160GLC Excavator Operation and Test (PIN: 1FF160GX_ _F055671— )
OPERATION & TEST TECHNICAL MANUAL 160GLC Excavator (PIN: 1FF160GX_ _F055671— ) TM13345X19 23APR18
Worldwide Construction And Forestry Division PRINTED IN U.S.A.
(ENGLISH)
Introduction 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.
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.
This is the safety-alert symbol. When this symbol is seen on the machine or in this manual, be alert for the potential of personal injury.
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.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
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. MM16284,0001A38 -19-19APR18-1/1
TM13345X19 (23APR18)
160GLC Excavator 042318 PN=2
Introduction
Manual Identification—READ THIS FIRST!
TX1156411 —UN—27MAR14
IMPORTANT: Use only supporting manuals designated for each specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual. Choosing the Correct Supporting Manuals 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. When necessary, product identification numbers are listed on the front covers of excavator manuals. These numbers are used to identify the correct supporting manual for the machine.
The product identification number (PIN) plate (1) is located on the front right corner of the cab. Each machine has a 17-character PIN (2) shown on PIN plate.
JOHN DEERE Product Identification Number *1FF160GXJFF055671*
2
EXCAVATOR 160G DEERE & COMPANY, MOLINE, ILLINOIS, USA
1
TX1198261 —UN—27JUL15
Product Identification Number
PIN Plate Location
Example of PIN Plate 1— PIN Plate
Continued on next page
TM13345X19 (23APR18)
2— 17-Character PIN
KR46761,0000F3D -19-18DEC17-1/2
160GLC Excavator 042318 PN=3
Introduction
The following is an example for a machine that meets Final Tier 4 and Stage IV emission levels:
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number.
17-Character PIN Example 1
2
3
4
5
6
7
8
1
F
F
1
6
0
G
X
• (1—3) World Code: Identifies location where machine is manufactured.
1FF .................. World Code (manufacturing location) 1DW ............. Davenport Works 1T8 ............... Thibodaux Works 1T0 ............... Dubuque Works 1FF ............... Deere—Hitachi (Kernersville, NC, USA) 1F9 ............... Deere—Hitachi (Indaiatuba, São Paulo, Brazil)
• (4—8) Machine Model Identifier: Identifies model number.
160G ................ Machine Model Identifier
NOTE: Characters 7—8 identify series and major machine configuration options. These characters will change from one machine to another. X ..................... Machine Option Code
9 _
10 _
11
12
13
14
15
16
17
F
0
5
5
6
7
1
_ ..................... Manufacturing Year Code (variable) D ................. 2013 E .................. 2014 F .................. 2015 G ................. 2016 H ................. 2017 I ................... 2018
• (11) Engine Emission Code: Represents engine emission certification.
F ..................... Engine Emission Code C ................. Tier 2 and Stage II D ................. Tier 3 and Stage III A E .................. Interim Tier 4 and Stage III B F .................. Final Tier 4 and Stage IV G ................. Interim Tier 4 and Stage III A (19-56 kW) H ................. Final Tier 4 and Stage III A (19-37 kW)
X .................. Base Machine
J .................. Final Tier 4 and Stage III B (37-56 kW)
R ................. HYEX Military Excavators
K .................. Final Tier 4 (8-19 kW)
• (9) Check Letter: This is a random character assigned
by the factory. This is not used in machine identification. _ ..................... Check Letter (variable)
• (10) Manufacturing Year Code: Identifies year of
• (12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to another.
055671 ............. Machine Serial Number
machine manufacture.
KR46761,0000F3D -19-18DEC17-2/2
TM13345X19 (23APR18)
160GLC Excavator 042318 PN=4
Introduction
Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:
John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA
FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments:
Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1
TM13345X19 (23APR18)
160GLC Excavator 042318 PN=5
Introduction
TM13345X19 (23APR18)
160GLC Excavator 042318 PN=6
Contents Section 9000—General Information
Group 99—Dealer Fabricated Tools
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—Information Controller (ICZ) Diagnostic Trouble Codes Group 50—Air Conditioner Controller (ACF) Diagnostic Trouble Codes Group 60—Premium Seat Controller (PSC) 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
Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2018 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2015, 2016, 2017
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Contents
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Contents
Section 9000 General Information
Page Page
Group 01—Safety Recognize Safety Information ................... 9000-01-1 Follow Safety Instructions.......................... 9000-01-1 Operate Only If Qualified ........................... 9000-01-1 Wear Protective Equipment....................... 9000-01-2 Avoid Unauthorized Machine Modifications.......................................... 9000-01-2 Control Pattern Selector—If Equipped ............................................... 9000-01-2 Add Cab Guarding for Special Uses ...................................................... 9000-01-2 Inspect Machine ........................................ 9000-01-3 Stay Clear of Moving Parts........................ 9000-01-3 Avoid High-Pressure Fluids ....................... 9000-01-3 Avoid High-Pressure Oils .......................... 9000-01-4 Work In Ventilated Area............................. 9000-01-4 Avoid Static Electricity Risk When Refueling ............................................... 9000-01-5 Prevent Fires ............................................. 9000-01-5 In Case of Machine Fire ............................ 9000-01-6 Prevent Battery Explosions ....................... 9000-01-6 Handle Chemical Products Safely.............. 9000-01-6 Handle Starting Fluid Safely ...................... 9000-01-7 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 9000-01-7 Exhaust Filter Ash Handling and Disposal................................................. 9000-01-7 Prepare for Emergencies........................... 9000-01-8 Clean Debris from Machine ....................... 9000-01-8 Use Steps and Handholds Correctly ................................................ 9000-01-8 Start Only From Operator's Seat ............... 9000-01-8 Use and Maintain Seat Belt ....................... 9000-01-9 Prevent Unintended Machine Movement.............................................. 9000-01-9 Avoid Work Site Hazards......................... 9000-01-10 Keep Riders Off Machine ........................ 9000-01-10 Avoid Backover Accidents ....................... 9000-01-11 Inspect and Maintain ROPS .................... 9000-01-11 Avoid Machine Tip Over .......................... 9000-01-12 Use Special Care When Lifting Objects ................................................ 9000-01-12 Travel Safely............................................ 9000-01-13 Prevent Acid Burns.................................. 9000-01-13 Add and Operate Attachments Safely................................................... 9000-01-13 Park and Prepare for Service Safely................................................... 9000-01-14 Service Cooling System Safely ............... 9000-01-14 Remove Paint Before Welding or Heating ................................................ 9000-01-15 Make Welding Repairs Safely ................. 9000-01-15 Drive Metal Pins Safely ........................... 9000-01-15 TM13345X19 (23APR18)
Clean Exhaust Filter Safely ..................... 9000-01-16
9000-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9000-2
160GLC Excavator 042318 PN=2
Group 01
Safety Recognize Safety Information T133555 —UN—15APR13
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.
T133588 —19—28AUG00
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.
TX,RECOGNIZE -19-28JUN10-1/1
Follow Safety Instructions
TS201 —UN—15APR13
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.
TX,FOLLOW -19-20JAN11-1/1
Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction.
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.
Operator should be familiar with the job site and surroundings before operating. Try all controls and TX,QUALIFIED -19-18JAN11-1/1
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=11
Safety
Wear Protective Equipment Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.
TS206 —UN—15APR13
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.
TX,WEAR,PE -19-22SEP10-1/1
Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or
reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always 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. AM40430,00000A9 -19-20AUG09-1/1
Control Pattern Selector—If Equipped This machine may be equipped with a control pattern selector valve. Ensure all bystanders are clear of machine
and area is large enough to operate machine functions. Verify the machine response to each control movement.
DB84312,00000A5 -19-07JUL15-1/1
Add Cab Guarding for Special Uses Special work situations or machine attachments could create an environment with falling or flying objects. Working near an overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or working in a waste management application, for example, could require added guarding to protect the operator.
Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer for information on protective guarding. TX,CABGUARD -19-12FEB13-1/1
TM13345X19 (23APR18)
9000-01-2
160GLC Excavator 042318 PN=12
Safety
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.
T6607AQ —UN—15APR13
Inspect machine carefully each day by walking around it before starting.
TX,INSPECT -19-08SEP10-1/1
Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting, or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
T133592 —UN—15APR13
Stay Clear of Moving Parts
TX,MOVING,PARTS -19-20JAN11-1/1
Avoid High-Pressure Fluids
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 from Deere & Company Medical Department in Moline, Illinois, U.S.A.
X9811 —UN—23AUG88
Escaping fluid under pressure can penetrate the skin causing serious injury.
DX,FLUID -19-06OCT16-1/1
TM13345X19 (23APR18)
9000-01-3
160GLC Excavator 042318 PN=13
Safety
Avoid High-Pressure Oils
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.
T133840 —UN—20SEP00
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.
T133509 —UN—15APR13
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
TX,HPOILS -19-20JAN11-1/1
Work In Ventilated Area
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
TS220 —UN—15APR13
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.
DX,AIR -19-17FEB99-1/1
TM13345X19 (23APR18)
9000-01-4
160GLC Excavator 042318 PN=14
Safety
Avoid Static Electricity Risk When Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge. RG22142 —UN—17MAR14
Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion.
RG21992 —UN—21AUG13
Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
DX,FUEL,STATIC,ELEC -19-12JUL13-1/1
T133552 —UN—15APR13
Prevent Fires Handle Fluids Safely: All fuels, most lubricants, and some coolant mixtures are flammable. Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep flammable debris (trash, leaves, twigs, straw, and so forth), 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.
T133553 —UN—07SEP00
Maintain Hoses, Tubes, and Wiring: Replace hoses and tubes 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 an extinguisher properly.
T133554 —UN—07SEP00
Be Aware of the Operating Environment: Airborne debris may contain sparks or embers. Do not operate near any flame.
TX,PREVENT,FIRE -19-09JUN16-1/1
TM13345X19 (23APR18)
9000-01-5
160GLC Excavator 042318 PN=15
Safety
In Case of Machine Fire CAUTION: Avoid personal injury from exposed flames. Maintain safe distance.
TS227 —UN—15APR13
• Turn the engine off. • Turn the battery disconnect switch to the OFF position, if equipped.
• If possible, fight the fire using the portable fire
extinguisher or other fire suppression equipment, if equipped. • Ensure that the fire does not spread to the surrounding area. Do not risk injury. If a fire is too far advanced, do not try to extinguish fire. • Call for help.
In Case of Machine Fire
CN93077,00000B2 -19-09FEB16-1/1
Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
TS204 —UN—15APR13
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Keep battery electrolyte levels properly maintained.
Battery Explosions MB60223,0000081 -19-01JUL15-1/1
Handle Chemical Products Safely
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.
TS1132 —UN—15APR13
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.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA -19-03MAR93-1/1
TM13345X19 (23APR18)
9000-01-6
160GLC Excavator 042318 PN=16
Safety
Handle Starting Fluid Safely Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables. TS1356 —UN—18MAR92
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container. Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.
DX,FIRE3 -19-14MAR14-1/1
Decommissioning — Proper Recycling and Disposal of Fluids and Components
TS1133 —UN—15APR13
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
• Use appropriate tools and personal protective
equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. • Follow instructions for specialized components. • Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. • Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. • Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. • Do not pour waste fluids onto the ground, down a drain, or into any water source. • Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);
filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. • Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. • Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. • Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1
Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations
governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal. TX,ASH,DISP -19-20JAN11-1/1
TM13345X19 (23APR18)
9000-01-7
160GLC Excavator 042318 PN=17
Safety
Prepare for Emergencies Be prepared if a fire starts.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
TS291 —UN—15APR13
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 -19-03MAR93-1/1
Clean Debris from Machine
Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.
T6669AG —UN—15APR13
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris.
TX,DEBRIS -19-20JAN11-1/1
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.
T133468 —UN—15APR13
Use Steps and Handholds Correctly
TX,STEPS -19-09FEB11-1/1
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.
T133715 —UN—15APR13
Start Only From Operator's Seat
TX,SOFOS -19-20JAN11-1/1
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=18
Safety
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 does not function properly.
T133716 —19—17APR13
Use and Maintain Seat Belt
The complete seat belt assembly should be replaced every three years, regardless of appearance. TX,SEAT,BELT -19-20JAN11-1/1
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.
T216779 —UN—22NOV05
Prevent Unintended Machine Movement
VD76477,000036D -19-19APR11-1/1
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9000-01-9
160GLC Excavator 042318 PN=19
Safety
Avoid Work Site Hazards T134986 —UN—31OCT00
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.
Work Site Hazards
T133650 —UN—27SEP00
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. Work Site Hazards
Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole. T133549 —UN—24AUG00
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.
Work Site Hazards TX03679,0001748 -19-08JUL15-1/1
Keep Riders Off Machine Only allow operator on machine.
T7273AH —UN—08JUN90
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.
Keep Riders Off Machine TX03679,0001726 -19-30JUN16-1/1
TM13345X19 (23APR18)
9000-01-10
160GLC Excavator 042318 PN=20
Safety
Avoid Backover Accidents
PC10857XW —UN—15APR13
Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and radar object detection systems, if equipped, to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.
TX,AVOID,BACKOVER -19-04MAR16-1/1
Inspect and Maintain ROPS
To maintain the ROPS:
A damaged rollover protective structure (ROPS) should be replaced, not reused.
• Replace missing hardware using correct grade
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.
• Check hardware torque. • Check isolation mounts for damage, looseness, or
hardware.
wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. TX,ROPS -19-20JAN11-1/1
TM13345X19 (23APR18)
9000-01-11
160GLC Excavator 042318 PN=21
Safety
Avoid Machine Tip Over T133716 —19—17APR13
Use seat belt at all times. Do not jump if the machine tips. Operator will be unlikely to jump clear and the machine may crush the operator. 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.
Use Seat Belt
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.
T133545 —UN—15SEP00
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.
Unloading Machine
T133803 —UN—27SEP00
Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.
Do Not Jump TX03679,00016DF -19-30JUN16-1/1
Use Special Care When Lifting Objects T133839 —UN—27SEP00
Never use this machine to lift people. Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave the seat when there is a raised load. Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over.
Use Special Care When Lifting Objects
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. TX03679,00016E1 -19-08JUL15-1/1
TM13345X19 (23APR18)
9000-01-12
160GLC Excavator 042318 PN=22
Safety
Travel Safely When working on steep slopes, travel as straight up and down as possible to prevent roll-over. T6964AD —UN—20DEC88
DO NOT PARK ON A HILLSIDE OR AN INCLINE. Always park the machine on level ground. Know the location of bystanders before moving the machine. Always keep the reverse warning alarm in working condition. The alarm warns bystanders when the machine starts to move in reverse.
Travel Safely
Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine. CN93077,00000B3 -19-01JUL15-1/1
Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5.
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: TS203 —UN—23AUG88
1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
DX,POISON -19-21APR93-1/1
Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect machine stability or reliability and could create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection
is required or recommended. 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.
TX,ATTACH -19-20JAN11-1/1
TM13345X19 (23APR18)
9000-01-13
160GLC Excavator 042318 PN=23
Safety
Park and Prepare for Service Safely Warn others of service work. Always park and prepare machine for service or repair properly.
• Park machine on a level surface and lower equipment T133332 —19—17APR13
to the ground.
• Place pilot shutoff lever in locked (UP) position. Stop engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in the operator's station.
Securely support machine or attachment before working under it.
• Do not support machine with any hydraulically actuated
Do Not Operate Tag
equipment.
• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
• Do not support machine with a single jack or other devices that may slip out of place.
TS229 —UN—23AUG88
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
Support Machine Properly OUT4001,000089A -19-02JUL15-1/1
Service Cooling System Safely
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.
TS281 —UN—15APR13
Explosive release of fluids from pressurized cooling system can cause serious burns.
TX,SURGE -19-19JAN11-1/1
TM13345X19 (23APR18)
9000-01-14
160GLC Excavator 042318 PN=24
Safety
Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1
Make Welding Repairs Safely T133547 —UN—15APR13
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. Heating Near Pressurized Fluid Lines
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.
Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. MB60223,0000212 -19-02JUL15-1/1
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.
T133738 —UN—15APR13
Drive Metal Pins Safely
TX,PINS -19-20JAN11-1/1
TM13345X19 (23APR18)
9000-01-15
160GLC Excavator 042318 PN=25
Safety
During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode.
TS227 —UN—15APR13
Clean Exhaust Filter Safely
Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.
Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures.
TS271 —UN—23AUG88
Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.
If service procedure requires engine to be running:
• Only engage power-driven parts required by service procedure
and machine
Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station.
TS1693 —UN—09DEC09
• Ensure that other people are clear of operator station
TS1695 —UN—07DEC09
Shut off engine and remove key (if equipped) before leaving the machine unattended.
DX,EXHAUST,FILTER -19-12JAN11-1/1
TM13345X19 (23APR18)
9000-01-16
160GLC Excavator 042318 PN=26
Section 9001 Diagnostics Contents Page Page
Group 10—Main Controller (MCZ) Diagnostic Trouble Codes Main Controller (MCZ) Diagnostic Trouble Codes ....................................... 9001-10-1 Controller Area Network 0 (CAN 0) Circuit Diagnostics................................. 9001-10-1 Controller Area Network 1 (CAN 1) Circuit Diagnostics................................. 9001-10-1 Interface Controller Area Network (N-CAN) Diagnostics ............................. 9001-10-1 Engine Controller Area Network (Engine CAN) Diagnostics .................... 9001-10-1 Aftertreatment Controller Area Network (AT CAN) Diagnostics.............. 9001-10-1 011000.02 — Abnormal EEPROM...............................................9001-10-1 Abnormal EEPROM Diagnostic Procedure..............................................9001-10-1 011001.02 — Abnormal RAM....................9001-10-2 Abnormal RAM Diagnostic Procedure..............................................9001-10-2 011002.02 — Abnormal A/D Converter ..............................................9001-10-3 Abnormal A/D Converter Diagnostic Procedure..............................................9001-10-3 011003.03 — Abnormal Sensor Voltage ..................................................9001-10-3 Abnormal Sensor Voltage Diagnostic Procedure..............................................9001-10-3 011006.02 — Engine Controller Communication Error ............................9001-10-4 011007.02 — (CAN 0) Data Converter Communication Error 1 .........................9001-10-4 011008.02 — (CAN 1) Data Converter Communication Error 2 .........................9001-10-4 011009.02 — (CAN 0) Monitor Controller Communication Error 1 ............................................................9001-10-5 011010.02 — (CAN 1) Monitor Controller Communication Error 2 ............................................................9001-10-5 011100.02 — Abnormal Engine Speed....................................................9001-10-5 Abnormal Engine Speed Diagnostic Procedure..............................................9001-10-5 011101.03 — Engine Speed Dial Sensor Circuit High Input ......................9001-10-5 Engine Speed Dial Sensor Circuit High Input Diagnostic Procedure...................9001-10-6 011101.04 — Engine Speed Dial Sensor Circuit Low Input .......................9001-10-7
Engine Speed Dial Sensor Circuit Low Input Diagnostic Procedure...................9001-10-7 011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input ......................................................9001-10-8 Pump 1 Delivery Pressure Sensor Circuit High Diagnostics ........................9001-10-8 011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input ....................................................9001-10-10 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-10 011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input ....................................................9001-10-12 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-12 011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input ....................................................9001-10-14 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-14 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input ....................................................9001-10-16 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-16 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input ....................................................9001-10-17 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-17 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input ....................................................9001-10-19 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-19 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input ....................................................9001-10-20 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-20 011301.03 — Swing Pressure Sensor Circuit High Input.................................9001-10-22 Continued on next page
TM13345X19 (23APR18)
9001-1
160GLC Excavator 042318 PN=1
Contents
Page
Page
Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-22 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input .....................9001-10-23 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-23 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input ....................9001-10-25 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-25 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input .....................9001-10-26 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-26 011303.03 — Arm In Pressure Sensor Circuit High Input.................................9001-10-27 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-28 011303.04 — Arm In Pressure Sensor Circuit Low Input .................................9001-10-29 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-29 011304.03 — Travel Pilot Pressure Sensor Circuit High Input ....................9001-10-30 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-30 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input .....................9001-10-32 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-32 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input ....................................................9001-10-33 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-33 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input ....................................................9001-10-35 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-35 011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input ....................................................9001-10-36 Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-36
011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input ....................................................9001-10-37 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-37 011400.02 — Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal.............................................9001-10-39 Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal Diagnostic Procedure............................................9001-10-39 011400.03 — Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current ................................................9001-10-41 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure............................................9001-10-41 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current ................................................9001-10-43 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................................9001-10-43 011401.02 — Torque Control Solenoid Valve Abnormal Feedback ..................9001-10-44 Torque Control Solenoid Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-44 011401.03 — Torque Control Solenoid Valve Feedback High Current ................................................9001-10-46 Torque Control Solenoid Valve Feedback High Current Diagnostic Procedure............................................9001-10-46 011401.04 — Torque Control Solenoid Valve Feedback Low Current ..............9001-10-48 Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure............................................9001-10-48 011402.02 — Dig Regenerative Solenoid Valve Feedback Current Abnormal.............................................9001-10-49 Dig Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure..........................9001-10-49 011402.03 — Dig Regenerative Solenoid Valve Feedback Current High.....................................................9001-10-51 Dig Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure............................................9001-10-51 011402.04 — Dig Regenerative Solenoid Valve Feedback Current Low......................................................9001-10-53 Dig Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure............................................9001-10-53 Continued on next page
TM13345X19 (23APR18)
9001-2
160GLC Excavator 042318 PN=2
Contents
Page
Page
011403.02 — Arm Regenerative Solenoid Valve Feedback Current Abnormal.............................................9001-10-54 Arm Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure..........................9001-10-54 011403.03 — Arm Regenerative Solenoid Valve Feedback Current High.....................................................9001-10-56 Arm Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure............................................9001-10-56 011403.04 — Arm Regenerative Solenoid Valve Feedback Current Low......................................................9001-10-58 Arm Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure............................................9001-10-58 011407.02 — Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal.............................................9001-10-59 Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal Diagnostic Procedure..........................9001-10-59 011407.03 — Power Dig/Travel Speed Solenoid Valve Feedback Current High.....................................................9001-10-61 Power Dig/Travel Speed Solenoid Valve Feedback Current High Diagnostic Procedure..........................9001-10-61 011407.04 — Power Dig/Travel Speed Solenoid Valve Feedback Current Low......................................................9001-10-63 Power Dig/Travel Speed Solenoid Valve Feedback Current Low Diagnostic Procedure..........................9001-10-63 011408.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal.............................................9001-10-64 011408.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High.....................................................9001-10-64 011408.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low......................................................9001-10-65 011409.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal.............................................9001-10-65 011409.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High.....................................................9001-10-65 011409.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low......................................................9001-10-65 011410.02 — Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback ............................................9001-10-65
Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-65 011410.03 — Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current ................................................9001-10-67 Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure............................................9001-10-67 011410.04 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current ................................................9001-10-69 Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................................9001-10-69 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback ............................9001-10-70 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current .......................9001-10-70 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current........................9001-10-71 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback ............................9001-10-71 011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current .......................9001-10-71 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current........................9001-10-71 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback ............................9001-10-71 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current .......................9001-10-71 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current........................9001-10-71 011457.02 — 2-Speed Activation Solenoid Valve Disconnected .....................9001-10-71 2-Speed Activation Solenoid Valve Disconnected Diagnostic Procedure............................................9001-10-71 011458.02 — Selector Valve Solenoid Valve Disconnected.............................9001-10-73 Selector Valve Solenoid Valve Disconnected Diagnostic Procedure............................................9001-10-73 011459.02 — Idle Stop Relay Circuit Malfunction..........................................9001-10-75 Idle Stop Relay Circuit Malfunction Diagnostic Procedure..........................9001-10-75
Continued on next page
TM13345X19 (23APR18)
9001-3
160GLC Excavator 042318 PN=3
Contents
Page
Page
011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage........................................9001-10-76 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure............................................9001-10-76 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage.........................................9001-10-77 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure............................................9001-10-77 011812.02 — OPT Electric Lever 1 Neutral Abnormal ................................9001-10-79 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure..........................9001-10-79 011813.02 — OPT Electric Lever 1 Abnormal Operation ............................9001-10-80 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure............................................9001-10-80 011816.02 — OPT Solenoid 1 Feedback Abnormal ............................9001-10-82 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure............................................9001-10-82 011816.03 — OPT Solenoid 1 Feedback Current High .......................9001-10-83 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure............................................9001-10-84 011816.04 — OPT Solenoid 1 Feedback Current Low........................9001-10-85 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure............................................9001-10-85 011817.02 — OPT Solenoid 2 Feedback Abnormal ............................9001-10-87 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure............................................9001-10-87 011817.03 — OPT Solenoid 2 Feedback Current High .......................9001-10-88 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure............................................9001-10-89 011817.04 — OPT Solenoid 2 Feedback Current Low........................9001-10-90 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62)
Feedback Low Current Diagnostic Procedure............................................9001-10-90 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input ....................................................9001-10-92 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................................9001-10-92 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input ....................................................9001-10-93 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-93 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)..........................................9001-10-94 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................................9001-10-94 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)..........................................9001-10-96 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-96 011995.03 — Arm Roll-Out Pilot Pressure Sensor Circuit High Input ....................................................9001-10-97 Arm Roll-Out Pressure Sensor Circuit High Diagnostic Procedure .................9001-10-97 011995.04 — Arm Roll-Out Pilot Pressure Sensor Circuit Low Input ....................................................9001-10-98 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-98 011997.03 — Bucket Roll-Out Pressure Sensor Circuit High ...........................9001-10-100 Bucket Roll-Out Pressure Sensor Circuit High Diagnostic Procedure..........................................9001-10-100 011997.04 — Bucket Roll-Out Pressure Sensor Circuit Low ............................9001-10-101 Bucket Roll-Out Pressure Sensor Circuit Low Diagnostic Procedure..........................................9001-10-101 015016.03 — Right Analog Stroke Sensor Circuit High Input ..................9001-10-103 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure..........................................9001-10-103 015016.04 — Right Analog Stroke Sensor Circuit Low Input ...................9001-10-104 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor
Continued on next page
TM13345X19 (23APR18)
9001-4
160GLC Excavator 042318 PN=4
Contents
Page
Page
Circuit Low Input Diagnostic Procedure..........................................9001-10-104 020010.02 — Abnormal Exhaust Filter ..................................................9001-10-105 Abnormal Exhaust Filter Diagnostic Procedure..........................................9001-10-105 020011.02 — Electric Lever Alarm.................................................9001-10-106 Electric Control Lever Alarm Diagnostic Procedure..........................................9001-10-106 020062.02 — Hydraulic Oil Temperature Alarm............................9001-10-106 020303.02 — Electric Lever Pilot Cut Alarm.................................................9001-10-106 Electric Control Lever Alarm Diagnostic Procedure..........................................9001-10-106
002030.09 — (CAN 0) Flex Power Controller Communication Error ......................................................9001-20-9 002228.09 — (CAN 0) Main Controller (MCZ) Communication Error .................9001-20-9 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault.....................9001-20-9 003353.31 — Alternator Excitation Fault ......................................................9001-20-9 Alternator Excitation Fault Diagnostic Procedure............................................9001-20-10 003516.01 — Diesel Exhaust Fluid Concentration Extremely Low......................................................9001-20-11 003516.07 — Diesel Exhaust Fluid Concentration Invalid ..........................9001-20-11 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault ....................................................9001-20-12 003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault ................9001-20-12 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault......................9001-20-12 003719.15 — Calculated Soot Level Slightly High ........................................9001-20-13 004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance ..................................9001-20-13 Diagnostic Procedure ..............................9001-20-14 004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance...................................9001-20-17 Diagnostic Procedure ..............................9001-20-17 004366.16 — DEF Tank Temperature Moderately High ..................................9001-20-21 Diagnostic Procedure ..............................9001-20-21 004366.18 — DEF Tank Insufficient Heating Fault.......................................9001-20-24 Diagnostic Procedure ..............................9001-20-25 005484.05 — Reversing Fan Solenoid Open Circuit ........................................9001-20-27 Reversing Fan Solenoid Open Circuit Diagnostic Procedure..........................9001-20-27 005484.06 — Reversing Fan Solenoid Short Circuit ........................................9001-20-28 Reversing Fan Solenoid Short Circuit Diagnostic Procedure..........................9001-20-28 520956.06 — Battery Disconnect Indicator Light Short to Ground ................................................9001-20-29 Battery Disconnect Indicator Light Short to Ground Diagnostic Procedure............................................9001-20-29
Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes ..................... 9001-20-1 000111.07 — Coolant Level Low—Moderately Severe Level......................................................9001-20-1 Coolant Level Low—Moderately Severe Level Diagnostic Procedure..............................................9001-20-1 000647.05 — Variable Speed Fan Solenoid Open Circuit ...........................9001-20-2 Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure.................9001-20-2 000647.06 — Variable Speed Fan Solenoid High Current...........................9001-20-3 Variable Speed Fan Solenoid High Current Diagnostic Procedure..............................................9001-20-3 000647.16 — Reversing Fan Switch Active Too Long.....................................9001-20-4 Reversing Fan Switch Active Too Long Diagnostic Procedure............................9001-20-4 001639.00 — Fan Speed High—Moderately Severe Level......................................................9001-20-5 Fan Speed High—Moderately Severe Level Diagnostic Procedure ..................9001-20-5 001639.01 — Fan Speed Low—Most Severe Level .........................................9001-20-7 Fan Speed Low—Most Severe Level Diagnostic Procedure............................9001-20-7 001639.18 — Fan Speed Low—Moderately Severe Level......................................................9001-20-8 001761.01 — Diesel Exhaust Fluid Extremely Low.......................................9001-20-8 001761.18 — Diesel Exhaust Fluid Very Low ...............................................9001-20-9
Group 30—Monitor Controller (DSZ) Diagnostic Trouble Codes Monitor Controller (DSZ) Diagnostic Trouble Codes ..................... 9001-30-1 Continued on next page
TM13345X19 (23APR18)
9001-5
160GLC Excavator 042318 PN=5
Contents
Page
Page
013000.02 — Flash Memory Failure 1 ............................................................9001-30-1 Flash Memory Failure 1 Diagnostic Procedure..............................................9001-30-1 013001.02 — Flash Memory Failure 2 ............................................................9001-30-1 Flash Memory Failure 2 Diagnostic Procedure..............................................9001-30-1 013002.02 — ECU Communication Error ......................................................9001-30-1 013003.02 — Main Controller (MCZ) Communication Error 1 .........................9001-30-2 013004.02 — Main Controller (MCZ) Communication Error 2 .........................9001-30-2 013005.02 — Monitor Controller (DSZ) Communication Error 1 .........................9001-30-2 013006.02 — Monitor Controller (DSZ) Communication Error 2 .........................9001-30-2 013007.02 — Machine Controller (BCZ) Communication Error..................9001-30-2 020113.02 — System Error Alarm.....................................................9001-30-2
Data Converter Diagnostics.......................9001-40-5 014006.02 — Communication Terminal: Communication Error ......................................................9001-40-5 Communication Terminal: Communication Error Diagnostic Procedure..............................................9001-40-5 014008.02 — Abnormal Internal RAM ......................................................9001-40-6 Data Converter Diagnostics.......................9001-40-6 014009.02 — CAN Communication Error 2 ...................................................9001-40-6 014021.02 — Communication Terminal Security Error ........................................9001-40-7 014022.02 — SIM Card Error....................9001-40-7 014023.02 — Security Error ......................9001-40-7 020100.02 — Overheat Alarm...................9001-40-7 020101.02 — Engine Warning Alarm.....................................................9001-40-7 020102.02 — Engine Oil Pressure Alarm.....................................................9001-40-7 020103.02 — Alternator Alarm ..................9001-40-7 Alternator Alarm Diagnostic Procedure..............................................9001-40-7 020105.02 — Hydraulic Oil Filter Restriction Alarm...................................9001-40-8 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure............................9001-40-8 020106.02 — Air Cleaner Restriction Alarm.....................................................9001-40-9 020107.02 — Water Separator Alarm.....................................................9001-40-9 020109.02 — Pilot Control Shut-Off Lever Alarm...........................................9001-40-9 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure............................9001-40-9 020110.02 — Fuel Filter Restriction Alarm...................................................9001-40-10 020114.02 — Overheat Alarm (Immediately After the Key is Turned ON)......................................................9001-40-10 020135.02 — Exhaust Filter Regeneration Unnecessary Warning ...............................................9001-40-10 020149.02 — EGR Gas Temperature Alarm...................................................9001-40-10 020150.02 — Coolant Level Alarm...................................................9001-40-10 020151.02 — Engine Warning Alarm...................................................9001-40-10 020152.02 — Engine Oil Pressure Alarm...................................................9001-40-11 020153.02 — Air Cleaner Restriction Alarm...................................................9001-40-11 020154.02 — Fuel Filter Restriction Alarm...................................................9001-40-11 020155.02 — Engine Output Reduction Alarm...................................................9001-40-11
Group 40—Information Controller (ICZ) Diagnostic Trouble Codes Information Controller (ICZ) Diagnostic Trouble Codes ..................... 9001-40-1 013303.02 — Abnormal Monitor Internal Temperature Sensor.................9001-40-1 Monitor Internal Temperature Sensor Diagnostic Procedure............................9001-40-1 013304.02 — Alternator Alarm ..................9001-40-1 Alternator Alarm Diagnostic Procedure..............................................9001-40-1 013305.02 — Abnormal Manual Glow EXT Output ...........................................9001-40-2 013310.03 — Coolant Temperature Sensor Short Circuit ..............................9001-40-2 013311.03 — Fuel Level Sensor Open Circuit ....................................................9001-40-2 Fuel Level Sensor Open Circuit Diagnostic Procedure............................9001-40-2 013311.04 — Fuel Level Sensor Shorted Circuit ......................................9001-40-3 Fuel Level Sensor Shorted Circuit Diagnostic Procedure............................9001-40-3 013334.02 — Radiator Water Temp Receive Error ........................................9001-40-4 014000.02 — CAN Communication Error 1 ...................................................9001-40-4 014001.02 — Flash Memory Read/Write Error ...................................9001-40-4 Data Converter Diagnostics.......................9001-40-4 014002.02 — External RAM Read/Write Error ...................................9001-40-5 Data Converter Diagnostics.......................9001-40-5 014003.02 — Abnormal EEPROM...............................................9001-40-5
Continued on next page
TM13345X19 (23APR18)
9001-6
160GLC Excavator 042318 PN=6
Contents
Page
Page
020156.02 — Cooling Performance Decrease Alarm ..................................9001-40-11 020157.02 — Cooling Performance Decrease Alarm ..................................9001-40-11 032000.02 — Coolant Temperature Pre Alarm ............................................9001-40-11 032001.02 — Hydraulic Oil Temperature Pre Alarm .......................9001-40-11 032002.02 — Hydraulic and Ambient Temperature Difference Pre Alarm...................................................9001-40-11
51 — Abnormal High/Low Refrigerant Pressure..............................................9001-50-14 Abnormal High/Low Refrigerant Pressure Diagnostic Procedure..................9001-50-14 91 — Communication Error .....................9001-50-15 92 — CAN Bus Off Error .........................9001-50-15
Group 50—Air Conditioner Controller (ACF) Diagnostic Trouble Codes Air Conditioner Controller (ACF) Diagnostic Trouble Codes ..................... 9001-50-1 11 — Open Circuit in Air Recirculation Sensor...................................................9001-50-1 Open Circuit in Air Recirculation Sensor Diagnostic Procedure............................9001-50-1 12 — Short-Circuited Air Recirculation Sensor...................................................9001-50-2 Short-Circuited Air Recirculation Sensor Diagnostic Procedure......................9001-50-2 13 — Open Circuit in Ambient Air Temperature Sensor..............................9001-50-4 Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure..............................................9001-50-4 14 — Short-Circuited Ambient Air Temperature Sensor..............................9001-50-5 Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure..............................................9001-50-5 18 — Short-Circuited Solar Radiation Sensor...................................................9001-50-7 Short-Circuited Solar Radiation Sensor Diagnostic Procedure............................9001-50-7 21 — Open Circuit in Air Conditioner Freeze Control Switch...........................9001-50-8 Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure..............................................9001-50-8 22 — Short-Circuited Air Conditioner Freeze Control Switch.........................9001-50-10 Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure............................................9001-50-10 43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor..........................................9001-50-11 Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure..........................9001-50-11 44 — Abnormal Air Conditioner and Heater Mixer Servomotor ....................9001-50-12 Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure............................................9001-50-12
TM13345X19 (23APR18)
Group 60—Premium Seat Controller (PSC) Diagnostic Trouble Codes Premium Seat Controller (PSC) Diagnostic Trouble Codes ..................... 9001-60-1 0 — Cushion Blower Minimum Voltage ..................................................9001-60-2 1 — Back Blower Minimum Voltage ..................................................9001-60-2 2 — Cushion Blower Short to Power ....................................................9001-60-3 3 — Back Blower Short to Power ....................................................9001-60-3 4 — Cushion Fan Power Transistor Short to Ground.....................................9001-60-4 5 — Back Fan Power Transistor Short to Ground ..............................................9001-60-4 6 — Cushion Fan Power Transistor Open Circuit ..........................................9001-60-5 7 — Back Fan Power Transistor Open Circuit ....................................................9001-60-5 8 — Lower Thermal Duct Module Temperature Sensor Short to Ground ..................................................9001-60-6 9 — Upper Thermal Duct Module Temperature Sensor Short to Ground ..................................................9001-60-7 10 — Lower Thermal Duct Module Temperature Sensor Open Circuit ....................................................9001-60-8 11 — Upper Thermal Duct Module Temperature Sensor Open Circuit ....................................................9001-60-9 12 — Lower Thermal Duct Module Short to Ground...................................9001-60-10 13 — Upper Thermal Duct Module Short to Ground...................................9001-60-11 14 — Lower Thermal Duct Module Open Circuit ........................................9001-60-12 15 — Upper Thermal Duct Module Open Circuit ........................................9001-60-13 16 — Lower Thermal Duct Module Over Temperature ...............................9001-60-14 17 — Upper Thermal Duct Module Over Temperature ...............................9001-60-15 21 — Thermal Duct Module Short to Power ..................................................9001-60-16
9001-7
160GLC Excavator 042318 PN=7
Contents
TM13345X19 (23APR18)
9001-8
160GLC Excavator 042318 PN=8
Group 10
Main Controller (MCZ) Diagnostic Trouble Codes Main Controller (MCZ) Diagnostic Trouble Codes For additional information on the main controller circuit, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
Main controller diagnostic trouble codes (DTCs) can be displayed on the monitor, by connection with Service ADVISOR™, or by connection with MPDr. See Reading Diagnostic Trouble Codes With Monitor Display or see Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
Service ADVISOR is a trademark of Deere & Company RH60123,0000EA0 -19-06FEB17-1/1
Controller Area Network 0 (CAN 0) Circuit Diagnostics There are five CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) DF89619,00B5874 -19-20DEC17-1/1
Controller Area Network 1 (CAN 1) Circuit Diagnostics There are five CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) DF89619,00B5883 -19-20DEC17-1/1
Interface Controller Area Network (N-CAN) Diagnostics There are five CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) DF89619,00B5884 -19-20DEC17-1/1
Engine Controller Area Network (Engine CAN) Diagnostics There are five CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) JL58967,00001D8 -19-20DEC17-1/1
Aftertreatment Controller Area Network (AT CAN) Diagnostics There are five CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) JL58967,00001EE -19-20DEC17-1/1
011000.02 — Abnormal EEPROM DF89619,00B57E4 -19-28JAN16-1/4
Abnormal EEPROM Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-1
DF89619,00B57E4 -19-28JAN16-2/4
160GLC Excavator 042318 PN=35
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Code Check
Clear and check again for diagnostic trouble codes (DTCs).
YES: Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is DTC 011000.02 still present?
YES: Code is still present, but machine is still operable. Go to Machine Function Check. NO: Main controller (MCZ) is OK. DF89619,00B57E4 -19-28JAN16-3/4
• 2
Machine Function Check
Is operation of machine normal? See Operational Checkout. (Group 9005-05.)
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.) DF89619,00B57E4 -19-28JAN16-4/4
011001.02 — Abnormal RAM DF89619,00B57E5 -19-28JAN16-1/4
Abnormal RAM Diagnostic Procedure DF89619,00B57E5 -19-28JAN16-2/4
• 1
Code Check
Clear and check again for diagnostic trouble codes (DTCs).
YES: Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is DTC 011001.02 still present?
YES: Code is still present, but machine is still operable. Go to Machine Function Check. NO: Main controller (MCZ) is OK. Continued on next page
TM13345X19 (23APR18)
9001-10-2
DF89619,00B57E5 -19-28JAN16-3/4
160GLC Excavator 042318 PN=36
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Machine Function Check
Is operation of machine normal? See Operational Checkout. (Group 9005-05.)
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.) DF89619,00B57E5 -19-28JAN16-4/4
011002.02 — Abnormal A/D Converter DF89619,00B57E6 -19-28JAN16-1/4
Abnormal A/D Converter Diagnostic Procedure DF89619,00B57E6 -19-28JAN16-2/4
• 1
Code Check
Clear and check again for diagnostic trouble codes (DTCs).
YES: Code is still present and machine does not operate. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is DTC 011002.02 still present?
YES: Code is still present, but machine is still operable. Go to Machine Function Check. NO: Main controller (MCZ) is OK. DF89619,00B57E6 -19-28JAN16-3/4
• 2
Machine Function Check
Is operation of machine normal? See Operational Checkout. (Group 9005-05.)
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.) DF89619,00B57E6 -19-28JAN16-4/4
011003.03 — Abnormal Sensor Voltage Individual sensor or component diagnostic trouble code (DTC) may also be present within this code. Engine speed dial may not function correctly when this code is present. DF89619,00B57E7 -19-28JAN16-1/4
Abnormal Sensor Voltage Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-3
DF89619,00B57E7 -19-28JAN16-2/4
160GLC Excavator 042318 PN=37
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Sensor Check
Key switch in OFF position.
If other sensor DTCs are present, disconnect harness to corresponding sensors.
YES: Go to Continuity Check.
Clear and check again for DTCs. Is DTC 011003.03 still present?
NO: Sensor malfunction. Replace sensor. DF89619,00B57E7 -19-28JAN16-3/4
• 2
Continuity Check
Key switch in OFF position.
Disconnect all connectors on main controller (MCZ) and to sensors corresponding with YES: Short circuit in codes displayed. Check for continuity between pins 1 and 3 of sensor harness connector. harness between main controller (MCZ) and sensor. Check harness. Repair or replace harness. Is there continuity between pins 1 and 3?
NO: Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.) DF89619,00B57E7 -19-28JAN16-4/4
011006.02 — Engine Controller Communication Error Engine Controller Communication Error For more information:
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
• See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.)
DF89619,00B57EA -19-12JUN14-1/1
011007.02 — (CAN 0) Data Converter Communication Error 1 (CAN 0) Data Converter Communication Error 1 For more information:
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
• See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.)
DF89619,00B57EB -19-12JUN14-1/1
011008.02 — (CAN 1) Data Converter Communication Error 2
• See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.)
(CAN 1) Data Converter Communication Error 2 For more information:
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B57EC -19-12JUN14-1/1
TM13345X19 (23APR18)
9001-10-4
160GLC Excavator 042318 PN=38
Main Controller (MCZ) Diagnostic Trouble Codes
011009.02 — (CAN 0) Monitor Controller Communication Error 1
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
• See Controller Area Network 1 (CAN 1) Circuit
(CAN 0) Monitor Controller Communication Error 1
Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN)
For more information:
Diagnostics. (Group 9001-10.)
DF89619,00B57ED -19-12JUN14-1/1
011010.02 — (CAN 1) Monitor Controller Communication Error 2
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
• See Controller Area Network 1 (CAN 1) Circuit
(CAN 1) Monitor Controller Communication Error 2
Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN)
For more information:
Diagnostics. (Group 9001-10.)
JL58967,00001D9 -19-05FEB15-1/1
011100.02 — Abnormal Engine Speed Engine speed is 4000 rpm or faster. DF89619,00B57EF -19-12JUN14-1/3
Abnormal Engine Speed Diagnostic Procedure NOTE: The main controller (MCZ) receives engine speed via CAN from the engine control unit (ECU). DF89619,00B57EF -19-12JUN14-2/3
• 1
Engine Speed Check
Verify engine speed with Service ADVISOR™ .
See Service ADVISOR™ Connection Procedure. (Group 9015-20.) For information on engine speeds, see Engine Speed Control System Operation. (Group 9010-05.)
YES: Check CAN wiring between controllers. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
Is engine speed within specification?
NO: Check engine controller DTC 190.0. See 000190.00 — Engine Speed Extremely High . (CTM120019.)
Service ADVISOR is a trademark of Deere & Company DF89619,00B57EF -19-12JUN14-3/3
011101.03 — Engine Speed Dial Sensor Circuit High Input
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Engine speed dial (R15) signal voltage is high (above 4.78 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
NOTE: Machine controller (MCZ) has detected an electrical short in the 5 V signal circuit for multiple sensors and the engine speed dial (R15). Multiple MCZ diagnostic trouble codes (DTCs) may be present. Continue following this procedure if DTCs are only for the engine speed dial (R15).
Continued on next page
TM13345X19 (23APR18)
9001-10-5
DF89619,00B57F0 -19-16APR18-1/6
160GLC Excavator 042318 PN=39
Main Controller (MCZ) Diagnostic Trouble Codes Engine Speed Dial Sensor Circuit High Input Diagnostic Procedure DF89619,00B57F0 -19-16APR18-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• 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.)
• Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(W2) Component Location. (Group 9015-10.)
DF89619,00B57F0 -19-16APR18-3/6
• 2
Voltage Check
Key switch in OFF position.
Disconnect cab harness-to-switch panel connector 3 (X29). Turn key switch to ON position. Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29). YES: Go to Signal Voltage Check. Is approximately 5 volts indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F0 -19-16APR18-4/6
• 3
Signal Voltage Check
Key switch in OFF position.
