 Blade Pump Supply Hose
41 Pilot Signal Manifold
52 Swing Motor
72 Center Joint
74 Control Valve (5 spool)
132 Fan Drive Pump
143 Blade Cylinder (2 used)
144 Blade Control Valve
146 Swing Parking Brake Shuttle Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
151 Blade Main Relief Valve
152 Blade Pump
153 Pilot Shutoff Valve
<- Go to Section TOC Section 9025 page 245 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 246 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 247 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
<- Go to Section TOC Section 9025 page 248 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
<- Go to Section TOC Section 9025 page 249 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
153 Pilot Shutoff Valve
172 Auxiliary Soleniod Valve
173 Auxiliary Pressure Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
<- Go to Section TOC Section 9025 page 250 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 251 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
13 Auxiliary (pilot)
14 Auxiliary (pilot)
15 Pump 1
16 Pump 2
28 Pilot Pump
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxiliary Flow Combiner Valve
120 Travel Flow Combiner Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
Y40 Selector Valve Solenoid Valve
<- Go to Section TOC Section 9025 page 252 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Two Pump Combined Flow Kit Schematic (auxiliary function active, 2-speed activation solenoid valve [Y43] energized)
<- Go to Section TOC Section 9025 page 253 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
15 Pump 1
16 Pump 2
28 Pilot Pump
41 Pilot Signal Manifold
45 Swing Park Brake Release Pilot Valve (port SH)
47 Pump 2 Flow Rate Pilot Valve (port SB)
48 Pump 1 Flow Rate Pilot Valve (port SA)
56 To Swing Park Brake
73 4-Spool Control Valve
74 5-Spool Control Valve
75 Right Travel Spool
76 Bucket Spool
81 Boom 1 Spool
90 Arm 2 Spool
93 Bypass Shutoff Valve
95 Swing Spool
97 Arm 1 Spool
104 Boom 2 Spool
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
110 Left Travel Spool
117 Main Relief and Power Dig Valve
118 Auxilairy Flow Combiner Valve
119 Check Valve—Flow Combiner Valve Circuit
120 Travel Flow Combiner Valve
155 From Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
179 To Pump 2 Flow Rate Solenoid Valve
180 To Torque Control Solenoid Valve
600 High-Pressure Oil
604 Return Oil
609 Pilot Oil
B60 Attachment Pressure Sensor
B61 Arm Out Pressure Sensor
DP To Solenoid Valve Manifold Port DP
DY To Solenoid Valve Manifold Port DY
Y43 2-Speed Activation Solenoid Valve
Y44 Flow Rate Adjustment Solenoid Valve
<- Go to Section TOC Section 9025 page 254 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 255 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 256 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
28 Pilot Pump
29 Pilot Filter and Bypass Valve
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
174 Auxiliary Attachment
175 Selector Valve Solenoid Valve
176 Selector Valve
Y40 Selector Valve Solenoid Valve
<- Go to Section TOC Section 9025 page 257 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 258 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
28 Pilot Pump
29 Pilot Filter and Bypass Valve
31 Hydraulic Oil Tank
37 Solenoid Valve Manifold
41 Pilot Signal Manifold
73 4-Spool Control Valve
74 5-Spool Control Valve
155 Shuttle Valve
170 Auxiliary Shuttle Valve
177 Flow Rate Select Solenoid Valve
178 Flow Rate Select Reducing Valve
<- Go to Section TOC Section 9025 page 259 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 260 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 261 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
17 To Pump 1 Regulator
18 To Pump 2 Regulator
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
37 Solenoid Valve Manifold
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 Arm 1 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)
49 Filter Screen (17 used)
50 Shuttle Valve (17 used)
56 From Swing Park Brake
77 To Bucket Flow Rate Control Valve (valve and poppet)
83 From Boom Flow Rate Control Valve (valve and poppet)
84 From Dig Regenerative Valve (2 used)
91 From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used)
93 To Bypass Shutoff Valve
94 From Arm Regenerative Cut Valve
98 To Arm 1 Flow Rate Control Valve (valve and poppet)
108 From Auxiliary Flow Rate Control Valve (valve and poppet)
118 From Auxiliary Function Flow Combiner Valve
120 To Travel Flow Combiner Valve
129 Orifice
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
153 Pilot Shutoff Valve
155 Shuttle Valve
200 From Main Relief and Power Dig Valve and Center Joint
201 To Pump 1 Control Pressure Sensor and Pump 1 Regulator
202 Blade Down (pilot)
203 Blade Up (pilot)
204 From Boom Lower Meter-In Cut Valve and Arm 1 Spool
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
Y10 Pilot Shutoff Solenoid
Y22 Dig Regenerative Solenoid (SF)
Y23 Arm Regenerative Solenoid (SC)
Y24 Power Dig Solenoid (SG)
Y27 Arm 2 Flow Control Solenoid (SI)
<- Go to Section TOC Section 9025 page 262 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 263 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
17 To Pump 1 Regulator
18 To Pump 2 Regulator
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
37 Solenoid Valve Manifold
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 Arm 1 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)
49 Filter Screen (17 used)
50 Shuttle Valve (17 used)
56 From Swing Park Brake
77 To Bucket Flow Rate Control Valve (valve and poppet)
83 From Boom Flow Rate Control Valve (valve and poppet)
84 From Dig Regenerative Valve (2 used)
91 From Arm 2 Flow Rate Control Valve (valve and poppet) (2 used)
93 To Bypass Shutoff Valve
94 From Arm Regenerative Cut Valve
98 To Arm 1 Flow Rate Control Valve (valve and poppet)
108 From Auxiliary Flow Rate Control Valve (valve and poppet)
118 From Auxiliary Function Flow Combiner Valve
120 To Travel Flow Combiner Valve
129 Orifice
145 Travel Flow Combiner Shuttle Valve
146 Swing Parking Brake Shuttle Valve
147 Blade Signal Selector Valve
148 Blade Signal Shuttle Valve
150 Blade Pilot Control Valve