Disconnect cab harness-to-main controller 30-pin connector D (X34). Disconnect cab harness-to-switch panel connector 3 (X29). Turn key switch to ON position. Check between pin 16 of cab harness-to-main controller 30-pin connector D (X34) and machine ground for voltage.
YES: Repair or replace harness. See appropriate harness.
Is voltage above 4.78 V indicated?
NO: Go to Harness Check. DF89619,00B57F0 -19-16APR18-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect cab harness-to-switch panel connector 3 (X29). Disconnect main controller connectors (X31—X36). Check for continuity between pin 16 of cab harness-to-main controller 30-pin connector YES: Circuit is short to D (X34) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57F0 -19-16APR18-6/6
TM13345X19 (23APR18)
9001-10-6
160GLC Excavator 042318 PN=40
Main Controller (MCZ) Diagnostic Trouble Codes
011101.04 — Engine Speed Dial Sensor Circuit Low Input
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Engine speed dial (R15) circuit signal voltage is low (below 0.22 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
NOTE: Machine controller (MCZ) has detected an electrical short in the 5 V signal circuit for multiple sensors and the engine speed dial (R15). Multiple MCZ diagnostic trouble codes (DTCs) may be present. Continue following this procedure if DTCs are only for the engine speed dial (R15). DF89619,00B57F1 -19-16APR18-1/6
Engine Speed Dial Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57F1 -19-16APR18-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• 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.)
• Cab harness-to-machine harness 100-pin connector (X3). See Machine Harness
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(W2) Component Location. (Group 9015-10.)
DF89619,00B57F1 -19-16APR18-3/6
• 2
Voltage Check
Key switch in OFF position.
Disconnect cab harness-to-switch panel connector 3 (X29). Turn key switch to ON position. Check voltage between pins 4 and 6 of cab harness-to-switch panel connector 3 (X29). YES: Go to Open Circuit Check. Is approximately 5 volts indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F1 -19-16APR18-4/6
• 3
Open Circuit Check
Key switch in OFF position.
Cab harness-to-switch panel connector 3 (X29) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between 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).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-7
DF89619,00B57F1 -19-16APR18-5/6
160GLC Excavator 042318 PN=41
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Cab harness-to-switch panel connector 3 (X29) disconnected. Check for continuity between pin 5 of cab harness-to-switch panel connector 3 (X29) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57F1 -19-16APR18-6/6
011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 delivery pressure sensor (B35) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
TK40086,000090D -19-08AUG16-1/7
Pump 1 Delivery Pressure Sensor Circuit High Diagnostics TK40086,000090D -19-08AUG16-2/7
• 1
Connector Check
Check connections between pump 1 delivery pressure sensor and main controller (MCZ) (A3). Are connectors clean and free of debris?
YES: Go to Pressure Sensor Check.
Are pins straight and do they make good contact when connected?
NO: Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.) TK40086,000090D -19-08AUG16-3/7
• 2
Pressure Sensor Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 1 delivery pressure sensor (B35). Disconnect pump 2 delivery pressure sensor (B37). Connect pump 1 delivery pressure sensor (B35) connector to pump 2 delivery pressure sensor (B37). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011200.03—Pump 1 Delivery Pressure Sensor Circuit High Input.
YES: Go to Sensor Circuit Check.
Is code active?
NO: Pump 1 delivery pressure sensor (B35) malfunction. Replace sensor. Continued on next page
TM13345X19 (23APR18)
9001-10-8
TK40086,000090D -19-08AUG16-4/7
160GLC Excavator 042318 PN=42
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Sensor Circuit Check
Key switch in OFF position.
Disconnect pump 1 delivery pressure sensor (B35). Turn key switch to ON position. Check for voltage between pin 1 and pin 3 of pump 1 delivery pressure sensor (B35) connector.
YES: Go to Short to Power Check.
Is voltage between 4.5—5.5 volts?
NO: Go to next step in this check.
Check for voltage between pump 1 delivery pressure sensor harness connector pin 1 and machine ground.
YES: Open circuit in harness between main controller (MCZ) and pump 1 delivery pressure sensor connector pin 3. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
Is voltage between 4.5—5.5 volts?
NO: Open circuit in harness between main controller (MCZ) and pump 1 delivery pressure sensor connector pin 1. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.) TK40086,000090D -19-08AUG16-5/7
• 4
Short to Power Check
Key switch in OFF position.
Disconnect pump 1 delivery pressure sensor (B35). Check for power between pump 1 delivery pressure sensor (B35) harness connector pin 2 and machine ground.
YES: Short to power in pump 1 delivery pressure sensor circuit. Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
Is power present?
NO: Go to Open Circuit Check. Continued on next page
TM13345X19 (23APR18)
9001-10-9
TK40086,000090D -19-08AUG16-6/7
160GLC Excavator 042318 PN=43
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Open Circuit Check
Key switch in OFF position.
Disconnect harness from pump 1 delivery pressure sensor (B35) and main controller (MCZ) (A3). Check for continuity between pump 1 delivery pressure sensor connector pin 2 and MCZ connector (X33) pin C14.
YES: Open circuit in pump 1 delivery pressure sensor circuit. Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. TK40086,000090D -19-08AUG16-7/7
011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 delivery pressure sensor (marked PP1) (B35) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F3 -19-12JUN14-1/7
Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57F3 -19-12JUN14-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 delivery pressure sensor (marked PP1) (B35). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-10
DF89619,00B57F3 -19-12JUN14-3/7
160GLC Excavator 042318 PN=44
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect pump 1 delivery pressure sensor (marked PP1) (B35). Disconnect pump 2 delivery pressure sensor (marked PP2) (B37). Connect pump 1 delivery pressure sensor (marked PP1) connector (B35) to pump 2 delivery pressure sensor (marked PP2) (B37). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 1 delivery pressure sensor (marked PP1) (B35) malfunction. Replace sensor. DF89619,00B57F3 -19-12JUN14-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 delivery pressure sensor (marked PP1) (B35). Turn key switch to ON position. Check pin 1 and pin 3 of pump 1 delivery pressure sensor connector (marked PP1) (B35) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F3 -19-12JUN14-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 1 delivery pressure sensor (marked PP1) (B35) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 2 of pump 1 delivery pressure sensor (marked PP1) YES: Go to Short Circuit connector (B35) and pin 14 of cab harness-to-main controller 17-pin connector C (X33). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F3 -19-12JUN14-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 1 delivery pressure sensor (marked PP1) (B35) disconnected. Check for continuity between pin 2 of pump 1 delivery pressure sensor (marked PP1) connector (B35) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57F3 -19-12JUN14-7/7
TM13345X19 (23APR18)
9001-10-11
160GLC Excavator 042318 PN=45
Main Controller (MCZ) Diagnostic Trouble Codes
011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 2 delivery pressure sensor (B37) signal voltage is high (above 4.5 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
BG71862,00002AB -19-19JUL16-1/7
Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure BG71862,00002AB -19-19JUL16-2/7
• 1
Connector Check
Check connections between pump 2 delivery pressure sensor (B37) and main controller (MCZ) (A3). Are connectors clean and free of debris?
YES: Go to Pressure Sensor Check.
Are pins straight and do they make good contact when connected?
NO: Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.) BG71862,00002AB -19-19JUL16-3/7
• 2
Pressure Sensor Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 2 delivery pressure sensor (B37). Disconnect pump 1 delivery pressure sensor (B35). Connect pump 2 delivery pressure sensor (B37) connector to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011202.03—Pump 2 Delivery Pressure Sensor Circuit High Input.
YES: Go to Sensor Circuit Check.
Is code active?
NO: Pump 2 delivery pressure sensor (B37) malfunction. Replace sensor. Continued on next page
TM13345X19 (23APR18)
9001-10-12
BG71862,00002AB -19-19JUL16-4/7
160GLC Excavator 042318 PN=46
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Sensor Circuit Check
Key switch in OFF position.
Disconnect pump 2 delivery pressure sensor (B37). Turn key switch to ON position. Check for voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor (B37) connector.
YES: Go to Short to Power Check.
Is voltage between 4.5—5.5 volts?
NO: Go to next step in this check.
Check for voltage between pump 2 delivery pressure sensor harness connector pin 1 and machine ground.
YES: Open circuit in harness between main controller (MCZ) and pump 2 delivery pressure sensor connector pin 3. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
Is voltage between 4.5—5.5 volts?
NO: Open circuit in harness between main controller (MCZ) and pump 2 delivery pressure sensor connector pin 1. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.) BG71862,00002AB -19-19JUL16-5/7
• 4
Short to Power Check
Key switch in OFF position.
Disconnect pump 2 delivery pressure sensor (B37). Check for power between pump 2 delivery pressure sensor (B37) harness connector pin 2 and machine ground.
YES: Short to power in pump 2 delivery pressure sensor circuit. Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
Is power present?
NO: Go to Open Circuit Check. Continued on next page
TM13345X19 (23APR18)
9001-10-13
BG71862,00002AB -19-19JUL16-6/7
160GLC Excavator 042318 PN=47
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Open Circuit Check
Key switch in OFF position.
Disconnect harness from pump 2 delivery pressure sensor (B37) and main controller (MCZ) (A3). Check for continuity between pump 2 delivery pressure sensor connector pin 2 and MCZ connector (X33) pin C15.
YES: Open circuit in pump 2 delivery pressure sensor circuit. Repair or replace harness. See Cab Harness (W1) Wiring Diagram, see Machine Harness (W2) Wiring Diagram, and see Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. BG71862,00002AB -19-19JUL16-7/7
011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 2 delivery pressure sensor (marked PP2) (B37) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F5 -19-28JAN16-1/7
Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57F5 -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 delivery pressure sensor (marked PP2) (B37). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-14
DF89619,00B57F5 -19-28JAN16-3/7
160GLC Excavator 042318 PN=48
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect pump 2 delivery pressure sensor (marked PP2) (B37). Disconnect pump 1 delivery pressure sensor (marked PP1) (B35). Connect pump 2 delivery pressure sensor (marked PP2) connector (B37) to pump 1 delivery pressure sensor (marked PP1) (B35). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 2 delivery pressure sensor (marked PP2) (B37) malfunction. Replace sensor. DF89619,00B57F5 -19-28JAN16-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 delivery pressure sensor (marked PP2) (B37). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor (marked PP2) connector (B37) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F5 -19-28JAN16-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 2 delivery pressure sensor (marked PP2) (B37) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 2 of pump 2 delivery pressure sensor (marked PP2) YES: Go to Short Circuit connector (B37) and pin 15 of cab harness-to-main controller 17-pin connector C (X33). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F5 -19-28JAN16-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 2 delivery pressure sensor (marked PP2) (B37) disconnected. Check for continuity between pin 2 of pump 2 delivery pressure sensor (marked PP2) connector (B37) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57F5 -19-28JAN16-7/7
TM13345X19 (23APR18)
9001-10-15
160GLC Excavator 042318 PN=49
Main Controller (MCZ) Diagnostic Trouble Codes
011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 control pressure sensor (marked PC1) (B36) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F6 -19-12JUN14-1/6
Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B57F6 -19-12JUN14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 control pressure sensor (marked PC1) (B36). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B57F6 -19-12JUN14-3/6
• 2
Component Check
Disconnect pump 1 control pressure sensor (marked PC1) (B36).
Disconnect pump 2 control pressure sensor (marked PC2) (B38). Connect pump 1 control pressure sensor (marked PC1) connector (B36) to pump 2 control pressure sensor (marked PC2) (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011206.03—Pump 1 Flow Control Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 1 control pressure sensor (marked PC1) (B36) malfunction. Replace sensor. DF89619,00B57F6 -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Turn key switch to ON position. Check between pin 2 of pump 1 control pressure sensor (marked PC1) connector (B36) YES: Repair or replace and machine ground for approximately 0.0 V. harness. See appropriate harness. Is correct voltage indicated?
NO: Go to Harness Check. Continued on next page
TM13345X19 (23APR18)
9001-10-16
DF89619,00B57F6 -19-12JUN14-5/6
160GLC Excavator 042318 PN=50
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Disconnect main controller connectors (X31—X36). Check for continuity between pin 8 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57F6 -19-12JUN14-6/6
011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 control pressure sensor (marked PC1) (B36) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F7 -19-28JAN16-1/7
Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57F7 -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 control pressure sensor (marked PC1) (B36). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-17
DF89619,00B57F7 -19-28JAN16-3/7
160GLC Excavator 042318 PN=51
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Disconnect pump 2 control pressure sensor (marked PC2) (B38). Connect pump 1 control pressure sensor (marked PC1) connector (B36) to pump 2 control pressure sensor (marked PC2) (B38). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011206.04—Pump 1 Flow Control Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 1 control pressure sensor (marked PC1) (B36) malfunction. Replace sensor. DF89619,00B57F7 -19-28JAN16-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 1 control pressure sensor (marked PC1) connector (B36) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F7 -19-28JAN16-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 1 control pressure sensor (marked PC1) (B36) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 2 of pump 1 control pressure sensor (marked PC1) connector (B36) and pin 8 of cab harness-to-main controller 17-pin connector C (X33).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F7 -19-28JAN16-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 1 control pressure sensor (marked PC1) (B36) disconnected. Check for continuity between pin 2 of pump 1 control pressure sensor (marked PC1) connector (B36) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57F7 -19-28JAN16-7/7
TM13345X19 (23APR18)
9001-10-18
160GLC Excavator 042318 PN=52
Main Controller (MCZ) Diagnostic Trouble Codes
011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 2 control pressure sensor (marked PC2) (B38) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F8 -19-12JUN14-1/6
Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B57F8 -19-12JUN14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 control pressure sensor (marked PC2) (B38). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B57F8 -19-12JUN14-3/6
• 2
Component Check
Disconnect pump 2 control pressure sensor (marked PC2) (B38).
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Connect pump 2 control pressure sensor (marked PC2) connector (B38) to pump 1 control pressure sensor (marked PC1) (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.03—Pump 2 Flow Control Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 2 control pressure sensor (marked PC2) (B38) malfunction. Replace sensor. DF89619,00B57F8 -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (marked PC2) (B38). Turn key switch to ON position. Check between pin 2 of pump 2 control pressure sensor (marked PC2) connector (B38) YES: Repair or replace and machine ground for approximately 0.0 V. harness. See appropriate harness. Is correct voltage indicated?
NO: Go to Harness Check. Continued on next page
TM13345X19 (23APR18)
9001-10-19
DF89619,00B57F8 -19-12JUN14-5/6
160GLC Excavator 042318 PN=53
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (marked PC2) (B38). Disconnect main controller connectors (X31—X36). Check for continuity between pin 13 of cab harness-to-main controller 17-pin connector YES: Circuit is short to C (X33) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57F8 -19-12JUN14-6/6
011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 2 control pressure sensor (marked PC2) (B38) signal is low. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B57F9 -19-03FEB17-1/7
Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57F9 -19-03FEB17-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 control pressure sensor (marked PC2) (B38). See Pump Harness (W8) 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.)
• Pump harness-to-machine harness connector (X40). See Machine Harness (W2)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-20
DF89619,00B57F9 -19-03FEB17-3/7
160GLC Excavator 042318 PN=54
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Disconnect pump 2 control pressure sensor (marked PC2) (B38).
Disconnect pump 1 control pressure sensor (marked PC1) (B36). Connect pump 2 control pressure sensor (marked PC2) connector (B38) to pump 1 control pressure sensor (marked PC1) (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.04—Pump 2 Flow Control Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Pump 2 control pressure sensor (marked PC2) (B38) malfunction. Replace sensor. DF89619,00B57F9 -19-03FEB17-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (marked PC2) (B38). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor (marked PC2) connector (B38) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F9 -19-03FEB17-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 2 control pressure sensor (marked PC2) (B38) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 2 of pump 2 control pressure sensor (marked PC2) YES: Go to Short Circuit connector (B38) and pin 13 of cab harness-to-main controller 17-pin connector C (X33). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57F9 -19-03FEB17-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 2 control pressure sensor (marked PC2) (B38) disconnected. Check for continuity between pin 2 of pump 2 control pressure sensor (marked PC2) connector (B38) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57F9 -19-03FEB17-7/7
TM13345X19 (23APR18)
9001-10-21
160GLC Excavator 042318 PN=55
Main Controller (MCZ) Diagnostic Trouble Codes
011301.03 — Swing Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Swing pressure sensor (B33) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B57FA -19-12JUN14-1/6
Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B57FA -19-12JUN14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Swing pressure sensor (B33). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B57FA -19-12JUN14-3/6
• 2
Component Check
Disconnect swing pressure sensor (B33).
Disconnect travel pressure sensor (B34). Connect swing pressure sensor connector (B33) to travel pressure sensor (B34). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011301.03—Swing Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Swing pressure sensor (B33) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-10-22
DF89619,00B57FA -19-12JUN14-4/6
160GLC Excavator 042318 PN=56
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect swing pressure sensor (B33). Turn key switch to ON position. Check voltage between pin 2 of swing pressure sensor connector (B33) and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B57FA -19-12JUN14-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect swing pressure sensor (B33). Disconnect main controller connectors (X31—X36). Check for continuity between pin 15 of cab harness-to-main controller 30-pin connector YES: Circuit is short to D (X34) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57FA -19-12JUN14-6/6
011301.04 — Swing Pilot Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Swing pressure sensor (B33) signal voltage is low. (Below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B57FB -19-12JUN14-1/7
Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57FB -19-12JUN14-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Swing pressure sensor (B33). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-23
DF89619,00B57FB -19-12JUN14-3/7
160GLC Excavator 042318 PN=57
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Disconnect swing pressure sensor (B33).
Disconnect travel pressure sensor (B34). Connect swing pressure sensor connector (B33) to travel pressure sensor (B34). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011301.04—Swing Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Swing pressure sensor (B33) malfunction. Replace sensor. DF89619,00B57FB -19-12JUN14-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect swing pressure sensor (B33). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of swing pressure sensor connector (B33) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FB -19-12JUN14-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Swing pressure sensor (B33) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of swing pressure sensor connector (B33) and pin 15 of cab harness-to-main controller 30-pin connector D (X34).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FB -19-12JUN14-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Swing pressure sensor (B33) disconnected. Check for continuity between pin 2 of swing pressure sensor connector (B33) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57FB -19-12JUN14-7/7
TM13345X19 (23APR18)
9001-10-24
160GLC Excavator 042318 PN=58
Main Controller (MCZ) Diagnostic Trouble Codes
011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input Boom up pressure sensor (B30) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B57FC -19-12JUN14-1/6
Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B57FC -19-12JUN14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Boom up pressure sensor (B30). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). 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.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B57FC -19-12JUN14-3/6
• 2
Component Check
Switch boom up pressure sensor connector (B30) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011302.03—Boom Up Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Boom up pressure sensor (B30) malfunction. Replace sensor. DF89619,00B57FC -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect boom up pressure sensor (B30). Turn key switch to ON position. Check between pin 2 of boom up pressure sensor connector (B30) and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. Continued on next page
TM13345X19 (23APR18)
9001-10-25
DF89619,00B57FC -19-12JUN14-5/6
160GLC Excavator 042318 PN=59
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Disconnect boom up pressure sensor (B30). Disconnect main controller connectors (X31—X36). Check for continuity between pin 6 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57FC -19-12JUN14-6/6
011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input Boom up pressure sensor (B30) signal voltage is low. (Below 0.1 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B57FD -19-03FEB17-1/7
Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57FD -19-03FEB17-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Boom up pressure sensor (B30). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• 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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-26
DF89619,00B57FD -19-03FEB17-3/7
160GLC Excavator 042318 PN=60
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Switch boom up pressure sensor connector (B30) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011302.04—Boom Up Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is completed.
NO: Boom up pressure sensor (B30) malfunction. Replace sensor. DF89619,00B57FD -19-03FEB17-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect boom up pressure sensor (B30). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of boom up pressure sensor connector (B30) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FD -19-03FEB17-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Boom up pressure sensor (B30) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of boom up pressure sensor connector (B30) and pin 6 of cab harness-to-main controller 30-pin connector D (X34).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FD -19-03FEB17-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Boom up pressure sensor (B30) disconnected. Check for continuity between pin 2 of boom up pressure sensor connector (B30) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57FD -19-03FEB17-7/7
011303.03 — Arm In Pressure Sensor Circuit High Input Arm in pressure sensor (B31) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
Continued on next page
TM13345X19 (23APR18)
9001-10-27
DF89619,00B57FE -19-12JUN14-1/6
160GLC Excavator 042318 PN=61
Main Controller (MCZ) Diagnostic Trouble Codes Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B57FE -19-12JUN14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm in pressure sensor (B31). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). 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.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B57FE -19-12JUN14-3/6
• 2
Component Check
Switch arm in pressure sensor connector (B31) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011303.03—Arm In Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Arm in pressure sensor (B31) malfunction. Replace sensor. DF89619,00B57FE -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect arm in pressure sensor (B31). Turn key switch to ON position. Check between pin 2 of arm in pressure sensor connector (B31) and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. Continued on next page
TM13345X19 (23APR18)
9001-10-28
DF89619,00B57FE -19-12JUN14-5/6
160GLC Excavator 042318 PN=62
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Disconnect arm in pressure sensor (B31). Disconnect main controller connectors (X31—X36). Check for continuity between pin 7 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B57FE -19-12JUN14-6/6
011303.04 — Arm In Pressure Sensor Circuit Low Input Arm in pressure sensor (B31) signal voltage is low. (Below 0.1 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B57FF -19-12JUN14-1/7
Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B57FF -19-12JUN14-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm in pressure sensor (B31). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
DF89619,00B57FF -19-12JUN14-3/7
• 2
Component Check
Switch arm in pressure sensor connector (B31) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011303.04—Arm In Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Arm in pressure sensor (B31) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-10-29
DF89619,00B57FF -19-12JUN14-4/7
160GLC Excavator 042318 PN=63
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect arm in pressure sensor (B31). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of arm in pressure sensor connector (B31) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FF -19-12JUN14-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Arm in pressure sensor (B31) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of arm in pressure sensor connector (B31) and pin 7 YES: Go to Short Circuit of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B57FF -19-12JUN14-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Arm in pressure sensor (B31) disconnected. Check for continuity between pin 2 of arm in pressure sensor connector (B31) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B57FF -19-12JUN14-7/7
011304.03 — Travel Pilot Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Travel pressure sensor (B34) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B5800 -19-12JUN14-1/6
Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-30
DF89619,00B5800 -19-12JUN14-2/6
160GLC Excavator 042318 PN=64
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Travel pressure sensor (B34). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). 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.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B5800 -19-12JUN14-3/6
• 2
Component Check
Disconnect travel pressure sensor (B34).
Disconnect swing pressure sensor (B33). Connect travel pressure sensor connector (B34) to swing pressure sensor (B33). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011304.03—Travel Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Travel pressure sensor (B34) malfunction. Replace sensor. DF89619,00B5800 -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect travel pressure sensor (B34). Turn key switch to ON position. Check between pin 2 of travel pressure sensor connector (B34) and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B5800 -19-12JUN14-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect travel pressure sensor (B34). Disconnect main controller connectors (X31—X36). Check for continuity between pin 9 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B5800 -19-12JUN14-6/6
TM13345X19 (23APR18)
9001-10-31
160GLC Excavator 042318 PN=65
Main Controller (MCZ) Diagnostic Trouble Codes
011304.04 — Travel Pilot Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Travel pressure sensor (B34) signal voltage is low. (Below 0.1 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B5801 -19-12JUN14-1/7
Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B5801 -19-12JUN14-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Travel pressure sensor (B34). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
DF89619,00B5801 -19-12JUN14-3/7
• 2
Component Check
Disconnect travel pressure sensor (B34).
Disconnect swing pressure sensor (B33). Connect travel pressure sensor connector (B34) to swing pressure sensor (B33). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011304.04—Travel Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Travel pressure sensor (B34) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-10-32
DF89619,00B5801 -19-12JUN14-4/7
160GLC Excavator 042318 PN=66
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect travel pressure sensor (B34). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of travel pressure sensor connector (B34) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B5801 -19-12JUN14-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Travel pressure sensor (B34) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of travel pressure sensor connector (B34) and pin 9 YES: Go to Short Circuit of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B5801 -19-12JUN14-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Travel pressure sensor (B34) disconnected. Check for continuity between pin 2 of travel pressure sensor connector (B34) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B5801 -19-12JUN14-7/7
011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input Front attachment pressure sensor (B32) signal voltage is high. (Above 4.5 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B5802 -19-12JUN14-1/6
Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-33
DF89619,00B5802 -19-12JUN14-2/6
160GLC Excavator 042318 PN=67
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Front attachment pressure sensor (B32). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). 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.)
• Cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B5802 -19-12JUN14-3/6
• 2
Component Check
Switch front attachment pressure sensor connector (B32) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011307.03—Front Attachment Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Front attachment pressure sensor (B32) malfunction. Replace sensor. DF89619,00B5802 -19-12JUN14-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect front attachment pressure sensor (B32). Turn key switch to ON position. Check between pin 2 of front attachment pressure sensor connector (B32) and machine YES: Repair or replace ground for approximately 0.0 V. harness. See appropriate harness. Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B5802 -19-12JUN14-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect front attachment pressure sensor (B31). Disconnect main controller connectors (X31—X36). Check for continuity between pin 14 of cab harness-to-main controller 30-pin connector YES: Circuit is short to D (X34) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B5802 -19-12JUN14-6/6
TM13345X19 (23APR18)
9001-10-34
160GLC Excavator 042318 PN=68
Main Controller (MCZ) Diagnostic Trouble Codes
011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input Front attachment pressure sensor (B32) signal voltage is low. (Below 0.1 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
DF89619,00B5803 -19-12JUN14-1/7
Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure DF89619,00B5803 -19-12JUN14-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Front attachment pressure sensor (B32). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 1 (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector F (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
DF89619,00B5803 -19-12JUN14-3/7
• 2
Component Check
Switch front attachment pressure sensor connector (B32) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011307.04—Front Attachment Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Front attachment pressure sensor (B32) malfunction. Replace sensor. DF89619,00B5803 -19-12JUN14-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect front attachment pressure sensor (B32). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of front attachment pressure sensor connector (B32) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-35
DF89619,00B5803 -19-12JUN14-5/7
160GLC Excavator 042318 PN=69
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Open Circuit Check
Key switch in OFF position.
Front attachment pressure sensor (B32) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of front attachment pressure sensor connector (B32) YES: Go to Short Circuit and pin 14 of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B5803 -19-12JUN14-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Front attachment pressure sensor (B32) disconnected. Check for continuity between pin 2 of front attachment pressure sensor connector (B32) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B5803 -19-12JUN14-7/7
011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Bucket curl pressure sensor (marked BKC) (B56) signal voltage is high (above 4.8 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B68BE -19-05DEC17-1/6
Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure DF89619,00B68BE -19-05DEC17-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Bucket curl pressure sensor (marked BKC) (B56). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
Continued on next page
TM13345X19 (23APR18)
9001-10-36
DF89619,00B68BE -19-05DEC17-3/6
160GLC Excavator 042318 PN=70
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Switch bucket curl pressure sensor (marked BKC) (B56) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011325.03—Bucket Roll-In Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Bucket curl pressure sensor (marked BKC) (B56) malfunction. Replace sensor. DF89619,00B68BE -19-05DEC17-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect bucket curl pressure sensor (marked BKC) (B56). Turn key switch to ON position. Check between pin 2 of bucket curl pressure sensor (marked BKC) (B56) connector and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B68BE -19-05DEC17-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect bucket curl pressure sensor (marked BKC) (B56). Disconnect main controller connectors (X31—X36). Check for continuity between pin 8 of cab harness-to-main controller 30-pin connector D (X34) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B68BE -19-05DEC17-6/6
011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Bucket curl pressure sensor (marked BKC) (B56) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B68BF -19-05DEC17-1/7
Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-37
DF89619,00B68BF -19-05DEC17-2/7
160GLC Excavator 042318 PN=71
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Bucket curl pressure sensor (marked BKC) (B56). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
DF89619,00B68BF -19-05DEC17-3/7
• 2
Component Check
Key switch in OFF position.
Switch bucket curl pressure sensor (marked BKC) (B56) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011325.04—Bucket Roll-In Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Bucket curl pressure sensor (marked BKC) (B56) malfunction. Replace sensor. DF89619,00B68BF -19-05DEC17-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect bucket curl pressure sensor (marked BKC) (B56). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of bucket curl pressure sensor (marked BKC) (B56) connector for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-38
DF89619,00B68BF -19-05DEC17-5/7
160GLC Excavator 042318 PN=72
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Open Circuit Check
Key switch in OFF position.
Bucket curl pressure sensor (marked BKC) (B56) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of bucket curl pressure sensor (marked BKC) (B56) YES: Go to Short Circuit connector and pin 8 of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B68BF -19-05DEC17-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Bucket curl pressure sensor (marked BKC) (B56) disconnected. Check for continuity between pin 2 of bucket curl pressure sensor (marked BKC) (B56) YES: Repair or replace connector and machine ground. harness. See appropriate harness. Is continuity indicated?
NO: Checks complete. DF89619,00B68BF -19-05DEC17-7/7
011400.02 — Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 2 flow rate limit solenoid (marked SB) (Y20) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·ft
DF89619,00B5804 -19-28JAN16-1/8
Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal Diagnostic Procedure DF89619,00B5804 -19-28JAN16-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (marked SB) (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) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-39
DF89619,00B5804 -19-28JAN16-3/8
160GLC Excavator 042318 PN=73
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (marked SB) (Y20) connector to torque control solenoid (marked ST) (Y21). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011400.02—Pump 2 Flow Rate Limit Solenoid Feedback Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is completed.
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid. DF89619,00B5804 -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 6 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B5804 -19-28JAN16-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Pump 2 flow rate limit solenoid (marked SB) (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to machine ground.
• Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. Continued on next page
TM13345X19 (23APR18)
9001-10-40
DF89619,00B5804 -19-28JAN16-6/8
160GLC Excavator 042318 PN=74
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B5804 -19-28JAN16-7/8
• 6
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Test pump 2 flow rate limit solenoid (marked SB) (Y20) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (marked SB) (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid. DF89619,00B5804 -19-28JAN16-8/8
011400.03 — Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
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.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B5805 -19-28JAN16-1/7
Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure DF89619,00B5805 -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (marked SB) (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) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-41
DF89619,00B5805 -19-28JAN16-3/7
160GLC Excavator 042318 PN=75
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (marked SB) (Y20) connector to torque control solenoid (marked ST) (Y21). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011400.03—Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid. DF89619,00B5805 -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 6 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B5805 -19-28JAN16-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B5805 -19-28JAN16-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Test pump 2 flow rate limit solenoid (marked SB) (Y20) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (marked SB) (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid. DF89619,00B5805 -19-28JAN16-7/7
TM13345X19 (23APR18)
9001-10-42
160GLC Excavator 042318 PN=76
Main Controller (MCZ) Diagnostic Trouble Codes
011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
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.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
JL58967,00001DA -19-05FEB15-1/7
Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure JL58967,00001DA -19-05FEB15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (marked SB) (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) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
JL58967,00001DA -19-05FEB15-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid (marked SB) (Y20) connector to torque control solenoid (marked ST) (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.04—Pump 2 Flow Rate Limit Solenoid Feedback Low Current. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-43
JL58967,00001DA -19-05FEB15-4/7
160GLC Excavator 042318 PN=77
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to pin 6 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
JL58967,00001DA -19-05FEB15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Pump 2 flow rate limit solenoid (marked SB) (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid (marked SB) (Y20) connector to machine ground.
• Pin 6 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. JL58967,00001DA -19-05FEB15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Test pump 2 flow rate limit solenoid (marked SB) (Y20) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (marked SB) (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (marked SB) (Y20) malfunction. Replace solenoid. JL58967,00001DA -19-05FEB15-7/7
011401.02 — Torque Control Solenoid Valve Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Torque control solenoid (marked ST) (Y21) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B5807 -19-28JAN16-1/8
Torque Control Solenoid Valve Abnormal Feedback Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-44
DF89619,00B5807 -19-28JAN16-2/8
160GLC Excavator 042318 PN=78
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Torque control solenoid (marked ST) (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) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
DF89619,00B5807 -19-28JAN16-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (marked ST) (Y21) connector to pump 2 flow rate limit solenoid (marked SB) (Y20). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011401.02—Torque Control Solenoid Abnormal Feedback. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid. DF89619,00B5807 -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of torque control solenoid (marked ST) (Y21) connector to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid (marked ST) (Y21) connector to pin 2 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
Continued on next page
TM13345X19 (23APR18)
9001-10-45
DF89619,00B5807 -19-28JAN16-5/8
160GLC Excavator 042318 PN=79
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Torque control solenoid (Y21) (marked ST) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of torque control solenoid (marked ST) (Y21) connector to machine ground. • Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. DF89619,00B5807 -19-28JAN16-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B5807 -19-28JAN16-7/8
• 6
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Test torque control solenoid (marked ST) (Y21) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (marked ST) (Y21) within specification?
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid. DF89619,00B5807 -19-28JAN16-8/8
011401.03 — Torque Control Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Torque control solenoid (marked ST) (Y21) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B5808 -19-28JAN16-1/7
Torque Control Solenoid Valve Feedback High Current Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-46
DF89619,00B5808 -19-28JAN16-2/7
160GLC Excavator 042318 PN=80
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Torque control solenoid (marked ST) (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) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
DF89619,00B5808 -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (marked ST) (Y21) connector to pump 2 flow rate limit solenoid (marked SB) (Y20). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011401.03—Torque Control Solenoid Feedback High Current. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid. DF89619,00B5808 -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of torque control solenoid (marked ST) (Y21) connector to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid (marked ST) (Y21) connector to pin 2 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B5808 -19-28JAN16-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 2 of cab harness-to-main controller 31-pin connector A (X31) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check.
Continued on next page
TM13345X19 (23APR18)
9001-10-47
DF89619,00B5808 -19-28JAN16-6/7
160GLC Excavator 042318 PN=81
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Test torque control solenoid (marked ST) (Y21) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (marked ST) (Y21) within specification?
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid. DF89619,00B5808 -19-28JAN16-7/7
011401.04 — Torque Control Solenoid Valve Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Torque control solenoid (marked ST) (Y21) feedback current below 56 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B5809 -19-28JAN16-1/7
Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure DF89619,00B5809 -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Torque control solenoid (marked ST) (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) and cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1) Component Location. (Group 9015-10.)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness. DF89619,00B5809 -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid (marked ST) (Y21) connector to pump 2 flow rate limit solenoid (marked SB) (Y20). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011401.04—Torque Control Solenoid Valve Feedback Low Current. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-48
DF89619,00B5809 -19-28JAN16-4/7
160GLC Excavator 042318 PN=82
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of torque control solenoid (marked ST) (Y21) connector to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid (marked ST) (Y21) connector to pin 2 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B5809 -19-28JAN16-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Torque control solenoid (marked ST) (Y21) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of torque control solenoid (marked ST) (Y21) connector to machine ground. • Pin 2 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. DF89619,00B5809 -19-28JAN16-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (marked ST) (Y21). Test torque control solenoid (marked ST) (Y21) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (marked ST) (Y21) within specification?
NO: Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid. DF89619,00B5809 -19-28JAN16-7/7
011402.02 — Dig Regenerative Solenoid Valve Feedback Current Abnormal
Over torquing will result in permanent damage to connector. Torque only to specification.
Dig regenerative solenoid (marked SF) (Y22) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580A -19-28JAN16-1/8
Dig Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-49
DF89619,00B580A -19-28JAN16-2/8
160GLC Excavator 042318 PN=83
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Dig regenerative solenoid (marked SF) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580A -19-28JAN16-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (marked SF) connector (Y22) to arm regenerative solenoid (marked SC) (Y23). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011402.02—Dig Regenerative Solenoid Feedback Current Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid. DF89619,00B580A -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid (marked SF) connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid (marked SF) connector (Y22) to pin 14 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
Continued on next page
TM13345X19 (23APR18)
9001-10-50
DF89619,00B580A -19-28JAN16-5/8
160GLC Excavator 042318 PN=84
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Dig regenerative solenoid (marked SF) (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (marked SF) (Y22) to machine ground. • Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. DF89619,00B580A -19-28JAN16-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B580A -19-28JAN16-7/8
• 6
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Test dig regenerative solenoid (marked SF) (Y22) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (marked SF) (Y22) within specification?
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid. DF89619,00B580A -19-28JAN16-8/8
011402.03 — Dig Regenerative Solenoid Valve Feedback Current High
Over torquing will result in permanent damage to connector. Torque only to specification.
Dig regenerative solenoid (marked SF) (Y22) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580B -19-28JAN16-1/7
Dig Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-51
DF89619,00B580B -19-28JAN16-2/7
160GLC Excavator 042318 PN=85
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Dig regenerative solenoid (marked SF) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580B -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (marked SF) connector (Y22) to arm regenerative solenoid (marked SC) (Y23). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011402.03—Dig Regenerative Solenoid Feedback Current High. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid. DF89619,00B580B -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid (marked SF) connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid (marked SF) connector (Y22) to pin 14 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B580B -19-28JAN16-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 14 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins? Continued on next page
TM13345X19 (23APR18)
9001-10-52
NO: Go to Solenoid Check. DF89619,00B580B -19-28JAN16-6/7
160GLC Excavator 042318 PN=86
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Test dig regenerative solenoid (marked SF) (Y22) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (marked SF) (Y22) within specification?
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid. DF89619,00B580B -19-28JAN16-7/7
011402.04 — Dig Regenerative Solenoid Valve Feedback Current Low
Over torquing will result in permanent damage to connector. Torque only to specification.
Dig regenerative solenoid (marked SF) (Y22) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580C -19-28JAN16-1/7
Dig Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure DF89619,00B580C -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Dig regenerative solenoid (marked SF) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580C -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid (marked SF) connector (Y22) to arm regenerative solenoid (marked SC) (Y23). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011402.04—Dig Regenerative Solenoid Feedback Current Low. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-53
DF89619,00B580C -19-28JAN16-4/7
160GLC Excavator 042318 PN=87
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid (marked SF) connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid (marked SF) connector (Y22) to pin 14 cab harness-to-main controller 31-pin connector A (X31).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B580C -19-28JAN16-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Dig regenerative solenoid (marked SF) (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (marked SF) (Y22) to machine ground. • Pin 14 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. DF89619,00B580C -19-28JAN16-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (marked SF) (Y22). Test dig regenerative solenoid (marked SF) (Y22) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (marked SF) (Y22) within specification?
NO: Dig regenerative solenoid (marked SF) (Y22) malfunction. Replace solenoid. DF89619,00B580C -19-28JAN16-7/7
011403.02 — Arm Regenerative Solenoid Valve Feedback Current Abnormal
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm regenerative solenoid (marked SC) (Y23) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580D -19-28JAN16-1/8
Arm Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-54
DF89619,00B580D -19-28JAN16-2/8
160GLC Excavator 042318 PN=88
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm regenerative solenoid (marked SC) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580D -19-28JAN16-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (marked SC) connector (Y23) to dig regenerative solenoid (marked SF) (Y22). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011403.02—Arm Regenerative Solenoid Feedback Current Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid. DF89619,00B580D -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid (marked SC) connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid (marked SC) connector (Y23) to pin 10 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
Continued on next page
TM13345X19 (23APR18)
9001-10-55
DF89619,00B580D -19-28JAN16-5/8
160GLC Excavator 042318 PN=89
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Arm regenerative solenoid (marked SC) (Y23) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm regenerative solenoid connector (marked SC) (Y23) to machine ground. • Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. DF89619,00B580D -19-28JAN16-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B580D -19-28JAN16-7/8
• 6
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Test arm regenerative solenoid (marked SC) (Y23) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (marked SC) (Y23) within specification?
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid. DF89619,00B580D -19-28JAN16-8/8
011403.03 — Arm Regenerative Solenoid Valve Feedback Current High
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm regenerative solenoid (marked SC) (Y23) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580E -19-28JAN16-1/7
Arm Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-56
DF89619,00B580E -19-28JAN16-2/7
160GLC Excavator 042318 PN=90
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm regenerative solenoid (marked SC) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580E -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (marked SC) connector (Y23) to dig regenerative solenoid (marked SF) (Y22). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011403.03—Arm Regenerative Solenoid Feedback Current High. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid. DF89619,00B580E -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid (marked SC) connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid (marked SC) connector (Y23) to pin 10 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B580E -19-28JAN16-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 10 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins? Continued on next page
TM13345X19 (23APR18)
9001-10-57
NO: Go to Solenoid Check. DF89619,00B580E -19-28JAN16-6/7
160GLC Excavator 042318 PN=91
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Test arm regenerative solenoid (marked SC) (Y23) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (marked SC) (Y23) within specification?
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid. DF89619,00B580E -19-28JAN16-7/7
011403.04 — Arm Regenerative Solenoid Valve Feedback Current Low
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm regenerative solenoid (marked SC) (Y23) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B580F -19-28JAN16-1/7
Arm Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure DF89619,00B580F -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm regenerative solenoid (marked SC) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B580F -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid (marked SC) connector (Y23) to dig regenerative solenoid (marked SF) (Y22). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011403.04—Arm Regenerative Solenoid Feedback Current Low. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-58
DF89619,00B580F -19-28JAN16-4/7
160GLC Excavator 042318 PN=92
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid (marked SC) connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid (marked SC) connector (Y23) to pin 10 cab harness-to-main controller 31-pin connector A (X31).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B580F -19-28JAN16-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Arm regenerative solenoid (marked SC) (Y23) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm regenerative solenoid (marked SC) connector (Y23) to machine ground. • Pin 10 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. DF89619,00B580F -19-28JAN16-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (marked SC) (Y23). Test arm regenerative solenoid (marked SC) (Y23) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (marked SC) (Y23) within specification?
NO: Arm regenerative solenoid (marked SC) (Y23) malfunction. Replace solenoid. DF89619,00B580F -19-28JAN16-7/7
011407.02 — Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal
Over torquing will result in permanent damage to connector. Torque only to specification.
Power dig/travel speed solenoid (marked SG) (Y24) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B58AA -19-28JAN16-1/8
Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-59
DF89619,00B58AA -19-28JAN16-2/8
160GLC Excavator 042318 PN=93
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Power dig/travel speed solenoid (marked SG) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B58AA -19-28JAN16-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Switch connectors of power dig/travel speed solenoid (marked SG) (Y24) with another solenoid in solenoid valve manifold. Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011407.02—Power Dig/Travel Speed Solenoid Feedback Current Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid. DF89619,00B58AA -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 13 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
Continued on next page
TM13345X19 (23APR18)
9001-10-60
DF89619,00B58AA -19-28JAN16-5/8
160GLC Excavator 042318 PN=94
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Power dig/travel speed solenoid (marked SG) (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of power dig/travel speed solenoid (marked SG) (Y24) to machine ground. • Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. DF89619,00B58AA -19-28JAN16-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. DF89619,00B58AA -19-28JAN16-7/8
• 6
Solenoid Check
Key switch in OFF position.
Power dig/travel speed solenoid (marked SG) (Y24) disconnected. Test power dig/travel speed solenoid (marked SG) (Y24) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is power dig/travel speed solenoid (marked SG) (Y24) within specification?
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid. DF89619,00B58AA -19-28JAN16-8/8
011407.03 — Power Dig/Travel Speed Solenoid Valve Feedback Current High
Over torquing will result in permanent damage to connector. Torque only to specification.
Power dig/travel speed solenoid (marked SG) (Y24) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B58AB -19-28JAN16-1/7
Power Dig/Travel Speed Solenoid Valve Feedback Current High Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-61
DF89619,00B58AB -19-28JAN16-2/7
160GLC Excavator 042318 PN=95
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Power dig/travel speed solenoid (marked SG) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B58AB -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Switch connectors of power dig/travel speed solenoid (marked SG) (Y24) with another solenoid in solenoid valve manifold. Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011407.03—Power Dig/Travel Speed Solenoid Feedback Current High. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid. DF89619,00B58AB -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 13 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B58AB -19-28JAN16-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 13 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins? Continued on next page
TM13345X19 (23APR18)
9001-10-62
NO: Go to Solenoid Check. DF89619,00B58AB -19-28JAN16-6/7
160GLC Excavator 042318 PN=96
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
Power dig/travel speed solenoid (marked SG) (Y24) disconnected. Test power dig/travel speed solenoid (marked SG) (Y24) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is power dig/travel speed solenoid (marked SG) (Y24) within specification?
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid. DF89619,00B58AB -19-28JAN16-7/7
011407.04 — Power Dig/Travel Speed Solenoid Valve Feedback Current Low
Over torquing will result in permanent damage to connector. Torque only to specification.
Power dig/travel speed solenoid (marked SG) (Y24) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B58AC -19-28JAN16-1/7
Power Dig/Travel Speed Solenoid Valve Feedback Current Low Diagnostic Procedure DF89619,00B58AC -19-28JAN16-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Power dig/travel speed solenoid (marked SG) (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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B58AC -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Switch connectors of power dig/travel speed solenoid (marked SG) (Y24) with another solenoid in solenoid valve manifold. Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011407.04—Power Dig/Travel Speed Solenoid Feedback Current Low. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-63
DF89619,00B58AC -19-28JAN16-4/7
160GLC Excavator 042318 PN=97
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig/travel speed solenoid (marked SG) (Y24). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig/travel speed solenoid (marked SG) (Y24) connector to pin 13 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 31-pin connector A (X31).
DF89619,00B58AC -19-28JAN16-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Power dig/travel speed solenoid (marked SG) (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of power dig/travel speed solenoid (marked SG) (Y24) to machine ground. • Pin 13 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. DF89619,00B58AC -19-28JAN16-6/7
• 5
Solenoid Check
Key switch in OFF position.
Power dig/travel speed solenoid (marked SG) (Y24) disconnected. Test power dig/travel speed solenoid (marked SG) (Y24) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is power dig/travel speed solenoid (marked SG) (Y24) within specification?
NO: Power dig/travel speed solenoid (marked SG) (Y24) malfunction. Replace solenoid. DF89619,00B58AC -19-28JAN16-7/7
011408.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal
Not applicable to machine.