153 Pilot Shutoff Valve
155 Shuttle Valve
200 From Main Relief and Power Dig Valve and Center Joint
201 To Pump 1 Control Pressure Sensor and Pump 1 Regulator
202 Blade Down (pilot)
203 Blade Up (pilot)
204 From Boom Lower Meter-In Cut Valve and Arm 1 Spool
604 Return Oil
609 Pilot Oil
B32 Front Attachment Pressure Sensor
B33 Swing Pressure Sensor
B34 Travel Pressure Sensor
Y10 Pilot Shutoff Solenoid
Y22 Dig Regenerative Solenoid (SF)
Y23 Arm Regenerative Solenoid (SC)
Y24 Power Dig Solenoid (SG)
Y27 Arm 2 Flow Control Solenoid (SI)
<- Go to Section TOC Section 9025 page 264 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 265 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
13 Plug—Auxiliary (pilot)
14 Plug—Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 Arm 1 Flow Rate Pilot Valve (port SE)
46 Bucket Flow Rate Pilot Valve (port SK)
51 From Swing Device
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
72 From Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regeneration Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 Plug (2 used)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
114 Orifice—Air Bleed (9 used)
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
<- Go to Section TOC Section 9025 page 266 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
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Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 268 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Boom Up (pilot)
2 Boom Down (pilot)
3 Arm Out (pilot)
4 Arm In (pilot)
5 Swing Left (pilot) (5-spool)
6 Swing Right (pilot) (5-spool)
7 Bucket Curl (pilot)
8 Bucket Dump (pilot)
9 Left Travel Forward (pilot)
10 Left Travel Reverse (pilot)
11 Right Travel Forward (pilot)
12 Right Travel Reverse (pilot)
13 Plug—Auxiliary (pilot)
14 Plug—Auxiliary (pilot)
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
36 Hydraulic Oil Cooler
43 Arm 1 Flow Rate Pilot Valve (port SE)
46 Bucket Flow Rate Pilot Valve (port SK)
51 From Swing Device
52 Swing Motor
61 Right Travel Motor
63 Left Travel Motor
72 From Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
75 Right Travel Spool
76 Bucket Spool
77 Bucket Flow Rate Control Valve (valve and poppet)
78 Bucket Regenerative Valve
79 Bucket Dump Circuit Relief and Anticavitation Valve
80 Bucket Curl Circuit Relief and Anticavitation Valve
81 Boom 1 Spool
82 Boom Regeneration Valve
83 Boom Flow Rate Control Valve (valve and poppet)
84 Dig Regenerative Valve
85 Boom Reduced Leakage Valve (valve and check valve)
86 Orifice
87 Boom Lower Meter-In Cut Valve
88 Boom Up Circuit Relief and Anticavitation Valve
89 Boom Down Circuit Relief and Anticavitation Valve
90 Arm 2 Spool
91 Arm 2 Flow Rate Control Valve (valve and poppet)
92 Check Valve (lift check)—Arm 2 Neutral Passage
93 Bypass Shutoff Valve
94 Arm Regenerative Valve
95 Swing Spool
96 Check Valve (lift check)—Swing Neutral Passage
97 Arm 1 Spool
98 Arm 1 Flow Rate Control Valve (valve and poppet)
100 Check Valve (lift check)—Dig Regenerative Circuit
101 Arm Reduced Leakage Valve (valve and poppet)
102 Arm In Circuit Relief and Anticavitation Valve
103 Arm Out Circuit Relief and Anticavitation Valve
104 Boom 2 Spool
105 Check Valve (lift check)—Boom 2 Power Circuit
107 Auxiliary Spool
108 Auxiliary Flow Rate Control Valve (valve and poppet)
109 Plug (2 used)
110 Left Travel Spool
111 Check Valve (lift check)—Left Travel Neutral Passage
112 Check Valve (lift check)—Left Travel Power Passage
113 Orifice—Left Travel Power Passage
114 Orifice—Air Bleed (9 used)
115 Main Relief Valve Isolation Check Valve—5-Spool
116 Main Relief Valve Isolation Check Valve—4-Spool
<- Go to Section TOC Section 9025 page 269 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 270 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
51 Swing Device
52 Swing Motor
53 Swing Motor Make-Up Check Valve (2 used)
54 Swing Crossover Relief Valve (2 used)
55 Swing Damper Valve
56 Swing Park Brake
57 Orifice
58 Check Valve
59 Flow Control Valve
73 To Right Control Valve Return Passage
95A From Swing Spool—Right Swing
95B From Swing Spool—Left Swing
205 To Swing Parking Brake Shuttle Valve and Swing Park Brake Release Pilot Valve (port SH)
604 Return Oil
<- Go to Section TOC Section 9025 page 271 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
60 Right Travel Device
61 Right Travel Motor
62 Left Travel Device
63 Left Travel Motor
64 Travel Park Brake (2 used)
65 Travel Speed Servo Piston (2 used)
66 Travel Speed Change Valve (2 used)
67 Shuttle Valve (2 used)
68 Travel Motor Crossover Relief Valve (4 used)
69 Check Valve (4 used)
70 Orifice (4 used)
71 Counterbalance Valve (2 used)
72 Center Joint
75A From Right Travel Spool—Forward
75B From Right Travel Spool—Reverse
<- Go to Section TOC Section 9025 page 272 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 273 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 274 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
17 Pump 1 Regulator
18 Pump 2 Regulator
27 Attenuator Hose (2 used)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
36 Hydraulic Oil Cooler
37A To Solenoid Valve Manifold
37B From Solenoid Valve Manifold
41 From Pilot Signal Manifold
47 From Pump 2 Flow Rate Pilot Valve (port SB)
52 From Swing Motor
72 From Center Joint
73A To Right Control Valve (4-spool)
73B From Right Control Valve (4-spool)
73C From Right Control Valve (4-spool
74A To Left Control Valve (5-spool)
74B From Left Control Valve (5-spool)
124 Oil Cooler Bypass Valve
128 Check Valve
132 Fan Drive Pump
133 To Fan Drive Motor
144A From Blade Control Valve
144B From Blade Control Valve
151 From Blade Main Relief Valve
152 Blade Pump
153 From Pilot Shutoff Valve
206 To Blade Main Relief Valve and Blade Control Valve
208 From Pump 1 Flow Rate Pilot Valve (port SA)
600 High Pressure Oil
604 Return Oil
609 Pilot Oil
B35 Pump 1 Delivery Pressure Sensor
B36 Pump 1 Control Pressure Sensor
B37 Pump 2 Delivery Pressure Sensor
B38 Pump 2 Control Pressure Sensor
Y20 Pump 2 Flow Rate Limit Solenoid (SB)
Y21 Torque Control Solenoid (ST)
For more information on fan drive, See Fan Drive Hydraulic System Schematic . (Group 9025-15.)