Exhaust aftertreatment solenoid valve (pump 1) (marked SZ) (Y12) current above 920 mA or below 60 mA. DF89619,00B68B4 -19-04DEC17-1/1
011408.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High
Not applicable to machine.
Exhaust aftertreatment solenoid valve (pump 1) (marked SZ) (Y12) current above 920 mA. DF89619,00B68B5 -19-04DEC17-1/1
TM13345X19 (23APR18)
9001-10-64
160GLC Excavator 042318 PN=98
Main Controller (MCZ) Diagnostic Trouble Codes
011408.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low
Exhaust aftertreatment solenoid valve (pump 1) (marked SZ) (Y12) feedback current below 60 mA. Not applicable to machine. DF89619,00B68B6 -19-04DEC17-1/1
011409.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal
Not applicable to machine.
Exhaust aftertreatment solenoid valve (bypass cut-off valve) (marked SJ) (Y13) feedback current above 920 mA or below 60 mA. DF89619,00B68B7 -19-04DEC17-1/1
011409.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High
Exhaust aftertreatment solenoid valve (bypass cut-off valve) (marked SJ) (Y13) feedback current above 920 mA. Not applicable to machine. DF89619,00B68B8 -19-04DEC17-1/1
011409.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low
Exhaust aftertreatment solenoid valve (bypass cut-off valve) (marked SJ) (Y13) feedback current below 60 mA. Not applicable to machine. DF89619,00B68B9 -19-04DEC17-1/1
011410.02 — Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 flow rate limit solenoid (marked SA) (Y26) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
MM16284,0001E6C -19-30OCT15-1/8
Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure MM16284,0001E6C -19-30OCT15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Pump 1 flow rate limit solenoid (Y26) 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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-65
MM16284,0001E6C -19-30OCT15-3/8
160GLC Excavator 042318 PN=99
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 1 flow rate limit solenoid (marked SA) (Y26). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 1 flow rate limit solenoid (Y26) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011410.02—Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. MM16284,0001E6C -19-30OCT15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 1 flow rate limit solenoid (Y26) connector to pin 26 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 1 flow rate limit solenoid (Y26) connector to pin 27 cab harness-to-main YES: Repair or replace controller 31-pin connector A (X31).
harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check. MM16284,0001E6C -19-30OCT15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Pump 1 flow rate limit solenoid (Y26) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 1 flow rate limit solenoid (Y26) connector to machine ground. • Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Go to Harness Check. Is continuity indicated?
NO: Short to ground. Repair or replace harness. See appropriate harness. MM16284,0001E6C -19-30OCT15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins? Continued on next page
TM13345X19 (23APR18)
9001-10-66
NO: Go to Solenoid Check. MM16284,0001E6C -19-30OCT15-7/8
160GLC Excavator 042318 PN=100
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Test pump 1 flow rate limit solenoid (Y26) and compare to specification. See Electrical Component Checks. (Group 9015-20.)
YES: Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is pump 1 flow rate limit solenoid (Y26) within specification?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. MM16284,0001E6C -19-30OCT15-8/8
011410.03 — Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 flow rate limit solenoid (marked SA) (Y26) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
MM16284,0001E6B -19-30OCT15-1/7
Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure MM16284,0001E6B -19-30OCT15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Pump 1 flow rate limit solenoid (Y26) 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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-67
MM16284,0001E6B -19-30OCT15-3/7
160GLC Excavator 042318 PN=101
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 1 flow rate limit solenoid (marked SA) (Y26). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 1 flow rate limit solenoid (Y26) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011410.03—Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. MM16284,0001E6B -19-30OCT15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Disconnect main controller connectors (X31). Check for continuity between:
• Pin 1 of pump 1 flow rate limit solenoid (Y26) connector to pin 26 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 1 flow rate limit solenoid (Y26) connector to pin 27 cab harness-to-main YES: Repair or replace controller 31-pin connector A (X31).
Is continuity indicated?
harness. See appropriate harness. NO: Go to Harness Check. MM16284,0001E6B -19-30OCT15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 27 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. MM16284,0001E6B -19-30OCT15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Test pump 1 flow rate limit solenoid (Y26) and compare to specification. See Electrical Component Checks. (Group 9015-20.)
YES: Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is pump 1 flow rate limit solenoid (Y26) within specification?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. MM16284,0001E6B -19-30OCT15-7/7
TM13345X19 (23APR18)
9001-10-68
160GLC Excavator 042318 PN=102
Main Controller (MCZ) Diagnostic Trouble Codes
011410.04 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 1 flow rate limit solenoid (marked SA) (Y260) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
MM16284,0001E6A -19-30OCT15-1/7
Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure MM16284,0001E6A -19-30OCT15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Pump 1 flow rate limit solenoid (Y26) 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)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
MM16284,0001E6A -19-30OCT15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 1 flow rate limit solenoid (marked SA) (Y26). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 1 flow rate limit solenoid (Y26) connector to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011410.04—Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. Continued on next page
TM13345X19 (23APR18)
9001-10-69
MM16284,0001E6A -19-30OCT15-4/7
160GLC Excavator 042318 PN=103
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Disconnect main controller connectors (X31). Check for continuity between:
• Pin 1 of pump 1 flow rate limit solenoid (Y26) connector to pin 26 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 1 flow rate limit solenoid (Y26) connector to pin 27 cab harness-to-main YES: Repair or replace controller 31-pin connector A (X31).
harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check. MM16284,0001E6A -19-30OCT15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Pump 1 flow rate limit solenoid (Y26) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 1 flow rate limit solenoid (Y26) connector to machine ground. • Pin 27 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Go to Solenoid Check. Is continuity indicated?
NO: Short to ground. Repair or replace harness. See appropriate harness. MM16284,0001E6A -19-30OCT15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 1 flow rate limit solenoid (Y26). Test pump 1 flow rate limit solenoid (Y26) and compare to specification. See Electrical Component Checks. (Group 9015-20.)
YES: Main controller (MCZ) malfunction. Replace main controller (MCZ). See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is pump 1 flow rate limit solenoid (Y26) within specification?
NO: Pump 1 flow rate limit solenoid (Y26) malfunction. Replace solenoid. MM16284,0001E6A -19-30OCT15-7/7
011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback
Not applicable to this machine. JL58967,00002FD -19-09OCT15-1/1
011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current
Not applicable to this machine. JL58967,00002FF -19-09OCT15-1/1
TM13345X19 (23APR18)
9001-10-70
160GLC Excavator 042318 PN=104
Main Controller (MCZ) Diagnostic Trouble Codes
011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current
Not applicable to this machine. JL58967,0000300 -19-09OCT15-1/1
011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback
Not applicable to this machine. JL58967,0000301 -19-09OCT15-1/1
011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current
Not applicable to this machine. JL58967,0000302 -19-09OCT15-1/1
011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current
Not applicable to this machine. JL58967,0000303 -19-09OCT15-1/1
011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback
Not applicable to this machine. JL58967,0000304 -19-09OCT15-1/1
011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current
Not applicable to this machine. JL58967,0000305 -19-09OCT15-1/1
011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current
Not applicable to this machine. JL58967,0000306 -19-09OCT15-1/1
011457.02 — 2-Speed Activation Solenoid Valve Disconnected
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
2-speed activation solenoid valve (Y43) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
NOTE: DTC 011457.02 may be a false code. If machine has 2-speed activation solenoid valve (Y43), proceed with 011457.02—2-Speed Activation Solenoid Valve Disconnected. If machine does not have 2-speed activation solenoid valve (Y43), switch machine to bucket mode and clear DTC. Operate machine and verify DTC is cleared. DF89619,00B5819 -19-28JAN16-1/7
2-Speed Activation Solenoid Valve Disconnected Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-71
DF89619,00B5819 -19-28JAN16-2/7
160GLC Excavator 042318 PN=105
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• 2-speed activation solenoid valve (Y43). See 2-Speed Harness (W32) Component Location. (Group 9015-10.)
• Attachment harness-to-two speed harness connector (X87). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
DF89619,00B5819 -19-28JAN16-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect 2-speed activation solenoid valve (Y43). Disconnect selector valve solenoid valve (Y40). Connect selector valve solenoid valve (Y40) to 2-speed activation solenoid valve (Y43). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011457.02—2-Speed Activation Solenoid Valve Disconnected. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: 2-speed activation solenoid valve (Y43) malfunction. Replace solenoid. DF89619,00B5819 -19-28JAN16-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect 2-speed activation solenoid valve (Y43). Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of 2-speed activation solenoid valve (Y43) to pin 3 cab harness-to-main controller 17-pin connector C (X33).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-72
DF89619,00B5819 -19-28JAN16-5/7
160GLC Excavator 042318 PN=106
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
2-speed activation solenoid valve (Y43) disconnected. Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 1 of 2-speed activation solenoid valve (Y43) to machine ground.
YES: Short to ground. Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check. DF89619,00B5819 -19-28JAN16-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 3 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Checks complete. DF89619,00B5819 -19-28JAN16-7/7
011458.02 — Selector Valve Solenoid Valve Disconnected Selector valve solenoid valve (Y40) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
NOTE: DTC 011458.02 may be a false code. If machine has selector valve solenoid valve (Y40), proceed with 011458.02—Selector Valve Solenoid Valve Disconnected. If machine does not have selector valve solenoid valve (Y40), switch machine to bucket mode and clear DTC. Operate machine and verify DTC is cleared.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in DF89619,00B581A -19-28JAN16-1/8
Selector Valve Solenoid Valve Disconnected Diagnostic Procedure DF89619,00B581A -19-28JAN16-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Selector valve solenoid valve (Y40). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 17-pin connector C (X33). See Cab Harness (W1)
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-73
DF89619,00B581A -19-28JAN16-3/8
160GLC Excavator 042318 PN=107
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect selector valve solenoid valve (Y40). Disconnect 2-speed activation solenoid valve (Y43). Connect selector valve solenoid valve (Y40) to 2-speed activation solenoid valve (Y43). Clear MCZ diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011458.02—Selector Valve Solenoid Valve Disconnected. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Selector valve solenoid valve (Y40) malfunction. Replace solenoid. DF89619,00B581A -19-28JAN16-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect selector valve solenoid valve (Y40). Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of selector valve solenoid valve (Y40) to pin 4 cab harness-to-main controller 17-pin connector C (X33).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B581A -19-28JAN16-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Selector valve solenoid valve (Y40) disconnected. Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 1 of selector valve solenoid valve (Y40) to machine ground.
YES: Short to ground. Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check. DF89619,00B581A -19-28JAN16-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 4 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check.
Continued on next page
TM13345X19 (23APR18)
9001-10-74
DF89619,00B581A -19-28JAN16-7/8
160GLC Excavator 042318 PN=108
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Test selector valve solenoid valve (Y40) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is selector valve solenoid valve (Y40) within specification?
NO: Selector valve solenoid valve (Y40) malfunction. Replace solenoid valve. DF89619,00B581A -19-28JAN16-8/8
011459.02 — Idle Stop Relay Circuit Malfunction DF89619,00B581B -19-03FEB17-1/6
Idle Stop Relay Circuit Malfunction Diagnostic Procedure DF89619,00B581B -19-03FEB17-2/6
• 1
Fuse Check
Key switch in OFF position.
Remove idle stop 5 A fuse (marked IDLE STOP) (F18) from fuse box (F50). See Fuse and Relay Specifications. (Group 9015-10.) Test idle stop 5 A fuse (marked IDLE STOP) (F18) for continuity.
YES: Go to Voltage Check.
Is continuity indicated?
NO: Replace fuse. DF89619,00B581B -19-03FEB17-3/6
• 2
Voltage Check
Install idle stop 5 A fuse (marked IDLE STOP) (F18) in fuse box (F50).
Key switch in ON position. Remove idle stop relay (K11). See Cab Harness (W1) Component Location. (Group 9015-10.) Check voltage at idle stop relay (K11) connector pin 1.
YES: Go to Relay Check.
Are approximately 24 volts present?
NO: Open circuit in cab harness (W1) between idle stop relay (K11) and idle stop 5 A fuse (marked IDLE STOP) (F18). Repair or replace harness. DF89619,00B581B -19-03FEB17-4/6
• 3
Relay Check
Key switch in OFF position.
Test idle stop relay (K11). See Electrical Component Checks. (Group 9015-20.)
YES: Go to Cab Harness (W1) Continuity Check.
Is idle stop relay (K11) within specification?
NO: Replace idle stop relay (K11).
Continued on next page
TM13345X19 (23APR18)
9001-10-75
DF89619,00B581B -19-03FEB17-5/6
160GLC Excavator 042318 PN=109
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Cab Harness (W1) Continuity Check
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.)
YES: Main controller (MCZ) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install. (Group 9015-20.)
Is continuity indicated in all circuits?
NO: Open circuit in cab harness. Repair or replace harness. DF89619,00B581B -19-03FEB17-6/6
011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage
Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is high (above 4.5 V). RH60123,0002250 -19-13APR16-1/6
Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure RH60123,0002250 -19-13APR16-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 24-pin connector B (X32). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - AFL solenoid pressure sensor (marked PS1) (B85). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
Continued on next page
TM13345X19 (23APR18)
9001-10-76
RH60123,0002250 -19-13APR16-3/6
160GLC Excavator 042318 PN=110
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011810.03—Electric Lever Operating Pressure Sensor 1 High Voltage. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor. RH60123,0002250 -19-13APR16-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Turn key switch to ON position. Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and YES: Repair or replace machine ground for approximately 0.0 V. harness. See appropriate harness. Is correct voltage indicated?
NO: Go to Harness Check. RH60123,0002250 -19-13APR16-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Disconnect main controller connectors (X31—X36). Check for continuity between pin 2 of cab harness-to-main controller 24-pin connector B (X32) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. RH60123,0002250 -19-13APR16-6/6
011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage
Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) signal voltage is low (below 0.1 V). RH60123,0002251 -19-13APR16-1/7
Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-77
RH60123,0002251 -19-13APR16-2/7
160GLC Excavator 042318 PN=111
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 24-pin connector B (X32). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - AFL solenoid pressure sensor (marked PS1) (B85). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,0002251 -19-13APR16-3/7
• 2
Component Check
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011810.04—Electric Lever Operating Pressure Sensor 1 Low Voltage. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: AFL solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor. RH60123,0002251 -19-13APR16-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect AFL solenoid pressure sensor (marked PS1) (B85). Turn key switch to ON position. Check voltage between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and YES: Repair or replace machine ground for approximately 0.0 V. harness. See appropriate harness. Is correct voltage indicated?
NO: Go to Open Circuit Check. RH60123,0002251 -19-13APR16-5/7
• 4
Open Circuit Check
Key switch in OFF position.
AFL solenoid pressure sensor (marked PS1) (B85) disconnected. Disconnect cab harness-to-main controller 24-pin connector B (X32). Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and pin 2 of cab harness-to-main controller 24-pin connector B (X32).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-78
RH60123,0002251 -19-13APR16-6/7
160GLC Excavator 042318 PN=112
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Short Circuit Check
Key switch in OFF position.
AFL solenoid pressure sensor (marked PS1) (B85) disconnected. Check for continuity between pin 2 of AFL solenoid pressure sensor (marked PS1) (B85) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0002251 -19-13APR16-7/7
011812.02 — OPT Electric Lever 1 Neutral Abnormal
(174 psi) is sensed at auxiliary function lever (AFL) solenoid pressure sensor (B85).
When OPT electric lever 1 (proportional slider) is in neutral, pressure above 1.2 MPa (12.0 bar) RH60123,00022D2 -19-21MAR17-1/5
OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure RH60123,00022D2 -19-21MAR17-2/5
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31). - Cab harness-to-main controller 24-pin connector B (X32). - Cab harness-to-main controller 17-pin connector C (X33).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Optional connector (X26). - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Pressure Sensor Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Secondary pilot shutoff solenoid (marked PiC) (Y66) connector. - Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) connector. - Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) connector. - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,00022D2 -19-21MAR17-3/5
• 2
Pressure Sensor Check
Key switch in OFF position.
Disconnect auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85). Test auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Solenoid Valve Check.
Is auxiliary function lever (AFL) solenoid pressure sensor within specification?
NO: Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-10-79
RH60123,00022D2 -19-21MAR17-4/5
160GLC Excavator 042318 PN=113
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Solenoid Valve Check
Key switch in OFF position.
Disconnect connectors to both auxiliary function lever (AFL) solenoids A and B. (Y61 and Y62). Key switch in ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Start engine and lower pilot shutoff lever. Press auxiliary function enable switch (S45). NOTE: Disregard any diagnostic trouble codes (DTCs) other than 011812.02.
YES: Solenoid valves sticking. Remove valves and inspect for debris, scoring, or damage. Repair or replace solenoid valves as required.
Does diagnostic trouble code (DTC) 011812.02 return?
NO: Checks complete. RH60123,00022D2 -19-21MAR17-5/5
011813.02 — OPT Electric Lever 1 Abnormal Operation
Secondary pilot shutoff solenoid (marked PiC) (Y66) current above 920 mA and below 70 mA with slow or no operation. RH60123,00022D3 -19-01SEP15-1/8
OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure RH60123,00022D3 -19-01SEP15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Optional connector (X26). - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Secondary pilot shutoff solenoid (marked PiC) (Y66). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
Continued on next page
TM13345X19 (23APR18)
9001-10-80
RH60123,00022D3 -19-01SEP15-3/8
160GLC Excavator 042318 PN=114
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66). Switch connectors of secondary pilot shutoff solenoid (marked PiC) (Y66) with another solenoid. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011813.02—OPT Electric Lever 1 Abnormal Operation. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid. RH60123,00022D3 -19-01SEP15-4/8
• 3
Continuity Check
Key switch in OFF position.
Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) connector to pin 6 of cab harness-to-main controller 17-pin connector C (X33).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,00022D3 -19-01SEP15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) to machine ground.
YES: Short to ground. Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check. RH60123,00022D3 -19-01SEP15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 17-pin connector C (X33) disconnected. Check for continuity between pin 6 of cab harness-to-main controller 17-pin connector C (X33) to all other pins on connector.
YES: Short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Go to Solenoid Check.
Continued on next page
TM13345X19 (23APR18)
9001-10-81
RH60123,00022D3 -19-01SEP15-7/8
160GLC Excavator 042318 PN=115
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Secondary pilot shutoff solenoid (marked PiC) (Y66) disconnected. Test secondary pilot shutoff solenoid (marked PiC) (Y66) and compare to specification. YES: Checks complete. See Electrical Component Specifications. (Group 9015-20.) Is secondary pilot shutoff solenoid (marked PiC) (Y66) within specification?
NO: Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid. RH60123,00022D3 -19-01SEP15-8/8
011816.02 — OPT Solenoid 1 Feedback Abnormal
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA and below 70 mA. RH60123,00022D4 -19-01SEP15-1/8
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure RH60123,00022D4 -19-01SEP15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,00022D4 -19-01SEP15-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.02—OPT Solenoid 1 Feedback Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-82
RH60123,00022D4 -19-01SEP15-4/8
160GLC Excavator 042318 PN=116
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main YES: Go to Short Circuit controller 31-pin connector A (X31). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,00022D4 -19-01SEP15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
AFL solenoid A (marked 1A) (Y61) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground. • Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,00022D4 -19-01SEP15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,00022D4 -19-01SEP15-7/8
• 6
Solenoid Check
Key switch in OFF position.
AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. RH60123,00022D4 -19-01SEP15-8/8
011816.03 — OPT Solenoid 1 Feedback Current High
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA. Continued on next page
TM13345X19 (23APR18)
9001-10-83
RH60123,00022D5 -19-01SEP15-1/7
160GLC Excavator 042318 PN=117
Main Controller (MCZ) Diagnostic Trouble Codes Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure RH60123,00022D5 -19-01SEP15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,00022D5 -19-01SEP15-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.03—OPT Solenoid 1 Feedback Current High. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. RH60123,00022D5 -19-01SEP15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main YES: Go to Harness controller 31-pin connector A (X31). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-84
RH60123,00022D5 -19-01SEP15-5/7
160GLC Excavator 042318 PN=118
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 23 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,00022D5 -19-01SEP15-6/7
• 5
Solenoid Check
Key switch in OFF position.
AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. RH60123,00022D5 -19-01SEP15-7/7
011816.04 — OPT Solenoid 1 Feedback Current Low
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) feedback current below 56 mA. RH60123,00022D6 -19-01SEP15-1/7
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure RH60123,00022D6 -19-01SEP15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
Continued on next page
TM13345X19 (23APR18)
9001-10-85
RH60123,00022D6 -19-01SEP15-3/7
160GLC Excavator 042318 PN=119
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect AFL solenoid B (marked 1B) (Y62). Connect AFL solenoid A (marked 1A) (Y61) connector to AFL solenoid B (marked 1B) (Y62). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011816.04—OPT Solenoid 1 Feedback Current Low. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. RH60123,00022D6 -19-01SEP15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid A (marked 1A) (Y61). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to pin 22 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid A (marked 1A) (Y61) connector to pin 23 of cab harness-to-main YES: Go to Short Circuit controller 31-pin connector A (X31).
Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,00022D6 -19-01SEP15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
AFL solenoid A (marked 1A) (Y61) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of AFL solenoid A (marked 1A) (Y61) connector to machine ground. • Pin 23 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. Continued on next page
TM13345X19 (23APR18)
9001-10-86
RH60123,00022D6 -19-01SEP15-6/7
160GLC Excavator 042318 PN=120
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
AFL solenoid A (marked 1A) (Y61) disconnected. Test AFL solenoid A (marked 1A) (Y61) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. RH60123,00022D6 -19-01SEP15-7/7
011817.02 — OPT Solenoid 2 Feedback Abnormal
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA and below 70 mA. RH60123,00022D7 -19-01SEP15-1/8
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure RH60123,00022D7 -19-01SEP15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,00022D7 -19-01SEP15-3/8
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.02—OPT Solenoid 2 Feedback Abnormal. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-10-87
RH60123,00022D7 -19-01SEP15-4/8
160GLC Excavator 042318 PN=121
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main YES: Go to Short Circuit controller 31-pin connector A (X31). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,00022D7 -19-01SEP15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
AFL solenoid B (marked 1B) (Y62) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground. • Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,00022D7 -19-01SEP15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,00022D7 -19-01SEP15-7/8
• 6
Solenoid Check
Key switch in OFF position.
AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. RH60123,00022D7 -19-01SEP15-8/8
011817.03 — OPT Solenoid 2 Feedback Current High
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA. Continued on next page
TM13345X19 (23APR18)
9001-10-88
RH60123,00022D8 -19-01SEP15-1/7
160GLC Excavator 042318 PN=122
Main Controller (MCZ) Diagnostic Trouble Codes Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure RH60123,00022D8 -19-01SEP15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,00022D8 -19-01SEP15-3/7
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.03—OPT Solenoid 2 Feedback Current High. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. RH60123,00022D8 -19-01SEP15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main YES: Go to Harness controller 31-pin connector A (X31). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-89
RH60123,00022D8 -19-01SEP15-5/7
160GLC Excavator 042318 PN=123
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 24 of cab harness-to-main controller 31-pin connector YES: Short to power. A (X31) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,00022D8 -19-01SEP15-6/7
• 5
Solenoid Check
Key switch in OFF position.
AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. RH60123,00022D8 -19-01SEP15-7/7
011817.04 — OPT Solenoid 2 Feedback Current Low
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) feedback current below 56 mA. RH60123,00022D9 -19-01SEP15-1/7
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure RH60123,00022D9 -19-01SEP15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
(Group 9015-10.) - Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
Continued on next page
TM13345X19 (23APR18)
9001-10-90
RH60123,00022D9 -19-01SEP15-3/7
160GLC Excavator 042318 PN=124
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect AFL solenoid A (marked 1A) (Y61). Connect AFL solenoid B (marked 1B) (Y62) connector to AFL solenoid A (marked 1A) (Y61). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011817.04—OPT Solenoid 2 Feedback Current Low. Is code active?
YES: Go to Continuity Check.
Return connectors to appropriate solenoids after check is complete.
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. RH60123,00022D9 -19-01SEP15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect AFL solenoid B (marked 1B) (Y62). Disconnect cab harness-to-main controller 31-pin connector A (X31). Check for continuity between:
• Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to pin 25 of cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of AFL solenoid B (marked 1B) (Y62) connector to pin 24 of cab harness-to-main YES: Go to Short Circuit controller 31-pin connector A (X31).
Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,00022D9 -19-01SEP15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
AFL solenoid B (marked 1B) (Y62) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of AFL solenoid B (marked 1B) (Y62) connector to machine ground. • Pin 24 of cab harness-to-main controller 31-pin connector A (X31) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. Continued on next page
TM13345X19 (23APR18)
9001-10-91
RH60123,00022D9 -19-01SEP15-6/7
160GLC Excavator 042318 PN=125
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
AFL solenoid B (marked 1B) (Y62) disconnected. Test AFL solenoid B (marked 1B) (Y62) and compare to specification. See Electrical Component Specifications. (Group 9015-20.)
YES: Checks complete.
Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. RH60123,00022D9 -19-01SEP15-7/7
011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Hydraulic oil temperature sensor (B40) voltage is high (above 4.35 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
JL58967,00001DB -19-18MAR15-1/6
Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure JL58967,00001DB -19-18MAR15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Hydraulic oil temperature sensor (B40). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Machine harness splice connector 2 (X104). See Machine Harness (W2) 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 17-pin connector C (X33) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
controller 26-pin connector F (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
JL58967,00001DB -19-18MAR15-3/6
• 2
Component Check
Key switch in OFF position.
Disconnect hydraulic oil temperature sensor (B40). Test hydraulic oil temperature sensor (B40) and compare to specification. See Electrical YES: Go to Open Circuit Component Specifications. (Group 9015-20.) Check. Is hydraulic oil temperature sensor (B40) within specification?
Continued on next page
TM13345X19 (23APR18)
9001-10-92
NO: Hydraulic oil temperature sensor (B40) malfunction. Replace sensor. JL58967,00001DB -19-18MAR15-4/6
160GLC Excavator 042318 PN=126
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Open Circuit Check
Key switch in OFF position.
Hydraulic oil temperature sensor (B40) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between:
• Pin 1 of hydraulic oil temperature sensor (B40) connector and pin 1 of cab harness-to-main controller 17-pin connector C (X33).
• Pin 2 of hydraulic oil temperature sensor (B40) connector and pin 16 of cab
YES: Go to Voltage Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 26-pin connector F (X36).
JL58967,00001DB -19-18MAR15-5/6
• 4
Voltage Check
Key switch in OFF position.
Hydraulic oil temperature sensor (B40) disconnected. Turn key switch to ON position. Check pin 1 of hydraulic oil temperature sensor (B40) connector for approximately 5 V.
YES: Checks complete.
Is correct voltage indicated?
NO: Short circuit to power. Repair or replace harness. See appropriate harness. JL58967,00001DB -19-18MAR15-6/6
011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Hydraulic oil temperature sensor 0.23 volts or less. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in. JL58967,00001DC -19-05FEB15-1/6
Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure JL58967,00001DC -19-05FEB15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Hydraulic oil temperature sensor (B40). See Machine Harness (W2) 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 17-pin connector C (X33) and cab harness-to-main
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
controller 26-pin connector F (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9001-10-93
JL58967,00001DC -19-05FEB15-3/6
160GLC Excavator 042318 PN=127
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect hydraulic oil temperature sensor (B40). Test hydraulic oil temperature sensor (B40) and compare to specification. See Electrical YES: Go to Voltage Check. Component Specifications. (Group 9015-20.) Is hydraulic oil temperature sensor (B40) within specification?
NO: Hydraulic oil temperature sensor (B40) malfunction. Replace sensor. JL58967,00001DC -19-05FEB15-4/6
• 3
Voltage Check
Key switch in OFF position.
Hydraulic oil temperature sensor (B40) disconnected. Turn key switch to ON position. Check between pin 1 and pin 2 on hydraulic oil temperature sensor (B40) connector for YES: Go to Short Circuit approximately 5 V. Check. Is correct voltage indicated?
NO: Open circuit. Repair or replace harness. See appropriate harness. JL58967,00001DC -19-05FEB15-5/6
• 4
Short Circuit Check
Key switch in OFF position.
Hydraulic oil temperature sensor (B40) disconnected. Check for continuity between pin 1 of hydraulic oil temperature sensor (B40) and machine ground.
YES: Short to ground. Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. JL58967,00001DC -19-05FEB15-6/6
015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)
Secondary hydraulic oil temperature sensor (B68) voltage is high (above 4.35 V). RH60123,0002273 -19-25AUG15-1/6
Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-94
RH60123,0002273 -19-25AUG15-2/6
160GLC Excavator 042318 PN=128
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
(Group 9015-10.) - Secondary hydraulic oil temperature sensor (B68). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,0002273 -19-25AUG15-3/6
• 2
Component Check
Key switch in OFF position.
Disconnect secondary hydraulic oil temperature sensor (B68). Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks. (Group 9015-20.)
YES: Go to Voltage Check.
Is secondary hydraulic oil temperature sensor within specification?
NO: Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor. RH60123,0002273 -19-25AUG15-4/6
• 3
Voltage Check
Key switch in OFF position.
Secondary hydraulic oil temperature sensor (B68) disconnected. Turn key switch to ON position. Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for more than 4.25 V.
YES: Go to Harness Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-95
RH60123,0002273 -19-25AUG15-5/6
160GLC Excavator 042318 PN=129
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Secondary hydraulic oil temperature sensor (B68) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between:
• Pin 1 of secondary hydraulic oil temperature sensor (B68) and pin 7 of cab harness-to-main controller 17-pin connector C (X33).
• Pin 2 of secondary hydraulic oil temperature sensor (B68) and pins 16 and 17 of cab
YES: Checks complete.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 26-pin connector F (X36).
RH60123,0002273 -19-25AUG15-6/6
015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)
Secondary hydraulic oil temperature sensor low (below 0.23 V). RH60123,0002274 -19-25AUG15-1/6
Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure RH60123,0002274 -19-25AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector 1 (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
(Group 9015-10.) - Secondary hydraulic oil temperature sensor (B68). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,0002274 -19-25AUG15-3/6
• 2
Component Check
Key switch in OFF position.
Disconnect secondary hydraulic oil temperature sensor (B68). Test secondary hydraulic oil temperature sensor and compare to specification. See Electrical Component Checks. (Group 9015-20.)
YES: Go to Voltage Check.
Is secondary hydraulic oil temperature sensor within specification?
NO: Secondary hydraulic oil temperature sensor (B68) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-10-96
RH60123,0002274 -19-25AUG15-4/6
160GLC Excavator 042318 PN=130
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Secondary hydraulic oil temperature sensor (B68) disconnected. Turn key switch to ON position. Check pin 1 and pin 2 of secondary hydraulic oil temperature sensor (B68) for less than 0.1 V.
YES: Checks complete.
Is correct voltage indicated?
NO: Go to Harness Check. RH60123,0002274 -19-25AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Secondary hydraulic oil temperature sensor (B68) disconnected. Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between pin 1 of secondary hydraulic oil temperature sensor (B68) YES: Checks complete. and pin 7 of cab harness-to-main controller 17-pin connector C (X33). Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0002274 -19-25AUG15-6/6
011995.03 — Arm Roll-Out Pilot Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm out pressure sensor (marked AMD) (B61) signal voltage is high (above 4.8 V).
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
DF89619,00B68C3 -19-05DEC17-1/6
Arm Roll-Out Pressure Sensor Circuit High Diagnostic Procedure DF89619,00B68C3 -19-05DEC17-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Arm out pressure sensor (marked AMD) (B61). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
Continued on next page
TM13345X19 (23APR18)
9001-10-97
DF89619,00B68C3 -19-05DEC17-3/6
160GLC Excavator 042318 PN=131
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Switch arm out pressure sensor (marked AMD) (B61) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011995.03—Arm Roll-Out Pilot Pressure Sensor Circuit High Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Arm out pressure sensor (marked AMD) (B61) malfunction. Replace sensor. DF89619,00B68C3 -19-05DEC17-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect arm out pressure sensor (marked AMD) (B61). Turn key switch to ON position. Check between pin 2 of arm out pressure sensor (marked AMD) (B61) connector and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B68C3 -19-05DEC17-5/6
• 4
Harness Check
Key switch in OFF position.
Arm out pressure sensor (marked AMD) (B61) disconnected. Disconnect main controller connectors (X31—X36). Check for continuity between pin 18 of cab harness-to-main controller 30-pin connector YES: Circuit is short to D (X34) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B68C3 -19-05DEC17-6/6
011995.04 — Arm Roll-Out Pilot Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm out pressure sensor (marked AMD) (B61) signal voltage is low (below 0.1 V).
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
DF89619,00B68C4 -19-05DEC17-1/7
Arm Roll-Out Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-98
DF89619,00B68C4 -19-05DEC17-2/7
160GLC Excavator 042318 PN=132
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Arm out pressure sensor (marked AMD) (B61). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
DF89619,00B68C4 -19-05DEC17-3/7
• 2
Component Check
Key switch in OFF position.
Switch arm out pressure sensor (marked AMD) (B61) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011995.04—Arm Roll-Out Pilot Pressure Sensor Circuit Low Input. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Arm out pressure sensor (marked AMD) (B61) malfunction. Replace sensor. DF89619,00B68C4 -19-05DEC17-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect arm out pressure sensor (marked AMD) (B61). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of arm out pressure sensor (marked AMD) (B61) connector for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-99
DF89619,00B68C4 -19-05DEC17-5/7
160GLC Excavator 042318 PN=133
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Open Circuit Check
Key switch in OFF position.
Arm out pressure sensor (marked AMD) (B61) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of arm out pressure sensor (marked AMD) (B61) connector and pin 18 of cab harness-to-main controller 30-pin connector D (X34).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B68C4 -19-05DEC17-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Arm out pressure sensor (marked AMD) (B61) disconnected. Check for continuity between pin 2 of arm out pressure sensor (marked AMD) connector YES: Repair or replace (B61) and machine ground. harness. See appropriate harness. Is continuity indicated?
NO: Checks complete. DF89619,00B68C4 -19-05DEC17-7/7
011997.03 — Bucket Roll-Out Pressure Sensor Circuit High
Over torquing will result in permanent damage to connector. Torque only to specification.
Bucket dump pressure sensor (marked BKD) (B57) signal voltage is high (above 4.8 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B68C5 -19-05DEC17-1/6
Bucket Roll-Out Pressure Sensor Circuit High Diagnostic Procedure DF89619,00B68C5 -19-05DEC17-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Bucket dump pressure sensor (marked BKD) (B57). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
Continued on next page
TM13345X19 (23APR18)
9001-10-100
DF89619,00B68C5 -19-05DEC17-3/6
160GLC Excavator 042318 PN=134
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Switch bucket dump pressure sensor (marked BKD) (B57) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011997.03—Bucket Roll-Out Pressure Sensor Circuit High. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Bucket dump pressure sensor (marked BKD) (B57) malfunction. Replace sensor. DF89619,00B68C5 -19-05DEC17-4/6
• 3
Voltage Check
Key switch in OFF position.
Bucket dump pressure sensor (marked BKD) (B57) disconnected. Turn key switch to ON position. Check between pin 2 of bucket dump pressure sensor (marked BKD) (B57) connector and machine ground for approximately 0.0 V.
YES: Repair or replace harness. See appropriate harness.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B68C5 -19-05DEC17-5/6
• 4
Harness Check
Key switch in OFF position.
Bucket dump pressure sensor (marked BKD) (B57) disconnected. Disconnect main controller connectors (X31—X36). Check for continuity between pin 14 of cab harness-to-main controller 30-pin connector YES: Circuit is short to D (X34) to all pins on all main controller connectors. power. Repair or replace harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. DF89619,00B68C5 -19-05DEC17-6/6
011997.04 — Bucket Roll-Out Pressure Sensor Circuit Low
Over torquing will result in permanent damage to connector. Torque only to specification.
Bucket dump pressure sensor (marked BKD) (B57) signal voltage is low (below 0.1 V). IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
DF89619,00B68C6 -19-05DEC17-1/7
Bucket Roll-Out Pressure Sensor Circuit Low Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-101
DF89619,00B68C6 -19-05DEC17-2/7
160GLC Excavator 042318 PN=135
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-machine harness 100-pin connector (X3). - Cab harness-to-main controller 30-pin connector D (X34). - Cab harness-to-main controller 26-pin connector F (X36).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Bucket dump pressure sensor (marked BKD) (B57). - Cab harness-to-machine harness 100-pin connector (X3). - Machine harness power splice (X98). - Machine harness ground splice (X104).
DF89619,00B68C6 -19-05DEC17-3/7
• 2
Component Check
Key switch in OFF position.
Switch bucket dump pressure sensor (marked BKD) (B57) to another properly working pressure sensor. Turn key switch to ON position. Clear main controller (MCZ) diagnostic trouble codes (DTCs). Operate machine. Check for active MCZ diagnostic trouble code 011997.04—Bucket Roll-Out Pressure Sensor Circuit Low. Is code active?
YES: Go to Voltage Check.
Return connectors to appropriate sensors after check is complete.
NO: Bucket dump pressure sensor (marked BKD) (B57) malfunction. Replace sensor. DF89619,00B68C6 -19-05DEC17-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect bucket dump pressure sensor (marked BKD) (B57). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of bucket dump pressure sensor (marked BKD) YES: Go to Open Circuit (B57) connector for approximately 5 V. Check. Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM13345X19 (23APR18)
9001-10-102
DF89619,00B68C6 -19-05DEC17-5/7
160GLC Excavator 042318 PN=136
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Open Circuit Check
Key switch in OFF position.
Disconnect bucket dump pressure sensor (marked BKD) (B57). Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of bucket dump pressure sensor (marked BKD) YES: Go to Short Circuit (B57) connector and pin 14 of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. DF89619,00B68C6 -19-05DEC17-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Disconnect bucket dump pressure sensor (marked BKD) (B57). Check for continuity between pin 2 of bucket dump pressure sensor (marked BKD) (B57) connector and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B68C6 -19-05DEC17-7/7
015016.03 — Right Analog Stroke Sensor Circuit High Input
Auxiliary function lever (AFL) proportional control switch (S29) voltage is high (above 4.5 V). RH60123,0002271 -19-29JUL15-1/5
Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure RH60123,0002271 -19-29JUL15-2/5
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
9015-10.) - Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). - Auxiliary function lever (AFL) connector 1 (X574).
Continued on next page
TM13345X19 (23APR18)
9001-10-103
RH60123,0002271 -19-29JUL15-3/5
160GLC Excavator 042318 PN=137
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Voltage Check
Key switch in the OFF position.
Disconnect AFL connector (marked R_GRIP) (X536). Turn key switch to ON position. Check between pin 3 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 0.0 V.
YES: Go to Harness Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0002271 -19-29JUL15-4/5
• 3
Harness Check
Key switch in the OFF position.
AFL connector (marked R_GRIP) (X536) disconnected. Disconnect main controller connectors (X31—X36). Check for continuity between pin 3 of AFL connector (marked R_GRIP) (X536) to all pins on all option controller connectors.
YES: Auxiliary function lever (AFL) proportional control switch (S29) malfunction. Replace switch.
Is continuity indicated between any circuits?
NO: Checks complete. RH60123,0002271 -19-29JUL15-5/5
015016.04 — Right Analog Stroke Sensor Circuit Low Input
Auxiliary function lever (AFL) proportional control switch (S29) voltage is low (below 0.1 V). RH60123,0002272 -19-29JUL15-1/6
Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure RH60123,0002272 -19-29JUL15-2/6
• 1
Connector Check
Key switch in the OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
9015-10.) - Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). - Auxiliary function lever (AFL) connector 1 (X574).
Continued on next page
TM13345X19 (23APR18)
9001-10-104
RH60123,0002272 -19-29JUL15-3/6
160GLC Excavator 042318 PN=138
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Voltage Check
Key switch in the OFF position.
Disconnect AFL connector (marked R_GRIP) (X536). Turn key switch to ON position. Check between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0002272 -19-29JUL15-4/6
• 3
Open Circuit Check
Key switch in the OFF position.
AFL connector (marked R_GRIP) (X536) disconnected. Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between:
• Pin 1 of AFL connector (marked R_GRIP) (X536) and pins 25 and 26 of cab harness-to-main controller 26-pin connector F (X36).
• Pin 2 of AFL connector (marked R_GRIP) (X536) and pins 16 and 17 of cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 26-pin connector F (X36).
RH60123,0002272 -19-29JUL15-5/6
• 4
Harness Check
Key switch in the OFF position.
AFL connector (marked R_GRIP) (X536) disconnected. Check for continuity between pin 1 of AFL connector (marked R_GRIP) (X536) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0002272 -19-29JUL15-6/6
020010.02 — Abnormal Exhaust Filter This code will set because of other codes that are present. DP09616,000072C -19-02SEP16-1/3
Abnormal Exhaust Filter Diagnostic Procedure Diagnose codes 011200, 011401, 011408, and 011409 first. DP09616,000072C -19-02SEP16-2/3
• 1
Code Check
Clear and check again for diagnostic trouble codes.
YES: Diagnose other codes first. See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Are other codes present?
NO: Checks complete. DP09616,000072C -19-02SEP16-3/3
TM13345X19 (23APR18)
9001-10-105
160GLC Excavator 042318 PN=139
Main Controller (MCZ) Diagnostic Trouble Codes
020011.02 — Electric Lever Alarm
NOTE: There will be other diagnostic trouble codes (DTCs) generated with this code. Correct all diagnostic trouble codes associated with auxiliary diagnostics before continuing with procedure.
Electric control lever system is abnormal.
RH60123,000223E -19-11AUG16-1/3
Electric Control Lever Alarm Diagnostic Procedure RH60123,000223E -19-11AUG16-2/3
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• Auxiliary function lever (AFL) harness (W75). See Auxiliary Function Lever (AFL)
YES: Signal error.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate harness.
Harness (W75) Component Location. (Group 9015-10.) - Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). - Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537). - Auxiliary function lever (AFL) connector 1 (X574). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
RH60123,000223E -19-11AUG16-3/3
020062.02 — Hydraulic Oil Temperature Alarm
See 011901.03 — Hydraulic Oil Temperature Sensor Circuit High and see 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low. (Group 9001-10.)
Hydraulic Oil Temperature Alarm Diagnose the diagnostic trouble codes (DTC) of main controller (MCZ) diagnostic trouble codes. BG71862,0000563 -19-12AUG15-1/1
020303.02 — Electric Lever Pilot Cut Alarm Electric control lever abnormal signal in neutral position.
NOTE: There will be other diagnostic trouble codes generated with this code. Correct all diagnostic trouble codes before continuing with procedure. JA92389,0000181 -19-06NOV15-1/3
Electric Control Lever Alarm Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-10-106
JA92389,0000181 -19-06NOV15-2/3
160GLC Excavator 042318 PN=140
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• See Cab Harness (W1) Component Location. (Group 9015-10.) - Cab harness-to-main controller 17-pin connector C (X33). - Cab harness-to-main controller 26-pin connector F (X36).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group
YES: Pilot signal error.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate harness.
9015-10.) - Right auxiliary function lever (AFL) connector (marked R_GRIP) (X536). - Left auxiliary function lever (AFL) connector (marked L_GRIP) (X537). - Auxiliary function lever (AFL) connector 1 (X574). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
JA92389,0000181 -19-06NOV15-3/3
TM13345X19 (23APR18)
9001-10-107
160GLC Excavator 042318 PN=141
Main Controller (MCZ) Diagnostic Trouble Codes
TM13345X19 (23APR18)
9001-10-108
160GLC Excavator 042318 PN=142
Group 20
Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes With Monitor Display. (Group 9015-20.)
• See Reading Diagnostic Trouble Codes With Service
For additional information on the engine control unit circuit, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
ADVISOR™ Diagnostic Application. (Group 9015-20.)
• See MPDr Application. (Group 9015-20.)
Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR™, or by connection with MPDr. Service ADVISOR is a trademark of Deere & Company JA66566,000171A -19-24FEB12-1/1
000111.07 — Coolant Level Low—Moderately Severe Level
Loss of coolant detected by engine coolant loss level sensor (B5009) in the surge tank. DF89619,00B58D0 -19-19JUN14-1/6
Coolant Level Low—Moderately Severe Level Diagnostic Procedure Alarm Level: Coolant Level Alarm Illuminated—Highlighted Yellow (warning) DF89619,00B58D0 -19-19JUN14-2/6
• 1
Coolant Level Check
Check coolant level in surge tank. See Check Engine Coolant Level. (Operator’s Manual.)
YES: Add coolant to surge tank and check cooling system for leaks.
Is coolant level low?
NO: Go to Connector Check. DF89619,00B58D0 -19-19JUN14-3/6
• 2
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Engine Interface Harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Location. (Group 9015-10.) - Engine coolant loss level sensor (B5009). - Engine control unit (ECU) connector 2 (X5502).
DF89619,00B58D0 -19-19JUN14-4/6
• 3
Component Check
Disconnect engine coolant loss level sensor (B5009).
YES: Engine coolant loss level sensor (B5009) malfunction. Replace sensor.
Does monitor indicate low coolant level?
NO: Go to Short to Ground Check Continued on next page
TM13345X19 (23APR18)
9001-20-1
DF89619,00B58D0 -19-19JUN14-5/6
160GLC Excavator 042318 PN=143
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 4
Short to Ground Check Engine coolant loss level sensor (B5009) disconnected.
Check continuity between engine coolant loss level sensor (B5009) connector pin 1 and machine ground.
YES: Checks complete.
Is continuity indicated?
NO: Repair or replace harness as necessary. DF89619,00B58D0 -19-19JUN14-6/6
000647.05 — Variable Speed Fan Solenoid Open Circuit
Variable speed fan solenoid (Y5014) open circuit. JL58967,00002E8 -19-07MAR18-1/5
Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) NOTE: Code will set when performing harness diagnostic mode test for Service ADVISOR™. Ignore code if only set due to performing this test. Service ADVISOR is a trademark of Deere & Company JL58967,00002E8 -19-07MAR18-2/5
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Variable speed fan solenoid (Y5014).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002E8 -19-07MAR18-3/5
• 2
Component Check
Disconnect and test variable speed fan solenoid (Y5014). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Open Circuit Check.