<- Go to Section TOC Section 9025 page 275 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
36 Hydraulic Oil Cooler
37 Solenoid Valve Manifold
38 Travel Pilot Control Valve
39 Left Pilot Control Valve
40 Right Pilot Control Valve
41 Pilot Signal Manifold
51 Swing Device
<- Go to Section TOC Section 9025 page 276 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 277 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 278 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
15 Pump 1 (4-spool)
16 Pump 2 (5-spool)
28 Pilot Pump
29 Pilot Filter and Bypass Valve
30 Pilot Pressure Regulating Valve
31 Hydraulic Oil Tank
36 Hydraulic Oil Cooler
41 Pilot Signal Manifold
51 Swing Device
72 Center Joint
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
125 Boom Cylinder (2 used)
126 Bucket Cylinder
127 Arm Cylinder
SA Pump 1 Flow Rate Pilot Valve Port
SB Pump 2 Flow Rate Pilot Valve Port
SH Swing Park Brake Release Port
<- Go to Section TOC Section 9025 page 279 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
<- Go to Section TOC Section 9025 page 280 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
1 Case Drain Line (fan drive motor to hydraulic oil tank)
2 Supply Line (hydraulic oil tank to fan drive pump)
3 Supply Line (fan drive pump to fan drive motor)
4 Return Line (fan drive motor to hydraulic oil return manifold)
5 Hydraulic Oil Return Manifold
6 Return Line (hydraulic oil cooler to hydraulic oil return manifold)
31 Hydraulic Oil Tank
132 Fan Drive Pump
133 Fan Drive Motor
B53 Fan Speed Sensor
Y9 Reversing Fan Solenoid (if equipped)
Y5005 Variable Speed Fan Solenoid
<- Go to Section TOC Section 9025 page 281 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
134 Fan Speed Control Valve
600 High Pressure Oil
604 Return Oil
Y5005 Variable Speed Fan Solenoid
<- Go to Section TOC Section 9025 page 282 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
31 Hydraulic Oil Tank
32 Return Filter
34 Filter Bypass
35 Suction Screen
132 Fan Drive Pump
133 Fan Drive Motor
135 Fan Speed and Reversing Control Valve (if equipped)
600 High Pressure Oil
604 Return Oil
Y9 Reversing Fan Solenoid
Y5005 Variable Speed Fan Solenoid
<- Go to Section TOC Section 9025 page 283 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Group 25 - Tests
JT05800 Digital Thermometer Installation
LEGEND:
A Temperature Probe
B Cable
C JT05800 Digital Thermometer
[1] - Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.
Digital Thermometer
JT05800
<- Go to Section TOC Section 9025 page 284 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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
JT05969 Thermo-Coupler
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.
JT02156A
Kit contains the analyzer, cable, two transducers, thermo-coupler, and a carry case.
JT02158
To display digital readings for temperature and single, multiple, or differential hydraulic oil pressure. Also reads vacuum when
used with 500 psi transducer.
JT02159
JT02161
<- Go to Section TOC Section 9025 page 285 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
JT02162
Thermo-Coupler
JT05969
Carry Case
312883
70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)
JT02160
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.
<- Go to Section TOC Section 9025 page 286 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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)
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
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.
[5] -
<- Go to Section TOC Section 9025 page 287 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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
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
3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip)
[6] -
→NOTE:
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.)
[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.
<- Go to Section TOC Section 9025 page 288 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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 bypass.
Run machine at slow idle. Operate each circuit a minimum of 3—5 minutes in each direction to flush any remaining
contaminants.
[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.)
[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.
Bypass 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.
<- Go to Section TOC Section 9025 page 289 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Park Machine
[2] - Position machine with arm cylinder fully retracted and bucket cylinder fully extended.
[5] -
LEGEND:
1 Pressure Release Button
2 Hydraulic Oil Tank Cover
Press pressure release button (1) to relieve hydraulic oil tank pressure.
<- Go to Section TOC Section 9025 page 290 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
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 Section 9025 page 291 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
[3] - Run machine at specification for approximately 5 minutes before operating any functions.
Power Mode Button Position ECO (economy) Mode if below -18°C (0°F)
[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.
110—130°F
<- Go to Section TOC Section 9025 page 292 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
3.8—4.8 MPa
3805—4805 kPa
Pilot System Pressure (slow idle)
39.0—49.0 bar
552—697 psi
3.5—5.0 MPa
3509—5012 kPa
Pilot System Pressure (fast idle)
36.0—51.0 bar
509—727 psi
0.078 MPa
78 kPa
Pilot Pressure Regulating Valve Shim [approximate per 0.25 mm (0.010 in.) shim]
0.78 bar
11.3 psi
0.157 MPa
157 kPa
Pilot Pressure Regulating Valve Shim [approximate per 0.50 mm (0.020 in.) shim]
1.57 bar
22.8 psi
0.304 MPa
304 kPa
Pilot Pressure Regulating Valve Shim [approximate per 1.00 mm (0.040 in.) shim]
3.04 bar
44.1 psi
25 N˙m
Plug-to-Pilot Pressure Regulating Valve Housing Torque
220 lb.-in.
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] -
<- Go to Section TOC Section 9025 page 293 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
1 Test Port
2 Adapter
3 JT02162 Transducer
4 Oil Sample Port (if equipped)
30 Pilot Pressure Regulating Valve
Adapter
JT02162
JT02156A
[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 Section 9025 page 294 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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.)
110—130°F
3805—4805
39.0—49.0 bar
552—697 psi
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] -
<- Go to Section TOC Section 9025 page 295 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
1 Test Port
2 Adapter
3 JT02162 Transducer
4 Oil Sample Port (if equipped)
30 Pilot Pressure Regulating Valve
Remove pilot pressure regulating valve (30). Add shims to increase pressure. Remove shims to decrease pressure.
Pilot Pressure Regulating Valve Shim [approximate per 0.25 mm (0.010 in.) shim] Pressure Change 0.078 MPa
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
Pilot Pressure Regulating Valve Shim [approximate per 1.00 mm (0.040 in.) shim] Pressure 0.304 MPa
304 kPa
3.04 bar
44.1 psi
220 lb.-in.
<- Go to Section TOC Section 9025 page 296 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
3.4—4.0 MPa
3432—4021 kPa
Control Valve Spool Actuating Pressure
34.3—40.2 bar
495—583 psi
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 Adaptor Tee
2 JT02162 Transducer
Adaptor Tee
JT02162
JT02156A
[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.)
110—130°F
<- Go to Section TOC Section 9025 page 298 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
<- Go to Section TOC Section 9025 page 299 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi
4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.
5.0 N˙m
Adjusting Screw-to-Nut Torque
45 lb.-in.
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] -
<- Go to Section TOC Section 9025 page 300 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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] -
Adaptor Tee
JT02162
JT02156A
<- Go to Section TOC Section 9025 page 301 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.)
110—130°F
[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] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.
Dig Regenerative Solenoid (port SF) Pressure Monitor Reading ± 0.2 MPa
<- Go to Section TOC Section 9025 page 302 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw
Solenoid 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.
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
0.157 in.
45 lb.-in.
<- Go to Section TOC Section 9025 page 303 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
<- Go to Section TOC Section 9025 page 304 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi
4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.
5.0 N˙m
Adjusting Screw-to-Nut Torque
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] -
<- Go to Section TOC Section 9025 page 305 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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] -
Adaptor Tee
JT02162
JT02156A
<- Go to Section TOC Section 9025 page 306 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.)
110—130°F
[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.
<- Go to Section TOC Section 9025 page 307 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
[10] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.
Arm Regenerative Solenoid (port SC) Pressure Monitor Reading ± 0.2 MPa
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 arm regenerative solenoid.
[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw
Solenoid 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.
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
0.157 in.
<- Go to Section TOC Section 9025 page 308 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
45 lb.-in.
<- Go to Section TOC Section 9025 page 309 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi
4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.
5.0 N˙m
Adjusting Screw-to-Nut Torque
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] -
<- Go to Section TOC Section 9025 page 310 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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] -
Adaptor Tee
JT02162
JT02156A
<- Go to Section TOC Section 9025 page 311 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.)
110—130°F
[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.
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] - Verify actual pressure reading at gauge is within the calculated pressure range from monitor.
Power Dig Solenoid (port SG) Pressure Monitor Reading ± 0.2 MPa
<- Go to Section TOC Section 9025 page 312 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 power dig solenoid.
[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw
Solenoid 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.
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
0.157 in.
45 lb.-in.
<- Go to Section TOC Section 9025 page 313 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
<- Go to Section TOC Section 9025 page 314 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.111 MPa
111 kPa
Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi
4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.
5.0 N˙m
Adjusting Screw-to-Nut Torque
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] -
<- Go to Section TOC Section 9025 page 315 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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] -
Adaptor Tee
JT02162
JT02156A
<- Go to Section TOC Section 9025 page 316 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.)
110—130°F
[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.
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] - Verify that the actual reading from gauge is within the calculated pressure range from monitor.
Arm 2 Flow Control Solenoid (port SI) Pressure Monitor Reading ± 0.2 MPa
<- Go to Section TOC Section 9025 page 317 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 arm 2 flow control solenoid.
[11] -
LEGEND:
4 Solenoid
5 Nut
6 Adjusting Screw
Solenoid 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.
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
0.157 in.
45 lb.-in.
<- Go to Section TOC Section 9025 page 318 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
<- Go to Section TOC Section 9025 page 319 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.111 MPa
111 kPa
Adjusting Screw Pressure Change (approximate per 1/4 turn)
1.11 bar
16.1 psi
4 mm
End of Adjusting Screw-to-Nut Length (maximum)
0.157 in.
5.0 N˙m
Adjusting Screw-to-Housing Nut Torque
45 lb.-in.
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
<- Go to Section TOC Section 9025 page 320 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Remove plug from torque control solenoid valve test port (2) in pump 1 regulator (1).
[3] -
Adapter
JT02162
JT02156A
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.)
110—130°F
<- Go to Section TOC Section 9025 page 321 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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] - Verify actual reading from gauge is within the calculated pressure range from monitor.
Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
→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.
<- Go to Section TOC Section 9025 page 322 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
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 Pressure Change (approximate per 1/4 turn) 0.111 MPa
111 kPa
1.11 bar
16.1 psi
0.157 in.
45 lb.-in.
<- Go to Section TOC Section 9025 page 323 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
1.03 MPa
1030 kPa
Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure (approximate)
10.3 bar
149 psi
3.70 MPa
3700 kPa
Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate)
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.)