Does variable speed fan solenoid (Y5014) test OK?
NO: Variable speed fan solenoid (Y5014) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-20-2
JL58967,00002E8 -19-07MAR18-4/5
160GLC Excavator 042318 PN=144
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Disconnect the following connectors:
• Variable speed fan solenoid (Y5014). • Engine control unit (ECU) connector 1 (X5501). • Engine control unit (ECU) connector 2 (X5502). Check for continuity between:
• Pin 1 of variable speed fan solenoid (Y5014) connector and pin 32 of engine control unit (ECU) connector 2 (X5502).
• Pin 2 of variable speed fan solenoid (Y5014) connector and pin 21 of engine control
YES: Program controller.
Is continuity indicated?
NO: Repair or replace harness as necessary.
unit (ECU) connector 1 (X5501).
JL58967,00002E8 -19-07MAR18-5/5
000647.06 — Variable Speed Fan Solenoid High Current
Variable speed fan solenoid (Y5014) high current. JL58967,00002E9 -19-13OCT15-1/6
Variable Speed Fan Solenoid High Current Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) JL58967,00002E9 -19-13OCT15-2/6
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Variable speed fan solenoid (Y5014).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002E9 -19-13OCT15-3/6
• 2
Component Check
Disconnect and test variable speed fan solenoid (Y5014). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Continuity Check.
Does variable speed fan solenoid (Y5014) meet specification?
NO: Variable speed fan solenoid (Y5014) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-20-3
JL58967,00002E9 -19-13OCT15-4/6
160GLC Excavator 042318 PN=145
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect variable speed fan solenoid (Y5014). Disconnect engine control unit (ECU) connector 1 (X5501). Disconnect engine control unit (ECU) connector 2 (X5502). Check for continuity between:
• Pin 1 of variable speed fan solenoid (Y5014) connector and pin 32 engine control unit (ECU) connector 2 (X5502).
• Pin 2 of variable speed fan solenoid (Y5014) connector and pin 21 engine control
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
unit (ECU) connector 1 (X5501).
JL58967,00002E9 -19-13OCT15-5/6
• 4
Harness Check
Key switch in OFF position.
Engine control unit (ECU) connector 1 (X5501) disconnected. Check for continuity between pin 32 of engine control unit (ECU) connector 2 (X5502) and all other pins on connector.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Checks complete. JL58967,00002E9 -19-13OCT15-6/6
000647.16 — Reversing Fan Switch Active Too Long
Reversing fan switch (S15) is stuck ON. JL58967,00002EA -19-13OCT15-1/7
Reversing Fan Switch Active Too Long Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) JL58967,00002EA -19-13OCT15-2/7
• 1
Observation Check
Is reversing fan switch (S15) being held for over 2 minutes?
YES: Advise operator of reversing fan function. See Reversing Fan Switch—If Equipped. (Operator’s Manual.) NO: Go to Function Check. JL58967,00002EA -19-13OCT15-3/7
• 2
Function Check
LOOK/FEEL: Is reversing fan switch (S15) stuck ON?
YES: Reversing fan switch (S15) malfunction. Replace switch. See Reversing Fan Switch Harness (W23) Component Location. (Group 9015-10.) NO: Go to Component Check.
Continued on next page
TM13345X19 (23APR18)
9001-20-4
JL58967,00002EA -19-13OCT15-4/7
160GLC Excavator 042318 PN=146
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Component Check
Disconnect reversing fan switch (S15). See Cab Harness (W1) Component Location. (Group 9015-10.) Place reversing fan switch (S15) in OFF position. Check for continuity between:
• Pin 1 and pin 3 of reversing fan switch (S15). • Pin 2 and pin 3 of reversing fan switch (S15).
Is continuity indicated?
YES: Reversing fan switch (S15) malfunction. Replace switch. See Reversing Fan Switch Harness (W23) Component Location. (Group 9015-10.) NO: Go to Harness Check. JL58967,00002EA -19-13OCT15-5/7
• 4
Harness Check
Check the following connectors for damage, corrosion, or debris:
• Reversing fan switch harness (W23). See Reversing Fan Switch Harness (W23) Component Location. (Group 9015-10.) - Reversing fan switch (S15) connector.
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.)
YES: Go to Short to Power Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
- Cab harness-to-reversing fan switch harness (X83). - Engine control unit (ECU) connector 3 (X5503).
See Reversing Fan Switch Harness (W23) Wiring Diagram. (Group 9015-10.) See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) JL58967,00002EA -19-13OCT15-6/7
• 5
Short to Power Check
Reversing fan switch (S15) in OFF position.
Key switch in ON position. Check for voltage at pins 18 and 19 of engine control unit (ECU) connector 3 (X5503).
YES: Circuit is short to power. Repair or replace harness as necessary.
Is voltage present?
NO: Checks complete. JL58967,00002EA -19-13OCT15-7/7
001639.00 — Fan Speed High—Moderately Severe Level
ECU detects higher fan speed than desired. JL58967,00002EB -19-08OCT15-1/7
Fan Speed High—Moderately Severe Level Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) Continued on next page
TM13345X19 (23APR18)
9001-20-5
JL58967,00002EB -19-08OCT15-2/7
160GLC Excavator 042318 PN=147
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Fan speed sensor (B5303).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Code Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002EB -19-08OCT15-3/7
• 2
Code Check
Check for active ECU diagnostic trouble codes.
YES: Variable speed fan solenoid malfunction. See 000647.05—Variable Speed Fan Solenoid Open Circuit. (Group 9001-20.)
Is ECU diagnostic trouble code 000647.05 present?
YES: Variable speed fan solenoid malfunction. See 000647.06—Variable Speed Fan Solenoid High Current. (Group 9001-20.)
Is ECU diagnostic trouble code 000647.06 present?
NO: Go to Solenoid Check. JL58967,00002EB -19-08OCT15-4/7
• 3
Solenoid Check
Test variable speed fan solenoid (Y5014). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Harness Check.
Does variable speed fan solenoid (Y5014) test OK?
NO: Variable speed fan solenoid (Y5014) malfunction. Replace solenoid. JL58967,00002EB -19-08OCT15-5/7
• 4
Harness Check
Fan speed sensor (B5303) disconnected.
Disconnect engine control unit (ECU) connector 1 (X5501). Check for continuity between:
• Pin B of fan speed sensor (B5303) connector and pin 50 of engine control unit (ECU) connector 1 (X5501).
• Pin C of fan speed sensor (B5303) connector and pin 53 of engine control unit (ECU) YES: Go to Fan Speed connector 1 (X5501).
Check.
Is continuity indicated?
NO: Repair or replace harness as necessary. Continued on next page
TM13345X19 (23APR18)
9001-20-6
JL58967,00002EB -19-08OCT15-6/7
160GLC Excavator 042318 PN=148
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 5
Fan Speed Check
Check fan speed. See Fan Speed Test. (Group 9025-25.)
YES: Checks complete.
Is fan speed within specification?
NO: Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation. (Group 9025-05.) JL58967,00002EB -19-08OCT15-7/7
001639.01 — Fan Speed Low—Most Severe Level
ECU detects zero fan speed. JL58967,00002EC -19-13OCT15-1/6
Fan Speed Low—Most Severe Level Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) JL58967,00002EC -19-13OCT15-2/6
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Fan speed sensor (B5303).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002EC -19-13OCT15-3/6
• 2
Voltage Check
Disconnect fan speed sensor (B5303).
Key switch in ON position. Check fan speed sensor (B5303) connector pin A for voltage.
YES: Repair or replace harness as necessary.
Is voltage greater than 5.0 V?
NO: Go to Open Circuit Check. Continued on next page
TM13345X19 (23APR18)
9001-20-7
JL58967,00002EC -19-13OCT15-4/6
160GLC Excavator 042318 PN=149
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Fan speed sensor (B5303) disconnected.
Disconnect engine control unit (ECU) connector 1 (X5501). Check for continuity between:
• Pin B of fan speed sensor (B5303) connector and pin 50 of engine control unit (ECU) connector 1 (X5501).
• Pin C of fan speed sensor (B5303) connector and pin 53 of engine control unit (ECU) YES: Go to Fan Speed connector 1 (X5501).
Check.
Is continuity indicated?
NO: Repair or replace harness as necessary. JL58967,00002EC -19-13OCT15-5/6
• 4
Fan Speed Check
Check fan speed. See Fan Speed Test. (Group 9025-25.)
YES: Fan speed sensor (B5303) malfunction. Replace sensor.
Is fan speed within specification?
NO: Diagnose fan speed malfunction. See Fan Drive Hydraulic System Operation. (Group 9025-05.) JL58967,00002EC -19-13OCT15-6/6
001639.18 — Fan Speed Low—Moderately Severe Level
For diagnostic procedure, see 001639.01—Fan Speed Low—Most Severe Level. (Group 9001-20.) JL58967,00002ED -19-08OCT15-1/1
001761.01 — Diesel Exhaust Fluid Extremely Low Diesel exhaust fluid (DEF) tank level sensor (B5601) is indicating the DEF tank is empty. NOTE: For machines with (S.N. —056599) See 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Diagnostic Test Box Information:
• Not Applicable Possible Causes: 1. DEF tank is empty. 2. DEF level is low and DEF supply module has lost suction. 3. DEF tank fluid level sensor float is stuck. 4. Component malfunction. Repair or replace DEF header. 5. Software malfunction. Program controller.
Alarm Level:
• Check Diagnostic Code Indicator Machine Response:
• Derate Engine Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
RH60123,0002B19 -19-29NOV16-1/1
TM13345X19 (23APR18)
9001-20-8
160GLC Excavator 042318 PN=150
Engine Control Unit (ECU) Diagnostic Trouble Codes
001761.18 — Diesel Exhaust Fluid Very Low
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
Diesel exhaust fluid (DEF) tank level sensor (B5601) is indicating a level below 0% of measurable tank volume.
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54)
NOTE: For machines with (S.N. —056599) See 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
Component Location. (Group 9015-10.)
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Possible Causes:
Machine Response:
1. DEF tank fluid is low. 2. DEF tank fluid level sensor float is stuck. 3. Component malfunction. Repair or replace DEF header. 4. Software malfunction. Program controller.
• Derate Engine Circuit Information:
RH60123,0002B1A -19-29NOV16-1/1
002030.09 — (CAN 0) Flex Power Controller Communication Error
Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning)
ECU did not receive a CAN message from flex power controller (A15).
See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) JS20420,0000D70 -19-07OCT16-1/1
002228.09 — (CAN 0) Main Controller (MCZ) Communication Error
Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning)
ECU did not receive a CAN message from main controller (MCZ) (A3).
See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) JS20420,0000D71 -19-10JUN14-1/1
003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) tank temperature sensor (B5211) signal is invalid.
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Possible Causes:
Machine Response:
1. Component malfunction. Repair or replace DEF header. 2. Software malfunction. Program controller.
• None Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
RH60123,000296D -19-31OCT16-1/1
003353.31 — Alternator Excitation Fault
Alarm Level:
Alternator output low.
Warning Alarm Illuminated—Highlighted Yellow (warning) Continued on next page
TM13345X19 (23APR18)
9001-20-9
DF89619,00B58D6 -19-19JUN14-1/6
160GLC Excavator 042318 PN=151
Engine Control Unit (ECU) Diagnostic Trouble Codes Alternator Excitation Fault Diagnostic Procedure DF89619,00B58D6 -19-19JUN14-2/6
• 1
Serpentine Belt Check Check serpentine belt for proper pulley alignment and damage. See Inspect Serpentine YES: Go to Alternator Belt. (Operator’s Manual.) Check. Is belt properly aligned and in good condition.
NO: Replace serpentine belt. DF89619,00B58D6 -19-19JUN14-3/6
• 2
Alternator Check
Verify proper operation of alternator. See Alternator Test. (Group 9015-20.)
YES: Go to Open Circuit Check.
Does alternator function properly?
NO: Replace alternator. DF89619,00B58D6 -19-19JUN14-4/6
• 3
Open Circuit Check
Disconnect wire 5246 LT BLU from alternator (G3) pin D+.
Disconnect engine control unit (ECU) connector 2 (X5502). Check for continuity between wire 5246 LT BLU and engine control unit (ECU) connector 2 (X5502) pin 34.
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness as necessary. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Engine Harness (W4) Wiring Diagram. (Group 9015-10.) DF89619,00B58D6 -19-19JUN14-5/6
• 4
Short Circuit Check
Wire 5246 LT BLU from alternator (G3) pin D+ disconnected.
Engine control unit (ECU) connector 2 (X5502) disconnected. Check for continuity between wire 5246 LT BLU and machine ground.
YES: Repair or replace harness as necessary. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Engine Harness (W4) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. DF89619,00B58D6 -19-19JUN14-6/6
TM13345X19 (23APR18)
9001-20-10
160GLC Excavator 042318 PN=152
Engine Control Unit (ECU) Diagnostic Trouble Codes
003516.01 — Diesel Exhaust Fluid Concentration Extremely Low
Diagnostic Test Box Information:
Diesel exhaust fluid (DEF) is contaminated or incorrect fluid in tank.
Possible Causes:
• Not Applicable
Alarm Level:
• Check Diagnostic Code Indicator Machine Response:
• None Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
Component Location:
1. Contaminated DEF. Drain, clean, and refill DEF tank. - See Testing Diesel Exhaust Fluid (DEF). (Operator’s Manual.) - See Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure. (Group 0530.) 2. Incorrect fluid in tank. Drain, clean, and refill DEF tank. - See Testing Diesel Exhaust Fluid (DEF). (Operator’s Manual.) - See Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure. (Group 0530.) 3. Component malfunction. Repair or replace DEF header. 4. Software malfunction. Program controller.
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
RH60123,000296F -19-03FEB17-1/1
003516.07 — Diesel Exhaust Fluid Concentration Invalid
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) tank concentration sensor (B5506) cannot obtain a valid reading with DEF tank level above 50% and DEF fluid temperature indicated above freezing.
Diagnostic Test Box Information:
Alarm Level:
Possible Causes:
• Check Diagnostic Code Indicator
1. DEF concentration sensor is obstructed. Inspect DEF header, concentration sensor, and baffle. See Testing Diesel Exhaust Fluid (DEF). (Operator’s Manual.) 2. Component malfunction. Repair or replace DEF header. 3. Software malfunction. Program controller.
Machine Response:
• None Circuit Information:
• Not Applicable
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
RH60123,0002970 -19-19JAN17-1/1
TM13345X19 (23APR18)
9001-20-11
160GLC Excavator 042318 PN=153
Engine Control Unit (ECU) Diagnostic Trouble Codes
003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault
Component Location:
Engine control unit (ECU) has lost communication with diesel exhaust fluid (DEF) header.
• See Diesel Exhaust Fluid (DEF) Harness (W54)
Alarm Level:
• See Machine Harness (W2) Component Location. (Group 9015-10.)
Component Location. (Group 9015-10.)
Diagnostic Test Box Information:
• Check Diagnostic Code Indicator
• Not Applicable
Machine Response:
Possible Causes:
• None Circuit Information:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-05.)
• See Exhaust Aftertreatment Circuit Theory of Operation.
1. Open or shorted circuit. See Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) 2. Component malfunction. Repair or replace DEF header. 3. Software malfunction. Program controller.
(Group 9015-05.)
RH60123,0002971 -19-31OCT16-1/1
003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Diesel exhaust fluid (DEF) concentration sensor (B5602) has malfunctioned.
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Possible Causes:
Machine Response:
1. Component malfunction. Repair or replace DEF header. 2. Software malfunction. Program controller.
• None Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
RH60123,0002972 -19-31OCT16-1/1
003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault Diesel exhaust fluid (DEF) header reports that DEF tank level sensor (B5601) has malfunctioned.
Component Location:
• See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Diagnostic Test Box Information:
Alarm Level:
• Not Applicable
• Check Diagnostic Code Indicator
Possible Causes:
Machine Response:
1. Component malfunction. Repair or replace DEF header. 2. Software malfunction. Program controller.
• None Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-05.)
RH60123,0002973 -19-31OCT16-1/1
TM13345X19 (23APR18)
9001-20-12
160GLC Excavator 042318 PN=154
Engine Control Unit (ECU) Diagnostic Trouble Codes
003719.15 — Calculated Soot Level Slightly High
For troubleshooting procedure, see 003719.00 — Calculated Soot Level Extremely High. (CTM120019.)
Calculated DPF soot level is slightly higher than expected. JS20420,0000D73 -19-11JUN14-1/1
004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance
NOTE: Diagnostics for diagnostic trouble code (DTC) 004366.06 must be followed before diagnosing this DTC.
The engine control unit (ECU) has detected coolant control valve (Y5019) circuit resistance is higher than expected.
12
1
32
23
54
43
4 1
2
1
3
Y5019 A1
TX1245353
X5037
X5502-20
5321 BRN
X5502-51
5324 YEL
21 22
4
5321 BRN 5324 YEL
TX1245353 —UN—06OCT17
X5502
Coolant Control Valve (Y5019) Wiring Diagram A1—Engine Control Unit (ECU) X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1
X5502—51—Return Y5019—Coolant Control Valve
X5502—Engine Control Unit (ECU) Connector 2 X5502—20—Supply
Alarm Level:
Additional References:
• Service Required Indicator
• See Control Unit Information and Overview Test. (CTM120119.)
Diagnostic Trouble Code (DTC) Induced Condition:
• Diesel exhaust fluid (DEF) dosing system is disabled for
the remainder of the key cycle and the selective catalyst reduction (SCR) derate counter becomes active. For more information on SCR system, see SCR System Derates. (CTM120119.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.)
see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
IMPORTANT: Pin damage occurs if anything other than the specified flex probe from JDG10466 Flex Probe Kit is used. DEF Tank Header Assembly Connector:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• For additional information on Service ADVISOR™,
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple Coolant Control Valve Connector:
Component Location:
• See Engine Interface Harness (W5) Component
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
• See Diesel Exhaust Fluid (DEF) Harness (W54)
ECU:
Diagnostic Test Box Information:
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
Location. (Group 9015-10.)
Component Location. (Group 9015-10.)
• Not Applicable Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9001-20-13
JR05199,0000E9C -19-18OCT17-1/11
160GLC Excavator 042318 PN=155
Engine Control Unit (ECU) Diagnostic Trouble Codes Diagnostic Procedure JR05199,0000E9C -19-18OCT17-2/11
• 1
Read DTCs and Store Snapshot Information
Ignition ON, engine OFF.
1. Verify coolant control valve (Y5019) is connected. 2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR, clear DTCs. 4. Using Service ADVISOR, perform DEF header coolant purge test. 5. Using Service ADVISOR, perform control unit information and overview test. Is DTC 004366.05 active or stored?
YES: Go to next check. NO: Checks complete. JR05199,0000E9C -19-18OCT17-3/11
• 2
Pin Check
Ignition OFF, engine OFF.
Disconnect coolant control valve (Y5019) and check pins 1 and 4. See Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
YES: Repair as necessary. See Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
Were any problems found?
NO: Go to next check. JR05199,0000E9C -19-18OCT17-4/11
• 3
Pin Check
Ignition OFF, engine OFF.
Disconnect engine interface harness-to-diesel exhaust fluid (DEF) harness connector 1 YES: Repair as necessary. (X5037) and check pins 21 and 22. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.) Were any problems found?
NO: Go to next check. JR05199,0000E9C -19-18OCT17-5/11
• 4
Pin Check
Disconnect engine control unit (ECU) connector 2 (X5502) and check pins 20 and 51. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
YES: Repair as necessary. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Were any problems found?
NO: Go to next check. Continued on next page
TM13345X19 (23APR18)
9001-20-14
JR05199,0000E9C -19-18OCT17-6/11
160GLC Excavator 042318 PN=156
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 5
Short to Voltage Check Connect engine interface harness-to-DEF harness connector 1 (X5037).
Ignition ON, engine OFF. Using a multimeter, measure voltage between coolant control valve (Y5019) connector pin 1 and ground. Using a multimeter, measure voltage between coolant control valve (Y5019) connector pin 4 and ground.
YES: Go to next check.
Are both measurements less than 0.5 V?
NO: Repair short to voltage in harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.) JR05199,0000E9C -19-18OCT17-7/11
• 6
Continuity Check
Ignition OFF, engine OFF.
Using a multimeter, measure the resistance between engine control unit (ECU) connector 2 (X5502) pin 20 and coolant control valve (Y5019) pin 1. Using a multimeter, measure the resistance between engine control unit (ECU) connector 2 (X5502) pin 51 and coolant control valve (Y5019) pin 4.
YES: Go to next check.
Are both resistance measurements less than 5 ohms?
NO: Repair open or high resistance in harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.) JR05199,0000E9C -19-18OCT17-8/11
• 7
Short to Ground Check Connect engine interface harness-to-DEF harness connector 1 (X5037).
Disconnect ECU connector 2 (X5502). Ignition OFF, engine OFF. Using a multimeter, measure resistance between coolant control valve (Y5019) connector pin 1 and ground. Using a multimeter, measure resistance between coolant control valve (Y5019) connector pin 4 and ground.
YES: Repair short to ground in harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
Is either measurement less than 100 kilo-ohms?
NO: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9001-20-15
JR05199,0000E9C -19-18OCT17-9/11
160GLC Excavator 042318 PN=157
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 8
Wire to Wire Check
Using a multimeter, measure the resistance between ECU connector 2 (X5502) pin 20 and all other pins in connector 2 (X5502). Using a multimeter, measure the resistance between ECU connector 2 (X5502) pin 51 and all other pins in connector 2 (X5502).
YES: Repair short in harness. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Is any measurement less than 100 kilo-ohms?
NO: Go to next check. JR05199,0000E9C -19-18OCT17-10/11
• 9
Replace Coolant Control Valve
1. Replace coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR, clear DTCs. 4. Using Service ADVISOR, perform DEF header coolant purge test. 5. Using Service ADVISOR, perform control unit information and overview test.
Is DTC 004366.05 active?
YES: Reprogram engine control unit (ECU). See Software and Hardware Verification. (CTM120119.) NO: Checks complete. JR05199,0000E9C -19-18OCT17-11/11
TM13345X19 (23APR18)
9001-20-16
160GLC Excavator 042318 PN=158
Engine Control Unit (ECU) Diagnostic Trouble Codes
004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance
The engine control unit (ECU) has detected coolant control valve (Y5019) circuit current is higher than expected.
12
1
32
23
54
43
4 1
2
1
3
Y5019 A1
TX1245353
X5037
X5502-20
5321 BRN
X5502-51
5324 YEL
21 22
4
5321 BRN 5324 YEL
TX1245353 —UN—06OCT17
X5502
Coolant Control Valve (Y5019) Wiring Diagram A1—Engine Control Unit (ECU) X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1
X5502—51—Return Y5019—Coolant Control Valve
X5502—Engine Control Unit (ECU) Connector 2 X5502—20—Supply
Alarm Level:
Additional References:
• Service Required Indicator
• See Control Unit Information and Overview Test. (CTM120119.)
Diagnostic Trouble Code (DTC) Induced Condition:
• Diesel exhaust fluid (DEF) dosing system is disabled for
the remainder of the key cycle and the selective catalyst reduction (SCR) derate counter becomes active. For more information on SCR system, see SCR System Derates. (CTM120119.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.)
see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
IMPORTANT: Pin damage occurs if anything other than the specified flex probe from JDG10466 Flex Probe Kit is used. DEF Tank Header Assembly Connector:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• For additional information on Service ADVISOR™,
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple Coolant Control Valve Connector:
Component Location:
• See Engine Interface Harness (W5) Component
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
• See Diesel Exhaust Fluid (DEF) Harness (W54)
ECU:
Diagnostic Test Box Information:
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
Location. (Group 9015-10.)
Component Location. (Group 9015-10.)
• Not Applicable Service ADVISOR is a trademark of Deere & Company JR05199,0000E9D -19-18OCT17-1/10
Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-20-17
JR05199,0000E9D -19-18OCT17-2/10
160GLC Excavator 042318 PN=159
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 1
Read DTCs and Store Snapshot Information
Ignition ON, engine OFF.
1. Verify coolant control valve (Y5019) is connected. 2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR, clear DTCs. 4. Using Service ADVISOR, perform DEF header coolant purge test. 5. Using Service ADVISOR, perform control unit information and overview test. Is DTC 004366.06 active or stored?
YES: Go to next check. NO: Checks complete. JR05199,0000E9D -19-18OCT17-3/10
• 2
Pin Check
Ignition OFF, engine OFF.
Disconnect coolant control valve (Y5019) and check pins 1 and 4. See Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
YES: Repair as necessary. See Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
Were any problems found?
NO: Go to next check. JR05199,0000E9D -19-18OCT17-4/10
• 3
Pin Check
Ignition OFF, engine OFF.
Disconnect engine interface harness-to-diesel exhaust fluid (DEF) harness connector 1 YES: Repair as necessary. (X5037) and check pins 21 and 22. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.) Were any problems found?
NO: Go to next check. JR05199,0000E9D -19-18OCT17-5/10
• 4
Pin Check
Disconnect engine control unit (ECU) connector (X5502) and check pins 20 and 51. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
YES: Repair as necessary. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Were any problems found?
NO: Go to next check. Continued on next page
TM13345X19 (23APR18)
9001-20-18
JR05199,0000E9D -19-18OCT17-6/10
160GLC Excavator 042318 PN=160
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 5
Short to Voltage Check Connect engine interface harness-to-DEF harness connector 1 (X5037).
Ignition ON, engine OFF. Using a multimeter, measure voltage between coolant control valve (Y5019) connector pin 1 and ground. Using a multimeter, measure voltage between coolant control valve (Y5019) connector pin 4 and ground.
YES: Go to next check.
Are both measurements less than 0.5 V?
NO: Repair short to voltage in harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.) JR05199,0000E9D -19-18OCT17-7/10
• 6
Short to Ground Check Connect engine interface harness-to-DEF harness connector 1 (X5037).
Verify that ECU connector (X5502) is disconnected. Ignition OFF, engine OFF. Using a multimeter, measure resistance between coolant control valve (Y5019) connector pin 1 and ground. Using a multimeter, measure resistance between coolant control valve (Y5019) connector pin 4 and ground.
YES: Repair short to ground in harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
Is either measurement less than 100 kilo-ohms?
NO: Go to next check. JR05199,0000E9D -19-18OCT17-8/10
• 7
Wire to Wire Check
Using a multimeter, measure the resistance between ECU connector (X5502) pin 20 and all other pins in connector (X5502). Using a multimeter, measure the resistance between ECU connector (X5502) pin 51 and all other pins in connector (X5502).
YES: Repair short in harness. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Is any measurement less than 100 kilo-ohms?
NO: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9001-20-19
JR05199,0000E9D -19-18OCT17-9/10
160GLC Excavator 042318 PN=161
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 8
Replace Coolant Control Valve
1. Replace coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR, clear DTCs. 4. Using Service ADVISOR, perform DEF header coolant purge test. 5. Using Service ADVISOR, perform control unit information and overview test.
Is DTC 004366.06 active?
YES: Reprogram engine control unit (ECU). See Software and Hardware Verification. (CTM120119.) NO: Checks complete. JR05199,0000E9D -19-18OCT17-10/10
TM13345X19 (23APR18)
9001-20-20
160GLC Excavator 042318 PN=162
Engine Control Unit (ECU) Diagnostic Trouble Codes
004366.16 — DEF Tank Temperature Moderately High
NOTE: Diagnostics for the following diagnostic trouble codes (DTCs) must be followed before diagnosing this DTC:
The engine control unit (ECU) has detected that the diesel exhaust fluid (DEF) tank temperature is higher than expected.
• 003031.03 • 003031.04 • 003031.12 • 004366.05 • 004366.06
12
1
32
23
54
43
4 1
2
1
3
Y5019 A1
TX1245353
X5037
X5502-20
5321 BRN
X5502-51
5324 YEL
21 22
4
5321 BRN 5324 YEL
TX1245353 —UN—06OCT17
X5502
Coolant Control Valve (Y5019) Wiring Diagram A1—Engine Control Unit (ECU) X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1
X5502—51—Return Y5019—Coolant Control Valve
X5502—Engine Control Unit (ECU) Connector 2 X5502—20—Supply
Alarm Level:
Additional References:
• Service Required Indicator
• See Control Unit Information and Overview Test. (CTM120119.)
Diagnostic Trouble Code (DTC) Induced Condition:
• Diesel exhaust fluid (DEF) dosing system is disabled for
the remainder of the key cycle and the selective catalyst reduction (SCR) derate counter becomes active. For more information on SCR system, see SCR System Derates. (CTM120119.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.)
see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
IMPORTANT: Pin damage occurs if anything other than the specified flex probe from JDG10466 Flex Probe Kit is used. DEF Tank Header Assembly Connector:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• For additional information on Service ADVISOR™,
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple Coolant Control Valve Connector:
Component Location:
• See Engine Interface Harness (W5) Component
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
• See Diesel Exhaust Fluid (DEF) Harness (W54)
ECU:
Diagnostic Test Box Information:
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
Location. (Group 9015-10.)
Component Location. (Group 9015-10.)
• Not Applicable Service ADVISOR is a trademark of Deere & Company JR05199,0000E9E -19-16OCT17-1/6
Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-20-21
JR05199,0000E9E -19-16OCT17-2/6
160GLC Excavator 042318 PN=163
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 1
Read DTCs and Store Snapshot Information
Ignition ON, engine OFF.
1. Verify coolant control valve (Y5019) is connected. 2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR™, clear DTCs. 4. Using Service ADVISOR™, perform DEF header coolant purge test. 5. Using Service ADVISOR™, perform control unit information and overview test. Is DTC 004366.16 active or stored?
YES: Go to next check. NO: No problem found. JR05199,0000E9E -19-16OCT17-3/6
• 2
Temperature Verification
Using Service ADVISOR™, perform DEF pump diagnostic test for 2 minutes.
Using Service ADVISOR™, monitor DEF tank fluid temperature. Using Service ADVISOR™, monitor DEF dosing unit temperature. After the test has run for 2 minutes, stop the DEF pump diagnostic test.
YES: Go to next check.
Are both measurements within 10°C (18°F)?
NO: Replace DEF tank header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.) JR05199,0000E9E -19-16OCT17-4/6
• 3
Short to Voltage Check Ignition OFF, engine OFF.
Disconnect coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) Ignition ON, engine OFF. Using a multimeter, measure voltage between coolant control valve (Y5019) connector pin 1 and ground.
YES: Repair short to voltage on harness. See Engine Interface Harness (W5) Wiring Diagram and see Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram. (Group 9015-10.)
Is voltage within 0.75 V of battery voltage?
NO: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9001-20-22
JR05199,0000E9E -19-16OCT17-5/6
160GLC Excavator 042318 PN=164
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 4
Coolant Control Valve Verification
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Do not open coolant system until the coolant temperature is below operating temperature. Always loosen cooling system filler cap, radiator cap, or drain valve slowly to relieve pressure. IMPORTANT: Ensure that the hose is secured to the container. If the valve is stuck open, coolant flows from the outlet port. Ignition OFF, engine OFF. Disconnect coolant supply and return lines from the coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) Attach a line to the coolant control valve outlet port and route to a suitable container. Using a regulated air supply no greater than 103 kPa (1.03 bar) (15 psi), blow air into the coolant control valve inlet port.
YES: Replace coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Does air or coolant flow from the outlet port?
NO: Reprogram engine control unit (ECU). See Software and Hardware Verification. (CTM120119.) JR05199,0000E9E -19-16OCT17-6/6
TM13345X19 (23APR18)
9001-20-23
160GLC Excavator 042318 PN=165
Engine Control Unit (ECU) Diagnostic Trouble Codes
004366.18 — DEF Tank Insufficient Heating Fault
NOTE: Diagnostics for the following diagnostic trouble codes (DTCs) must be followed before diagnosing this DTC:
The diesel exhaust fluid (DEF) temperature has not reached operating temperatures after an expected period of thawing.
• 003031.03 • 003031.04 • 003031.12 • 004366.05 • 004366.06 • 000110.17 • 000111.01 • 000111.17 • 000111.18 • 003516.09 • 004366.18
IMPORTANT: If DTC 004366.18 became active outdoors as a result of insufficient heating, and the engine is brought inside a shop where the DEF is able to thaw, this DTC will become stored after the engine completes a thawing cycle. This DTC will become active again after the engine goes back to a cold-weather environment if the root cause of the fault was not repaired.
12
1
32
23
54
4 1
2
43
1
3
Y5019 A1
TX1245353
X5037
X5502-20
5321 BRN
X5502-51
5324 YEL
21 22
4
5321 BRN 5324 YEL
TX1245353 —UN—06OCT17
X5502
Coolant Control Valve (Y5019) Wiring Diagram A1—Engine Control Unit (ECU) X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1
X5502—51—Return Y5019—Coolant Control Valve
X5502—Engine Control Unit (ECU) Connector 2 X5502—20—Supply
Alarm Level:
Additional References:
• Service Required Indicator
• See Control Unit Information and Overview Test. (CTM120119.)
Diagnostic Trouble Code (DTC) Induced Condition:
• Diesel exhaust fluid (DEF) dosing system is disabled for
the remainder of the key cycle and the selective catalyst reduction (SCR) derate counter becomes active. For more information on SCR system, see SCR System Derates. (CTM120119.)
Circuit Information:
• See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.)
see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
IMPORTANT: Pin damage occurs if anything other than the specified flex probe from JDG10466 Flex Probe Kit is used. DEF Tank Header Assembly Connector:
• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• For additional information on Service ADVISOR™,
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple Coolant Control Valve Connector:
Component Location:
• See Engine Interface Harness (W5) Component
• JDG10460—Female—Yellow/Purple • JDG10461—Male—Yellow/Purple
• See Diesel Exhaust Fluid (DEF) Harness (W54)
ECU:
Location. (Group 9015-10.)
Component Location. (Group 9015-10.)
• JDG10460—Female—Yellow/Purple
Diagnostic Test Box Information:
• Not Applicable Continued on next page
TM13345X19 (23APR18)
9001-20-24
JR05199,0000E9F -19-16OCT17-1/10
160GLC Excavator 042318 PN=166
Engine Control Unit (ECU) Diagnostic Trouble Codes
• JDG10461—Male—Yellow/Purple Service ADVISOR is a trademark of Deere & Company JR05199,0000E9F -19-16OCT17-2/10
Diagnostic Procedure JR05199,0000E9F -19-16OCT17-3/10
• 1
Preliminary Checks
Visually inspect the DEF tank header coolant supply and return hoses for restrictions.
Check coolant level in surge tank for correct coolant level. See Check Engine Coolant Level. (Operator’s Manual.)
YES: Repair problem and go to next check.
Any problems found?
NO: Go to next check. JR05199,0000E9F -19-16OCT17-4/10
• 2
Read DTCs and Store Snapshot Information
Ignition ON, engine OFF.
1. Check coolant control valve (Y5019) is connected. 2. Connect Service ADVISOR™ and record DTC and snapshot information. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 3. Using Service ADVISOR™, clear DTCs. 4. Using Service ADVISOR™, perform DEF header coolant purge test. 5. Using Service ADVISOR™, perform control unit information and overview test. Are any of the following DTCs active or stored?
• Any DTC with a suspect parameter number (SPN) of 003031 • 004366.05 • 004366.06 • 000110.17
YES: Troubleshoot active or stored DTC. NO: Go to next check. JR05199,0000E9F -19-16OCT17-5/10
• 3
DEF Tank Temperature NOTE: If the DEF tank is surrounded by a cover, remove the cover to Check ensure accurate temperature measurement.
Ignition ON, engine OFF. In Service ADVISOR™, monitor DEF tank fluid temperature. Using a non-contact temperature measurement tool, check the temperature of the DEF YES: Go to next check. tank near the bottom of the tank. Are both measurements within 10°C (18°F) of each other?
Continued on next page
TM13345X19 (23APR18)
9001-20-25
NO: Replace diesel exhaust fluid (DEF) tank header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.) JR05199,0000E9F -19-16OCT17-6/10
160GLC Excavator 042318 PN=167
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 4
Coolant Concentration NOTE: Improper coolant mixture or contamination may cause the coolant lines to and Coolant Lines become restricted. Oil in coolant can restrict the DEF header coolant filter. Restriction Check
Ignition OFF, engine OFF. Check coolant concentration for correct specification. See Testing Diesel Exhaust Fluid (DEF). (Operator’s Manual.) Inspect DEF coolant supply and return hoses and connectors leading to the DEF tank header for restrictions, blockage, or kinked. See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
YES: Repair as necessary.
Any problems found?
NO: Go to next check. JR05199,0000E9F -19-16OCT17-7/10
• 5
Coolant Control Valve Check
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Do not open coolant system until the coolant temperature is below operating temperature. Always loosen cooling system filler cap, radiator cap, or drain valve slowly to relieve pressure. IMPORTANT: Ensure that the hose is secured to the container. If the valve is stuck open, coolant flows from the outlet port. Ignition OFF, engine OFF. Disconnect coolant supply and return lines from the coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) Attach a line to the coolant control valve outlet port and route to a suitable container. Using a regulated air supply no greater than 103 kPa (1.03 bar) (15 psi), blow air into the coolant control valve inlet port.
YES: Replace coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
Does air or coolant flow from the outlet port?
NO: Go to next check. JR05199,0000E9F -19-16OCT17-8/10
• 6
Engine Coolant Temperature Check
NOTE: If engine is not able to run at high idle due to a final derate condition, perform emissions control system derate override in Service ADVISOR™.
Connect all previously disconnected components. Ignition ON, engine speed at high idle. Using Service ADVISOR™, monitor DEF tank fluid temperature. Using Service ADVISOR™, monitor engine coolant temperature. Using Service ADVISOR™, perform DEF header coolant purge test.
YES: Go to next check.
Does engine coolant reach coolant temperatures of 85—95°C (185—203°F)?
NO: Diagnose engine coolant temperature malfunction. See Engine Coolant Temperature Below Normal. (CTM120119.)
Continued on next page
TM13345X19 (23APR18)
9001-20-26
JR05199,0000E9F -19-16OCT17-9/10
160GLC Excavator 042318 PN=168
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 7
DEF Tank Temperature Ignition ON, engine speed at high idle. Check
In Service ADVISOR™, perform DEF header coolant purge test. Using Service ADVISOR™, monitor DEF tank fluid temperature. Operate engine for 20 minutes.
YES: Checks complete.
Does the DEF tank fluid temperature increase by more than 5°C (9°F) in 20 minutes?
NO: Replace coolant control valve (Y5019). See Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) JR05199,0000E9F -19-16OCT17-10/10
005484.05 — Reversing Fan Solenoid Open Circuit
Reversing fan solenoid (Y5015) open circuit. JL58967,00002EE -19-13OCT15-1/5
Reversing Fan Solenoid Open Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) JL58967,00002EE -19-13OCT15-2/5
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Reversing fan solenoid (Y5015).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002EE -19-13OCT15-3/5
• 2
Component Check
Disconnect and test reversing fan solenoid (Y5015). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Open Circuit Check.
Does reversing fan solenoid (Y5015) test OK?
NO: Reversing fan solenoid (Y5015) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-20-27
JL58967,00002EE -19-13OCT15-4/5
160GLC Excavator 042318 PN=169
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Open Circuit Check
Reversing fan solenoid (Y5015) disconnected.
Disconnect engine control unit (ECU) connector 1 (X5501). Disconnect engine control unit (ECU) connector 2 (X5502). Check for continuity between:
• Pin 1 of reversing fan solenoid (Y5015) connector and pin 26 of engine control unit (ECU) connector 2 (X5502).
• Pin 2 of reversing fan solenoid (Y5015) connector and pin 21 of engine control unit (ECU) connector 1 (X5501).
YES: Checks complete.
Is continuity indicated?
NO: Repair or replace harness as necessary. JL58967,00002EE -19-13OCT15-5/5
005484.06 — Reversing Fan Solenoid Short Circuit
Reversing fan solenoid (Y5015) short circuit. JL58967,00002EF -19-13OCT15-1/5
Reversing Fan Solenoid Short Circuit Diagnostic Procedure Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning) JL58967,00002EF -19-13OCT15-2/5
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Fan harness (W57). See Fan Harness (W57) Component Location. (Group 9015-10.) - Reversing fan solenoid (Y5015).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Engine control unit (ECU) connector 1 (X5501). - Engine control unit (ECU) connector 2 (X5502). - Fan harness connector (X5005).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) See Fan Harness (W57) Wiring Diagram. (Group 9015-10.) JL58967,00002EF -19-13OCT15-3/5
• 2
Component Check
Disconnect and test reversing fan solenoid (Y5015). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Short to Ground Check.
Does reversing fan solenoid (Y5015) test OK?
NO: Reversing fan solenoid (Y5015) malfunction. Replace solenoid.
Continued on next page
TM13345X19 (23APR18)
9001-20-28
JL58967,00002EF -19-13OCT15-4/5
160GLC Excavator 042318 PN=170
Engine Control Unit (ECU) Diagnostic Trouble Codes
• 3
Short to Ground Check Reversing fan solenoid (Y5015) disconnected.
Disconnect engine control unit (ECU) connector 2 (X5502). Check for continuity between reversing fan solenoid (Y5015) connector pin 1 and machine ground.
YES: Repair or replace harness as necessary.
Is continuity indicated?
NO: Checks complete. JL58967,00002EF -19-13OCT15-5/5
520956.06 — Battery Disconnect Indicator Light Short to Ground
Alarm Level: Warning Alarm Illuminated—Highlighted Yellow (warning)
ECU detected short to ground in battery disconnect indicator light circuit. DF89619,00B58D9 -19-19JUN14-1/5
Battery Disconnect Indicator Light Short to Ground Diagnostic Procedure DF89619,00B58D9 -19-19JUN14-2/5
• 1
Connector Check
Check the following connectors for damage, corrosion, or debris:
• Engine Interface Harness (W5). See Engine Interface Harness (W5) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors or pins.
Location. (Group 9015-10.) - Battery disconnect indicator light (E22). - Engine control unit (ECU) connector 3 (X5503).
See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.) DF89619,00B58D9 -19-19JUN14-3/5
• 2
Component Check
Disconnect and test battery disconnect indicator light (E22). See Electrical Component YES: Go to Short to Ground Specifications. (Group 9015-20.) Check. Is battery disconnect indicator light (E22) OK?
NO: Replace battery disconnect indicator light (E22). DF89619,00B58D9 -19-19JUN14-4/5
• 3
Short to Ground Check Key switch in OFF position.
Disconnect battery disconnect indicator light (E22). See Engine Interface Harness (W5) Component Location. (Group 9015-10.) Disconnect engine control unit (ECU) connector 3 (X5503). See Engine Interface Harness (W5) Component Location. (Group 9015-10.) Check for continuity between wire E330 WHT and machine ground.
YES: Repair or replace harness as necessary. See Engine Interface Harness (W5) Wiring Diagram. (Group 9015-10.)
Is continuity indicated?
NO: Checks complete. DF89619,00B58D9 -19-19JUN14-5/5
TM13345X19 (23APR18)
9001-20-29
160GLC Excavator 042318 PN=171
Engine Control Unit (ECU) Diagnostic Trouble Codes
TM13345X19 (23APR18)
9001-20-30
160GLC Excavator 042318 PN=172
Group 30
Monitor Controller (DSZ) Diagnostic Trouble Codes Monitor Controller (DSZ) Diagnostic Trouble Codes For additional information on the monitor controller circuit, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Monitor controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR™, or by connection with MPDr.
• See Reading Diagnostic Trouble Codes with Monitor Display. (Group 9015-20.)
• See Reading Diagnostic Trouble Codes with Service
ADVISOR™ Diagnostic Application. (Group 9015-20.)
• See MPDr Application. (Group 9015-20.) Service ADVISOR is a trademark of Deere & Company
AS79221,00003BB -19-20MAR18-1/1
013000.02 — Flash Memory Failure 1 Flash memory failure in monitor controller. DF89619,00B586F -19-10OCT16-1/3
Flash Memory Failure 1 Diagnostic Procedure DF89619,00B586F -19-10OCT16-2/3
• 1
Diagnostic Trouble Code Re-Check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 013000.02—Flash Memory Failure 1 still present?
NO: Monitor controller is OK. DF89619,00B586F -19-10OCT16-3/3
013001.02 — Flash Memory Failure 2 Flash memory failure in monitor controller. DF89619,00B5870 -19-10OCT16-1/3
Flash Memory Failure 2 Diagnostic Procedure DF89619,00B5870 -19-10OCT16-2/3
• 1
Diagnostic Trouble Code Re-Check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 013001.02—Flash Memory Failure 2 still present?
NO: Monitor controller is OK. DF89619,00B5870 -19-10OCT16-3/3
013002.02 — ECU Communication Error Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) DF89619,00B5828 -19-10OCT16-1/1
TM13345X19 (23APR18)
9001-30-1
160GLC Excavator 042318 PN=173
Monitor Controller (DSZ) Diagnostic Trouble Codes
013003.02 — Main Controller (MCZ) Communication Error 1
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) DF89619,00B5829 -19-10OCT16-1/1
013004.02 — Main Controller (MCZ) Communication Error 2
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) DF89619,00B582A -19-10OCT16-1/1
013005.02 — Monitor Controller (DSZ) Communication Error 1
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) DF89619,00B582B -19-10OCT16-1/1
013006.02 — Monitor Controller (DSZ) Communication Error 2
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) DF89619,00B582C -19-10OCT16-1/1
013007.02 — Machine Controller (BCZ) Communication Error
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) DF89619,00B582D -19-05DEC17-1/1
020113.02 — System Error Alarm
• See Controller Area Network 1 (CAN 1) Circuit
Faulty controller area network (CAN) circuit.