<- Go to Section TOC Section 9025 page 324 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
110—130°F
[4] - Return all control levers and pedals to neutral position. Place pilot shutoff lever in the unlock (DOWN) position.
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.
Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate) 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.)
<- Go to Section TOC Section 9025 page 325 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
34.0—36.5 MPa
34 000—36 500 kPa
Main Relief Valve Pressure
340—365 bar
4931—5294 psi
35.3—38.3 MPa
35 300—38 300 kPa
Power Dig Valve Pressure
353—383 bar
5120—5555 psi
2.95 MPa
2950 kPa
First Adjusting Plug Pressure Change (approximate per 1/4 turn)
29.5 bar
427 psi
49—55 N·m
24 mm Nut Torque
36—41 lb.-ft.
2.95 MPa
2950 kPa
Second Adjusting Plug Pressure Change (approximate per 1/4 turn)
29.5 bar
427 psi
59—69 N·m
27 mm Nut Torque
44—50 lb.-ft.
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] -
<- Go to Section TOC Section 9025 page 326 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 Section 9025 page 327 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Pump 1 Adapter
Pump 2 Adapter
-8 ORFS
JT02156A
JT02160
[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).
[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.)
<- Go to Section TOC Section 9025 page 328 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
110—130°F
[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 First Adjusting Plug
7 24 mm Nut
8 Second Adjusting Plug
9 27 mm Nut
10 Piston
73 Right Control Valve (4-spool)
74 Left Control Valve (5-spool)
117 Main Relief and Power Dig Valve
<- Go to Section TOC Section 9025 page 329 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
→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.)
340—365 bar
4931—5294 psi
353—383 bar
5120—5555 psi
[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 Section 9025 page 330 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
[16] - Turn second adjusting plug (8) IN to increase power dig relief pressure or turn adjusting plug OUT to decrease pressure.
Second Adjusting Plug Pressure Change (approximate per 1/4 turn) 2.95 MPa
2950 kPa
29.5 bar
427 psi
[17] - Hold second adjusting plug (8). Tighten 27 mm nut (9) to specification.
44—51 lb.-ft.
[20] - Turn first adjusting plug (6) OUT to decrease pressure within specified pressure for main relief valve.
First Adjusting Plug Pressure Change (approximate per 1/4 turn) 2.95 MPa
2950 kPa
29.5 bar
427 psi
[21] - Hold first adjusting plug (6). Tighten 24 mm nut (7) to specification.
36—41 lb.-ft.
<- Go to Section TOC Section 9025 page 331 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
37.3—38.3 MPa
37 300—38 300 kPa
Bucket Curl Pressure
373—383 bar
5410—5555 psi
39.2—40.2 MPa
39 200—40 200 kPa
Bucket Dump Pressure
392—402 bar
5685—5831 psi
37.3—38.3 MPa
37 300—38 300 kPa
Arm In Pressure
373—383 bar
5410—5555 psi
39.2—40.2 MPa
39 200—40 200 kPa
Arm Out Pressure
392—402 bar
5685—5831 psi
39.2—40.2 MPa
39 200—40 200 kPa
Boom Up Pressure
392—402 bar
5685—5831 psi
37.3—38.3 MPa
37 300—38 300 kPa
Boom Down Pressure
373—383 bar
5410—5555 psi
2.65 MPa
2650 kPa
Circuit Relief Valve Pressure Change (approximate per 1/4 turn)
26.5 bar
385 psi
20 N·m
Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque
177 lb.-in.
Purpose of this test is to verify 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] -
<- Go to Section TOC Section 9025 page 332 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 Section 9025 page 333 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Pump 1 Adapter
Pump 2 Adapter
(-8 ORFS)
JT02156A
JT02160
[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).
[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.)
<- Go to Section TOC Section 9025 page 334 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
110—130°F
[9] -
<- Go to Section TOC Section 9025 page 335 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
373—383 bar
5410—5555 psi
392—402 bar
5685—5831 psi
373—383 bar
5410—5555 psi
392—402 bar
5685—5831 psi
<- Go to Section TOC Section 9025 page 336 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
392—402 bar
5685—5831 psi
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.
Circuit Relief Valve Pressure Change (approximate per 1/4 turn) 2.65 MPa
2650 kPa
26.5 bar
385 psi
177 lb.-in.
[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.)
<- Go to Section TOC Section 9025 page 337 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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
45—55°C
Hydraulic Oil Temperature
110—130°F
27.5 MPa
27 500 kPa
Blade Up Relief Valve (approximate)
275 bar
3989 psi
39.2 MPa
39 200 kPa
Blade Down Relief Valve (approximate)
392 bar
5685 psi
3.8 MPa
3378 kPa
Blade Main Relief Valve Pressure Change (approximate per 1/4 turn)
34 bar
490 psi
9.82 N·m
24 mm Lock Nut Torque
7.2 lb·ft
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] -
<- Go to Section TOC Section 9025 page 338 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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
JT02156A
<- Go to Section TOC Section 9025 page 339 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
[5] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
110—130°F
[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.
20 600 kPa
206 bar
2990 psi
39 200 kPa
392 bar
5685 psi
[9] -
<- Go to Section TOC Section 9025 page 340 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
1 24 mm Lock Nut
2 Adjusting Screw
136 Blade Main Relief Valve
Combination Wrench 24 mm
[10] - Turn adjusting screw (2) to change blade main relief valve setting. Turn clockwise to increase pressure; turn counter
clockwise to decrease pressure.
Blade Main Relief Valve Pressure Change (approximate per 1/4 turn) 3.8 MPa
3378 kPa
34 bar
490 psi
7.2 lb·ft
[13] -
→NOTE:
Adjustments to circuit relief valves should not be attempted. Replace circuit relief valves as necessary.
<- Go to Section TOC Section 9025 page 341 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
137 Blade Control Valve
141 Blade Up Circuit Relief and Anticavitation Valve
142 Blade Down Circuit Relief and Anticavitation Valve
If pressure specification cannot be achieved by adjusting blade main relief valve replace circuit relief and anticavitation valves
(141 and 142).
<- Go to Section TOC Section 9025 page 342 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
33.0—35.5 MPa
33 000—35 500 kPa
Swing Motor Crossover Relief Valve Pressure
330—355 bar
4787—5150 psi
1.0 MPa
1000 kPa
Swing Motor Crossover Relief Adjusting Screw Pressure Change (approximate per 1/4 turn)
10 bar
142 psi
49 N·m
Swing Motor Crossover Relief Valve Lock Nut
36 lb.-ft.
Purpose of this test is to verify 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] -
<- Go to Section TOC Section 9025 page 343 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 Section 9025 page 344 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Adapter
Pump 2 Adapter
-8 ORFS
JT02156A
JT02160
[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.)
[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.)
<- Go to Section TOC Section 9025 page 345 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
110—130°F
[8] - Actuate swing function over relief. Record pressure reading. Repeat for opposite direction.
330—355 bar
4787—5150 psi
[9] -
<- Go to Section TOC Section 9025 page 346 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
Swing Motor Crossover Relief Adjusting Screw Pressure Change Pressure Change (approximate per 1/4 turn) 1.00 MPa
1000 kPa
10 bar
142 psi
36 lb.-ft.
<- Go to Section TOC Section 9025 page 347 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
34.0—36.5 MPa
34 000—36 500 kPa
Travel Motor Crossover Relief Valve Pressure
344—3650 bar
4931—5294 psi
0.9 MPa
900 kPa
Crossover Relief Valve Shim Pressure Change [per 0.5 mm (0.02 in.)]
9 bar
130 psi
310 N˙m
Crossover Relief Valve Torque
230 lb.-ft.
Purpose of test is to check that the travel motor crossover relief valve pressure is within specification.
[1] -
<- Go to Section TOC Section 9025 page 348 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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 Section 9025 page 349 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Adapter
Pump 2 Adapter
-8 ORFS
JT02156A
JT02160
[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).
[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] -
<- Go to Section TOC Section 9025 page 350 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
6 76.2 mm (3 in.) OD Pin
Install 76.2 mm (3 in.) OD pin (6) or round bar stock between sprocket and track frame to stall travel motor.
110—130°F
[9] -
LEGEND:
68 Travel Motor Crossover Relief Valve (2 used)
Hold power dig switch. Slowly actuate the travel function for the crossover relief valve (68) being checked.
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] -
LEGEND:
22 Poppet
23 Spring Seat
24 Shim
25 Spring
Remove crossover relief valve. Add or remove shims (24) to adjust pressure.
Crossover Relief Valve Shim Pressure Change [per 0.5 mm (0.02 in.)] 0.9 MPa
900 kPa
9 bar
130 psi
<- Go to Section TOC Section 9025 page 352 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
230 lb.-ft.
[13] - Hold power dig switch. Actuate travel function at stall to check adjustment.
<- Go to Section TOC Section 9025 page 353 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
One Revolution of Raised Track Cycle Time (with pump regulator pilot line disconnected) 24.4—26.4 seconds
Stop Watch
Combination Wrench 17 mm
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.)
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] -
<- Go to Section TOC Section 9025 page 354 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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
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°
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.
[8] - Actuate travel function to full speed. Record cycle time for one revolution.
Stop Watch
To time test.
[9] -
<- Go to Section TOC Section 9025 page 355 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
5 Minimum Flow Adjusting Screw
6 17 mm Nut
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
One Revolution of Raised Track (with pump regulator pilot line disconnected) Cycle Time 24.4—26.4 seconds
Adjust regulators so cycle times are approximately the same for each track.
<- Go to Section TOC Section 9025 page 356 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
3 mm
End of Maximum Flow Adjusting Screw to 13 mm Nut Distance
0.125 in. (1/8 in.)
Combination Wrench 13 mm
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.)
110—130°F
[4] -
<- Go to Section TOC Section 9025 page 357 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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
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
[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 Section 9025 page 358 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
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
<- Go to Section TOC Section 9025 page 359 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
Specifications
SPECIFICATIONS (continued)
1/4 turn clockwise increases minimum pump flow rate approximately 6.2
L/min.
Minimum Flow Adjusting Screw Turn
1/4 turn clockwise increases minimum pump flow rate approximately 1.7
gpm
20 N·m
Minimum Flow Rate Adjusting Screw 17 mm Nut Torque
180 lb.-in.
10 N·m
Maximum Flow Rate Adjusting Screw 13 mm Nut Torque
89 lb.-in.
30 N·m
Flow Adjusting Cartridge (track cycle time) 30 mm Nut Torque
22 lb.-ft.
30 N·m
Load Adjusting Cartridge (outer spring) (pressure to flow control-torque adjustment) Torque
22 lb.-ft.
10 N·m
Load Adjusting Screw (inner spring) (pressure to flow control-torque adjustment) Torque
89 lb.-in.
Vacuum Pump
Flowmeter
1020 mm (40 in.) x 1 in. Hose with 90° flange fitting end (Code 62)
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 Section 9025 page 360 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
times to specified cycle times indicates low pump flow. Do the following appropriate procedures before continuing test:
[1] -
LEGEND:
1 Pump 1 Delivery Port
2 Pump 2 Delivery Port
3 Pump 1 and Pump 2 Regulator
73 Front Control Valve (4-spool)
74 Rear Control Valve (5-spool)
<- Go to Section TOC Section 9025 page 361 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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
[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.)
DFT1218
[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.
Elbow Fitting
Flowmeter
T107068
1020 mm (40 in.) x 1 in. hose with 90° flange fitting end (Code 62)
[5] -
<- Go to Section TOC Section 9025 page 362 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
LEGEND:
6 Arm In Pilot Line
41 Pilot Signal Manifold
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.