• See Interface Controller Area Network (N-CAN)
For more information:
• See Engine Controller Area Network (Engine CAN)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B583F -19-08MAY14-1/1
TM13345X19 (23APR18)
9001-30-2
160GLC Excavator 042318 PN=174
Group 40
Information Controller (ICZ) Diagnostic Trouble Codes Information Controller (ICZ) Diagnostic Trouble Codes NOTE: The information controller (ICZ) is an internal controller of the monitor controller (DSZ). For additional information on the information controller (ICZ) circuit, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Information controller (ICZ) diagnostic trouble codes (DTCs) can be displayed on the monitor, by 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.)
Service ADVISOR is a trademark of Deere & Company DF89619,00B5848 -19-12JUN14-1/1
013303.02 — Abnormal Monitor Internal Temperature Sensor
The monitor screen becomes dark. DF89619,00B584A -19-28AUG17-1/4
Monitor Internal Temperature Sensor Diagnostic Procedure DF89619,00B584A -19-28AUG17-2/4
• 1
Temperature Check
Check temperature in or around monitor controller.
YES: Go to Screen Check.
Is temperature above 85°C (185°F)?
NO: Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.) DF89619,00B584A -19-28AUG17-3/4
• 2
Screen Check
Cool monitor controller and observe monitor screen.
YES: Monitor controller is OK.
Does monitor screen return to normal as monitor cooled?
NO: Monitor controller malfunction. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.) DF89619,00B584A -19-28AUG17-4/4
013304.02 — Alternator Alarm Alternator output above 33.5 volts. DF89619,00B584B -19-28AUG17-1/3
Alternator Alarm Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-40-1
DF89619,00B584B -19-28AUG17-2/3
160GLC Excavator 042318 PN=175
Information Controller (ICZ) Diagnostic Trouble Codes
• 1
Alternator Output Check
Measure alternator output. See Alternator Test. (Group 9015-20.)
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is voltage below 33.5 volts?
NO: Alternator malfunction. Repair or replace alternator. DF89619,00B584B -19-28AUG17-3/3
013305.02 — Abnormal Manual Glow EXT Output
Not applicable to this machine. DF89619,00B584C -19-28AUG17-1/1
013310.03 — Coolant Temperature Sensor Short Circuit
Not applicable to this machine. DF89619,00B584D -19-28AUG17-1/1
013311.03 — Fuel Level Sensor Open Circuit Fuel level sensor (B18) open circuit. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
JL58967,00001E5 -19-28AUG17-1/5
Fuel Level Sensor Open Circuit Diagnostic Procedure JL58967,00001E5 -19-28AUG17-2/5
• 1
Resistance Check
Disconnect fuel level sensor (B18) and check sensor resistance.
Is sensor resistance within specifications?
YES: Go to Harness Check.
Fuel Level Sensor Specifications Float Position
Resistance (ohms)
Upper Limit (FULL)
6—10
3/4
26
1/2
33—43
1/4
53
Alarm Level
82—88
Lower Limit (EMPTY)
90—100 Continued on next page
TM13345X19 (23APR18)
9001-40-2
NO: Fuel level sensor (B18) malfunction. Replace sensor.
JL58967,00001E5 -19-28AUG17-3/5
160GLC Excavator 042318 PN=176
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Harness Check
Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor (B18) connector. Check for continuity between monitor controller 28-pin connector A (X20) pin 18 and fuel level sensor (B18) connector pin 2.
YES: Go to Component Check.
Is continuity indicated?
NO: Repair or replace harness. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.) JL58967,00001E5 -19-28AUG17-4/5
• 3
Component Check
Disconnect monitor controller 28-pin connector A (X20).
Check for continuity between monitor controller (DSZ) (A4) pin A18 and ground.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is continuity indicated?
NO: Monitor controller is OK. JL58967,00001E5 -19-28AUG17-5/5
013311.04 — Fuel Level Sensor Shorted Circuit
Over torquing will result in permanent damage to connector. Torque only to specification.
Fuel level sensor (B18) shorted to ground. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in. JL58967,00001E6 -19-28AUG17-1/5
Fuel Level Sensor Shorted Circuit Diagnostic Procedure JL58967,00001E6 -19-28AUG17-2/5
• 1
Resistance Check
Disconnect fuel level sensor (B18) and check sensor resistance.
Is sensor resistance within specifications?
YES: Go to Harness Check.
Fuel Level Sensor Specifications Float Position
Resistance (ohms)
Upper Limit (FULL)
6—10
3/4
26
1/2
33—43
1/4
53
Alarm Level
82—88
Lower Limit (EMPTY)
90—100 Continued on next page
TM13345X19 (23APR18)
9001-40-3
NO: Fuel level sensor (B18) malfunction. Replace sensor.
JL58967,00001E6 -19-28AUG17-3/5
160GLC Excavator 042318 PN=177
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Harness Check
Disconnect fuel level sensor (B18).
Check for continuity between fuel level connector pin 2 and ground.
YES: Go to Component Check.
Is continuity indicated?
NO: Monitor controller is OK. JL58967,00001E6 -19-28AUG17-4/5
• 3
Component Check
Disconnect monitor controller 28-pin connector A (X20).
Check for continuity between monitor controller (DSZ) (A4) pin A18 and ground.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is continuity indicated?
NO: Short circuit in harness between monitor controller and fuel level sensor (B18). JL58967,00001E6 -19-28AUG17-5/5
013334.02 — Radiator Water Temp Receive Error
Not applicable to this machine. DF89619,00B5850 -19-06JUN14-1/1
014000.02 — CAN Communication Error 1
• See Controller Area Network 1 (CAN 1) Circuit
CAN Communication Error 1
• See Interface Controller Area Network (N-CAN)
For more information:
• See Engine Controller Area Network (Engine CAN)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B5881 -19-22MAR18-1/1
014001.02 — Flash Memory Read/Write Error DF89619,00B5852 -19-16MAY14-1/3
Data Converter Diagnostics Flash Memory Read/Write Error in monitor controller. DF89619,00B5852 -19-16MAY14-2/3
• 1
Diagnostic Trouble Code Re-check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 014001.02—Flash Memory Read/Write Error still present?
NO: Monitor controller is OK. DF89619,00B5852 -19-16MAY14-3/3
TM13345X19 (23APR18)
9001-40-4
160GLC Excavator 042318 PN=178
Information Controller (ICZ) Diagnostic Trouble Codes
014002.02 — External RAM Read/Write Error DF89619,00B5853 -19-16MAY14-1/3
Data Converter Diagnostics External RAM Read/Write Error in monitor controller. DF89619,00B5853 -19-16MAY14-2/3
• 1
Diagnostic Trouble Code Re-check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 014002.02—External RAM Read/Write Error still present?
NO: Monitor controller is OK. DF89619,00B5853 -19-16MAY14-3/3
014003.02 — Abnormal EEPROM DF89619,00B5854 -19-16MAY14-1/3
Data Converter Diagnostics Abnormal EEPROM in monitor controller. DF89619,00B5854 -19-16MAY14-2/3
• 1
Diagnostic Trouble Code Re-check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 014003.02—Abnormal EEPROM still present?
NO: Monitor controller is OK. DF89619,00B5854 -19-16MAY14-3/3
014006.02 — Communication Terminal: Communication Error JL58967,00001EC -19-07SEP16-1/5
Communication Terminal: Communication Error Diagnostic Procedure JL58967,00001EC -19-07SEP16-2/5
• 1
Fuse Check
Key switch in OFF position.
Remove fuses (F6001 and F6003). Check fuses (F6001 and F6003) for continuity.
YES: Go to Power Check.
Is continuity indicated?
NO: Replace defective fuses. Continued on next page
TM13345X19 (23APR18)
9001-40-5
JL58967,00001EC -19-07SEP16-3/5
160GLC Excavator 042318 PN=179
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Power Check
Key switch in OFF position.
Disconnect satellite (SAT) module control unit 48-pin connector (X6015). See Satellite (SAT) Harness (W6003) Component Location. (Group 9015-10.) Turn key switch to ON position. Check for voltage between pins M1 and M2 on satellite (SAT) module control unit 48-pin connector (X6015).
YES: Go to Harness Check.
Is voltage between 22—25 volts?
NO: Repair or replace harness. See appropriate harness. JL58967,00001EC -19-07SEP16-4/5
• 3
Harness Check
Key switch in OFF position.
Disconnect satellite (SAT) module control unit 48-pin connector (X6015). Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). Check continuity between:
• Pin A1 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A2 on modular telematics gateway (MTG) control unit 48-pin connector (X6014).
• Pin A2 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A1 on YES: Go to Interface modular telematics gateway (MTG) control unit 48-pin connector (X6014).
Is continuity indicated?
Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.) NO: Repair or replace harness. See appropriate harness. JL58967,00001EC -19-07SEP16-5/5
014008.02 — Abnormal Internal RAM DF89619,00B5856 -19-16MAY14-1/3
Data Converter Diagnostics Abnormal Internal RAM in monitor controller. DF89619,00B5856 -19-16MAY14-2/3
• 1
Diagnostic Trouble Code Re-check
Clear codes and check for code again.
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is diagnostic trouble code (DTC) 014008.02—Abnormal Internal RAM still present?
NO: Monitor controller is OK. DF89619,00B5856 -19-16MAY14-3/3
014009.02 — CAN Communication Error 2
• See Controller Area Network 1 (CAN 1) Circuit
CAN Communication Error 2
• See Interface Controller Area Network (N-CAN)
For more information:
• See Engine Controller Area Network (Engine CAN)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B5882 -19-22MAY14-1/1
TM13345X19 (23APR18)
9001-40-6
160GLC Excavator 042318 PN=180
Information Controller (ICZ) Diagnostic Trouble Codes
• See Controller Area Network 1 (CAN 1) Circuit
014021.02 — Communication Terminal Security Error
Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN)
Security failure of mobile communication equipment. For more information:
Diagnostics. (Group 9001-10.)
• See Engine Controller Area Network (Engine CAN) Diagnostics. (Group 9001-10.)
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B5858 -19-16MAY14-1/1
014022.02 — SIM Card Error For more information, see JDLink™ / (MTG) Technical Manual. (TM114519.) If (MTG) is 4G see JDLink™ (MTG) 4G LTE Technical Manual. (TM143019). JDLink is a trademark of Deere & Company DF89619,00B5859 -19-26OCT17-1/1
014023.02 — Security Error
• See Controller Area Network 1 (CAN 1) Circuit
Communication error with the main controller (MCZ).
• See Interface Controller Area Network (N-CAN)
For more information:
• See Engine Controller Area Network (Engine CAN)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
DF89619,00B585A -19-16MAY14-1/1
020100.02 — Overheat Alarm Not applicable to this machine. DF89619,00B585B -19-27MAY14-1/1
020101.02 — Engine Warning Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B585C -19-16MAY14-1/1
020102.02 — Engine Oil Pressure Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B585D -19-16MAY14-1/1
020103.02 — Alternator Alarm Alternator output above 33.5 volts. DF89619,00B585E -19-27MAY14-1/3
Alternator Alarm Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-40-7
DF89619,00B585E -19-27MAY14-2/3
160GLC Excavator 042318 PN=181
Information Controller (ICZ) Diagnostic Trouble Codes
• 1
Alternator Output Check
Measure alternator output. See Alternator Test. (Group 9015-20.)
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is voltage below 33.5 volts?
NO: Alternator malfunction. Repair or replace alternator. DF89619,00B585E -19-27MAY14-3/3
020105.02 — Hydraulic Oil Filter Restriction Alarm 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.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
JL58967,00001E7 -19-10FEB15-1/5
Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure JL58967,00001E7 -19-10FEB15-2/5
• 1
Filter Check
Replace hydraulic oil filter. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.) YES: Go to Hydraulic Oil Filter Restriction Switch Check. Is DTC 020105.2 still present?
NO: Checks complete. JL58967,00001E7 -19-10FEB15-3/5
• 2
Hydraulic Oil Filter Restriction Switch Check
Key switch in OFF position.
Disconnect hydraulic oil filter restriction switch (B27). See Machine Harness (W2) Component Location. (Group 9015-10.) Check for continuity between terminals of hydraulic oil filter restriction switch.
YES: Hydraulic oil filter restriction switch malfunction. Replace switch.
Is continuity indicated?
NO: Go to Circuit Check. Continued on next page
TM13345X19 (23APR18)
9001-40-8
JL58967,00001E7 -19-10FEB15-4/5
160GLC Excavator 042318 PN=182
Information Controller (ICZ) Diagnostic Trouble Codes
• 3
Circuit Check
Key switch in OFF position.
Disconnect monitor controller 36-pin connector B (X21) and hydraulic oil filter restriction switch (B27). Check for continuity between pin 13 on monitor controller 36-pin connector B (X21) and machine ground.
YES: Short to ground. Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.) JL58967,00001E7 -19-10FEB15-5/5
020106.02 — Air Cleaner Restriction Alarm Not applicable to this machine. DF89619,00B5860 -19-27MAY14-1/1
020107.02 — Water Separator Alarm Not applicable to this machine. DF89619,00B5861 -19-27MAY14-1/1
020109.02 — Pilot Control Shut-Off Lever Alarm DF89619,00B5862 -19-16MAY14-1/6
Pilot Control Shut-Off Lever Alarm Diagnostic Procedure DF89619,00B5862 -19-16MAY14-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Cab harness-to-pilot shutoff switch harness connector (X65). See Pilot Shutoff Switch Harness (W11) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location. (Group 9015-10.)
Check cab harness-to-pilot shutoff switch harness connector (X65) for corrosion, loose fit, bent/pressed out pins or crimp malfunctions.
YES: Go to Code Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector(s) or pin(s) as needed. DF89619,00B5862 -19-16MAY14-3/6
• 2
Code Check
Clear codes and check for code again.
YES: Go to Pilot Shutoff Switch 1 (S3) Check.
Is diagnostic trouble code (DTC) 020109.02—Pilot Control Shut-Off Lever Alarm present?
NO: Monitor controller is OK.
Continued on next page
TM13345X19 (23APR18)
9001-40-9
DF89619,00B5862 -19-16MAY14-4/6
160GLC Excavator 042318 PN=183
Information Controller (ICZ) Diagnostic Trouble Codes
• 3
Pilot Shutoff Switch 1 (S3) Check
Pilot control shutoff lever in locked (UP) position.
Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff switch harness connector (X65).
YES: Short in pilot shutoff switch harness (W11). Repair or replace harness.
Is continuity indicated?
NO: Go to Pilot Shutoff Switch 2 (S4) Check. DF89619,00B5862 -19-16MAY14-5/6
• 4
Pilot Shutoff Switch 2 (S4) Check
Pilot control shutoff lever in unlocked (DOWN) position.
Connect positive (+) lead of multimeter to pin 1 and negative (-) lead of multimeter to pin 3 on cab harness-to-pilot shutoff switch harness connector (X65).
YES: Short in pilot shutoff switch harness (W11). Repair or replace harness.
Is continuity indicated?
NO: Checks complete. DF89619,00B5862 -19-16MAY14-6/6
020110.02 — Fuel Filter Restriction Alarm Not applicable to this machine. DF89619,00B5863 -19-27MAY14-1/1
020114.02 — Overheat Alarm (Immediately After the Key is Turned ON)
Not applicable to this machine. DF89619,00B5864 -19-27MAY14-1/1
020135.02 — Exhaust Filter Regeneration Unnecessary Warning
Not applicable to this machine. DF89619,00B5865 -19-18JUN14-1/1
020149.02 — EGR Gas Temperature Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B5866 -19-16MAY14-1/1
020150.02 — Coolant Level Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B5867 -19-27MAY14-1/1
020151.02 — Engine Warning Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B5868 -19-27MAY14-1/1
TM13345X19 (23APR18)
9001-40-10
160GLC Excavator 042318 PN=184
Information Controller (ICZ) Diagnostic Trouble Codes
020152.02 — Engine Oil Pressure Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B5869 -19-27MAY14-1/1
020153.02 — Air Cleaner Restriction Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B586A -19-27MAY14-1/1
020154.02 — Fuel Filter Restriction Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B586B -19-27MAY14-1/1
020155.02 — Engine Output Reduction Alarm Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU).
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
DF89619,00B586C -19-27MAY14-1/1
020156.02 — Cooling Performance Decrease Alarm
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU). DF89619,00B586D -19-27MAY14-1/1
020157.02 — Cooling Performance Decrease Alarm
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Diagnose the diagnostic trouble codes (DTCs) of the engine control unit (ECU). DF89619,00B586E -19-27MAY14-1/1
032000.02 — Coolant Temperature Pre Alarm Not applicable to this machine. JS20420,00011F6 -19-12MAY15-1/1
032001.02 — Hydraulic Oil Temperature Pre Alarm
Not applicable to this machine. JS20420,00011F7 -19-12MAY15-1/1
032002.02 — Hydraulic and Ambient Temperature Difference Pre Alarm
Not applicable to this machine. JS20420,00011F8 -19-12MAY15-1/1
TM13345X19 (23APR18)
9001-40-11
160GLC Excavator 042318 PN=185
Information Controller (ICZ) Diagnostic Trouble Codes
TM13345X19 (23APR18)
9001-40-12
160GLC Excavator 042318 PN=186
Group 50 Air Conditioner Controller (ACF) Diagnostic Trouble Codes Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• See Reading Diagnostic Trouble Codes With Monitor Display. (Group 9015-20.)
Air conditioner controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR™, or by connection with MPDr.
• See Reading Diagnostic Trouble Codes With Service
ADVISOR™ Diagnostic Application. (Group 9015-20.)
• See MPDr Application. (Group 9015-20.)
Service ADVISOR is a trademark of Deere & Company RH60123,0000F17 -19-06FEB17-1/1
11 — Open Circuit in Air Recirculation Sensor
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
Air recirculation sensor (B55) is above normal operating voltage.
• See System Functional Schematic. (Group 9015-10.) • See Electrical Component Specifications. (Group 9015-20.)
Additional References:
JA66566,0003392 -19-16JUN14-1/7
Open Circuit in Air Recirculation Sensor Diagnostic Procedure JA66566,0003392 -19-16JUN14-2/7
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air recirculation sensor (B55). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Component Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003392 -19-16JUN14-3/7
• 2
Component Check
Turn key switch to OFF position.
Disconnect air recirculation sensor (B55). Measure resistance between pins 1 and 2 on sensor.
YES: Go to Voltage Check.
Does resistance meet specification? See Electrical Component Specifications. (Group 9015-20.)
NO: Air recirculation sensor (B55) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-50-1
JA66566,0003392 -19-16JUN14-4/7
160GLC Excavator 042318 PN=187
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 3
Voltage Check
Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of sensor for approximately 5 V. • Pin 2 of sensor for 0.0 V.
YES: Go to Short to Power Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003392 -19-16JUN14-5/7
• 4
Short to Power Check
Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Disconnect air conditioner controller (ACF) (A7). Turn key switch to ON position Check for voltage at pin 2 of sensor for 0.0 V.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is voltage indicated?
NO: Go to Harness Check. JA66566,0003392 -19-16JUN14-6/7
• 5
Harness Check
Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check for continuity between pin 6 of air conditioner controller (ACF) (A7) connector and all other remaining pins on connector (A7).
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. JA66566,0003392 -19-16JUN14-7/7
12 — Short-Circuited Air Recirculation Sensor
• See Air Conditioning System Cycle of Operation.
Air recirculation sensor (B55) circuit is open.
• See System Functional Schematic. (Group 9015-10.) • See Electrical Component Specifications. (Group
(Group 9031-05.)
9015-20.)
Additional References:
JA66566,0003394 -19-16JUN14-1/7
Short-Circuited Air Recirculation Sensor Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-50-2
JA66566,0003394 -19-16JUN14-2/7
160GLC Excavator 042318 PN=188
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air recirculation sensor (B55). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Component Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003394 -19-16JUN14-3/7
• 2
Component Check
Turn key switch to OFF position.
Disconnect air recirculation sensor (B55). Measure resistance between pins 1 and 2 on sensor.
YES: Go to Voltage Check.
Does resistance meet specification? See Electrical Component Specifications. (Group 9015-20.)
NO: Air recirculation sensor (B55) malfunction. Replace sensor. JA66566,0003394 -19-16JUN14-4/7
• 3
Voltage Check
Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of sensor (B55) for approximately 5 V. • Pin 2 of sensor (B55) for 0.0 V. Is correct voltage indicated?
YES: Go to Continuity Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003394 -19-16JUN14-5/7
• 4
Continuity Check
Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 2 of sensor and pin 6 of air conditioner controller.
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. Continued on next page
TM13345X19 (23APR18)
9001-50-3
JA66566,0003394 -19-16JUN14-6/7
160GLC Excavator 042318 PN=189
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 5
Short to Ground Check Turn key switch to OFF position.
Air recirculation sensor (B55) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 2 of sensor and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. JA66566,0003394 -19-16JUN14-7/7
13 — Open Circuit in Ambient Air Temperature Sensor
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
• See System Functional Schematic. (Group 9015-10.) • See Electrical Component Specifications. (Group
Ambient air temperature sensor (B22) is above normal operating voltage.
9015-20.)
Additional References: DF89619,00B587B -19-16JUN14-1/7
Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure DF89619,00B587B -19-16JUN14-2/7
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Ambient air temperature sensor (B22) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7) and air conditioner 10-pin connector (X52). See
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate wiring diagram or schematic.
Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
DF89619,00B587B -19-16JUN14-3/7
• 2
Component Check
Turn key switch to OFF position.
Disconnect ambient air temperature sensor (B22). Measure resistance between pins 1 and 2 on sensor.
YES: Go to Voltage Check.
Does resistance meet specification? See Electrical Component Specifications. (Group 9015-20.)
NO: Ambient air temperature sensor (B22) malfunction. Replace sensor.
Continued on next page
TM13345X19 (23APR18)
9001-50-4
DF89619,00B587B -19-16JUN14-4/7
160GLC Excavator 042318 PN=190
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 3
Voltage Check
Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of sensor for approximately 5 V. • Pin 2 of sensor for 0.0 V.
YES: Go to Short to Power Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587B -19-16JUN14-5/7
• 4
Short to Power Check
Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Disconnect air conditioner controller (ACF) (A7). Turn key switch to ON position. Check for voltage at pin 2 of sensor for 0.0 V.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is voltage indicated?
NO: Go to Harness Check. DF89619,00B587B -19-16JUN14-6/7
• 5
Harness Check
Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check for continuity between pin 4 of air conditioner controller (ACF) (A7) connector and all other remaining pins on connector (A7).
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. DF89619,00B587B -19-16JUN14-7/7
14 — Short-Circuited Ambient Air Temperature Sensor
• See Air Conditioning System Cycle of Operation.
Ambient air temperature sensor (B22) circuit is open.
• See System Functional Schematic. (Group 9015-10.) • See Electrical Component Specifications. (Group
(Group 9031-05.)
9015-20.)
Additional References:
DF89619,00B587C -19-16JUN14-1/7
Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-50-5
DF89619,00B587C -19-16JUN14-2/7
160GLC Excavator 042318 PN=191
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Ambient air temperature sensor (B22) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7) and air conditioner 10-pin connector (X52). See
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate wiring diagram or schematic.
Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
DF89619,00B587C -19-16JUN14-3/7
• 2
Component Check
Turn key switch to OFF position.
Disconnect ambient air temperature sensor (B22). Measure resistance between pins 1 and 2 on sensor.
YES: Go to Voltage Check.
Does resistance meet specification? See Electrical Component Specifications. (Group 9015-20.)
NO: Ambient air temperature sensor (B22) malfunction. Replace sensor. DF89619,00B587C -19-16JUN14-4/7
• 3
Voltage Check
Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of sensor for approximately 5 V. • Pin 2 of sensor for 0.0 V.
YES: Go to Continuity Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587C -19-16JUN14-5/7
• 4
Continuity Check
Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 2 of sensor and pin 4 of controller.
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. Continued on next page
TM13345X19 (23APR18)
9001-50-6
DF89619,00B587C -19-16JUN14-6/7
160GLC Excavator 042318 PN=192
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 5
Short to Ground Check Turn key switch to OFF position.
Ambient air temperature sensor (B22) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 2 of sensor and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. DF89619,00B587C -19-16JUN14-7/7
18 — Short-Circuited Solar Radiation Sensor
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
Solar sensor (B21) circuit is open.
• See System Functional Schematic. (Group 9015-10.)
Additional References: DF89619,00B587D -19-16JUN14-1/6
Short-Circuited Solar Radiation Sensor Diagnostic Procedure DF89619,00B587D -19-16JUN14-2/6
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Solar sensor (B21) and cab harness-to-monitor harness connector (X17). See Monitor Harness (W3) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7) and air conditioner 10-pin connector (X52). See
YES: Go to Voltage Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate wiring diagram or schematic.
Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
DF89619,00B587D -19-16JUN14-3/6
• 2
Voltage Check
Turn key switch to OFF position.
Solar sensor (B21) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of sensor for approximately 5 V. • Pin 2 of sensor for 0.0 V.
YES: Go to Continuity Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. Continued on next page
TM13345X19 (23APR18)
9001-50-7
DF89619,00B587D -19-16JUN14-4/6
160GLC Excavator 042318 PN=193
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 3
Continuity Check
Turn key switch to OFF position.
Solar sensor (B21) disconnected. Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 2 of sensor and pin 3 of controller.
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587D -19-16JUN14-5/6
• 4
Short to Ground Check Turn key switch to OFF position.
Solar sensor (B21) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 2 of sensor and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Solar sensor (B21) malfunction. Replace sensor. DF89619,00B587D -19-16JUN14-6/6
21 — Open Circuit in Air Conditioner Freeze Control Switch
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
• See System Functional Schematic. (Group 9015-10.)
Air conditioner freeze control switch (B41) circuit is open. Additional References:
JA66566,0003395 -19-26MAR18-1/7
Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure JA66566,0003395 -19-26MAR18-2/7
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air conditioner freeze control switch (B41). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Component Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Continued on next page
TM13345X19 (23APR18)
9001-50-8
Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003395 -19-26MAR18-3/7
160GLC Excavator 042318 PN=194
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 2
Component Check
Turn key switch to OFF position.
Disconnect air conditioner freeze control switch (B41). Measure resistance between pins 1 and 2 on switch. See Air Conditioner Freeze Control Switch Test. (Group 9031-25.)
YES: Go to Voltage Check.
Does resistance meet specification?
NO: Air conditioner freeze control switch (B41) malfunction. Replace switch. JA66566,0003395 -19-26MAR18-4/7
• 3
Voltage Check
Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of switch for approximately 5 V. • Pin 2 of switch for 0.0 V. Is correct voltage indicated?
YES: Go to Short to Power Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003395 -19-26MAR18-5/7
• 4
Short to Power Check
Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Disconnect air conditioner controller (ACF) (A7). Turn key switch to ON position. Check for voltage at pin 2 of switch for 0.0 V.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is voltage indicated?
NO: Go to Harness Check. JA66566,0003395 -19-26MAR18-6/7
• 5
Harness Check
Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check for continuity between pin 5 of connector (A7) and all other remaining pins on connector (A7).
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. JA66566,0003395 -19-26MAR18-7/7
TM13345X19 (23APR18)
9001-50-9
160GLC Excavator 042318 PN=195
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
22 — Short-Circuited Air Conditioner Freeze Control Switch
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
• See System Functional Schematic. (Group 9015-10.)
Air conditioner freeze control switch (B41) circuit is open. Additional References:
JA66566,0003396 -19-26MAR18-1/7
Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure JA66566,0003396 -19-26MAR18-2/7
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air conditioner freeze control switch (B41). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Component Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. JA66566,0003396 -19-26MAR18-3/7
• 2
Component Check
Turn key switch to OFF position.
Disconnect air conditioner freeze control switch (B41). Measure resistance between pins 1 and 2 on switch. See Air Conditioner Freeze Control Switch Test. (Group 9031-25.)
YES: Go to Voltage Check.
Does resistance meet specification?
NO: Air conditioner freeze control switch (B41) malfunction. Replace switch. JA66566,0003396 -19-26MAR18-4/7
• 3
Voltage Check
Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of switch for approximately 5 V. • Pin 2 of switch for 0.0 V.
YES: Go to Continuity Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. Continued on next page
TM13345X19 (23APR18)
9001-50-10
JA66566,0003396 -19-26MAR18-5/7
160GLC Excavator 042318 PN=196
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 4
Continuity Check
Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 2 of switch and pin 5 of controller.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Go to Short to Ground Check. JA66566,0003396 -19-26MAR18-6/7
• 5
Short to Ground Check Turn key switch to OFF position.
Air conditioner freeze control switch (B41) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 2 of switch and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Checks complete. JA66566,0003396 -19-26MAR18-7/7
43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor
Additional References:
Air conditioner and heater blower port change servomotor (M10) malfunction.
• See System Functional Schematic. (Group 9015-10.)
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
DF89619,00B587E -19-16JUN14-1/6
Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure DF89619,00B587E -19-16JUN14-2/6
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air conditioner and heater blower port change servomotor (M10). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner and heater mixer servomotor (M11). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Voltage Check. Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Continued on next page
TM13345X19 (23APR18)
9001-50-11
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587E -19-16JUN14-3/6
160GLC Excavator 042318 PN=197
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 2
Voltage Check
Turn key switch to OFF position.
Disconnect air conditioner and heater blower port change servomotor (M10). Turn key switch to ON position. Check for voltage at:
• Pin 1 of servomotor for approximately 5 V. • Pin 3 of servomotor for 0 V.
YES: Go to Continuity Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587E -19-16JUN14-4/6
• 3
Continuity Check
Turn key switch to OFF position.
Air conditioner and heater blower port change servomotor (M10) disconnected. Air conditioner and heater mixer servomotor (M11) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check for continuity between pin 3 of air conditioner and heater blower port change servomotor (M10) and pin 25 of air conditioner controller (ACF) (A7).
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587E -19-16JUN14-5/6
• 4
Short to Ground Check Turn key switch to OFF position.
Air conditioner and heater blower port change servomotor (M10) disconnected. Air conditioner and heater mixer servomotor (M11) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 3 of air conditioner and heater blower port change servomotor (M10) and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Air conditioner and heater blower port change servomotor (M10) malfunction. Replace servomotor. DF89619,00B587E -19-16JUN14-6/6
44 — Abnormal Air Conditioner and Heater Mixer Servomotor
Additional References:
Air conditioner and heater mixer servomotor (M11) malfunction.
• See System Functional Schematic. (Group 9015-10.)
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
DF89619,00B587F -19-16JUN14-1/6
Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9001-50-12
DF89619,00B587F -19-16JUN14-2/6
160GLC Excavator 042318 PN=198
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air conditioner and heater blower port change servomotor (M10). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner and heater mixer servomotor (M11). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) YES: Go to Voltage Check. Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587F -19-16JUN14-3/6
• 2
Voltage Check
Turn key switch to OFF position.
Disconnect air conditioner and heater mixer servomotor (M11). Turn key switch to ON position. Check for voltage at:
• Pin 1 of servomotor for approximately 5 V. • Pin 3 of servomotor for 0 V. Is correct voltage indicated?
YES: Go to Continuity Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B587F -19-16JUN14-4/6
• 3
Continuity Check
Turn key switch to OFF position.
Air conditioner and heater mixer servomotor (M11) disconnected. Air conditioner and heater blower port change servomotor (M10) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check for continuity between pin 3 of air conditioner and heater mixer servomotor (M11) and pin 7 of air conditioner controller (ACF) (A7).
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. Continued on next page
TM13345X19 (23APR18)
9001-50-13
DF89619,00B587F -19-16JUN14-5/6
160GLC Excavator 042318 PN=199
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 4
Short to Ground Check Turn key switch to OFF position.
Air conditioner and heater mixer servomotor (M11) disconnected. Air conditioner and heater blower port change servomotor (M10) disconnected. Air conditioner controller (ACF) (A7) disconnected. Check continuity between pin 3 of air conditioner and heater mixer servomotor (M11) and machine ground.
YES: Repair or replace harness. See appropriate wiring diagram or schematic.
Is continuity indicated?
NO: Air conditioner and heater mixer servomotor (M11) malfunction. Replace servomotor. DF89619,00B587F -19-16JUN14-6/6
51 — Abnormal High/Low Refrigerant Pressure
Additional References:
Air conditioner high/low-pressure switch (B20) circuit is open.
• See System Functional Schematic. (Group 9015-10.)
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
DF89619,00B5880 -19-16APR15-1/6
Abnormal High/Low Refrigerant Pressure Diagnostic Procedure DF89619,00B5880 -19-16APR15-2/6
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Air conditioner high/low-pressure switch (B20) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7) and air conditioner 10-pin connector (X52). See
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace harness. See appropriate wiring diagram or schematic.
Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
DF89619,00B5880 -19-16APR15-3/6
• 2
Component Check
Turn key switch to OFF position.
Disconnect air conditioner high/low-pressure switch (B20). Check continuity between pins 1 and 2 on air conditioner high/low-pressure switch (B20). YES: Air conditioner high/low-pressure switch (B20) malfunction. Replace pressure switch. Is continuity indicated?
NO: Go to Voltage Check. Continued on next page
TM13345X19 (23APR18)
9001-50-14
DF89619,00B5880 -19-16APR15-4/6
160GLC Excavator 042318 PN=200
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
• 3
Voltage Check
Turn key switch to OFF position.
Air conditioner high/low-pressure switch (B20) disconnected. Turn key switch to ON position. Check for voltage at:
• Pin 1 of air conditioner high/low-pressure switch (B20) for machine voltage. • Pin 2 of air conditioner high/low-pressure switch (B20) for 0 V. Is correct voltage indicated?
YES: Go to Continuity Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B5880 -19-16APR15-5/6
• 4
Continuity Check
Turn key switch to OFF position.
Air conditioner high/low-pressure switch (B20) disconnected. Disconnect air conditioner compressor clutch (Y11). Check for continuity between pin 2 of air conditioner high/low-pressure switch (B20) and machine ground.
YES: Checks complete.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. DF89619,00B5880 -19-16APR15-6/6
91 — Communication Error CAN communication malfunction.
For more information, see Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,0000F22 -19-22MAR18-1/1
92 — CAN Bus Off Error CAN Bus Off malfunction.
For more information, see Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,0000F23 -19-22MAR18-1/1
TM13345X19 (23APR18)
9001-50-15
160GLC Excavator 042318 PN=201
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
TM13345X19 (23APR18)
9001-50-16
160GLC Excavator 042318 PN=202
Group 60
Premium Seat Controller (PSC) Diagnostic Trouble Codes Premium Seat Controller (PSC) Diagnostic Trouble Codes
1 2
3 4
5 6
Premium seat controller (PSC) diagnostic trouble codes (DTCs) are indicated by a color sequence of LEDs displayed on the heated/cooled seat switch (S37). The DTC sequence will flash 10 times upon pressing the switch. In order to display DTCs multiple times, power will need to be cycled by turning the key switch OFF and ON. Record color and light sequence to determine DTC. 1— Low LED (blue) 2— Low LED (red) 3— Medium LED (blue) 4— Medium LED (red)
5— High LED (blue) 6— High LED (red) S37— Heated/Cooled Seat Switch
TX1252052 —UN—12FEB18
S37
Heated/Cooled Seat Switch Premium Seat Controller (PSC) Diagnostic Trouble Codes Blue LED Low (1)
Medium (3)
Red LED High (5)
Low (2)
Medium (4)
X
See 0—Cushion Blower Minimum Voltage. (Group 9001-60.) X
X
See 1—Back Blower Minimum Voltage. (Group 9001-60.)
X
See 2—Cushion Blower Short to Power. (Group 9001-60.) X
See 3—Back Blower Short to Power. (Group 9001-60.)
X
See 4—Cushion Fan Power Transistor Short to Ground. (Group 9001-60.)
X
X
See 5—Back Fan Power Transistor Short to Ground. (Group 9001-60.)
X
X
X
X
DTC
High (6)
X
See 6—Cushion Fan Power Transistor Open Circuit. (Group 9001-60.) See 7—Back Fan Power Transistor Open Circuit. (Group 9001-60.)
X
See 8—Lower Thermal Duct Module Temperature Sensor Short to Ground. (Group 9001-60.)
X
X X
X
X
See 9—Upper Thermal Duct Module Temperature Sensor Short to Ground. (Group 9001-60.)
X
See 10—Lower Thermal Duct Module Temperature Sensor Open Circuit. (Group 9001-60.) X
See 11—Upper Thermal Duct Module Temperature Sensor Open Circuit. (Group 9001-60.)
X
See 12—Lower Thermal Duct Module Short to Ground. (Group 9001-60.)
X
X
See 13—Upper Thermal Duct Module Short to Ground. (Group 9001-60.)
X
X
X X
X
X X
X X X
See 14—Lower Thermal Duct Module Open Circuit. (Group 9001-60.) See 15—Upper Thermal Duct Module Open Circuit. (Group 9001-60.)
X
See 16—Lower Thermal Duct Module Over Temperature. (Group 9001-60.) Continued on next page
TM13345X19 (23APR18)
9001-60-1
DF89619,00B6909 -19-19FEB18-1/2
160GLC Excavator 042318 PN=203
Premium Seat Controller (PSC) Diagnostic Trouble Codes Premium Seat Controller (PSC) Diagnostic Trouble Codes X
X
X
X
See 17—Upper Thermal Duct Module Over Temperature. (Group 9001-60.) X
See 21—Thermal Duct Module Short to Power. (Group 9001-60.) DF89619,00B6909 -19-19FEB18-2/2
0 — Cushion Blower Minimum Voltage Minimum voltage detected from premium seat blower (M15) at pin A4 of premium seat controller (PSC) (A26).
X638
2
X641 24
4
5
X638 13
A26 12
3
1
A = X641
A20
BLK
4
BLK
A4
WHT
3
WHT
A12
RED
2
RED
M15
TX1252186
TX1252186 —UN—12FEB18
1
Premium Seat Blower Circuit Schematic A26— Premium Seat Controller (PSC) M15— Premium Seat Blower
X638— Premium Seat Blower Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
Additional References:
• Seat Heating and Cooling Operations Inoperable
• None
Circuit Information:
Possible Causes:
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
1. 2. 3. 4.
Circuit is shorted to ground. Circuit is open. Component malfunction. Software malfunction. Replace controller. DF89619,00B690A -19-19FEB18-1/1
1 — Back Blower Minimum Voltage Not applicable to machine. DF89619,00B690B -19-07FEB18-1/1
TM13345X19 (23APR18)
9001-60-2
160GLC Excavator 042318 PN=204
Premium Seat Controller (PSC) Diagnostic Trouble Codes
2 — Cushion Blower Short to Power Battery voltage detected from premium seat blower (M15) at pin A4 of premium seat controller (PSC) (A26).
X638
2
X641 24
4
5
X638 13
A26 12
3
1
A = X641
A20
BLK
4
BLK
A4
WHT
3
WHT
A12
RED
2
RED
M15
TX1252186
TX1252186 —UN—12FEB18
1
Premium Seat Blower Circuit Schematic A26— Premium Seat Controller (PSC) M15— Premium Seat Blower
X638— Premium Seat Blower Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to power. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B690C -19-19FEB18-1/1
3 — Back Blower Short to Power Not applicable to machine. DF89619,00B690D -19-07FEB18-1/1
TM13345X19 (23APR18)
9001-60-3
160GLC Excavator 042318 PN=205
Premium Seat Controller (PSC) Diagnostic Trouble Codes
4 — Cushion Fan Power Transistor Short to Ground
Premium seat blower (M15) transistor circuit is shorted to ground.
X638
2
X641 24
4
5
X638 13
A26 12
3
1
A = X641
A20
BLK
4
BLK
A4
WHT
3
WHT
A12
RED
2
RED
M15
TX1252186
TX1252186 —UN—12FEB18
1
Premium Seat Blower Circuit Schematic A26— Premium Seat Controller (PSC) M15— Premium Seat Blower
X638— Premium Seat Blower Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to ground. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B690E -19-19FEB18-1/1
5 — Back Fan Power Transistor Short to Ground
Not applicable to machine. DF89619,00B690F -19-07FEB18-1/1
TM13345X19 (23APR18)
9001-60-4
160GLC Excavator 042318 PN=206
Premium Seat Controller (PSC) Diagnostic Trouble Codes
6 — Cushion Fan Power Transistor Open Circuit
Premium seat blower (M15) transistor circuit is open.
X638
2
X641 24
4
5
X638 13
A26 12
3
1
A = X641
A20
BLK
4
BLK
A4
WHT
3
WHT
A12
RED
2
RED
M15
TX1252186
TX1252186 —UN—12FEB18
1
Premium Seat Blower Circuit Schematic A26— Premium Seat Controller (PSC) M15— Premium Seat Blower
X638— Premium Seat Blower Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6910 -19-19FEB18-1/1
7 — Back Fan Power Transistor Open Circuit Not applicable to machine. DF89619,00B6911 -19-09FEB18-1/1
TM13345X19 (23APR18)
9001-60-5
160GLC Excavator 042318 PN=207
Premium Seat Controller (PSC) Diagnostic Trouble Codes
8 — Lower Thermal Duct Module Temperature Sensor Short to Ground
Lower thermal duct module (R21) temperature sensor circuit is shorted to ground. X640
2
3
4
X641 24
X640
13
A21
BRN
3
LT GRN
A2
GRN
4
LT GRN
A26 12
1
A = X641
R21
TX1252187
TX1252187 —UN—12FEB18
1
Lower Thermal Duct Module Temperature Sensor Circuit Schematic A26— Premium Seat Controller (PSC) R21— Lower Thermal Duct Module
X640— Lower Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to ground. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6912 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-6
160GLC Excavator 042318 PN=208
Premium Seat Controller (PSC) Diagnostic Trouble Codes
9 — Upper Thermal Duct Module Temperature Sensor Short to Ground
Upper thermal duct module (R20) temperature sensor circuit is shorted to ground. X639
2
3
4
X641 24
X639
13
A22
BRN
3
LT GRN
A3
GRN
4
LT GRN
A26 12
1
A = X641
R20
TX1252188
TX1252188 —UN—12FEB18
1
Upper Thermal Duct Module Temperature Sensor Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
X639— Upper Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to ground. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6913 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-7
160GLC Excavator 042318 PN=209
Premium Seat Controller (PSC) Diagnostic Trouble Codes
10 — Lower Thermal Duct Module Temperature Sensor Open Circuit
Lower thermal duct module (R21) temperature sensor circuit is open. X640
2
3
4
X641 24
X640
13
A21
BRN
3
LT GRN
A2
GRN
4
LT GRN
A26 12
1
A = X641
R21
TX1252187
TX1252187 —UN—12FEB18
1
Lower Thermal Duct Module Temperature Sensor Circuit Schematic A26— Premium Seat Controller (PSC) R21— Lower Thermal Duct Module
X640— Lower Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6914 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-8
160GLC Excavator 042318 PN=210
Premium Seat Controller (PSC) Diagnostic Trouble Codes
11 — Upper Thermal Duct Module Temperature Sensor Open Circuit
Upper thermal duct module (R20) temperature sensor circuit is open. X639
2
3
4
X641 24
X639
13
A22
BRN
3
LT GRN
A3
GRN
4
LT GRN
A26 12
1
A = X641
R20
TX1252188
TX1252188 —UN—12FEB18
1
Upper Thermal Duct Module Temperature Sensor Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
X639— Upper Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6915 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-9
160GLC Excavator 042318 PN=211
Premium Seat Controller (PSC) Diagnostic Trouble Codes
12 — Lower Thermal Duct Module Short to Ground
Lower thermal duct module (R21) circuit is shorted to ground. X640
X642
2
3
4
X640
5
3
1
6
4
2
A26
B6
YEL
2
YEL
B1
BLU
1
BLU
B = X642
R21
TX1252189
TX1252189 —UN—12FEB18
1
Lower Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R21— Lower Thermal Duct Module
X640— Lower Thermal Module Connector X642— Premium Seat Controller (PSC) Connector B
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to ground. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6916 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-10
160GLC Excavator 042318 PN=212
Premium Seat Controller (PSC) Diagnostic Trouble Codes
13 — Upper Thermal Duct Module Short to Ground
Upper thermal duct module (R20) circuit is shorted to ground. X639
X642
2
3
4
X639
5
3
1
6
4
2
A26
B4
YEL
2
YEL
B2
BLU
1
BLU
B = X642
R20
TX1252190
TX1252190 —UN—12FEB18
1
Upper Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
X639— Upper Thermal Module Connector X642— Premium Seat Controller (PSC) Connector B
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to ground. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6917 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-11
160GLC Excavator 042318 PN=213
Premium Seat Controller (PSC) Diagnostic Trouble Codes
14 — Lower Thermal Duct Module Open Circuit
Lower thermal duct module (R21) circuit is open. X640
X642 5 6
3 4
2
3
4
X640 1 2
A26
B6
YEL
2
YEL
B1
BLU
1
BLU
B = X642
R21
TX1252189
TX1252189 —UN—12FEB18
1
Lower Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R21— Lower Thermal Duct Module
X640— Lower Thermal Module Connector X642— Premium Seat Controller (PSC) Connector B
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6919 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-12
160GLC Excavator 042318 PN=214
Premium Seat Controller (PSC) Diagnostic Trouble Codes
15 — Upper Thermal Duct Module Open Circuit
Upper thermal duct module (R20) circuit is open. X639
X642 5 6
3 4
2
3
4
X639 1 2
A26
B4
YEL
2
YEL
B2
BLU
1
BLU
B = X642
R20
TX1252190
TX1252190 —UN—12FEB18
1
Upper Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
X639— Upper Thermal Module Connector X642— Premium Seat Controller (PSC) Connector B
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is open. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B691A -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-13
160GLC Excavator 042318 PN=215
Premium Seat Controller (PSC) Diagnostic Trouble Codes
16 — Lower Thermal Duct Module Over Temperature
Premium seat controller (PSC) (A26) detects lower thermal duct module (R21) is over temperature.
X641
X640 13
1 12
2
3
4
1
X640
X642 5 6
3
1
4
2
TX1252317
A21
BRN
3
LT GRN LT GRN
A26
A2
GRN
4
A = X641 B = X642
B6
YEL
2
YEL
B1
BLU
1
BLU
R21
TX1252317 —UN—13FEB18
24
Lower Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R21— Lower Thermal Duct Module
X640— Lower Thermal Module X642— Premium Seat Controller Connector (PSC) Connector B X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to power. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B691B -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-14
160GLC Excavator 042318 PN=216
Premium Seat Controller (PSC) Diagnostic Trouble Codes
17 — Upper Thermal Duct Module Over Temperature
Premium seat controller (PSC) (A26) detects upper thermal duct module (R20) is over temperature.