[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
<- Go to Section TOC Section 9025 page 363 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
JT02156A
JT02160
[9] - Warm hydraulic oil to specification by closing flowmeter loading valve to increase pressure.
110—130°F
[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.
Pump 1 or Pump 2
Pump 1 or Pump 2 Flow Rate 59—67 L/min. at 27 MPa
[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.
<- Go to Section TOC Section 9025 page 364 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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:
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
180 lb.-in.
[16] -
<- Go to Section TOC Section 9025 page 365 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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 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
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) Turn 1/4 turn clockwise decreases flow rate approximately 10.4 L/min.
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
22 lb.-ft.
[18] -
IMPORTANT:
Avoid possible pump damage. Do not turn load adjusting cartridge more than one turn.
<- Go to Section TOC Section 9025 page 366 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
b. Turn load adjusting cartridge (12) clockwise 1/4 turn to increase flow rate.
Item Measurement Specification
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) Torque 10 N·m
89 lb.-in.
<- Go to Section TOC Section 9025 page 367 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
Calibrated Container
[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
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 Section 9025 page 368 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Cap
9/16-18 F 37°
Calibrated Container
[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.
[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.
[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 Section 9025 page 369 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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.)
<- Go to Section TOC Section 9025 page 370 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
0.3—1.2 L/min
0.08—0.32 gpm
Travel Motor with Track Raised Leakage
1.8 L/min (maximum allowable)
0.48 gpm (maximum allowable)
0.3—1.9 L/min
0.08—0.50 gpm
Travel Motor Stalled Leakage
2.5 L/min (maximum allowable)
0.66 gpm (maximum allowable)
Calibrated Container
[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
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 joint to hydraulic oil tank return
1
manifold)
2 Hydraulic Oil Tank Return Manifold
3 Calibrated Container
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°
Calibrated Container
[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.)
0.08—0.32 gpm
[7] -
LEGEND:
4 76.2 mm (3 in.) Outside Diameter Pin
<- Go to Section TOC Section 9025 page 372 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM 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.
[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.
0.08—0.50 gpm
[9] - Remove cap and connect return line to hydraulic oil tank return manifold.
[10] -
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 joint may be leaking. To isolate
leakage in travel motor or center joint, 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 Section 9025 page 373 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
[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.)
<- Go to Section TOC Section 9025 page 374 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
750 kg
Bucket Load Weight (approximate)
1654 lb.
10 mm
Boom Cylinder Drift (maximum allowable for 5 minutes)
0.39 in.
20 mm
Arm Cylinder Drift (maximum allowable for 5 minutes)
0.79 in.
15 mm
Bucket Cylinder Drift (maximum allowable for 5 minutes)
0.59 in.
110 mm
Bottom of Bucket-to-Ground Drift (maximum allowable for 5 minutes)
4.33 in.
5 mm
Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.20 in.
15 mm
Arm Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.59 in.
10 mm
Bucket Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
0.39 in.
100 mm
Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes)
3.94 in.
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.
[1] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
110—130°F
1654 lb.
[3] -
<- Go to Section TOC Section 9025 page 375 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.
0.39 in.
0.79 in.
0.59 in.
4.33 in.
Tape Measure
<- Go to Section TOC Section 9025 page 376 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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.)
[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.
0.20 in.
0.59 in.
0.39 in.
3.94 in.
<- Go to Section TOC Section 9025 page 377 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
45—55°C
Hydraulic Oil Temperature
110—130°F
47 L/min.
New, Typical Flow Rate
12.4 gpm
40 L/min.
Used, Minimum Flow Rate
10.6 gpm
24.8—25.2 MPa
24 800—25 200 kPa
Fan Drive Circuit Pressure
248—252 bar
3600—3650 psi
JT05984 Flowmeter
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.)
[3] -
LEGEND:
1 Pressure Line (fan drive pump to fan drive motor)
133 Fan Drive Motor
Y5005 Variable Speed Fan Solenoid
Disconnect pressure line (1) coming from fan drive pump and connect JT05984 Flowmeter in-line using hose containing -10
ORFS female ends.
Flowmeter
JT05984
<- Go to Section TOC Section 9025 page 378 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Test Hose
[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.)
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.
12.4 gpm
10.6 gpm
<- Go to Section TOC Section 9025 page 379 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
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:
[10] - Connect variable speed fan solenoid. See Engine Interface Harness (W5) Component Location . (Group 9015-10.)
<- Go to Section TOC Section 9025 page 380 130G Excavator Diagnostic
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
SPECIFICATIONS
50—60°C
Hydraulic Oil Temperature
122—140°F
Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation . (Group
9025-05.)
[1] -
LEGEND:
1 Fan Blade
2 JT05709 Reflective Tape
133 Fan Drive Motor
Y5005 Variable Speed Fan Solenoid
[2] - Install JT05709 Reflective Tape (2) on one fan blade (1).
Reflective Tape
JT05709
JT05719
<- Go to Section TOC Section 9025 page 381 130G Excavator Diagnostic
HEATING AND AIR CONDITIONING (g) by Belgreen v2.0
[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.)
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).
[7] - Measure fan speed with JT05719 Handheld Digital Tachometer. Record result.
[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.)
<- Go to Section TOC Section 9031 page 382 130G Excavator Diagnostic
130G Excavator Diagnostic (g) by Belgreen v2.1
LEGEND:
1 Evaporator
2 Compressor
3 Condenser
4 Circulation Blower Motor
5 Expansion Valve
6 Receiver-Dryer
7 High Pressure Liquid
8 High Pressure Gas
9 Low Pressure Liquid
10 Low Pressure Gas
11 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).
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.)
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.)
Action:
Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.)
Result:
( 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:
NO:Replace air conditioner and heater 20 amp fuse (F3) (marked HEATER).
Action:
Check air conditioner compressor belt for proper pulley alignment and damage. See Inspect Serpentine Belt . (Operator′s
Manual.)
Result:
NO:Replace belt. See Serpentine Belt Remove and Install . (Group 0510.)
Action:
Turn key switch to ON position. Turn fan speed switch to maximum speed.
Result:
YES:Checks complete.
NO: See Air Conditioning Does Not Cool Interior of Cab . (Group 9031-15.)
Action:
Check cab fresh air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check cab recirculating air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check windows and doors to make sure seals are in good condition.
Result:
Action:
Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection . (Group 9031-25.)
Result:
YES:Reroute or re-index hoses. Replace kinked or collapsed hoses. See Heater and Air Conditioner Component Location .
(Group 9031-15.)
Action:
Result:
Action:
Result:
Action:
Result:
YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control
switch.
Action:
Check air conditioner system operating pressures. See R134a Air Conditioning System Test . (Group 9031-25.)
Result:
YES:Checks complete.
Action:
Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)
Result:
Action:
Result:
YES:Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control
switch.
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.)
Result:
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.)
Result:
YES:Checks complete.
Action:
Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)
Result:
Action:
Check cab fresh air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check cab recirculating air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Result:
Action:
Check to see if heater core is leaking engine coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.)
Result:
NO:Checks complete.
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.)
Action:
Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting . (Group 9015-16.)
Result:
( 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:
Action:
Check cab fresh air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check cab recirculating air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Operate the blower speed switch in low, medium, and high speed modes. See Switch Panel 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.
Action:
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.)
Action:
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.)
Action:
Result:
YES:Checks complete.
NO:Replace max hi relay (K17). See Cab Harness (W1) Component Location . (Group 9015-10.)
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.)
Result:
NO:Replace air conditioner and heater blower motor. See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)
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:
Action:
Disconnect blower motor resistor (R17). See Heater and Air Conditioner Harness (W41) Component Location . (Group 9015-10.)
Check for continuity between blower motor resistor (R17) connector pin 4 and air conditioner 4-pin connector (X51) pin 1.
Is continuity indicated?
Result:
NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness.
Action:
Disconnect air conditioner controller (A7) connector. See Heater and Air Conditioner Harness (W41) Component Location .
(Group 9015-10.)
Check for continuity between air conditioner controller (A7) connector pins 4 and 9 and air conditioner 4-pin connector (X51)
pin 1.
Result:
NO:Open in heater and air conditioner harness (W41) ground circuit. Repair or replace harness.
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:
NO:Open in cab harness (W1) ground circuit. Repair or replace harness. See Cab Harness (W1) Component Location . (Group
9015-10.)
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.)
Result:
( 16 ) Power Check
Action:
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.)
Result:
NO:Repair or replace cab harness (W1) or heater and air conditioner harness (W41).
Action:
Turn key switch to ON position. Set blower speed switch to maximum speed. See Switch Panel 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.)
Result:
YES:Checks complete.
NO:Replace air conditioner controller (ACF). See Air Conditioner Controller (ACF) Remove and Install . (Group 9015-20.)
Action:
Check heater system for proper operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)
Result:
( 2 ) Coolant Check
Action:
Check engine coolant level. See Check Engine Coolant Level . (Operator’s Manual.)
Result:
NO:Fill with proper coolant to specification. See Check Engine Coolant Level . (Operator’s Manual.)
Action:
Check cab fresh air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check cab recirculating air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check heater hoses. See Heater and Air Conditioner Component Location . (Group 9031-15.)
Result:
Action:
Result:
Action:
Result:
NO:Checks complete.
Action:
Check cab fresh air filter for debris or air flow restrictions.
Result:
YES:Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters . (Operator’s Manual.)
Action:
Check to see if the heater core is leaking coolant. See Heater and Air Conditioner Component Location . (Group 9031-15.)
Result:
Action:
Result:
Action:
Result:
NO:Correct air conditioner problem. See Air Conditioning System Does Not Operate . (Group 9031-15.)
Action:
Check to make sure the servo motor(s) are opening doors correctly.
Result:
YES:Checks complete.
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.)
LEGEND:
1 Heater and Air Conditioner Unit
2 Heater Return Line
3 Heater Supply Line
Group 25 - Tests
Refrigerant Cautions and Proper Handling
Service Equipment and Tools
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts 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 contact 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.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.
Action:
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:
NO:Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that
will require replacement.
Action:
sss:
sss:
sss:
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:
( 3 ) Condenser Check
Action:
sss:
sss:
Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Result:
Action:
sss:
Are fan blades in good condition, not worn, bent, broken, or missing?
sss:
Result:
Action:
sss:
sss:
Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
sss:
Is condensation drain hose attached and in good condition, not kinked, damaged, or clogged?
Result:
Action:
sss:
Result:
Action:
sss:
sss:
Result:
YES:Checks complete.
[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.)
SPECIFICATIONS
25 mm per second
Leak Detector Probe Speed
1 in. per second
[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.
[4] - Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
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 joints, 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.
SPECIFICATIONS
Thermometer
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
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.
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
[6] - Open both low and high pressure valves on refrigerant recovery, recycling, and charging station.
[9] - Press the blower motor speed switch to turn the air conditioner ON. See Cab Heater and Air Conditioner . (Operator′s
Manual.)
[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.
[16] - If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart . (Group
9031-25.)
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
Cold, Sweating, or
Expansion Valve Closed Low Low Frosting Heavily at Warm Warm Hot Slightly Cool
Valve Outlet
Slightly Cool to
Condenser Malfunction High High Hot Hot Hot Warm
Warm
Cold, Sweating, or
Expansion Valve Open High High Warm Warm Hot Slightly Cool
Frosting Heavily
Plugged Condenser,
Normal High Cool Warm Warm Hot Slightly Cool
Overcharge of Refrigerant
Heater Valve Stuck Open Normal Normal Cool Warm Warm Hot Warm
Split Flange Hose Cap is used with split clamp halves to close 1 in. split flange.