X641
X639
1 12
2
3
4
1
X639
X642 5
3
1
A26 6
4
2
A = X641 B = X642
A22
BRN
A3
GRN
3 4
LT GRN
LT GRN
B4
YEL
2
YEL
B2
BLU
1
BLU
R20
TX1252318
TX1252318 —UN—13FEB18
13
24
Upper Thermal Duct Module Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
X639— Upper Thermal Module X642— Premium Seat Controller Connector (PSC) Connector B X641— Premium Seat Controller (PSC) Connector A
Code-Induced Condition:
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to power. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B691C -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-15
160GLC Excavator 042318 PN=217
Premium Seat Controller (PSC) Diagnostic Trouble Codes
21 — Thermal Duct Module Short to Power Thermal duct module (R20 or R21) circuit is shorted to power. X639
1
2
3
4
X639 B4
YEL
2
YEL
B2
BLU
1
BLU
X642
X640
3
1
4
2
A26 6
B = X642
B6
YEL
B1
BLU
2
YEL
1
BLU
R21 X640
1
2
3
4
TX1252192
TX1252192 —UN—13FEB18
5
R20
Thermal Duct Module Temperature Sensor Circuit Schematic A26— Premium Seat Controller (PSC) R20— Upper Thermal Duct Module
R21— Lower Thermal Duct Module X639— Upper Thermal Module Connector
Code-Induced Condition:
X640— Lower Thermal Module Connector X642— Premium Seat Controller (PSC) Connector B
• Not Applicable
• Seat Heating and Cooling Operations Inoperable
Additional References:
Circuit Information:
• None
• See System Functional Schematic. (Group 9015-15.) Component Location:
• See Premium Seat Harness (W87) Component Location. (Group 9015-15.)
Possible Causes: 1. Circuit is shorted to power. 2. Component malfunction. 3. Software malfunction. Replace controller.
Diagnostic Test Box Information: DF89619,00B6920 -19-19FEB18-1/1
TM13345X19 (23APR18)
9001-60-16
160GLC Excavator 042318 PN=218
Contents
Section 9005 Operational Checkout Procedure
Page
Group 10—Operational Checkout Procedure Operational Checkout................................ 9005-10-1 Diagnostic Trouble Code Check................9005-10-1 Operational Checks—Key Switch Off, Engine Off Checks ................................9005-10-1 Operational Checks—Key Switch On, Engine Off Checks ................................9005-10-4 Operational Checks—Key Switch On, Engine On Checks ..............................9005-10-17
TM13345X19 (23APR18)
9005-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9005-2
160GLC Excavator 042318 PN=2
Group 10
Operational Checkout Procedure Operational Checkout to doing checkout. The machine must be at operating temperature for many of the checks. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
This procedure is used to check operation of machine. The procedure is designed so the operator can do a walk-around inspection, check machine operation, and perform specific checks from the operator's seat. If there is a problem with machine, diagnostic information in this checkout will help pinpoint the probable cause. This information may allow the operator 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
Read each check completely before performing. If no problem is found, the operator will be instructed to go to the next check. If a problem is indicated, the operator 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). Before performing any check or test below, verify battery disconnect is turned to the ON position. JJ03229,0001128 -19-23JAN18-1/55
Diagnostic Trouble Code Check JJ03229,0001128 -19-23JAN18-2/55
Display and Clear Trouble Always check for diagnostic trouble codes and correct them before performing Codes operational checkout. Diagnostic trouble codes can be displayed by using one of the following methods:
• Monitor • With Service ADVISOR™ • MPDr
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, or see MPDr Application. (Group 9015-20.)
LOOK: Are diagnostic trouble codes present?
NO: Proceed with operational checkout.
Service ADVISOR is a trademark of Deere & Company JJ03229,0001128 -19-23JAN18-3/55
Operational Checks—Key Switch Off, Engine Off Checks Continued on next page
TM13345X19 (23APR18)
9005-10-1
JJ03229,0001128 -19-23JAN18-4/55
160GLC Excavator 042318 PN=221
Operational Checkout Procedure Horn Circuit Check
TX1159741 —UN—02MAY14
Horn Circuit 1— Horn Button Key switch in OFF position. Press horn button (1) on top of left pilot control lever.
YES: Go to next check.
LISTEN: Does horn sound?
NO: Check horn 10 A fuse (F19) (marked HORN). See Fuse and Relay Specifications. (Group 9015-10.)
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.
NO: Check horn wiring harness. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in Continued on next page
TM13345X19 (23APR18)
9005-10-2
JJ03229,0001128 -19-23JAN18-5/55
160GLC Excavator 042318 PN=222
Operational Checkout Procedure Hour Meter and Fuel Gauge Checks
2 PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086727 —UN—11JAN11
Switch Panel
50.0 h
1
10:00 AM 11 H
E
F
6
0.00 gal/h C
TX1160748 —UN—15MAY14
Hour Meter and Fuel Gauge Screen 1— Hour Meter 2— Home Button 6— Fuel Gauge 11— Diesel Exhaust Fluid (DEF) Gauge Press and hold home button (2) until default screen appears. LOOK: Does hour meter (1) display machine hours?
Continued on next page
TM13345X19 (23APR18)
9005-10-3
YES: Go to next check.
JJ03229,0001128 -19-23JAN18-6/55
160GLC Excavator 042318 PN=223
Operational Checkout Procedure LOOK: Does fuel gauge (6) display correct fuel level?
NO: Check radio backup 10 A fuse (F9) (marked BACK UP). See Fuse and Relay Specifications. (Group 9015-10.)
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.
NO: Check wiring. See Cab Harness (W1) Wiring Diagram and see Monitor Harness (W3) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
JJ03229,0001128 -19-23JAN18-7/55
Operational Checks—Key Switch On, Engine Off Checks Continued on next page
TM13345X19 (23APR18)
9005-10-4
JJ03229,0001128 -19-23JAN18-8/55
160GLC Excavator 042318 PN=224
Operational Checkout Procedure Monitor Start-Up Check
TX1086287A —UN—28DEC10
System Starting Screen
TX1160713A —UN—15MAY14
Default Screen 1— System Starting Screen 2— 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 approximately 2 seconds and then the default screen (2) is displayed. Turn key switch to ON position. LOOK: Does monitor display system starting screen?
YES: Go to next check.
LOOK: Does default screen with hour meter appear after system starting screen disappears?
NO: Check power on 5 A fuse (F17) (marked POWER ON). See Fuse and Relay Specifications. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9005-10-5
JJ03229,0001128 -19-23JAN18-9/55
160GLC Excavator 042318 PN=225
Operational Checkout Procedure Monitor, Gauges, and Battery Relay Checks
TX1160749A —UN—15MAY14
Default Screen 50.0 h ECO 10:00 AM
H
E
8
F
0.00 gal/h
C
AUTO
24.0˚C
FM VOL
CH1
81.3 ST MHz
TX1160750 —UN—15MAY14
Engine Preheat Indicator 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 11— Diesel Exhaust Fluid (DEF) Gauge 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. Turn key switch to ON position. LISTEN: Does battery relay click?
YES: Go to next check. Continued on next page
TM13345X19 (23APR18)
9005-10-6
JJ03229,0001128 -19-23JAN18-10/55
160GLC Excavator 042318 PN=226
Operational Checkout Procedure LOOK: Does engine coolant temperature gauge (5) display correct engine coolant temperature?
NO: Battery relay does not click. Verify battery disconnect is turned to the ON position.
LOOK: Does fuel gauge (6) display correct fuel level?
NO: Check battery 45 A fuse (F61). See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Does diesel exhaust fluid (DEF) gauge (11) display correct fluid level?
NO: Check key switch and battery relay. See Electrical Component Checks. (Group 9015-20.)
LOOK: Does hour meter (4) display machine hours?
NO: Check wiring. See System Functional Schematic, see Cab Harness (W1) Wiring Diagram, and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
LOOK: Does work mode indicator (1) display correct work mode (bucket or attachment)?
NO: Monitor does not come on. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Does travel mode indicator (7) display correct travel mode?
NO: Check wiring. See Cab Harness (W1) Wiring Diagram and see Monitor Harness (W3) Wiring Diagram. (Group 9015-10.)
LOOK: Does power mode indicator (3) display correct power mode?
NO: Neither engine coolant temperature gauge nor fuel gauge moves. Check gauge sensor and wiring. See Cab Harness (W1) Wiring Diagram and see Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
LOOK: Does engine preheat indicator (8) appear on monitor and then disappear after glow plugs reach specific temperature?
NO: Other than normal indicator lights remain on. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application, see Reading Diagnostic Trouble Codes With Monitor Display, or 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.
NO: Check glow plug wiring. See Glow Plug Harness (W40) Wiring Diagram and see Glow Plug Harness (W40) Component Location. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in Continued on next page
TM13345X19 (23APR18)
9005-10-7
JJ03229,0001128 -19-23JAN18-11/55
160GLC Excavator 042318 PN=227
Operational Checkout Procedure Rear Camera Check
TX1160715A —UN—15MAY14
Default Screen 5— Default Screen
TX1086306A —UN—28DEC10
Main Menu Screen 1— Main Menu Screen
TX1086272A —UN—27DEC10
Switch Panel 2— Monitor Dial 3— Back Button 4— Home Button
Continued on next page
TM13345X19 (23APR18)
9005-10-8
JJ03229,0001128 -19-23JAN18-12/55
160GLC Excavator 042318 PN=228
Operational Checkout Procedure
CAUTION: To avoid possible injury or death to operator or others, the rear view camera image is designed to supplement other safety practices and is not intended to be the sole method of collision avoidance. Always be alert and aware of the surroundings when operating this machine. Turn key to ON position. When the default screen (5) is displayed, press monitor dial (2) on the switch panel. LOOK: Does main menu screen (1) display? Rotate monitor dial to highlight settings menu. Press monitor dial. LOOK: Does settings menu display? At settings menu, rotate monitor dial to highlight rear view camera monitor. Press monitor dial to display rear view camera monitor menu. LOOK: Does rear view camera monitor menu display? Press monitor dial to turn camera ON (enable). Press home button (4).
TX1160752A —UN—15MAY14
Rear View Image 6— Rear View Image LOOK: Does rear view image (6) display on default screen? Repeat above steps. At rear view camera monitor menu, press monitor dial to turn camera OFF (disable). Press home button.
YES: Go to next check.
LOOK: Does default screen appear without rear view image?
NO: See Rear Camera Harness (W19) Component Location and see Rear Camera Harness (W19) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9005-10-9
JJ03229,0001128 -19-23JAN18-13/55
160GLC Excavator 042318 PN=229
Operational Checkout Procedure Travel Lever and Pedal Neutral Checks
TX1157583 —UN—09APR14
Travel Lever and Pedal 1— Forward 2— Rearward Push both travel levers and pedals forward (1), then release. Pull both travel levers and pedals rearward (2), then release. FEEL: Do levers and pedals require equal effort to operate in forward and reverse?
YES: Go to next check.
LOOK: Do levers and pedals return to neutral at the same time when released?
NO: Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Disassemble and Assemble. (Group 3360.)
Continued on next page
TM13345X19 (23APR18)
9005-10-10
JJ03229,0001128 -19-23JAN18-14/55
160GLC Excavator 042318 PN=230
Operational Checkout Procedure Light Circuit Checks
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT
ACC
N O
ON
OFF
START
PUSH MODE
1 2 3 4 5
OFF 1 2
3
6 7 8 9 0
TX1086747 —UN—11JAN11
Switch Panel 3— Work Light Switch Turn work light switch (3) to first position. LOOK: Is monitor panel back light and base machine work light on? LOOK: Does switch panel illuminate? Turn light switch to second position. LOOK: Does base machine work light stay on and switch panel stay illuminated?
YES: Go to next check.
LOOK: Does boom work light and cab roof lights (if equipped) come on and monitor back panel light change to night mode?
NO: Check work and boom lights 20 A fuse (F1) (marked LAMP), data converter and main controller battery power 5 A fuse (F10) (marked CONTROLLER), front cab light 1 10 A fuse (F22) (marked CAB LAMP FRONT), and front cab light 2 10 A fuse (F32) (marked CAB LAMP FRONT +2). See Fuse and Relay Specifications. (Group 9015-10.)
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.
NO: Check wiring harness. See System Functional Schematic. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
Continued on next page
TM13345X19 (23APR18)
9005-10-11
See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) JJ03229,0001128 -19-23JAN18-15/55
160GLC Excavator 042318 PN=231
Operational Checkout Procedure Rear Cab Light (if equipped)
TX1250182A —UN—18JAN18
Rear Cab Light Switch S36— Rear Cab Light Switch NOTE: Rear cab light switch (S36) position may vary depending on machine configuration.
YES: Go to next check.
Turn rear cab light switch (S36) to the ON position.
NO: Check rear cab light 10 A fuse (marked CAB LAMP REAR) (F23).See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Is light illuminated on rear of cab?
NO: Check wiring harness. See System Functional Schematic. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9005-10-12
JJ03229,0001128 -19-23JAN18-16/55
160GLC Excavator 042318 PN=232
Operational Checkout Procedure Windshield Wiper Control Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT
START
4
N O
ON
OFF
ACC
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086748 —UN—11JAN11
Switch Panel 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 first INT position. LOOK: Does wiper operate intermittently (8-second interval)? Turn windshield wiper and washer switch to second INT position. LOOK: Does wiper operate intermittently, but faster than when in first position (5-second interval)? Turn windshield wiper and washer switch to third INT position. LOOK: Does wiper operate intermittently, but faster than when in second position (3-second interval)? Turn windshield wiper and washer switch to ON position. LOOK: Does wiper operate continuously? Turn windshield wiper and washer switch to OFF position. LOOK: Does wiper arm stop and retract to left side of windshield?
YES: Go to next check.
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.
NO: Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) See Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
9005-10-13
JJ03229,0001128 -19-23JAN18-17/55
160GLC Excavator 042318 PN=233
Operational Checkout Procedure Windshield Washer Control Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT
START
4
N O
ON
OFF
ACC
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086748 —UN—11JAN11
Switch Panel 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. Press windshield wiper and washer switch (4). LOOK: Is washer fluid supplied to windshield? Press and hold windshield wiper and washer switch for 3 seconds.
YES: Go to next check.
LOOK: Does wiper start and continue operating until switch is released?
NO: Check washer fluid level. See Check Windshield Washer Fluid Level. (Operator’s Manual.)
Release windshield wiper and washer switch.
NO: Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Does wiper stop and retract to left side of windshield?
NO: Check wiring harness. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
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.
NO: Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in Continued on next page
TM13345X19 (23APR18)
9005-10-14
JJ03229,0001128 -19-23JAN18-18/55
160GLC Excavator 042318 PN=234
Operational Checkout Procedure Windshield Wiper Circuit Check
2 1
TX1001270 —UN—14DEC05
Front Window Release Handle 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. Slide lock pin (1) inward, then down into notch. Pull lock release bar (2) toward operator’s seat. While holding lower handle on window, pull window up and back as far as it can go. Slide lock pin into cab frame boss hole and rotate downward into the locked position.
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT
START
4
N O
ON
OFF
ACC
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086748 —UN—11JAN11
Switch Panel 4— Windshield Wiper and Washer Switch Turn windshield wiper and washer switch (4) to ON position. LISTEN: Does wiper circuit click?
YES: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9005-10-15
JJ03229,0001128 -19-23JAN18-19/55
160GLC Excavator 042318 PN=235
Operational Checkout Procedure LOOK: Does wiper remain stationary in park position?
NO: Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications. (Group 9015-10.)
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.
NO: Check wiper wiring. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
Continued on next page
TM13345X19 (23APR18)
9005-10-16
See Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.) JJ03229,0001128 -19-23JAN18-20/55
160GLC Excavator 042318 PN=236
Operational Checkout Procedure Windshield Washer Circuit Check
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. YES: Go to next check.
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
H
A/I A/I ON OFF OFF INT OFF
START
4
ACC
N O
ON
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086748 —UN—11JAN11
Switch Panel 4— Windshield Wiper and Washer Switch
NO: Check washer fluid level. See Check Windshield Washer Fluid Level. (Operator's Manual.)
Press windshield wiper and washer switch (4) and hold for 3 seconds.
NO: Check windshield wiper and washer 10 A fuse (F2) (marked WIPER). See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Is washer fluid supplied to windshield?
NO: Check wiring harness. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
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.
NO: Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
JJ03229,0001128 -19-23JAN18-21/55
Operational Checks—Key Switch On, Engine On Checks Continued on next page
TM13345X19 (23APR18)
9005-10-17
JJ03229,0001128 -19-23JAN18-22/55
160GLC Excavator 042318 PN=237
Operational Checkout Procedure Monitor and Gauge Circuit Checks
TX1160754A —UN—15MAY14
Operating Screen 1— Power Mode Indicator 2— Hour Meter 3— Engine Coolant Temperature Gauge 4— Fuel Gauge 5— Alarm Indicator 11— Diesel Exhaust Fluid (DEF) Gauge 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.
YES: Go to next check.
LOOK: Do all alarm indicator displays remain off after engine starts?
NO: Engine oil pressure alarm displayed. Immediately stop engine and check engine oil level. See Check Engine Oil Level. (Operator’s Manual.)
LOOK: Does alarm indicator remain off after engine starts?
IF OK: Check engine oil pressure. See Engine Oil Pressure Check. (CTM120019.)
LOOK: Does engine coolant temperature gauge (3) display correct engine coolant temperature?
NO: Alternator alarm indicator displayed. Check alternator drive belt.
LOOK: Does fuel gauge (4) display correct fuel level?
IF OK: Check alternator. See Alternator Test. (Group 9015-20.)
LOOK: Does diesel exhaust fluid (DEF) gauge (11) display correct fluid level?
NO: Other alarm indicators display on monitor. See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-18
JJ03229,0001128 -19-23JAN18-23/55
160GLC Excavator 042318 PN=238
Operational Checkout Procedure Pilot Shutoff Circuit Check
1
TX1093762 —UN—28JUN13
Engine Speed Dial
TX1093763 —UN—19JUL11
Locked 1— Engine Speed Dial CAUTION: Avoid possible injury. Machine may move during this check. Make sure area is clear and large enough to operate all machine functions. Turn engine speed dial (1) to L (slow idle) position. Place pilot shutoff lever in locked (UP) position. Slowly actuate dig and travel functions. LOOK: Do dig and travel functions operate?
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.)
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.
NO: Continue check.
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
TX1093764 —UN—19JUL11
Unlocked Place pilot shutoff lever in unlocked (DOWN) position. Slowly actuate dig and travel functions.
Continued on next page
TM13345X19 (23APR18)
9005-10-19
JJ03229,0001128 -19-23JAN18-24/55
160GLC Excavator 042318 PN=239
Operational Checkout Procedure LOOK: Do dig and travel functions operate?
YES: Go to next check.
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.
NO: See Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
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.)
Continued on next page
TM13345X19 (23APR18)
9005-10-20
JJ03229,0001128 -19-23JAN18-25/55
160GLC Excavator 042318 PN=240
Operational Checkout Procedure Reversing Fan System (if equipped)
TX1015264A —UN—09JAN07
Reversing Fan Switch
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM
3
PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT OFF
ACC N O
ON
START
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1088406 —UN—21FEB11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Blower Speed Switch 9— Reversing Fan Switch Place pilot shutoff lever in unlocked (DOWN) position. Turn engine speed dial (1) to H (fast idle) position. Warm hydraulic oil to greater than 12°C (54°F). Turn auto-idle switch (2) to A/I OFF position. Press blower speed switch (3) OFF. Press reversing fan switch (9) to MANUAL position. LISTEN: Does fan speed slow down? LOOK/LISTEN: After approximately 20 seconds, does the fan speed increase and rotate in reverse direction for approximately 30 seconds? LISTEN/LOOK: Does the fan speed slow for approximately 20 seconds? Does fan direction return to normal? LISTEN: Does fan speed increase?
YES: Go to next check.
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.
NO: See Reversing Fan Switch Harness (W23) Wiring Diagram, see Reversing Fan Switch Harness (W23) Component Location, and see Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
Continued on next page
TM13345X19 (23APR18)
9005-10-21
JJ03229,0001128 -19-23JAN18-26/55
160GLC Excavator 042318 PN=241
Operational Checkout Procedure Engine Speed Dial Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
ACC
N O
ON
OFF
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Mode Switch 4— Power Mode Button Turn auto-idle switch (2) to A/I OFF position. Place pilot shutoff lever in locked (UP) position.
YES: Go to next check.
Turn engine speed dial (1) clockwise.
NO: Check data converter and main controller battery power 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications. (Group 9015-10.)
LISTEN: Does engine speed increase?
IF OK: Check engine speed dial on monitor display. See Service Menu. (Group 9015-16.)
Turn engine speed dial counterclockwise.
NO: See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
LISTEN: Does engine speed decrease?
NO: Check wiring harness. See System Functional Schematic. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9005-10-22
JJ03229,0001128 -19-23JAN18-27/55
160GLC Excavator 042318 PN=242
Operational Checkout Procedure ECO (economy) Mode and PWR (power) Mode Checks
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn auto-idle switch (2) to A/I OFF position. Turn engine speed dial (1) to H (fast idle) position. Press and release power mode button until ECO (economy) mode is displayed on monitor. LOOK/LISTEN: Does engine speed decrease? Press and release power mode button (4) until PWR (power) mode is displayed on monitor.
YES: Go to next check.
LOOK/LISTEN: Does engine speed increase?
NO: For additional information on engine speed and power mode, see Engine Speed Control System Operation. (Group 9010-05.)
Continued on next page
TM13345X19 (23APR18)
9005-10-23
JJ03229,0001128 -19-23JAN18-28/55
160GLC Excavator 042318 PN=243
Operational Checkout Procedure H/P (high power) Mode Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn auto-idle switch (2) to A/I OFF position.
YES: Go to next check.
Turn engine speed dial (1) to H (fast idle) position.
NO: Check data converter and main controller battery power 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.)
Press and release power mode button (4) until H/P (high power) mode is displayed on monitor.
NO: Check main controller (MCZ) pressure sensors. See Electrical Component Specifications. (Group 9015-20.)
Actuate arm in function over relief.
NO: See System Functional Schematic. (Group 9015-10.)
LOOK/LISTEN: Does engine speed increase as function goes over relief?
NO: See H/P (High Power) Function Does Not Operate, PWR (Power) Mode Is Normal. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-24
JJ03229,0001128 -19-23JAN18-29/55
160GLC Excavator 042318 PN=244
Operational Checkout Procedure Auto-Idle Circuit Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn engine speed dial (1) to H (fast idle) position. Press and release power mode button (4) until H/P (high power) mode is displayed on monitor. Turn auto-idle switch (2) to A/I OFF position. Place pilot shutoff lever in unlocked (DOWN) position. Turn auto-idle switch to A/I ON position. LOOK/LISTEN: Does engine speed decrease after 4—6 seconds? Slowly actuate dig function.
YES: Go to next check.
LOOK/LISTEN: Does engine speed return to fast idle?
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.)
Continued on next page
TM13345X19 (23APR18)
9005-10-25
JJ03229,0001128 -19-23JAN18-30/55
160GLC Excavator 042318 PN=245
Operational Checkout Procedure Travel Alarm Check
A
B
C TX1095497 —UN—09AUG11
Travel Alarm A—Pilot Shutoff Lever B—Travel Lever and Pedal Forward C—Travel Lever and Pedal Rearward CAUTION: Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to operate machine. Place pilot shutoff lever (A) in unlocked (DOWN) position. Push travel levers or pedals forward (B).
YES: Go to next check.
LISTEN: Does travel alarm sound?
NO: Check optional and attachment connector 5 A fuse (F5) (marked OPT. 1 ALT). See Fuse and Relay Specifications. (Group 9015-10.)
Pull travel levers or push pedals rearward (C).
NO: Check wiring. See Travel Alarm Circuit Theory of Operation. (Group 9015-15.)
LISTEN: Does travel alarm sound?
NO: See Travel Alarm Harness (W26) Component Location and see Travel Alarm Harness (W26) Wiring Diagram. (Group 9015-10.) Continued on next page
TM13345X19 (23APR18)
9005-10-26
JJ03229,0001128 -19-23JAN18-31/55
160GLC Excavator 042318 PN=246
Operational Checkout Procedure Travel Alarm Cancel Switch Circuit Check
TX1086700A —UN—08JAN11
Left Console 1— Reversing Fan Switch 2— Seat Heater Switch 3— Travel Alarm Cancel Switch CAUTION: Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to operate machine. NOTE: Travel alarm must operate for this check. Place pilot shutoff lever in unlocked (DOWN) position. Push travel pedals or levers and allow travel alarm to operate for a minimum of 12 seconds.
YES: Go to next check.
LISTEN: Does travel alarm sound?
NO: Check optional and attachment connector 5 A fuse (F5) (marked OPT. 1 ALT). See Fuse and Relay Specifications. (Group 9015-10.)
While continuing travel, push travel alarm cancel switch (3).
NO: Check wiring. See Travel Alarm Circuit Theory of Operation. (Group 9015-15.)
LISTEN: Does travel alarm stop sounding?
NO: See Travel Alarm Cancel Switch Harness (W16) Component Location and see Travel Alarm Cancel Switch Harness (W16) Wiring Diagram. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9005-10-27
JJ03229,0001128 -19-23JAN18-32/55
160GLC Excavator 042318 PN=247
Operational Checkout Procedure Hydraulic Oil Tank Pressurization Check
1
2 TX1093766 —UN—28JUN13
Hydraulic Oil Tank Cover 1— 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. Raise boom to full height, then lower boom to ground. Slowly depress pressure release button (1) on hydraulic oil tank cover (2).
YES: Go to next check.
LISTEN: Is air heard escaping from the pressure release button on hydraulic oil tank cover?
NO: Replace hydraulic oil tank cover. JJ03229,0001128 -19-23JAN18-33/55
Control Lever Pattern Check—Excavator Pattern
1
5 7
4
3
2
8
6
TX1093767 —UN—28JUN13
Control Lever Pattern Check—Excavator Pattern 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. Turn engine speed dial to L (slow idle) position. Place pilot shutoff lever in unlocked (DOWN) position.
YES: Go to next check.
Slowly move hydraulic levers to all positions.
NO: See Control Lever Pattern Operation. (Operator's Manual.)
LOOK: Do bucket, boom, arm, and swing move according to pattern?
NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-28
JJ03229,0001128 -19-23JAN18-34/55
160GLC Excavator 042318 PN=248
Operational Checkout Procedure Control Lever Pattern Check—Backhoe Pattern
5
1 7
4
3
6
8
2
TX1093769 —UN—28JUN13
Control Lever Pattern Check—Backhoe Pattern 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. Turn engine speed dial to L (slow idle) position. Place pilot shutoff lever in unlocked (DOWN) position.
YES: Go to next check.
Slowly move hydraulic levers to all positions.
NO: See Control Lever Pattern Operation. (Operator's Manual.)
LOOK: Do bucket, boom, arm, and swing move according to pattern?
NO: See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-29
JJ03229,0001128 -19-23JAN18-35/55
160GLC Excavator 042318 PN=249
Operational Checkout Procedure Swing Dynamic Braking Check
45˚
90˚
TX1095482 —UN—28JUN13
Swing Dynamic Braking
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 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. Position upperstructure with boom to the front. Move arm to the extended position, bucket to the retracted position, and bucket-to-arm pivot pin at same level as boom-to-frame pivot pin. Turn engine speed dial (1) to H (fast idle) position. Press and release power mode button (4) until PWR (power) mode is displayed on monitor. Fully actuate swing function. Swing clockwise 90 degrees and then release lever. LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever? Position upperstructure with boom to the front.
Continued on next page
TM13345X19 (23APR18)
9005-10-30
YES: Go to next check.
JJ03229,0001128 -19-23JAN18-36/55
160GLC Excavator 042318 PN=250
Operational Checkout Procedure Fully actuate swing function. Swing counterclockwise 90 degrees and then release lever. NO: Perform Swing Motor Leakage Test. (Group 9025-25.) Perform Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever?
Continued on next page
TM13345X19 (23APR18)
9005-10-31
NO: Check swing valve spool and spring. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) JJ03229,0001128 -19-23JAN18-37/55
160GLC Excavator 042318 PN=251
Operational Checkout Procedure Swing Park Brake and Circuit Drift Checks
TX1093770 —UN—28JUN13
Machine Position Fill the bucket with dirt. Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine approximately 300 mm (1 ft) with the boom and insert a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin. Position upperstructure with cab over travel motors, perpendicular to tracks. Turn engine speed dial to L (slow idle) position. Wait approximately 5 minutes with all functions in neutral. NOTE: Function does not need to be fully actuated to disengage the swing park brake. Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10 seconds. LOOK: Does upperstructure hold position when swing park brake is engaged? LOOK: Does upperstructure move only slightly when swing park brake is disengaged? Swing upperstructure 180 degrees counterclockwise and repeat procedure. Turn engine speed dial to L (slow idle) position. Wait approximately 5 minutes with all functions in neutral.
YES: Go to next check.
Slowly actuate bucket load function to disengage the swing park brake. Do not hold the NO: Upperstructure moves function over relief for more than 10 seconds. 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.) LOOK: Does upperstructure hold position when swing park brake is engaged?
NO: Upperstructure movement is excessive when park brake is disengaged. Perform Swing Motor Leakage Test. (Group 9025-25.)
LOOK: Does upperstructure move only slightly when swing park brake is disengaged? NO: Check swing spool in the control valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) Continued on next page
TM13345X19 (23APR18)
9005-10-32
JJ03229,0001128 -19-23JAN18-38/55
160GLC Excavator 042318 PN=252
Operational Checkout Procedure Swing Power Check
TX1093770 —UN—28JUN13
Machine Position
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Fill the bucket with dirt. Position machine on a hillside with a slope of approximately 25%. If a hill is not available, raise one side of machine approximately 300 mm (1 ft) with the boom and insert a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-to-frame pivot pin. Swing upperstructure clockwise so it is 90 degrees to the slope. Turn engine speed dial (1) to H (fast idle) position. Press and release power mode button (4) until H/P (high power) mode is displayed on monitor. Actuate the swing function to swing uphill. LOOK: Does upperstructure swing uphill?
YES: Go to next check.
Swing upperstructure 180 degrees counterclockwise and repeat procedure.
NO: Perform Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)
Continued on next page
TM13345X19 (23APR18)
9005-10-33
JJ03229,0001128 -19-23JAN18-39/55
160GLC Excavator 042318 PN=253
Operational Checkout Procedure Actuate the swing function to swing uphill.
NO: Check swing motor leakage. Perform Swing Motor Leakage Test. (Group 9025-25.)
LOOK: Does upperstructure swing uphill?
NO: Check swing spool in control valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) JJ03229,0001128 -19-23JAN18-40/55
Dig Function Drift Check (loaded bucket)
TX1095487 —UN—28JUN13
Machine Position—Loaded Bucket Fill bucket with material to specification. Specification Loaded Bucket—Weight (approximate)................................................................ 825 kg 1829 lb Position bucket at maximum reach with bucket pivot pin at same height as boom pivot pin. Retract arm cylinder, then extend about 50 mm (2 in). Extend bucket cylinder, then retract about 50 mm (2 in). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Measure distance from bottom of bucket to ground. Compare measurements to specifications. Dig Function Drift Specifications (loaded bucket)—Specification Boom Cylinder—Drift............................................................................................ 10 mm 0.39 in Arm Cylinder—Drift............................................................................................... 20 mm 0.79 in Bucket Cylinder—Drift........................................................................................... 15 mm 0.59 in Bottom Of Bucket-to-Ground—Drift.................................................................... 100 mm 3.94 in
YES: Go to next check.
LOOK: Is cylinder drift within specification?
NO: See Load Drifts Down When Control Lever Is In Neutral Position. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-34
JJ03229,0001128 -19-23JAN18-41/55
160GLC Excavator 042318 PN=254
Operational Checkout Procedure Dig Function Drift Check (empty bucket)
TX1109902 —UN—28JUN13
Machine Position—Empty Bucket Empty bucket of material. Extend arm cylinder, then retract about 50 mm (2 in). Extend bucket cylinder, then retract about 50 mm (2 in). Lower boom until arm tip position above ground is 1 m (40 in). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Measure distance from arm tip to ground. Compare measurements to specifications. Dig Function Drift Specifications (empty bucket)—Specification Boom Cylinder—Drift.............................................................................................. 5 mm 0.20 in Arm Cylinder—Drift............................................................................................... 15 mm 0.59 in Bucket Cylinder—Drift........................................................................................... 10 mm 0.39 in Arm Tip-to-Ground—Drift.................................................................................... 110 mm 4.33 in
YES: Go to next check.
LOOK: Is cylinder drift within specification?
NO: See Load Drifts Down When Control Lever Is In Neutral Position. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-35
JJ03229,0001128 -19-23JAN18-42/55
160GLC Excavator 042318 PN=255
Operational Checkout Procedure Swing Priority Circuit Check
CAUTION: Avoid possible injury. Make sure area is clear and large enough to swing extended arm and bucket. Machine must be on level ground.
TX1095439 —UN—10AUG11
Swing Priority Check
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button IMPORTANT: 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. Position machine as shown. Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press and release power mode button (4) until PWR (power) mode is displayed on monitor. From a running start, operate swing function and record time required for 3 complete revolutions. Divide that time by three to get an average time for 1 revolution. Specification Swing Function—Time (3 revolution)...........................................................12.3—14.3 s Position machine as shown, arm extended, bucket curled, and upperstructure 90 degrees to tracks. Turn engine speed dial (1) to H (fast idle) position. Press and release 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. Continued on next page
TM13345X19 (23APR18)
9005-10-36
JJ03229,0001128 -19-23JAN18-43/55
160GLC Excavator 042318 PN=256
Operational Checkout Procedure Operate swing function and slowly actuate arm in function when upperstructure is in line with tracks. Record time required for 1 complete revolution. NOTE: Swing speed should not slow when actuating arm in.
YES: Go to next check.
LOOK: Does swing speed remain unchanged when actuating arm in?
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.) JJ03229,0001128 -19-23JAN18-44/55
Control Valve Lift Check Test
TX1095449 —UN—28JUN13
Control Valve Lift
1
TX1093762 —UN—28JUN13
Engine Speed Dial 1— Engine Speed Dial Turn engine speed dial (1) to L (slow idle) position. Position machine as shown. Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).
YES: See Load Falls When Control Valve is Actuated To Raise Load. (Group 9025-15.)
LOOK: Do functions move in opposite direction as pilot control levers are first moved, then change direction as levers are moved farther?
NO: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9005-10-37
JJ03229,0001128 -19-23JAN18-45/55
160GLC Excavator 042318 PN=257
Operational Checkout Procedure Travel Speed Selection Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to slow speed (turtle) mode. Actuate travel function to full speed. Turn travel speed switch to fast speed (rabbit) mode. LOOK: Does machine travel speed increase? Actuate a dig function and then return to neutral. LOOK: Does machine travel speed decrease and then increase as dig function is actuated and then released? Turn travel speed switch to slow speed (turtle) mode.
YES: Go to next check.
LOOK: Does machine travel speed decrease?
NO: Check travel pressure sensor (B34) and travel speed switch (S11). See Electrical Component Specifications. (Group 9015-20.) See Travel Motor Speed Circuit Operation. (Group 9025-05.)
Continued on next page
TM13345X19 (23APR18)
9005-10-38
JJ03229,0001128 -19-23JAN18-46/55
160GLC Excavator 042318 PN=258
Operational Checkout Procedure Travel System Tracking Check
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.)
9
TX1120783 —UN—20AUG12
Machine Position 9— Bucket Height Fully extend arm cylinder and bucket cylinder. Position boom so bucket height (9) is approximately 400 mm (16 in) above ground.
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Turn travel speed switch (3) to fast speed (rabbit) mode. Press and release power mode button (4) until PWR (power) mode is displayed on monitor.
Continued on next page
TM13345X19 (23APR18)
9005-10-39
JJ03229,0001128 -19-23JAN18-47/55
160GLC Excavator 042318 PN=259
Operational Checkout Procedure
6
8
7 5
6 TX1120481 —UN—17AUG12
Tracking Check 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. Observe direction of mistrack. Create a straight test line 20 m (66 ft) (7) long between two points on track print (8). Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.
YES: Go to next check.
Repeat procedure in reverse travel.
NO: Check track sag. See Check and Adjust Track Sag. (Operator’s Manual.)
LOOK: Does machine mistrack less than 200 mm (7.87 in)?
NO: Perform Travel Motor Leakage Test or perform Pump Flow Test. (Group 9025-25.)
Continued on next page
TM13345X19 (23APR18)
9005-10-40
JJ03229,0001128 -19-23JAN18-48/55
160GLC Excavator 042318 PN=260
Operational Checkout Procedure Travel System Tracking Checks While Operating a Dig Function
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button NOTE: Machine will slow down during this test. Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to fast speed (rabbit) mode. Operate machine at full speed forward on a flat and level surface. After machine is moving, actuate arm out from neutral to full actuation and extend the arm.
YES: See Machine Mistracks Left During Combined Travel and Dig Functions. (Group 9025-15.)
LOOK: Does machine mistrack excessively when the arm is extended?
NO: Go to next check.
Continued on next page
TM13345X19 (23APR18)
9005-10-41
JJ03229,0001128 -19-23JAN18-49/55
160GLC Excavator 042318 PN=261
Operational Checkout Procedure Travel System Maneuverability Check PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4 TX1086753 —UN—11JAN11
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button Turn engine speed dial (1) to H (fast idle) position. Turn travel speed switch (3) to fast speed (rabbit) mode. Drive machine at full speed forward down a slope. Turn in each direction. LOOK: Does each track slow down in response to pedal or lever movement in order to turn? Repeat the procedure in reverse travel. Turn travel speed switch to fast speed (rabbit) mode. Drive machine at full speed in reverse down a slope. Turn in each direction.
YES: Go to next check.
LOOK: Does each track slow down in response to pedal or lever movement in order to NO: See Function Does turn? Not Stop When Control Lever Released. (Group 9025-15.) Continued on next page
TM13345X19 (23APR18)
9005-10-42
JJ03229,0001128 -19-23JAN18-50/55
160GLC Excavator 042318 PN=262
Operational Checkout Procedure Cycle Times Check CAUTION: Prevent possible injury from unexpected machine movement. Clear all persons from the area before operating machine. NOTE: For accurate cycle time readings, hydraulic oil must be at operating temperature.
PUSH MENU/SET
5
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
min -1
L
1
H
2
A/I A/I ON OFF OFF INT
N O
ON
OFF
ACC
START
3
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
4
TX1136301 —UN—10MAY13
Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch 3— Travel Speed Switch 4— Power Mode Button 5— Monitor Dial Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press and release power mode button (4) until PWR (power) mode is displayed on monitor. Rotate monitor dial (5) to highlight and select Bucket mode from Work Mode menu. See Main Menu—Work Mode. (Operator’s Manual.)
TX1095475 —UN—11AUG11
Boom
TX1095499 —UN—28JUN13
Arm, Bucket, Swing Move machine to position shown for each test. Record cycle time for each function. Continued on next page
TM13345X19 (23APR18)
9005-10-43
JJ03229,0001128 -19-23JAN18-51/55
160GLC Excavator 042318 PN=263
Operational Checkout Procedure Specification Boom Raise (cylinder extend)—Cycle Time.................................................................................................................2.9—3.5 s Boom Lower (cylinder retract)—Cycle Time.................................................................................................................1.9—2.5 s Arm In (cylinder extend)—Cycle Time.............................................................3.5—4.1 s Arm Out (cylinder retract)—Cycle Time...........................................................2.5—3.1 s Bucket Load (cylinder extend)—Cycle Time.................................................................................................................3.1—3.7 s Bucket Dump (cylinder retract)—Cycle Time.................................................................................................................1.9—2.5 s Swing Left or Right, 3 Revolutions From a Running Start—Cycle Time......................................................................12.3—14.3 s Drive 20 m (65 ft) From a Running Start (check in forward and reverse with travel speed switch in FAST position)—Cycle Time.............................................................................................................12.7—15.4 s Drive 20 m (65 ft) From a Running Start (check in forward and reverse with travel speed switch in SLOW position)—Cycle Time.............................................................................................................19.4—23.2 s Track Raised for 3 Revolutions From a Running Start (check in forward and reverse with travel mode switch in FAST position)—Cycle Time..................................................................................14.9—18.9 s Track Raised for 3 Revolutions From a Running Start (check in forward and reverse with travel mode switch in SLOW position)—Cycle Time..................................................................................24.2—28.2 s
YES: Go to next check.
LOOK: Does machine perform within specifications?
NO: See All Hydraulic Functions Slow, see Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal, see Swing Speed Slow During Arm In Function, or see Swing Speed Slow in Both Directions. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9005-10-44
JJ03229,0001128 -19-23JAN18-52/55
160GLC Excavator 042318 PN=264
Operational Checkout Procedure Heater and Air Conditioner Circuit Check PUSH MENU/SET
5
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
L
/VOL /PWR
H PUSH
VOL/PWR
6 min -1
L
H
A/I A/I ON OFF OFF INT
ACC
OFF
N O
ON
START
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086866 —UN—13JAN11
Switch Panel 5— Temperature Control/Mode Switch 6— Blower Speed Switch Start engine and warm to normal operating temperature. Turn temperature control/mode switch (5) clockwise to maximum heat position. FEEL: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position.
YES: Checks complete.
LISTEN: Does air conditioner compressor clutch solenoid “click”?
NO: Heater does not operate. Check air conditioner and heater 20 A fuse (F3) (marked HEATER). See Fuse and Relay Specifications. (Group 9015-10.)
FEEL: Does cool air come from the vents?
NO: Check wiring harnesses. See Cab Harness (W1) Wiring Diagram and see Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
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.
NO: Check system operation. See Heater and Air Conditioner Operational Checks. (Group 9031-25.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in Continued on next page
TM13345X19 (23APR18)
9005-10-45
JJ03229,0001128 -19-23JAN18-53/55
160GLC Excavator 042318 PN=265
Operational Checkout Procedure Heater and Air Conditioner Controls Check (automatic temperature control)
PUSH MENU/SET
PUSH
5
MODE
PUSH
TUNE/AM-FM PUSH
/VOL /PWR
H
L
PUSH
VOL/PWR
6 min -1
L
H
A/I A/I ON OFF OFF INT
ACC
OFF
N O
ON
START
PUSH MODE
1 2 3 4 5
OFF 1 2
6 7 8 9 0
TX1086866 —UN—13JAN11
Switch Panel 50.0 h ECO 10:00 AM
H
E
F
0.00 gal/h
C
9 8
AUTO
24.0˚C
10
FM VOL
CH1
81.3 ST MHz
7 TX1160755 —UN—15MAY14
Monitor—Air Conditioner and Heater Display 5— Temperature Control/Mode Switch 6— Blower Speed Switch 7— Fan Speed 8— AUTO Display 9— Vent Position 10— Temperature Setting Key ON, press blower speed switch (6). Start engine and warm to normal operating temperature. Press blower speed switch. LISTEN: Does air conditioner compressor clutch solenoid “click”? LOOK: Does AUTO display (8), display on monitor? LOOK: Does monitor display vent position (9), fan speed (7), and temperature setting (10)? Turn temperature control/mode switch (5) clockwise to maximum heat position. LOOK: Does vent position change? LOOK: Does temperature setting increase? Continued on next page
TM13345X19 (23APR18)
9005-10-46
JJ03229,0001128 -19-23JAN18-54/55
160GLC Excavator 042318 PN=266
Operational Checkout Procedure FEEL: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position. LOOK: Does vent position change? LOOK: Does temperature setting decrease? FEEL: Does cool air come from the vents? Press blower speed switch. LISTEN: Does air conditioner compressor clutch solenoid “click”? (Air conditioner and heater are ON in manual mode.) LOOK: Does AUTO display go OFF? Turn temperature control/mode switch clockwise to maximum heat position. LOOK: Does vent position change? LOOK: Does temperature setting increase? FEEL: Does warm air come from the vents? Turn temperature control/mode switch counterclockwise to maximum cold position. LOOK: Does vent position change? LOOK: Does temperature setting decrease? FEEL: Does cool air come from the vents? Press temperature control/mode switch. LOOK: Does vent position change? Repeat for all four vent positions. LOOK: Does vent position change each time switch is pressed?
YES: Checks complete.
Press blower speed switch.
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.)
LOOK: Are air conditioner and heater OFF? (Press blower speed switch to start air conditioner and heater.)
NO: Check system operation. See Heater and Air Conditioner Operational Checks. (Group 9031-25.)
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.
NO: Check wiring harnesses. See Cab Harness (W1) Wiring Diagram and see Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb·in
JJ03229,0001128 -19-23JAN18-55/55
TM13345X19 (23APR18)
9005-10-47
160GLC Excavator 042318 PN=267
Operational Checkout Procedure
TM13345X19 (23APR18)
9005-10-48
160GLC Excavator 042318 PN=268
Section 9010 Engine Contents Page
Group 05—Theory of Operation Engine Identification .................................. 9010-05-1 John Deere Engine.................................... 9010-05-1 Engine Fuel System Component Location ................................................. 9010-05-3 Engine Cooling System Component Location ............................. 9010-05-7 Diesel Exhaust Fluid (DEF) System Component Location ........................... 9010-05-14 Cold Weather Starting Aid ....................... 9010-05-17 Engine Speed Control System Operation............................................. 9010-05-18 Group 15—Diagnostic Information John Deere Engine.................................... 9010-15-1 Group 20—Adjustments John Deere Engine.................................... 9010-20-1 Group 25—Tests John Deere Engine.................................... 9010-25-1
TM13345X19 (23APR18)
9010-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9010-2
160GLC Excavator 042318 PN=2
Group 05
Theory of Operation Engine Identification
JOHN DEERE Product Identification Number *1FF160GXJFF055671*
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.
2
EXCAVATOR 160G DEERE & COMPANY, MOLINE, ILLINOIS, USA
Product identification numbers (PINs) are listed on the front covers of excavator manuals. These numbers are used to identify the correct supporting manual for the machine.
1
Product Serial Number Identification
TX1198261 —UN—27JUL15
Choosing the Correct Supporting Manuals
PIN Plate (17-character)
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.
1— PIN Plate
2— 17-Character PIN
JJ03229,0001166 -19-12OCT15-1/2
Engine Model Number Identification
3
4
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.
*PE4045R123456*
The 9-character engine model number corresponds to a specific engine emissions level. Engine Model Number 4045HT077
4045HT077
Engine Emissions Level Final Tier 4
DEERE & COMPANY
MOLINE, ILLINOIS
MADE IN MEXICO
Engine Serial Number Plate
4— 9-Character Engine Model Number
TX1102614A —UN—03DEC11
3— Engine Serial Number Plate
TX1198580 —UN—29JUL15
Engine Serial Number
Engine Emissions Level Identification
Engine Serial Number Plate Location—4045HT077 JJ03229,0001166 -19-12OCT15-2/2
John Deere Engine NOTE: For proper engine identification, see Engine Identification. (Group 9010-05.)
For additional information on John Deere PowerTech™ engines and components for engine model 4045HT077, see the following component technical manual (CTM).
• See 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
PowerTech is a trademark of Deere & Company JJ03229,0001167 -19-07JUN16-1/1
TM13345X19 (23APR18)
9010-05-1
160GLC Excavator 042318 PN=271
Theory of Operation
TM13345X19 (23APR18)
9010-05-2
160GLC Excavator 042318 PN=272
Theory of Operation
Engine Fuel System Component Location TX1251536 —UN—31JAN18
Y1
Y2
Y3
Y4
14 14 17
16
18
15
11
19
21 8
Y5002
20 B5113
Y5501 22
14 12
11
7
5
1 3
4 B5209
B5107
B5600
13
2
10
B18 8 9
TX1251536 Engine Fuel System Component Location Continued on next page
TM13345X19 (23APR18)
9010-05-3
160GLC Excavator 042318 PN=273
DB95148,0002351 -19-01FEB18-1/2
Theory of Operation
TM13345X19 (23APR18)
9010-05-4
160GLC Excavator 042318 PN=274
Theory of Operation 1— Fuel Tank 2— Fuel Tank Drain Hose 3— Primary Fuel Filter and Water Separator 4— Final Fuel Filter 5— Primary Fuel Filter and Water Separator-to-Final Fuel Filter Line 7— Fuel Cooler 8— Fuel Pump-to-Fuel Cooler Hose 9— Fuel Cooler-to-Fuel Tank Hose 10— Fuel Tank-to-Primary Fuel Filter and Water Separator Hose 11— Fuel Inlet Manifold-to-Fuel Pump Line
Y1— Electronic Injector 1 12— Fuel Inlet Manifold 19— High-Pressure Common (cylinder 1) 13— Final Fuel Filter-to-Fuel Inlet Rail-to-Electronic Injector 4 Y2— Electronic Injector 2 Manifold Hose (cylinder 4) Line (cylinder 2) 14— Fuel Pump and 20— High-Pressure Common Rail High-Pressure Common 21— Fuel Pump-to-High-Pressure Y3— Electronic Injector 3 (cylinder 3) Rail-to-Fuel Pump Line Common Rail Line Y4— Electronic Injector 4 15— Fuel Pump 22— Fuel Shutoff Valve (if (cylinder 4) 16— High-Pressure Common equipped) Y5002—Suction Control Valve Rail-to-Electronic Injector 1 B18— Fuel Level Sensor (SCR) (cylinder 1) Line B5107—Inlet Fuel Pressure Y5501—Fuel Transfer Pump 17— High-Pressure Common Sensor Rail-to-Electronic Injector 2 B5113—Fuel Rail Pressure (cylinder 2) Line Sensor 18— High-Pressure Common B5209—Fuel Temperature Sensor Rail-to-Electronic Injector 3 B5600—Water-in-Fuel (WIF) (cylinder 3) Line Sensor
DB95148,0002351 -19-01FEB18-2/2
TM13345X19 (23APR18)
9010-05-5
160GLC Excavator 042318 PN=275
Theory of Operation
TM13345X19 (23APR18)
9010-05-6
160GLC Excavator 042318 PN=276
Theory of Operation
Engine Cooling System Component Location Engine Cooling System Component Location (S.N. —056599) TX1231003 —UN—20DEC16
5 1
Y5020
3
3 2
9 13 8 11
3
4
18
6
2
7 17
5
14 18 16 9 10
8
1
10
20 A5507 9
Y5019
TX1231003 Engine Cooling System Component Location (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9010-05-7
160GLC Excavator 042318 PN=277
JL58967,0000737 -19-19DEC16-1/4
Theory of Operation
TM13345X19 (23APR18)
9010-05-8
160GLC Excavator 042318 PN=278
Theory of Operation 1— Radiator 2— Thermostat Housing Outlet-to-Radiator Hose 3— Deaeration Hose (2 used) 4— Exhaust Gas Recirculation (EGR) Actuator Valve 5— Surge Tank 6— Surge Tank-to-Coolant Pump Hose 7— Exhaust Gas Recirculation (EGR) Cooler
8— Diesel Exhaust Fluid (DEF) Coolant Supply Hose 9— Diesel Exhaust Fluid (DEF) Coolant Return Hose 10— Radiator-to-Coolant Pump Inlet Hose 11— Exhaust Gas Recirculation (EGR) Cooler Coolant Return Tube 13— Thermostat Housing
14— Coolant Pump 16— Exhaust Gas Recirculation (EGR) Actuator Valve-to-Engine Block Line 17— Thermostat Housing-toExhaust Gas Recirculation (EGR) Actuator Valve Line 18— Coolant Pump-toThermostat Housing Line (2 used)
Continued on next page
TM13345X19 (23APR18)
9010-05-9
20— Coolant Filter A5507—Diesel Exhaust Fluid (DEF) Tank Header Assembly Y5019—Diesel Exhaust Fluid (DEF) Coolant Control Valve Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector
JL58967,0000737 -19-19DEC16-2/4
160GLC Excavator 042318 PN=279
Theory of Operation
TM13345X19 (23APR18)
9010-05-10
160GLC Excavator 042318 PN=280
Theory of Operation
Engine Cooling System Component Location (S.N. 056600— ) TX1229663 —UN—20DEC16
5 1
Y5020
3
3 2
9 13 8 11
3
4
18
6
2
7 17
5
14 18 16 9 10
8
1
10
8 9
Y5019
9
A5507B
TX1229663 Engine Cooling System Component Location (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
9010-05-11
160GLC Excavator 042318 PN=281
JL58967,0000737 -19-19DEC16-3/4
Theory of Operation
TM13345X19 (23APR18)
9010-05-12
160GLC Excavator 042318 PN=282
Theory of Operation 1— Radiator 2— Thermostat Housing Outlet-to-Radiator Hose 3— Deaeration Hose (2 used) 4— Exhaust Gas Recirculation (EGR) Actuator Valve 5— Surge Tank 6— Surge Tank-to-Coolant Pump Hose 7— Exhaust Gas Recirculation (EGR) Cooler
8— Diesel Exhaust Fluid (DEF) Tank Heater Supply Hose 9— Diesel Exhaust Fluid (DEF) Tank Heater Return Hose 10— Radiator-to-Coolant Pump Inlet Hose 11— Exhaust Gas Recirculation (EGR) Cooler Coolant Return Tube
13— Thermostat Housing A5507B—Diesel Exhaust Fluid 14— Coolant Pump (DEF) Tank Header B 16— Exhaust Gas Recirculation Y5019—Coolant Control Valve (EGR) Actuator Y5020—Diesel Exhaust Fluid Valve-to-Engine Block Line (DEF) Dosing Injector 17— Thermostat Housing-toExhaust Gas Recirculation (EGR) Actuator Valve Line 18— Coolant Pump-toThermostat Housing Line (2 used) JL58967,0000737 -19-19DEC16-4/4
TM13345X19 (23APR18)
9010-05-13
160GLC Excavator 042318 PN=283
Theory of Operation
Diesel Exhaust Fluid (DEF) System Component Location Diesel Exhaust Fluid (DEF) System Component Location (S.N. —056599)
3 4
5
A5507 2
4 1 5
B5501
6
Y5020 1
A5507
1
2 TX1200577
TX1200577 —UN—01OCT15
3
Diesel Exhaust Fluid (DEF) System Component Location (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9010-05-14
JL58967,0000738 -19-16DEC16-1/4
160GLC Excavator 042318 PN=284
Theory of Operation 1— Diesel Exhaust Fluid (DEF) Injector Pressure Line 2— Diesel Exhaust Fluid (DEF) Tank 3— Diesel Exhaust Fluid (DEF) Tank Breather Filter
4— Diesel Exhaust Fluid (DEF) Dosing Unit Supply Line 5— Diesel Exhaust Fluid (DEF) Dosing Unit Return Line 6— Diesel Exhaust Fluid (DEF) Decomposition Tube
A5507—Diesel Exhaust Fluid (DEF) Tank Header Assembly B5501—Diesel Exhaust Fluid (DEF) Dosing Unit Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector Continued on next page
TM13345X19 (23APR18)
9010-05-15
JL58967,0000738 -19-16DEC16-2/4
160GLC Excavator 042318 PN=285
Theory of Operation Diesel Exhaust Fluid (DEF) System Component Location (S.N. 056600— )
3 5 4
A5507B 2
4 1 5
B5501
6
Y5020 1
A5507B
1
2 TX1229809
TX1229809 —UN—01DEC16
3
Diesel Exhaust Fluid (DEF) System Component Location (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
9010-05-16
JL58967,0000738 -19-16DEC16-3/4
160GLC Excavator 042318 PN=286
Theory of Operation 1— Diesel Exhaust Fluid (DEF) Injector Pressure Line 2— Diesel Exhaust Fluid (DEF) Tank 3— Diesel Exhaust Fluid (DEF) Tank Breather Filter
4— Diesel Exhaust Fluid (DEF) Dosing Unit Supply Line 5— Diesel Exhaust Fluid (DEF) Dosing Unit Return Line 6— Diesel Exhaust Fluid (DEF) Decomposition Tube
A5507B—Diesel Exhaust Fluid (DEF) Tank Header B B5501—Diesel Exhaust Fluid (DEF) Dosing Unit Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector JL58967,0000738 -19-16DEC16-4/4
Cold Weather Starting Aid Glow plugs provide three possible stages of cold start aid: preheat, run-up heat, and reheat. If engine control unit (ECU) determines charge air cooler outlet temperature is below a predetermined setpoint (see table below), ECU sends current to glow plug relay, energizing the relay. With relay energized, glow plugs heat the air in the combustion chamber for the duration indicated in the following glow plugs preheat time table. The operator may start engine at any time during preheat; however, the ECU will de-energize the glow plug relay during cranking.
Run-up heat time is dependent on how long engine takes to increase speed from 10 rpm to 800—1000 rpm. The maximum run-up heat time allowed is 60 seconds. If preheat time is 0, then run-up heat is not performed. After engine has started and reached 800—1000 rpm, the ECU will determine if a reheat period is necessary using charge air cooler outlet temperature and comparing the results to glow plugs reheat time table below. If preheat time is 0, then reheat is not performed. For more information concerning cold weather starting aid, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
GLOW PLUGS PREHEAT TIME
GLOW PLUGS REHEAT TIME
Charge Air Cooler Outlet Temperature
Preheat Time
Charge Air Cooler Outlet Temperature
Reheat Time
-25°C (-13°F)
25 sec.*
-15°C (5°F)
12 sec.
-15°C (5°F)
25 sec.*
-10°C (14°F)
12 sec.
-10°C (14°F)
15 sec.*
-5°C (23°F)
12 sec.
-5°C (23°F)
5 sec.*
0°C (32°F)
12 sec.
0°C (32°F)
5 sec.*
5°C (41°F)
12 sec.
5°C (41°F)
2 sec.*
8°C (46°F)
0 sec.
8°C (46°F)
0 sec.*
*Add 10 seconds to allow operator to notice lamp turned off and then crank. JJ03229,0000ED6 -19-23APR15-1/1
TM13345X19 (23APR18)
9010-05-17
160GLC Excavator 042318 PN=287
Theory of Operation
Engine Speed Control System Operation Engine Speeds Engine Speed Dial Setting
Pilot Shutoff Lever Position
Auto-Idle
Coolant Temperature
Hydraulic Oil Temperature
Control Lever Setting
ECO Control Enabled/Disabled
Load
Revolutions Per Minute (rpm)
Slow Idle
Lock
-
> 50°C > 122°F
> 0°C > 32°F
-
-
-
850—950
Slow Idle
Unlock
-
> 50°C > 122°F
> 0°C > 32°F
Neutral
-
No Load
850—950
Fast Idle
Unlock
ON
> 50°C > 122°F
> 0°C > 32°F
Neutral
-
No Load
1150—1250
Auto Warm-Up Slow Idle
Lock
OFF
-
< 0°C < 32°F
-
-
-
1300—1500
Slow Idle
Lock
OFF
25—50°C 77—122°F
> 0°C > 32°F
-
-
-
1150—1250
Slow Idle
Lock
OFF
< 25°C < 77°F
> 0°C > 32°F
-
-
-
1350—1450
-
-
-
2150—2250
Neutral
-
No Load
Fast Idle Speed in Corresponding Mode
Heater Control Enabled (all power modes) Fast Idle
Fast Idle
Lock
Unlock
OFF
< 5°C < 41°F
-
OFF
< 5°C < 41°F
-
H/P (high power) Mode Fast Idle
Unlock
OFF
-
Fast Idle
Unlock
OFF
-
-
Boom Up, Arm In, or Boom Up and Arm In
-
Over Relief
2150—2250
-
Fast Travel
-
Over Relief
2150—2250
PWR (power) Mode Fast Idle
Unlock
OFF
-
-
Neutral
Enabled
No Load
1850—1950
Fast Idle
Unlock
OFF
-
-
Neutral
Disabled
No Load
1950—2050
Fast Idle
Unlock
OFF
-
-
Fast Travel
-
Over Relief
2150—2250
Neutral
-
No Load
1800—1900
ECO (economy) Mode -
-
Fast Idle
Unlock
OFF
Slow Idle
Lock
OFF
Manual Regeneration Engine Speed -
-
-
1750—1850
OFF
Auto Regeneration Engine Speed -
-
-
1150—1250
Slow Idle
-
Continued on next page
TM13345X19 (23APR18)
9010-05-18
JF80813,0000212 -19-17OCT17-1/7
160GLC Excavator 042318 PN=288
Theory of Operation The engine speed is controlled by the following items: • Engine speed dial (1) • Power mode - H/P (high power) - PWR (power) - ECO (economy) • Work mode • Travel HP (high power) mode control • Heater control • Auto-idle control • Auto warm-up control • Engine coolant temperature management • Idle speed-up control • ECO control • Cold fluid component protection (CFCP) system
PUSH MENU/SET
PUSH
MODE
PUSH
TUNE/AM-FM PUSH
/AUTO /OFF
H
L
PUSH
VOL/PWR
min -1
1
H
2
A/I A/I ON OFF OFF INT
ACC N O
ON
OFF
3
START
Engine Speed Dial
TX1131978 —UN—28JUN13
L
PUSH MODE
1 2 3 4 5
The purpose of the engine speed dial is to control the engine speed via operator input.
OFF 1 2
6 7 8 9 0
The main controller (MCZ) uses input signals from the engine speed dial, hydraulic pressure sensors, and temperature sensors to determine appropriate engine speed. The main controller then sends a signal via controller area network (CAN) to the engine control unit (ECU). The ECU then sets engine rpm.
4 Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch
3— Travel Mode Switch 4— Power Mode Button
H/P (High Power) Mode The purpose of H/P mode is to increase engine speed using certain hydraulic functions. The main controller sends a signal to the ECU via CAN to raise engine rpm when the following conditions are met:
• Power mode: H/P. • Work mode: Bucket. • Engine speed dial set to fast idle. • Arm in, boom up, or a combination of both functions
The main controller uses input signals from the travel pressure sensor, engine speed dial, travel mode switch (3), and delivery pressure sensors to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to increase engine speed when the following conditions are met:
• Engine speed dial set to fast idle. • Travel mode switch is at fast (rabbit) speed position. • Travel pressure sensor is on. • Either pump 1 or pump 2 delivery pressure sensor must
actuated.
• Pump delivery pressure high.
indicate high pressure.
PWR (Power) Mode
Heater Control
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.
NOTE: Heater control engine mode is independent of heating and air conditioning system operation. Operation of heating and air conditioning system will not change engine speeds.
ECO (Economy) Mode 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 (4), and pump delivery pressure sensors, and then sends a signal via CAN to the ECU to reduce engine rpm when the following conditions are met:
• Engine speed dial set to greater than ECO mode speed. • Power mode: ECO. Travel HP (High Power) Mode Control The purpose of travel HP mode control is to increase engine speed for faster travel.
The purpose of the heater control selection is to accelerate the warm-up speed of the cab heater by increasing the engine speed at low engine coolant temperature. The main controller sends a signal via CAN to the ECU to increase the engine rpm when the following conditions are met:
• Engine speed dial set to fast idle. • Engine coolant temperature is 5°C (41°F) or lower. • Pilot shutoff lever in the locked (UP) position. Heater control selection is activated when the key switch is turned ON and is deactivated if any other engine speed controls are activated.
Continued on next page
TM13345X19 (23APR18)
9010-05-19
JF80813,0000212 -19-17OCT17-2/7
160GLC Excavator 042318 PN=289
Theory of Operation
Heater control selection can be activated or deactivated in the monitor or MPDr. See Machine Setting. (Group 9015-16.) Also, see Heater Control Disable and Enable. (Group 9015-20.)
until the engine coolant temperature rises above 50°C (122°F). 4. Only after the engine coolant temperature has risen above 50°C (122°F) will the warm-up circuit deactivate and engine run at user-selected idle speed.
Auto-Idle Control
Engine Coolant Temperature Management
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 functions are actuated.
NOTE: If engine coolant temperature management (ECTM) is unable to achieve desired coolant temperature after 80 minutes, exhaust temperature management (ETM) will not activate. Key cycle is required to reset ECTM and ETM.
The main controller uses input signals from hydraulic pressure sensors, 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.
The main controller sends a signal via CAN to the ECU to adjust engine rpm according to the following conditions:
Auto-idle is activated when the following conditions are met:
• Auto-idle switch (2) in the auto-idle ON position. • No functions activated for approximately 4 seconds. • Engine speed is greater than auto-idle speed. Auto-idle control is deactivated when the following conditions are met:
• Auto-idle switch turned to OFF position. • A hydraulic function is actuated. • Power mode button is pressed from ECO to PWR, PWR to H/P, or H/P to ECO.
• Engine speed dial is turned to change engine speed. When auto-idle is deactivated, the engine rpm increases to the setting of the engine speed dial. Auto Warm-Up Control The purpose of auto warm-up control is to increase engine coolant and hydraulic oil temperatures to proper operating temperatures. Warm-up is achieved by increasing engine speed. The main controller determines 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) will the main controller send a signal to the ECU to run the engine between 1300—1500 rpm until the hydraulic oil temperature rises 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 rises 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
1. Only when coolant temperature is below 60°C (140°F) will the main controller send a signal to the ECU to run engine at 1200 rpm for up to 20 minutes or until engine coolant reaches 60°C (140°F). 2. Only when coolant temperature is below 60°C (140°F) will the main controller send a signal to the ECU to run engine at 1400 rpm for up to 20 minutes (after the engine has already ran for 20 minutes at 1200 rpm) or until engine coolant reaches 60°C (140°F). 3. Only when coolant temperature is below 60°C (140°F) will the main controller send a signal to the ECU to run engine at 1600 rpm for up to 40 minutes (after the engine has already ran for 20 minutes at 1200 rpm and 20 minutes at 1400 rpm or until engine coolant reaches 60°C (140°F). 4. Only after the engine coolant temperature has risen above 60°C (140°F) will the warm-up control deactivate and engine run at user-selected idle speed. Idle Speed-Up Control The purpose of the idle speed-up control is to increase the engine rpm when a function is actuated at slow idle. The main controller uses these input signals from the travel pressure sensor, front attachment pressure sensor, and engine speed dial to determine appropriate engine speed. The main controller then sends a signal via CAN to the ECU to increase the engine rpm. Idle speed-up is activated when the following conditions are met:
• Engine speed set to slow idle. • Function is actuated. ECO Control The purpose of ECO control is to reduce engine speed from fast idle in order to reduce fuel consumption and noise level. Fast idle engine speed will be reduced immediately after no functions are active. Main controller sends a signal to the ECU using CAN communication after functions are set to neutral. When any hydraulic function is actuated, engine speed will increase. ECO control, in addition to auto-idle, is a function to reduce engine speed. ECO control can be enabled and disabled through MPDr.
Continued on next page
TM13345X19 (23APR18)
9010-05-20
JF80813,0000212 -19-17OCT17-3/7
160GLC Excavator 042318 PN=290
Theory of Operation
TX1241579 —UN—11JUL17
Cold Fluid Component Protection (CFCP) CFCP protects components from damage by allowing engine coolant and hydraulic oil time to warm up in low temperatures if engine speed dial is set to high during start-up.
CFCP Icon
After start-up, CFCP icon on the monitor will illuminate until hydraulic oil temperature and engine coolant temperature conditions have been met. Required conditions are shown below: JF80813,0000212 -19-17OCT17-4/7
Engine Coolant Temperature Less Than 3°C (37°F) and Hydraulic Oil Temperature Less Than 0°C (32°F)
3
FAST IDLE
1
TX1241947 —UN—20JUL17
ENGINE SPEED
4
1200
SLOW IDLE 0
15 2 TIME (seconds)
300
TX1241947 Engine Coolant Temperature (less than 3°C [37°F]) and Hydraulic Oil Temperature (less than 0°C [32°F]) 1— Engine Speed
3— Fast Idle 4— Slow Idle
2— Time (seconds)
Machine will operate at slow idle (4) for 15 seconds, and then increase to 1200 rpm. When engine coolant temperature is greater than 3°C (37°F) and hydraulic
oil temperature is greater than 0°C (32°F) or after 300 seconds, machine will operate at engine speed dial setting. Continued on next page
TM13345X19 (23APR18)
9010-05-21
JF80813,0000212 -19-17OCT17-5/7
160GLC Excavator 042318 PN=291
Theory of Operation
Engine Coolant Temperature Less Than 3°C (37°F) and Hydraulic Oil Temperature Greater Than 0°C (32°F)
3
FAST IDLE
1
TX1241948 —UN—20JUL17
ENGINE SPEED
4
1200
SLOW IDLE 0
15 2 TIME (seconds)
300
TX1241948 Engine Coolant Temperature (less than 3°C [37°F]) and Hydraulic Oil Temperature (greater than 0°C [32°F]) 1— Engine Speed
3— Fast Idle 4— Slow Idle
2— Time (seconds)
Machine will operate at slow idle (4) for 15 seconds. Machine will then operate at engine speed dial setting. JF80813,0000212 -19-17OCT17-6/7
Engine Coolant Temperature Greater Than 3°C (37°F) and Hydraulic Oil Temperature Less Than 0°C (32°F)
3
FAST IDLE
1
TX1241950 —UN—20JUL17
ENGINE SPEED
4
1200
SLOW IDLE 15 2 TIME (seconds)
300
TX1241950 Engine Coolant Temperature (greater than 3°C [37°F]) and Hydraulic Oil Temperature (less than 0°C [32°F]) 1— Engine Speed
3— Fast Idle 4— Slow Idle
2— Time (seconds)
Machine will operate at 1200 rpm. When hydraulic oil temperature is greater than 0°C (32°F) or after 300 seconds, machine will operate at engine speed dial setting. JF80813,0000212 -19-17OCT17-7/7
TM13345X19 (23APR18)
9010-05-22
160GLC Excavator 042318 PN=292
Group 15
Diagnostic Information John Deere Engine
• See 4045 PowerTech™ OEM Diesel Engines (Final Tier
NOTE: For proper engine identification, see Engine Identification. (Group 9010-05.)
4/Stage IV Platform). (CTM120119.)
For additional information on John Deere PowerTech™ engines and components for engine model 4045HT077, see the following component technical manual (CTM). PowerTech is a trademark of Deere & Company DF89619,00B685B -19-08NOV17-1/1
TM13345X19 (23APR18)
9010-15-1
160GLC Excavator 042318 PN=293
Diagnostic Information
TM13345X19 (23APR18)
9010-15-2
160GLC Excavator 042318 PN=294
Group 20
Adjustments John Deere Engine
• See 4045 PowerTech™ OEM Diesel Engines (Final Tier
NOTE: For proper engine identification, see Engine Identification. (Group 9010-05.)
4/Stage IV Platform). (CTM120119.)
For additional information on John Deere PowerTech™ engines and components for engine model 4045HT077, see the following component technical manual (CTM). PowerTech is a trademark of Deere & Company DF89619,00B685C -19-08NOV17-1/1
TM13345X19 (23APR18)
9010-20-1
160GLC Excavator 042318 PN=295
Adjustments
TM13345X19 (23APR18)
9010-20-2
160GLC Excavator 042318 PN=296
Group 25
Tests John Deere Engine
• See 4045 PowerTech™ OEM Diesel Engines (Final Tier
NOTE: For proper engine identification, see Engine Identification. (Group 9010-05.)
4/Stage IV Platform). (CTM120119.)
For additional information on John Deere PowerTech™ engines and components for engine model 4045HT077, see the following component technical manual (CTM). PowerTech is a trademark of Deere & Company DF89619,00B685D -19-08NOV17-1/1
TM13345X19 (23APR18)
9010-25-1
160GLC Excavator 042318 PN=297
Tests
TM13345X19 (23APR18)
9010-25-2
160GLC Excavator 042318 PN=298
Section 9015 Electrical System Contents Page Page
Group 05—System Information Electrical Diagram Information .................. 9015-05-1 Group 10—System Diagrams Explanation of Wire Markings.................... 9015-10-1 Fuse and Relay Specifications .................. 9015-10-1 System Functional Schematic, Component Location, and Wiring Diagram Master Legend ........................ 9015-10-5 System Functional Schematic ................. 9015-10-13 Cab Harness (W1) Component Location ............................................... 9015-10-79 Cab Harness (W1) Wiring Diagram ............................................... 9015-10-87 Machine Harness (W2) Component Location ............................................. 9015-10-119 Machine Harness (W2) Wiring Diagram ............................................. 9015-10-123 Monitor Harness (W3) Component Location ............................................. 9015-10-140 Monitor Harness (W3) Wiring Diagram ............................................. 9015-10-142 Engine Harness (W4) Component Location ............................................. 9015-10-145 Engine Harness (W4) Wiring Diagram ............................................. 9015-10-148 Engine Interface Harness (W5) Component Location ......................... 9015-10-153 Engine Interface Harness (W5) Wiring Diagram.................................. 9015-10-161 Front Engine Harness (W7) Component Location ......................... 9015-10-181 Front Engine Harness (W7) Wiring Diagram ............................................. 9015-10-185 Pump Harness (W8) Component Location ............................................. 9015-10-189 Pump Harness (W8) Wiring Diagram ............................................. 9015-10-193 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location ......................... 9015-10-195 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram ............................................. 9015-10-195 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Component Location ......................... 9015-10-195 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram.................................. 9015-10-196 Pilot Shutoff Switch Harness (W11) Component Location ......................... 9015-10-197
Pilot Shutoff Switch Harness (W11) Wiring Diagram.................................. 9015-10-199 Heated Air Seat Harness (W14) Component Location ......................... 9015-10-202 Heated Air Seat Harness (W14) Wiring Diagram.................................. 9015-10-203 Multi-Function Pilot Control Lever Harness (W15) Component Location ............................................. 9015-10-204 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram.......... 9015-10-207 Travel Alarm Cancel Switch Harness (W16) Component Location ............................................. 9015-10-209 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram.......... 9015-10-209 Attachment Harness (W17) Component Location ......................... 9015-10-210 Attachment Harness (W17) Wiring Diagram ............................................. 9015-10-213 Rear Camera Harness (W19) Component Location ......................... 9015-10-215 Rear Camera Harness (W19) Wiring Diagram.................................. 9015-10-216 Pilot Shutoff Valve Harness (W21) Component Location ......................... 9015-10-217 Pilot Shutoff Valve Harness (W21) Wiring Diagram.................................. 9015-10-218 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location ............................................. 9015-10-218 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram.......... 9015-10-219 Reversing Fan Switch Harness (W23) Component Location............... 9015-10-219 Reversing Fan Switch Harness (W23) Wiring Diagram ....................... 9015-10-220 Seat Heater Switch Harness (W24) Component Location ......................... 9015-10-220 Seat Heater Switch Harness (W24) Wiring Diagram.................................. 9015-10-221 Attachment Interface Harness (W25) Component Location—If Equipped ........................................... 9015-10-222 Attachment Interface Harness (W25) Wiring Diagram—If Equipped ........................................... 9015-10-223 Travel Alarm Harness (W26) Component Location ......................... 9015-10-224 Travel Alarm Harness (W26) Wiring Diagram ............................................. 9015-10-225 Continued on next page
TM13345X19 (23APR18)
9015-1
160GLC Excavator 042318 PN=1
Contents
Page
Page
Starter Switch Harness (W29) Component Location ......................... 9015-10-225 Starter Switch Harness (W29) Wiring Diagram.................................. 9015-10-226 2-Speed Harness (W32) Component Location ......................... 9015-10-226 2-Speed Harness (W32) Wiring Diagram ............................................. 9015-10-228 Fuel Injector Harness (W38) Component Location ......................... 9015-10-229 Fuel Injector Harness (W38) Wiring Diagram ............................................. 9015-10-231 Glow Plug Harness (W40) Component Location ......................... 9015-10-235 Glow Plug Harness (W40) Wiring Diagram ............................................. 9015-10-238 Heater and Air Conditioner Harness (W41) Component Location............... 9015-10-239 Heater and Air Conditioner Harness (W41) Wiring Diagram ....................... 9015-10-241 Cab Roof Light Harness (W44) Component Location ......................... 9015-10-243 Cab Roof Light Harness (W44) Wiring Diagram.................................. 9015-10-244 Cab Roof Light Jumper Harness (W45) Component Location............... 9015-10-244 Cab Roof Light Jumper Harness (W45) Wiring Diagram ....................... 9015-10-245 Cab Roof Light 1 Relay Harness (W46) Component Location............... 9015-10-245 Cab Roof Light 1 Relay Harness (W46) Wiring Diagram ....................... 9015-10-246 Cab Roof Light 2 Relay Harness (W47) Component Location............... 9015-10-246 Cab Roof Light 2 Relay Harness (W47) Wiring Diagram ....................... 9015-10-247 Heater and Air Conditioner Relay Harness (W51) Component Location ............................................. 9015-10-248 Heater and Air Conditioner Relay Harness (W51) Wiring Diagram.......... 9015-10-250 Exhaust Aftertreatment Harness (W53) Component Location............... 9015-10-253 Exhaust Aftertreatment Harness (W53) Wiring Diagram ....................... 9015-10-256 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location ............................................. 9015-10-261 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram.......... 9015-10-269 Fan Harness (W57) Component Location ............................................. 9015-10-277 Fan Harness (W57) Wiring Diagram ............................................. 9015-10-280 Engine Light Harness (W58) Component Location ......................... 9015-10-283 Engine Light Harness (W58) Wiring Diagram ............................................. 9015-10-283
Auxiliary Solenoid Harness (W61) Component Location ......................... 9015-10-285 Auxiliary Solenoid Harness (W61) Wiring Diagram.................................. 9015-10-286 Diesel Particulate Filter (DPF) Harness (W62) Component Location ............................................. 9015-10-288 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram.......... 9015-10-290 Auxiliary Function Lever (AFL) Harness (W75) Component Location ............................................. 9015-10-294 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram.......... 9015-10-297 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location ......................... 9015-10-301 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram ............................................. 9015-10-304 USB Harness (W82) Component Location ............................................. 9015-10-305 USB Harness (W82) Wiring Diagram ............................................. 9015-10-305 USB Jumper Harness (W83) Component Location ......................... 9015-10-305 USB Jumper Harness (W83) Wiring Diagram ............................................. 9015-10-306 Rear Cab Light Switch Harness (W84) Component Location............... 9015-10-307 Rear Cab Light Switch Harness (W84) Wiring Diagram ....................... 9015-10-308 Rear Cab Light Relay Harness (W85) Component Location............... 9015-10-308 Rear Cab Light Relay Harness (W85) Wiring Diagram ....................... 9015-10-309 Rear Cab Light Harness (W86) Component Location ......................... 9015-10-309 Rear Cab Light Harness (W86) Wiring Diagram.................................. 9015-10-310 Premium Seat Harness (W87) Component Location ......................... 9015-10-311 Premium Seat Harness (W87) Wiring Diagram.................................. 9015-10-313 Satellite (SAT) Harness (W6003) Component Location ......................... 9015-10-315 Satellite (SAT) Harness (W6003) Wiring Diagram.................................. 9015-10-315 Group 15—Sub-System Diagnostics Controller Area Network (CAN) Theory of Operation............................... 9015-15-1 Starting and Charging Circuit Theory of Operation............................... 9015-15-9 Monitor Controller (DSZ) Circuit Theory of Operation............................. 9015-15-19 Engine Control Unit (ECU) Circuit Theory of Operation............................. 9015-15-29 Continued on next page
TM13345X19 (23APR18)
9015-2
160GLC Excavator 042318 PN=2
Contents
Page
Exhaust Aftertreatment Circuit Theory of Operation............................. 9015-15-64 Main Controller (MCZ) Circuit Theory of Operation............................. 9015-15-79 Machine Controller (BCZ) Circuit Theory of Operation............................. 9015-15-95 Windshield Wiper and Washer Circuit Theory of Operation ................. 9015-15-97 Lighting Circuit Theory of Operation........................................... 9015-15-101 Travel Alarm Circuit Theory of Operation........................................... 9015-15-110 Pilot Shutoff Circuit Theory of Operation........................................... 9015-15-113 Attachment Control Circuit Theory of Operation....................................... 9015-15-116 Group 16—Monitor Operation Service Menu............................................. 9015-16-1 Troubleshooting......................................... 9015-16-1 Monitoring.................................................. 9015-16-2 Controller Version ...................................... 9015-16-5 Issued Warning Record ............................. 9015-16-5 Operation................................................... 9015-16-6 Machine Setting......................................... 9015-16-7 Monitor Setting ........................................ 9015-16-11 Alarm Setting ........................................... 9015-16-13 Exhaust Filter No. .................................... 9015-16-13 Group 20—References Reading Diagnostic Trouble Codes with Monitor Display .............................. 9015-20-1 Service ADVISOR™ Diagnostic Application ............................................. 9015-20-1 Service ADVISOR™ Connection Procedure .............................................. 9015-20-2 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................... 9015-20-3 MPDr Application....................................... 9015-20-5 MPDr Connection Procedure..................... 9015-20-6 Controller Area Network (CAN) Circuit Test............................................. 9015-20-7 Controller Area Network (CAN) Diagnostics .........................................9015-20-10 Electrical Component Specifications ...................................... 9015-20-17 Alternator Test ......................................... 9015-20-20 Electrical Component Checks ................. 9015-20-21 Component Checks .................................9015-20-17 Battery Remove and Install ..................... 9015-20-30 Rear Cover Remove and Install .............. 9015-20-32 Main Controller (MCZ) Remove and Install ............................................ 9015-20-34 Monitor Controller (DSZ) Remove and Install ............................................ 9015-20-35 Heater Control Disable and Enable ................................................. 9015-20-35
TM13345X19 (23APR18)
9015-3
160GLC Excavator 042318 PN=3
Contents
TM13345X19 (23APR18)
9015-4
160GLC Excavator 042318 PN=4
Group 05
System Information Electrical Diagram Information
Explanation of Wire Markings System Functional Schematic Diagram
TX1077066 —UN—02FEB11
NOTE: All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in the OFF position.
Continued on next page
TM13345X19 (23APR18)
9015-05-1
DS35042,0000040 -19-04JAN11-1/8
160GLC Excavator 042318 PN=303
System Information
System Functional Schematic Example 1— Continuity Chart 2— Power Wires 3— Routing Location Information 4— Wire Identification 5— Ground Wires 7— Section Number
8— Component Name 9— Component Identification Number 10— Component Schematic Symbol 11— Connector Identification Number 12— Connector
13— Connector Pin Information F21— Battery Power 40 Amp Fusible Link F22— Alternator Power 60 Amp Fusible Link G1—Battery
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.
Continued on next page
TM13345X19 (23APR18)
G2—Battery K14— Battery Relay S1— Key Switch W5—Battery To Frame Ground W6—Engine To Frame Ground
9015-05-2
DS35042,0000040 -19-04JAN11-2/8
160GLC Excavator 042318 PN=304
System Information
TX1001167 —UN—02FEB11
Wiring Diagram
Wiring Diagram Example
Continued on next page
TM13345X19 (23APR18)
9015-05-3
DS35042,0000040 -19-04JAN11-3/8
160GLC Excavator 042318 PN=305
System Information 1— Wire Number 2— Wire End #1 Termination Location 3— Wire Color 4— Wire End #2 Termination Location
5— Wiring Diagram Wire Legend 6— Component Identification Number 7— Connector End View
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.
8— Wire Number 9— Connector Pin Number 10— Connector Pin Number 11— Wire Number 12— Wire Color
13— Wire Termination Location 14— Wire Harness
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.
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). Continued on next page
TM13345X19 (23APR18)
9015-05-4
DS35042,0000040 -19-04JAN11-4/8
160GLC Excavator 042318 PN=306
System Information
T195714 —UN—30OCT03
Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-05-5
DS35042,0000040 -19-04JAN11-5/8
160GLC Excavator 042318 PN=307
System Information 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
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.
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.
Component Location Diagram
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.
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.
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.
Connector End View Diagram
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.
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.
Continued on next page
TM13345X19 (23APR18)
9015-05-6
DS35042,0000040 -19-04JAN11-6/8
160GLC Excavator 042318 PN=308
System Information
Electrical Schematic Symbols T143000 —UN—21JUN01
DS35042,0000040 -19-04JAN11-7/8
Continued on next page
TM13345X19 (23APR18)
9015-05-7
160GLC Excavator 042318 PN=309
System Information 1— Battery 2— Wire Splice 3— Fuse 4— Circuit Breaker 5— Fusible Link 6— Power Outlet 7— Alternator 8— Air Conditioner Compressor 9— Compressor 10— Liquid Pump 11— Antenna 12— Diode 13— Zener Diode 14— Capacitor 15— Magnet 16— Flasher 17— Buzzer 18— Horn 19— Alarm 20— Clock 21— Internal Ground 22— Single Point Ground 23— External Ground 24— Sensor 25— Sensor with Normally Open Switch 26— Speed Sensor 27— Rotary Sensor 28— Single Element Bulb 29— Dual Element Bulb
30— Solenoid Operated Hydraulic Valve With Suppression Diode 31— Solenoid Normally Open 32— Solenoid Normally Closed 33— Starter Motor 34— Starter Motor 35— DC Motor 36— DC Stepping Motor 37— Wiper Motor 38— Blower Motor 39— Servo Motor 40— Speedometer 41— Tachometer 42— Temperature Gauge 43— Liquid Level Gauge 44— Gauge 45— Hourmeter 46— Resistor 47— Variable Resistor 48— Manually Adjusted Variable Resistor 49— Multi-Pin Connector 50— Single Pin Connector
51— Connector 52— 4 Pin Relay 53— 5 Pin Relay 54— 5 Pin Relay With Internal Suppression Diode 55— 5 Pin Relay With Internal Suppression Resistor 56— Key Switch 57— Temperature Switch Normally Open 58— Temperature Switch Normally Closed 59— Pressure Switch Normally Open 60— Pressure Switch Normally Closed 61— Liquid Level Switch Normally Open 62— Liquid Level Switch Normally Closed 63— Momentary Switch Normally Open 64— Momentary Switch Normally Closed 65— Toggle Switch Normally Open
66— Toggle Switch Normally Closed 67— 2 Way Toggle Switch Normally Open 68— 2 Way Toggle Switch Normally Closed 69— Manual Switch Operation 70— Push Switch Operation 71— Pull Switch Operation 72— Turn Switch Operation 73— Toggle Switch Operation 74— Pedal Switch Operation 75— Key Switch Operation 76— Detent Switch Operation 77— Temperature Sensor 78— Solar Sensor 79— Pressure Sensor 80— Liquid Level Sensor
DS35042,0000040 -19-04JAN11-8/8
TM13345X19 (23APR18)
9015-05-8
160GLC Excavator 042318 PN=310
Group 10
System Diagrams Explanation of Wire Markings Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on some connector drawings simply as reference numbers, useful in tracing wires through the harness. Some wires are solid wire colors. These would be identified by one color name such as RED or BLK or GRN. Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a wire identified as RED/WHT would be a primarily RED wire, with a WHT stripe. A wire identified as WHT/RED would be a primarily WHT wire with a RED stripe. Following is a listing of wire color abbreviations used on drawings.
• BLK—Black
• BLU—Blue • BRN—Brown • CABLE—Bare Wire • DK GRN—Dark Green • GRN—Green • GRY—Grey • LT BLU—Light Blue • LT GRN—Light Green • ORG—Orange • PNK—Pink • PUR—Purple • RED—Red • SK BLU—Sky Blue • TAN—Tan • VLT—Violet • WHT—White • YEL—Yellow DS35042,0000038 -19-15MAR11-1/1
TX1185467A —UN—19FEB15
Fuse and Relay Specifications
Relay Block and Fuse Box Component Location 1— Relay Block
F50— Fuse Box
F51— Fuse Box 2 Continued on next page
TM13345X19 (23APR18)
9015-10-1
DP27668,00009DF -19-14FEB18-1/4
160GLC Excavator 042318 PN=311
System Diagrams
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)
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 Connector 5 A Fuse (marked OPT. 3 BATT)
Continued on next page
TM13345X19 (23APR18)
9015-10-2
F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F20 F19 F18 F17 F16 F15 F14 F13 F12 F11
TX1086711 —UN—28JUN13
Fuse Box
Fuse Box
DP27668,00009DF -19-14FEB18-2/4
160GLC Excavator 042318 PN=312
System Diagrams
Additional fuses located inside left front service door:
• F6001—JDLink™ Unswitched Power 7.5 A Fuse • F6003—JDLink™ Switched Power 7.5 A Fuse Additional fuses located near engine control unit (ECU):
• F5004—Flex Power Controller (FPC) In-Line 10 A Fuse Additional fuses located in the engine compartment:
• F45—Starter In-Line 30 A Fuse • F63—Glow Plug 50 A Fuse
F30 F29 F28 F27 F26 F25 F24 F23 F22 F21
F40 F39 F38 F37 F36 F35 F34 F33 F32 F31
Additional fuses located under cover behind cooling package door:
• F46—Engine Light In-Line 7.5 A Fuse • F60—Alternator 65 A Fuse • F61—Battery 45 A Fuse 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) F27— Not Used (S.N. —057099) F27— Seat Heat/Cool 20 A Fuse (marked SEAT_HEAT/COOL) (S.N. 057100— ) F28— Not Used F29— Not Used F30— Not Used
TX1086712 —UN—28JUN13
Fuse Box 2
Fuse Box 2
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) F37— Engine Control Unit (ECU) 20 A Fuse (marked ECU P3) F38— Fuel Transfer Pump and Controllers 20 A Fuse (marked ECU P4) F39— Not Used F40— Not Used
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-3
DP27668,00009DF -19-14FEB18-3/4
160GLC Excavator 042318 PN=313
System Diagrams
Relay Block
K11
K12 K8 K7
K9 K10
K6
K5
K2
K3
TX1161301 —UN—22MAY14
K1
K4 K13
TX1161301
Relay Block K1—Load Dump Relay K4—Starter Cut Relay K2—Pilot Shutoff Solenoid Relay K5—Security Relay K3—Security Alarm Relay K6—Windshield Wiper Relay K7—Work Light Relay
K8—Boom Light Relay K9—Windshield Washer Relay K10— Horn Relay K11— Idle Stop Relay
Additional relays located in the engine compartment:
• K34—Starter Relay
• K16—Glow Plug Relay
Additional relays located behind cab seat:
Additional relays are located by the air conditioning unit:
• K20—Seat Heater Relay • K21—Cab Roof Light 1 Relay • K22—Cab Roof Light 2 Relay • K23—Rear Cab Light Relay • K30—Right Solenoid Relay B • K31—Right Solenoid Relay A • K32—Left Solenoid Relay B • K33—Left Solenoid Relay A
• K15—Air Conditioner Blower Motor Relay • K17—Max-Hi Relay • K18—Air Conditioner Compressor Clutch Relay Additional relays located under cover behind cooling package door:
• K19—Battery Relay
K12— Accessory Cut Relay K13— Key Cut Relay
DP27668,00009DF -19-14FEB18-4/4
TM13345X19 (23APR18)
9015-10-4
160GLC Excavator 042318 PN=314
System Diagrams
System Functional Schematic, Component Location, and Wiring Diagram Master Legend
• B60—Attachment Pressure Sensor (SE9) (W17) • B61—Arm Out Pressure Sensor (S.N. —057099) (SE9)
• A1—Engine Control Unit (ECU) (SE10, SE11, SE12,
• B61—Arm Out Pressure Sensor (S.N. 057100— )
• A3—Main Controller (MCZ) (SE7, SE8, SE9, SE10)
• B61—Not Used (S.N. 057100— ) (W32) • B68—Secondary Hydraulic Oil Temperature Sensor
SE13, SE14, SE15, SE16, SE17, SE18) (W5)
(SE9) (W2)
(W1)
• A4—Monitor Controller (DSZ) (SE4, SE5, SE6) (W3) • A5—Data Converter (SE23) (W1) • A6—Radio (SE21) (W1) • A7—Air Conditioner Controller (ACF) (SE26) (W41) • A8—12-Volt Power Converter (SE20) (W1) • A10—Monitor (SE6) (W3) • A11—Machine Controller (BCZ) (SE22) (W1) • A12—Rear Camera (SE6) (W19) • A15—Flex Power Controller (FPC) (SE11) (W5) • A25—Premium Seat Power Converter (SE35) (W87) • A26—Premium Seat Controller (PSC) (SE35) (W87) • A5507—Diesel Exhaust Fluid (DEF) Tank Header
(W32)
(SE33) (W76)
• B80—Seat Temperature Switch 1 (SE29) • B81—Seat Temperature Switch 2 (SE29) • B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (SE33) (W76)
• B5009—Engine Coolant Loss Level Sensor (SE12) (W57)
• B5101—Engine Oil Pressure Sensor (SE12) (W4) • B5102—Exhaust Manifold Pressure Sensor (SE12) (W4)
• B5103—Exhaust Gas Recirculation (EGR) Delta
Assembly (SE14) (W54) • A5507B—Diesel Exhaust Fluid (DEF) Tank Header B (SE14) (W54) • A6000—Modular Telematics Gateway (MTG) Controller (SE24) (W5) • A6001—GPS/Cellular Antenna (SE24) • A6002—Satellite (SAT) Module Control Unit (if equipped) (SE24) • A6003—Satellite (SAT) Antenna (SE23) • B18—Fuel Level Sensor (SE4) (W2) • B20—Air Conditioner High/Low-Pressure Switch (SE25) (W2) • B21—Solar Sensor (SE27) (W3) • B22—Ambient Air Temperature Sensor (SE27) (W2) • B23—High Note Horn (SE25) (W2) • B24—Low Note Horn (SE25) (W2) • B25—Right Speaker (SE21) • B26—Left Speaker (SE21) • B27—Hydraulic Oil Filter Restriction Switch (if equipped) (SE4) • B30—Boom Up Pressure Sensor (marked PI1) (SE7) (W2) • B31—Arm In Pressure Sensor (marked PI2) (SE8) (W2) • B32—Front Attachment Pressure Sensor (marked FRT) (SE8) (W2) • B33—Swing Pressure Sensor (marked S3) (SE8) (W2) • B34—Travel Pressure Sensor (marked TR) (SE8) (W2) • B35—Pump 1 Delivery Pressure Sensor (marked PP1) (SE8) (W8) • B36—Pump 1 Control Pressure Sensor (marked PC1) (SE8) (W8) • B37—Pump 2 Delivery Pressure Sensor (marked PP2) (SE9) (W8) • B38—Pump 2 Control Pressure Sensor (marked PC2) (SE9) (W8) • B40—Hydraulic Oil Temperature Sensor (SE9) (W2) • B41—Air Conditioner Freeze Control Switch (SE27) (W41) • B55—Air Recirculation Sensor (SE27) (W41) • B56—Bucket Curl Pressure Sensor (marked BKC) (S.N. 057100— ) (SE8) (W2) • B57—Bucket Dump Pressure Sensor (S.N. 057100— ) (SE8) (W2)
Pressure Sensor (SE11) (W4)
• B5104—Intake Manifold Pressure Sensor (SE11) (W4) • B5105—Crankcase Pressure Sensor (SE15) (W4) • B5107—Inlet Fuel Pressure Sensor (SE12) (W4) • B5108—Engine Coolant Pressure Sensor (SE12) (W4) • B5109—Exhaust Filter Delta Pressure Sensor (SE16) (W62)
• B5113—Fuel Rail Pressure Sensor (SE15) (W4) • B5201—Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor (SE16)
• B5202—Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor (SE16)
• B5204—Exhaust Filter Temperature Module (SE16) (W62)
• B5205—Charge Air Cooler Outlet Temperature Sensor (SE14) (W4)
• B5206—Manifold Air Temperature (MAT) Sensor (SE14) (W4)
• B5207—Exhaust Gas Recirculation (EGR) Temperature Sensor (SE10) (W4)
• B5208—Engine Coolant Temperature Sensor (SE12) (W7)
• B5209—Fuel Temperature Sensor (SE12) (W4) • B5211—Diesel Exhaust Fluid (DEF) Tank Temperature Sensor (SE14) (W54)
• B5213—Diesel Particulate Filter (DPF) Outlet Pressure Sensor (SE16)
• B5214—Diesel Particulate Filter (DPF) Inlet Pressure Sensor (SE16)
• B5216—Selective Catalytic Reduction (SCR) Inlet Temperature Sensor (SE16)
• B5217—Aftertreatment Inlet NOx Sensor (SE15) • B5218—Aftertreatment Outlet NOx Sensor (SE15) • B5301—Crankshaft Position Sensor (SE13) (W7) • B5302—Camshaft Position Sensor (SE13) (W7) • B5303—Fan Speed Sensor (SE11) (W57) • B5500—Intake Air Sensor (SE13) (W7) • B5501—Diesel Exhaust Fluid (DEF) Dosing Unit (SE15) (W54)
• B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor (SE15) (W62)
• B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor (SE15) (W53)
Continued on next page
TM13345X19 (23APR18)
9015-10-5
JJ03229,0001176 -19-06APR18-1/7
160GLC Excavator 042318 PN=315
System Diagrams
• B5506—Diesel Exhaust Fluid (DEF) Tank Concentration
Sensor (SE14) (W54) • B5600—Water-in-Fuel (WIF) Sensor (SE12) (W5) • B5601—Diesel Exhaust Fluid (DEF) Tank Level Sensor (SE14) (W54) • E1—Work Light (SE20) (W2) • E2—Boom Light (SE20) (W2) • E3—Cab Dome Light (SE22) (W1) • E5—Switch Panel Back Light 1 (SE6) • E6—Switch Panel Back Light 2 (SE5) • E7—Switch Panel Back Light 3 (SE6) • E8—Switch Panel Back Light 4 (SE6) • E9—Key Switch Light (SE23) • E10—Switch Panel Back Light 5 (SE23) • E11—Cab Roof Light 1 (SE28) (W44) • E12—Cab Roof Light 2 (SE28) (W44) • E13—Cab Roof Light 3 (SE28) (W44) • E14—Cab Roof Light 4 (SE28) (W44) • E15—Engine Compartment Light (S.N. —056599) (SE21) (W58) • E15—Engine Compartment Light (S.N. 056600— ) (SE11) (W58) • E18—Rear Cab Light (SE34) (W86) • E22—Battery Disconnect Indicator Light (SE2) (W5) • E5601—Diesel Exhaust Fluid (DEF) Dosing Unit Pressure Line Heater (SE18) (W54) • E5602—Diesel Exhaust Fluid (DEF) Dosing Unit Supply Line Heater (SE18) (W54) • E5603—Diesel Exhaust Fluid (DEF) Dosing Unit Return Line Heater (SE18) (W54) • F1—Work and Boom Lights 20 A Fuse (marked LAMP) (SE20) (W1) • F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) (SE19) (W1) • F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) (SE25) (W1) • F4—Solenoid 20 A Fuse (marked SOLENOID) (SE3) (W1) • F5—Optional and Attachment Connector 5 A Fuse (marked OPT. 1 ALT) (SE9) (W1) • F6—Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) (SE20) (W1) • F7—Start Position Signal 5 A Fuse (marked START) (SE2) (W1) • F8—Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) (SE10) (W1) • F9—Radio Backup 10 A Fuse (marked BACK UP) (SE4) (W1) • F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) (SE7) (W1) • F11—Travel Alarm 5 A Fuse (marked TRAVEL ALARM) (SE9) (W1) • F12—Radio and Dome 5 A Fuse (marked RADIO) (SE21) (W1) • F13—Lighter 10 A Fuse (marked LIGHTER) (SE21) (W1) • F14—Monitor 5 A Fuse (marked MONITOR) (SE4) (W1) • F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) (SE21) (W1) • F16—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) (SE20) (W1)
• F17—Power On 5 A Fuse (marked POWER ON) (SE4) (W1)
• F18—Idle Stop 5 A Fuse (marked IDLE STOP) (SE1) (W1)
• F19—Horn 10 A Fuse (marked HORN) (SE25) (W1) • F20—Optional Connector 5 A Fuse (marked OPT. 3 BATT) (SE20) (W1)
• F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) (SE29) (W1)
• F22—Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) (SE28) (W1)
• F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) (SE28) (W1)
• F24—IMMOBI 5 A Fuse (marked IMOBI) (SE28) (W1) • F25—Quick Hitch 5 A Fuse (marked QUICK HITCH) (SE28) (W1)
• F26—Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX_3) (SE28) (W1)
• F27—Not Used (S.N. —057099) (W1) • F27—Seat Heat/Cool 20 A Fuse (marked
SEAT_HEAT/COOL) (S.N. 057100— ) (SE29) (W1)
• F28—Not Used (W1) • F29—Not Used (W1) • F30—Not Used (W1) • F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) (SE29) (W1)
• F32—Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) (SE28) (W1)
• F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) (SE28) (W1)
• F34—Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX_2) (SE28) (W1)
• F35—Service ADVISOR™Diagnostic Connector 5 A Fuse (marked DIAG) (SE20) (W1)
• F36—Engine Control Unit (ECU) 20 A Fuse (marked ECU P2) (SE18) (W1)
• F37—Engine Control Unit (ECU) 20 A Fuse (marked ECU P3) (SE18) (W1)
• F38—Fuel Transfer Pump and Controllers 20 A Fuse (marked ECU P4) (SE14) (W1)
• F39—Not Used (W1) • F40—Not Used (W1) • F45—Starter In-Line 30 A Fuse (SE2) (W5) • F46—Engine Light In-Line 7.5 A Fuse (S.N. —056599) (SE21) (W5)
• F46—Engine Light In-Line 7.5 A Fuse (S.N. 056600— ) (SE10) (W5)
• F50—Fuse Box (W1) • F51—Fuse Box 2 (W1) • F60—Alternator 65 A Fuse (SE1) (W2) • F61—Battery 45 A Fuse (SE1) (W2) • F62—Wiper Motor Assembly Circuit Breaker (SE19) • F63—Glow Plug 50 A Fuse (SE18) (W40) • F5004—Flex Power Controller (FPC) In-Line 10 A Fuse (SE10) (W5)
• F6001—JDLink™ Unswitched Power 7.5 A Fuse (SE24) (W5)
• F6003—JDLink™ Switched Power 7.5 A Fuse (SE24) (W5)
• G1—Battery (SE1) • G2—Battery (SE1) • G3—Alternator (SE3) (W2), (W4), (W40) Continued on next page JJ03229,0001176 -19-06APR18-2/7
TM13345X19 (23APR18)
9015-10-6
160GLC Excavator 042318 PN=316
System Diagrams
• G5—12-Volt Power Outlet (SE20) (W1) • G6—USB Connector (S.N. 057100— ) (SE20) (W83) • H2—Security Alarm (SE4) (W1) • H3—Monitor Warning Alarm (SE4) (W3) • H4—Travel Alarm (SE9) (W26) • K1—Load Dump Relay (SE3) (W1) • K2—Pilot Shutoff Solenoid Relay (SE3) (W1) • K3—Security Alarm Relay (SE4) (W1) • K4—Starter Cut Relay (SE2) (W1) • K5—Security Relay (SE2) (W1) • K6—Windshield Wiper Relay (SE19) (W1) • K7—Work Light Relay (SE20) (W1) • K8—Boom Light Relay (SE20) (W1) • K9—Windshield Washer Relay (SE19) (W1) • K10—Horn Relay (SE25) (W1) • K11—Idle Stop Relay (SE1) (W1) • K12—Accessory Cut Relay (SE1) (W1) • K13—Key Cut Relay (SE1) (W1) • K15—Air Conditioner Blower Motor Relay (SE25) (W51) • K16—Glow Plug Relay (SE17) (W40) • K17—Max-Hi Relay (SE26) (W51) • K18—Air Conditioner Compressor Clutch Relay (SE25) (W51)
• K19—Battery Relay (SE1) (W2), (W5) • K20—Seat Heater Relay (SE29) (W14) • K21—Cab Roof Light 1 Relay (SE29) (W46) • K22—Cab Roof Light 2 Relay (SE28) (W47) • K23—Rear Cab Light Relay (SE34) (W85) • K30—Right Solenoid Relay B (SE30) (W15) • K31—Right Solenoid Relay A (SE30) (W15) • K31—Right Solenoid Relay A (marked RSW1) (SE31) (W75)
• K32—Left Solenoid Relay B (SE30) (W15) • K32—Left Solenoid Relay B (marked LSW1) (SE31)
(W41)
• R17—Blower Motor Resistor (SE26) (W41) • R18—Seat Heater (SE29) (W14) • R19—Glow Plug Resistor (SE18) (W40) • R20—Upper Thermal Duct Module (SE35) (W87) • R21—Lower Thermal Duct Module (SE35) (W87) • R90—Diesel Particulate Filter (DPF) Regen Active Lamp Resistor (W5)
• R92—Service ADVISOR™ Remote (SAR) Switch Accept LED Resistor (W5)
• R93—Service ADVISOR™ Remote (SAR) Switch Decline LED Resistor (W5)
• R5601—CAN 0 Termination Resistor (SE11) (W5) • R5603—Engine CAN Termination Resistor (SE13) (W7) • R5605—Aftertreatment CAN Termination Resistor (SE15) (W62)
• S1—Key Switch (SE1) (W29) • S2—Cab Dome Light Switch (SE22) • S3—Pilot Shutoff Switch 1 (SE3) (W11) • S4—Pilot Shutoff Switch 2 (SE3) (W11) • S5—Horn Switch (SE25) (W1), (W75) • S7—Power Dig Switch (SE10, SE31) (W1) or (W75) • S8—Auto-Idle Switch (SE7) • S9—Windshield Wiper and Washer Switch (SE23) • S10—Work Light Switch (SE6) • S11—Travel Mode Switch (SE7) • S12—Power Mode Button (SE7) • S13—Travel Alarm Cancel Switch (SE9) (W16) • S14—Door Switch (SE23) (W1) • S15—Reversing Fan Switch (SE16) (W23) • S16—Exhaust Filter Parked Cleaning Switch (SE16) (W9)
• S18—Service ADVISOR™ Remote (SAR) Switch (SE11) (W10)
(W75)
• K33—Left Solenoid Relay A (SE30) (W15) • K33—Left Solenoid Relay A (marked LSW3) (SE32)
• S21—Blower Motor Speed Switch (SE5) • S22—Temperature Control/Mode Switch (SE5) • S23—Radio Volume and Power Switch (SE6) • S24—Radio Tuning Switch (SE5) • S25—Monitor Dial (SE5) • S26—Back Button (SE5) • S27—Home Button (SE5) • S28—Window Switch (SE19) • S29—Auxiliary Function Lever (AFL) Proportional
(W75)
• K34—Starter Relay (SE2) (W5) • M1—Starter Motor (SE2) (W5) • M5—Windshield Wiper Motor (SE19) • M6—Windshield Washer Motor (SE19) (W2) • M7—Air Conditioner and Heater Blower Motor (SE26) (W41)
• M9—Air Conditioner and Heater Internal and External
• R16—Blower Motor Resistor and Thermofuse (SE26)
Control Switch (SE31) (W75)
Servo Motor (SE27) (W41) • M10—Air Conditioner and Heater Blower Port Change Servo Motor (SE27) (W41) • M11—Air Conditioner and Heater Mixer Servo Motor (SE27) (W41) • M12—Seat Air Compressor Motor (SE29, SE34) (W14), (W87) • M15—Premium Seat Blower (SE35) (W87) • R1—Glow Plug 1 (SE18) (W40) • R2—Glow Plug 2 (SE18) (W40) • R3—Glow Plug 3 (SE18) (W40) • R4—Glow Plug 4 (SE18) (W40) • R9—Lighter (SE21) (W1) • R10—Interface CAN Resistor 1 (SE23) (W1) • R11—Interface CAN Resistor 2 (SE24) (W5) • R15—Engine Speed Dial (SE7) (W1)
• S30—Right Pilot Control Lever Switch B (marked B) (SE30) (W15)
• S31—Right Pilot Control Lever Switch A (marked A) (SE30) (W15)
• S31—Right Pilot Control Lever Switch A (SE31) (W75) • S32—Left Pilot Control Lever Switch B (marked B) (SE30) (W15) or (W75)
• S33—Left Pilot Control Lever Switch A (marked C) (SE30) (W15) or (W75)
• S34—Right Enable Switch (SE30) (W15), (W22) • S34—Right Enable Switch (marked ON/OFF) (SE31) (W75)
• S35—Left Enable Switch (SE30) (W15), (W22) • S35—Left Enable Switch (marked ON/OFF) (SE31) (W75)
• S36—Rear Cab Light Switch (SE34) (W84) (W87) • S37—Heated/Cooled Seat Switch (SE35) Continued on next page JJ03229,0001176 -19-06APR18-3/7
TM13345X19 (23APR18)
9015-10-7
160GLC Excavator 042318 PN=317
System Diagrams
• S40—Hydraulic Oil Temperature Switch (if equipped)
(SE4) • S45—Auxiliary Function Enable Switch (marked AFL_SW) (SE32) (W75) • S50—0 Key (SE5) • S51—1 Key (SE5) • S52—2 Key (SE5) • S53—3 Key (SE5) • S54—4 Key (SE5) • S55—5 Key (SE5) • S56—6 Key (SE5) • S57—7 Key (SE5) • S58—8 Key (SE5) • S59—9 Key (SE5) • S60—Keypad (SE6) • S61—Seat Compressor Switch (SE29, SE34) (W87) • S62—Seat Heater Switch (SE29) (W24) • S90—Engine Compartment Light Switch (S.N. —056599) (SE21) (W58) • S90—Engine Compartment Light Switch (S.N. 056600— ) (SE10) (W58) • S91—Battery Disconnect Switch (SE1) • V1—Battery Relay Diode (SE1) (W1) • V2—Not Used (SE4) (W1) • V3—Load Dump Relay Diode (SE3) (W1) • V4—Security Diode (SE2) (W1) • V5—Starter Cut Relay Diode (SE3) (W1) • V6—Auxiliary Power Connector Diode (SE21) (W1) • V7—Start Relay Diode (SE2) (W1) • V8—Air Conditioner Clutch Diode (SE25) (W1) • V9—Pilot Shutoff Diode (SE3) (W1) • V10—Starter Protection Diode (SE1) (W1) • V11—Accessory Cut Diode (SE1) (W1) • V12—Starter Cut Diode (SE2) (W1) • V13—Work Light 1 Diode (SE22) (W1) • V14—Work Light 2 Diode (SE22) (W1) • V20—Pilot Shutoff Switch Diode (SE3) (W11) • V22—Pilot Shutoff Solenoid Diode (SE32) (W75) • V30—Right Solenoid Diode B (SE30) (W61) • V31—Right Solenoid Diode A (SE30) (W61) • V32—Left Solenoid Diode B (SE30) (W61) • V33—Left Solenoid Diode A (SE30) (W61) • V40—Selector Valve Solenoid Valve Diode (if equipped) (SE8) (W17) • V41—Secondary Relief Solenoid Valve Diode (if equipped) (SE8) (W17) • V43—2-Speed Activation Solenoid Valve Diode (if equipped) (SE9) (W32) • V44—Starter Relay Diode (SE2) (W5) • W1—Cab Harness (W1) • W2—Machine Harness (W2) • W3—Monitor Harness (W3) • W4—Engine Harness (W4) • W5—Engine Interface Harness (W5) • W7—Front Engine Harness (W7) • W8—Pump Harness (W8) • W9—Exhaust Filter Parked Cleaning Switch Harness (W9) • W10—Service ADVISOR™ Remote (SAR) Switch Harness (W10) • W11—Pilot Shutoff Switch Harness (W11) • W14—Heated Air Seat Harness (W14)
• W15—Multi-Function Pilot Control Lever Harness (W15) • W16—Travel Alarm Cancel Switch Harness (W16) • W17—Attachment Harness (W17) • W19—Rear Camera Harness (W19) • W21—Pilot Shutoff Valve Harness (W21) • W22—Auxiliary 3-Button Cancel Switch Harness (W22) • W23—Reversing Fan Switch Harness (W23) • W24—Seat Heater Switch Harness (W24) • W25—Attachment Interface Harness (W25) • W26—Travel Alarm Harness (W26) • W29—Starter Switch Harness (W29) • W32—2-Speed Harness (W32) • W35—Cab Harness Ground 1 (W1) • W36—Cab Harness Ground 2 (W1) • W37—Cab Harness Ground 3 (W1) • W38—Fuel Injector Harness (W38) • W39—Engine Interface Harness Ground (W5) • W40—Glow Plug Harness (W40) • W41—Heater and Air Conditioner Harness (W41) • W44—Cab Roof Light Harness (W44) • W45—Cab Roof Light Jumper Harness (W45) • W46—Cab Roof Light 1 Relay Harness (W46) • W47—Cab Roof Light 2 Relay Harness (W47) • W51—Heater and Air Conditioner Relay Harness (W51) • W53—Exhaust Aftertreatment Harness (W53) • W54—Diesel Exhaust Fluid (DEF) Harness (W54) • W57—Fan Harness (W57) • W58—Engine Light Harness (W58) • W60—Radio Antenna (SE21) • W61—Auxiliary Solenoid Harness (W61) • W62—Diesel Particulate Filter (DPF) Harness (W62) • W75—Auxiliary Function Lever (AFL) Harness (W75) • W76—Auxiliary Function Lever (AFL) Solenoid Harness (W76)
• W82—USB Harness (S.N. 057100— ) (W82) • W83—USB Jumper Harness (S.N. 057100— ) (W83) • W84—Rear Cab Light Switch Harness (W84) • W85—Rear Cab Light Relay Harness (W85) • W86—Rear Cab Light Harness (W86) • W87—Premium Seat Harness (W87) • W6003—Satellite (SAT) Harness (W6003) • X1—Service ADVISOR™ Diagnostic Connector (SE12) (W1)
• X2—MPDr 6-Pin Connector (SE6) (W1) • X3—Cab Harness-to-Machine Harness 100-Pin Connector (SE4, SE6, SE19) (W1), (W2)
• X10—Machine Controller 8-Pin Connector A (SE22) (W1)
• X11—Machine Controller 20-Pin Connector B (SE22) (W1)
• X17—Cab Harness-to-Machine Harness Connector (SE4) (W1), (W3)
• X18—Monitor 12-Pin Connector C (SE6) (W3) • X19—Monitor 2-Pin Connector G (SE6) (W3) • X20—Monitor Controller 28-Pin Connector A (SE4, SE5, SE6) (W1)
• X21—Monitor Controller 36-Pin Connector B (SE4, SE5, SE6) (W1)
• X22—Monitor Controller 16-Pin Connector D (SE4, SE5, SE6) (W1)
• X23—Monitor Controller 12-Pin Connector C (SE4, SE5, SE6) (W3)
Continued on next page
TM13345X19 (23APR18)
9015-10-8
JJ03229,0001176 -19-06APR18-4/7
160GLC Excavator 042318 PN=318
System Diagrams
• X24—Monitor Controller 2-Pin Connector G (SE4, SE5,
SE6) (W3) • X25—Cab Harness Auxiliary Power Connector 1 (marked AUX+/-) (SE21) (W1) • X26—Optional Connector (SE20, SE29, SE31, SE33) (W1), (W15) or (W75), (W82) • X27—Cab Harness-to-Switch Panel Connector 1 (SE23) (W1) • X28—Cab Harness-to-Switch Panel Connector 2 (SE5) (W1) • X29—Cab Harness-to-Switch Panel Connector 3 (SE6, SE7) (W1) • X30—Cab Harness-to-Switch Panel Connector 4 (SE5) (W1) • X31—Cab Harness-to-Main Controller 31-Pin Connector A (SE7, SE8, SE9, SE10) (W1) • X32—Cab Harness-to-Main Controller 24-Pin Connector B (SE7, SE8, SE9, SE10) (W1) • X33—Cab Harness-to-Main Controller 17-Pin Connector C (SE7, SE8, SE9, SE10) (W1) • X34—Cab Harness-to-Main Controller 30-Pin Connector D (SE7, SE8, SE9, SE10) (W1) • X35—Cab Harness-to-Main Controller 24-Pin Connector E (SE7, SE8, SE9, SE10) (W1) • X36—Cab Harness-to-Main Controller 26-Pin Connector F (SE7, SE8, SE9, SE10) (W1) • X37—Cab Harness-to-Exhaust Filter Switch Harness Connector (W1), (W9) • X39—Cab Harness-to-Window Switch (SE19) (W1) • X40—Pump Harness-to-Machine Harness Connector (SE7, SE8, SE9) (W2), (W8) • X42—CAN 1 Connector (SE10) (W1) • X45—Option 2 12-Pin Connector (not used) (W1) • X46—Attachment Connector (SE8, SE9) (W2), (W17) • X46A—Attachment Connector A (W25) • X46B—Attachment Connector B (W25) • X47—Cab Harness-to-Key Switch Harness Connector (SE1) (W1), (W29) • X50—Cab Harness-to-Travel Alarm Cancel Switch Harness Connector (W1), (W16) • X51—Air Conditioner 4-Pin Connector (W1), (W41) • X51A—Air Conditioner 4-Pin Connector (W51) • X51B—Air Conditioner 4-Pin Connector (W51) • X52—Air Conditioner 10-Pin Connector (W1), (W41) • X52A—Air Conditioner 10-Pin Connector (W51) • X52B—Air Conditioner 10-Pin Connector (W51) • X53—Seat Heater Switch Harness 3-Pin Connector (marked SEAT HEATER) (W14), (W24) • X54—Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) (SE29) (W1), (W14) • X55—Front Cab Light 1 Connector (marked CAB LAMP FRONT) (SE29) (W1), (W46) • X56—Front Cab Light 2 Connector (marked CAB LAMP FRONT +2) (SE28) (W1), (W47) • X57—Rear Cab Light Connector (marked CAB LAMP REAR) (SE28, SE34) (W1), (W85) • X58—Warning Light Connector (marked WARNING LAMP) (SE28) (W1) • X59—Satellite Communication Connector (marked IMMOBI) (SE28) (W1) • X61—Quick Hitch Connector (marked QUICK HITCH) (SE28) (W1)
• X62—Cab Auxiliary Power Connector 2 (marked AUX_2) (SE28) (W1)
• X63—Cab Auxiliary Power Connector 3 (marked AUX_3) (SE28) (W1)
• X64—Machine Harness-to-Rear Camera Harness Connector (SE6) (W2), (W19)
• X65—Cab Harness-to-Pilot Shutoff Switch Harness Connector (SE3) (W1), (W11)
• X67—Machine Harness Auxiliary Power Connector (SE1) (W2)
• X73—Cab Harness-to-Speakers Connector (SE21) (W1)
• X74—Cab Harness-to-Service ADVISOR™ Remote
(SAR) Switch Harness (marked ADV-SW) (W1), (W10)
• X75—Cab Harness-to-Pilot Shutoff Valve Harness Connector (SE2) (W1), (W21)
• X76—Cab Harness Connector 1 (marked HMST) (not used) (SE4) (W1)
• X77—Radio Auxiliary Connector (SE21) (W1) • X78—Optional Switch (W1) • X81—Multi-Function Pilot Control Lever
Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector (W15), (W22) • X82—Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector (W15), (W22) • X83—Cab Harness-to-Reversing Fan Switch Harness (marked VSF-SW) (SE16) (W1), (W23) • X86—Machine Harness-to-Travel Alarm Harness Connector (SE9) (W2), (W26) • X87—Attachment Harness-to-2-Speed Harness Connector (W17), (W32) • X88—Glow Plug Harness-to-Glow Plug Connector (W40) • X90—Machine Harness-to-Hydraulic Oil Temperature Switch Connector (SE4) (W2) • X98—Machine Harness Power Splice (W2) • X99—Cab Ground Splice (W1) • X104—Machine Harness Ground Splice (W2) • X135—Pilot Shutoff Switch Harness Splice 1 (W11) • X136—Pilot Shutoff Switch Harness Splice 2 (W11) • X137—Pilot Shutoff Switch Harness Splice 3 (W11) • X140—5030 BLK Splice 1 (W5) • X143—5624 YEL Splice (W5) • X144—5643 ORG Splice (W5) • X145—5658 GRY Splice (W5) • X147—5625 GRN Splice (W5) • X148—G02 BLK Splice (S.N. —056599) (W5) • X148—G002 BLK Splice (S.N. 056600— ) (W5) • X149—E03 WHT Splice (S.N. —056599) (W5) • X149—E003 WHT Splice (S.N. 056600— ) (W5) • X150—G01 BLK Splice 1 (S.N. —056599) (W5) • X150—G001 BLK Splice 1 (S.N. 056600— ) (W5) • X152—1356 YEL Splice 1 (W5) • X153—1357 GRN Splice 1 (W5) • X156—5030 BLK Splice 2 (W5) • X160—5783 ORG Splice (W5) • X162—P307 RED Splice (W5) • X163—P04 RED Splice 1 (S.N. —056599) (W5) • X163—P004 RED Splice 1 (S.N. 056600— ) (W5) • X164—M12 YEL Splice 1 (S.N. —056599) (W5) • X164—M012 YEL Splice 1 (S.N. 056600— ) (W5)
Continued on next page
TM13345X19 (23APR18)
9015-10-9
JJ03229,0001176 -19-06APR18-5/7
160GLC Excavator 042318 PN=319
System Diagrams
• X165—M13 GRN Splice 1 (S.N. —056599) (W5) • X165—M013 GRN Splice 1 (S.N. 056600— ) (W5) • X166—R02 BLK Splice 1 (S.N. —056599) (W5) • X166—R002 BLK Splice 1 (S.N. 056600— ) (W5) • X167—1357 GRN Splice 2 (W5) • X168—1356 YEL Splice 2 (W5) • X169—5796 BLU Splice (W5) • X170—W43 BLU Splice (S.N. —056599) (W5) • X170—W043 BLU Splice (S.N. 056600— ) (W5) • X171—W42 BLU Splice (S.N. —056599) (W5) • X171—W042 BLU Splice (S.N. 056600— ) (W5) • X172—R02 BLK Splice 2 (S.N. —056599) (W5) • X172—R002 BLK Splice 2 (S.N. 056600— ) (W5) • X173—M13 GRN Splice 2 (S.N. —056599) (W5) • X173—M013 GRN Splice 2 (S.N. 056600— ) (W5) • X174—M12 YEL Splice 2 (S.N. —056599) (W5) • X174—M012 YEL Splice 2 (S.N. 056600— ) (W5) • X175—Machine Harness-to-Engine Interface Harness Connector 1 (SE2) (W2), (W5) • X176—5022 RED Splice (W5) • X177—5122 RED Splice (W5) • X178—5222 RED Splice (W5) • X179—G01 BLK Splice 2 (S.N. —056599) (W5) • X179—G001 BLK Splice 2 (S.N. 056600— ) (W5) • X181—5410 CLR Splice (W5) • X183—P04 RED Splice 2 (S.N. —056599) (W5) • X183—P004 RED Splice 2 (S.N. 056600— ) (W5) • X187—M12 YEL Splice 3 (S.N. —056599) (W5) • X187—M012 YEL Splice 3 (S.N. 056600— ) (W5) • X188—M13 GRN Splice 3 (S.N. —056599) (W5) • X188—M013 GRN Splice 3 (S.N. 056600— ) (W5) • X189—R02 BLK Splice 3 (S.N. —056599) (W5) • X189—R002 BLK Splice 3 (S.N. 056600— ) (W5) • X190—P04 RED Splice 3 (S.N. —056599) (W5) • X190—P004 RED Splice 3 (S.N. 056600— ) (W5) • X195—5410 SHIELD Splice 2 (W5) • X200—5604 YEL Splice 1 (W53) • X201—5605 GRN Splice 1 (W53) • X202—5030 BLK Splice 1 (W53) • X203—5636 BLU Splice (W53) • X208—5625 GRN Splice (W62) • X209—5602 RED Splice (W53) • X210—5634 YEL Splice (W62) • X215—5643 ORG Splice (W57) • X222—5625 GRN Splice (W54) • X223—5604 YEL Splice (W54) • X224—5605 GRN Splice (W54) • X225—5602 RED Splice (W5) • X240—5410 BLK Splice 1 (W4) • X241—5410 BLK Splice 2 (W4) • X242—5410 BLK Splice 3 (W4) • X243—5030 BLK Splice 1 (W7) • X244—5030 BLK Splice 2 (W7) • X245—5030 BLK Splice 3 (W7) • X247—5030 BLK Splice 4 (W4) • X248—5631 BRN Splice (W4) • X249—5633 ORG Splice (W4) • X252—5623 ORG Splice (W4) • X253—5614 YEL Splice (W4) • X254—5626 LT BLU Splice (W4) • X255—5624 YEL Splice (W4) • X256—5625 DK GRN Splice (W4) TM13345X19 (23APR18)
• X257—5804 YEL Splice 1 (W7) • X258—5605 DK GRN Splice 1 (W7) • X261—5826 LT BLU Splice 1 (W4) • X262—5030 BLK Splice 5 (W4) • X263—5804 YEL Splice 3 (W7) • X264—5805 DR GRN Splice 3 (W7) • X266—5826 BLU Splice (W5) • X450—G05 BLK Splice (W61) • X451—H01 GRN Splice (W61) • X452—H02 GRN Splice (W61) • X534—Right Auxiliary Solenoid Connector (marked SR/H) (SE30, SE32) (W15), (W61) or (W75)
• X535—Left Auxiliary Solenoid Connector (marked SL/H) (SE30, SE32) (W15), (W61) or (W75)
• X536—Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) (SE31) (W75)
• X537—Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) (SE31) (W75)
• X543—Horn Switch Connector (SE25, SE31) (W1), (W75)
• X544—Power Dig Switch Connector (SE10, SE32) (W1), (W75)
• X573—Exhaust Solenoid Harness Connector (not used) (W1)
• X574—Auxiliary Function Lever (AFL) Connector 1 (SE10, SE32) (W1), (W75)
• X575—Auxiliary Function Lever (AFL) Connector 2 (SE10) (W1)
• X577—Auxiliary Function Lever (AFL) Harness-to-
Auxiliary Function Lever (AFL) Solenoid Harness Connector (SE33) (W75), (W76) • X580—Cab Roof Light Harness Connector (SE28) (W44), (W45) • X581—Cab Roof Light Jumper Harness Connector 1 (SE28) (W45), (W46) • X582—Cab Roof Light Jumper Harness Connector 2 (SE28) (W45), (W47) • X590—Exhaust Solenoid Harness Connector (not used) (W2) • X603—Not Used (S.N. 057100— ) (W1) • X623A—Cab Harness CAN Connector A (marked DSZ) (S.N. 057100— ) (W1) • X623B—Cab Harness CAN Connector B (marked BCZ) (S.N. 057100— ) (W1) • X630—Premium Seat Harness Connector (marked 24V POWER) (SE29, SE34) (W1), (W87) • X630A—Premium Seat Harness Jumper Connector A (W87) • X630B—Premium Seat Harness Jumper Connector B (W87) • X631—USB Harness Connector (marked USB) (S.N. 057100— ) (W82), (W83) • X632—Rear Cab Light Harness Connector (SE34) (W85), (W86) • X633—Rear Cab Light Switch Harness Connector (marked CAB LAMP REAR) (SE34) (W84), (W85) • X634—Premium Seat Compressor Harness Connector (marked COMPRESSOR) (SE34) (W87) • X635—Heated/Cooled Seat Switch Connector (SE35) (W87) • X636—Premium Seat Power Converter Connector (marked INVERTER) (SE35) (W87) Continued on next page
9015-10-10
JJ03229,0001176 -19-06APR18-6/7
160GLC Excavator 042318 PN=320
System Diagrams
• X637—Heat Cool Lumbar Connector (marked
HEAT/COOL LUMBAR) (SE35) (W87) • X638—Premium Seat Blower Connector (SE35) (W87) • X639—Upper Thermal Module Connector (SE35) (W87) • X640—Lower Thermal Module Connector (SE35) (W87) • X641—Premium Seat Controller (PSC) Connector A (SE35) (W87) • X642—Premium Seat Controller (PSC) Connector B (SE35) (W87) • X5000—Engine Harness-to-Fuel Injector Harness Connector (SE13) (W4) • X5001—Static Ground (W4) • X5005—Fan Harness Connector (W5), (W57) • X5015—Engine Interface Harness-to-Engine Harness Connector 1 (SE12, SE14, SE15) (W4), (W5) • X5016—Engine Interface Harness-to-Engine Harness Connector 2 (SE11, SE14) (W4), (W5) • X5018—Machine Harness-to-Engine Interface Harness Connector 2 (SE10, SE11, SE14, SE15, SE16, SE18, SE24) (W2), (W5) • X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1 (W5), (W54) • X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector (W5), (W53) • X5040—Engine Interface Harness-to-Fan Harness Connector (W5), (W57) • X5041—Fan Harness-to-Engine Light Harness Connector (W57), (W58) • X5068—Engine Interface Harness-to-Engine Harness Connector 3 (SE13, SE14) (W4), (W5) • X5070—Exhaust Aftertreatment Harness-to-Diesel Particulate Filter (DPF) Harness Connector (W53), (W62) • X5141—Engine Harness-to-Front Engine Harness Connector (W4), (W7) • X5142—Engine Interface Harness-to-Engine Light Harness Connector (W5), (W58) • X5501—Engine Control Unit (ECU) Connector 1 (SE10, SE11, SE12, SE13, SE14, SE15, SE16, SE17, SE18) (W5) • X5502—Engine Control Unit (ECU) Connector 2 (SE10, SE11, SE12, SE13, SE14, SE15, SE16, SE17, SE18) (W5) • X5503—Engine Control Unit (ECU) Connector 3 (SE10, SE11, SE12, SE13, SE14, SE15, SE16, SE17, SE18) (W5) • X5604—Engine Harness-to-Glow Plug Harness Connector (W4), (W40) • X6007—JDLink™ Harness Ground 1 (SE24) • X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector (SE24) (W5) • X6015—Satellite (SAT) Module Control Unit 48-Pin Connector (SE24) (W6003)
• X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector (SE24) (W5), (W6003)
• Y1—Electronic Injector 1 (cylinder 1) (SE13) • Y2—Electronic Injector 2 (cylinder 2) (SE13) • Y3—Electronic Injector 3 (cylinder 3) (SE13) • Y4—Electronic Injector 4 (cylinder 4) (SE13) • Y10—Pilot Shutoff Solenoid (SE2) (W21) • Y11—Air Conditioner Compressor Clutch (SE25) (W2) • Y20—Pump 2 Flow Rate Limit Solenoid (marked SB) (SE7) (W8)
• Y21—Torque Control Solenoid (marked ST) (SE7) (W8) • Y22—Dig Regenerative Solenoid (marked SF) (SE7) (W2)
• Y23—Arm Regenerative Solenoid (marked SC) (SE7) (W2)
• Y24—Power Dig/Travel Speed Solenoid (marked SG) (SE8) (W2)
• Y26—Pump 1 Flow Rate Limit Solenoid (marked SA) (SE7) (W8)
• Y34—Right Solenoid (marked SR/H) (SE30) (W61) • Y34A—Right Solenoid Connector A (marked SR/H) (W61)
• Y34B—Right Solenoid Connector B (marked SR/H) (W61)
• Y35—Left Solenoid (marked SL/H) (SE30) (W61) • Y35A—Left Solenoid Connector A (marked SL/H) (W61) • Y35B—Left Solenoid Connector B (marked SL/H) (W61) • Y40—Selector Valve Solenoid Valve (if equipped) (SE8) (W17)
• Y41—Secondary Relief Solenoid Valve (if equipped) (SE8) (W17)
• Y43—2-Speed Activation Solenoid Valve (if equipped) (SE9) (W32)
• Y44—Flow Rate Adjustment Solenoid Valve (if equipped) (SE8) (W32)
• Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (SE33) (W76)
• Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (SE33) (W76)
• Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC) (SE33) (W76)
• Y5002—Suction Control Valve (SCR) (SE17) (W7) • Y5014—Variable Speed Fan Solenoid (SE17) (W57) • Y5015—Reversing Fan Solenoid (SE17) (W57) • Y5019—Coolant Control Valve (SE14) (W54) • Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector (SE18) (W53)
• Y5024—Fuel Rail Pressure Relief Valve (PRV) (SE14) (W7)
• Y5400—Exhaust Gas Recirculation (EGR) Valve (SE12) (W4)
• Y5402—Exhaust Throttle Actuator (SE12) (W4) • Y5501—Fuel Transfer Pump (SE17) (W5)
Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company JJ03229,0001176 -19-06APR18-7/7
TM13345X19 (23APR18)
9015-10-11
160GLC Excavator 042318 PN=321
System Diagrams
TM13345X19 (23APR18)
9015-10-12
160GLC Excavator 042318 PN=322
System Diagrams
System Functional Schematic TX1254650 —UN—10APR18
RED GRN
GRN
K19 BATTERY RELAY
-
G2 BATTERY
F60 65A FUSE
-
S91 BATTERY DISCONNECT SWITCH
TO SE15 X5018 (PIN C)
BLK
BLK
BLK
1
V7 START RELAY DIODE
2
E22 BATTERY DISCONNECT INDICATOR TO LIGHT
SE1
4
K34 STARTER RELAY
G02 BLK G02 BLK WHT RED WHT
System Functional Schematic (SE1—SE3) (1 of 12) Continued on next page
TM13345X19 (23APR18)
9015-10-13
160GLC Excavator 042318 PN=323
WHT
RED
LT BLU
WHT
RED
1
B
K1 LOAD DUMP RELAY
3
2
5
4
RED
X65
M1 STARTER MOTOR
ORG
1
3
1
ORG
BLU
YEL 2
V9 PILOT SHUTOFF DIODE
WHT
3
X65
V20 PILOT SHUTOFF SWITCH DIODE
ORG 2
X65
SE2 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1254650
S
E03 WHT
V44 STARTER RELAY DIODE
G02
SE14 A1 (X5503 PIN 30)
WHT RED WHT
3
F45 30A FUSE
WHT
1
S4 PILOT SHUTOFF SWITCH 2
S3 PILOT SHUTOFF SWITCH 1
WHT
G1 BATTERY
E13 WHT
RED
+
(S.N. —056599)
BLK
2
TO SE4 A4 (PIN A17)
RED
VLT/GRN
3
1
P22 RED
E
ORG
4
V5 STARTER CUT RELAY DIODE
G3 ALTERNATOR
BLU
5
X175
+ BLK
V1 BATTERY RELAY DIODE
A
RED
WHT
WHT
E
2
K4 STARTER CUT RELAY
3
D+
BLK
B
S
(S.N. 056600— )
B1+
WHT
BLK
FROM SE21 F46
WHT
1
4
VLT
F7 5A FUSE
G02 BLK
RED
FROM SE10 F46
X67
5
K2 PILOT SHUTOFF SOLENOID RELAY
RED
RED
VLT/GRN
F61 50A FUSE
BLK
2
2
WHT/RED
1
RED
X47
4
3
VLT/GRN WHT/RED
WHT/RED
WHT/BLK
3
BLK
WHT/RED
5
VLT/RED
VLT/GRN
VLT/GRN
ST
2
1
RED
TO SE7 A3 (PIN C5)
K5 SECURITY RELAY
BLU
BLU
3
RED
4
1
RED
YEL/GRN BLU
RED
BLK
V10 STARTER PROTECTION DIODE
WHT/RED
M
RED
PNK/BLK
YEL/GRN
WHT
G2
RED
YEL/BLK YEL/BLK
X75
RED
5
V4 SECURITY DIODE
P22 RED
WHT/GRN
4
RED
RED
BLK
G1
4
5
PNK/WHT
VLT/WHT
5
2
1
K13 KEY CUT RELAY
3
V3 LOAD DUMP RELAY DIODE
TO SE14 A1 (X5502 PIN 34)
TO SE18 F63
ORG
2
1
YEL/GRN
K11 IDLE STOP RELAY
BAT
TO SE21 F13
TO SE7 A3 (PIN F1,F2,F3)
WHT
3
3
2
1
F4 20A FUSE
Y10 PILOT SHUTOFF SOLENOID
WHT
WHT/BLK YEL/GRN 1
WHT
4
RED
E03 WHT
1
5
RED
TO SE21 F15
2
2
E03 WHT
WHT/BLU
F18 5A FUSE
YEL/BLK GRN/WHT PNK/BLK
VLT/GRN
ACC
S1 KEY SWITCH
K12 ACCESSORY CUT RELAY
RED
RED
HEAT OFF ACC ON START
6
V11 ACCESSORY CUT DIODE
BLU
RED
3
V12 STARTER CUT DIODE
BLU
1
GRN
WHT
BLU
BLU
BLU
BLU BLU
RED GRN WHT YEL/BLK GRN/WHT
VLT/GRN
WHT
YEL/BLK
RED
M ST
E03 WHT
ACC
VLT/RED
G2
GRN/WHT
G1
YEL/BLK
B
POSITION HEAT OFF ACC ON START
TO SE10 A3 (PIN F13)
VLT WHT
SE3 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-1/34
System Diagrams
TM13345X19 (23APR18)
9015-10-14
160GLC Excavator 042318 PN=324
System Diagrams E22— Battery Disconnect K2—Pilot Shutoff Solenoid Relay V3— Load Dump Relay Diode X65— Cab Harness-to-Pilot Indicator Light V4— Security Diode K4—Starter Cut Relay Shutoff Switch Harness F4— Solenoid 20 A Fuse (marked K5—Security Relay V5— Starter Cut Relay Diode Connector SOLENOID) V7— Start Relay Diode K11— Idle Stop Relay X67— Machine Harness Auxiliary F7— Start Position Signal 5 A V9— Pilot Shutoff Diode K12— Accessory Cut Relay Power Connector Fuse (marked START) V10— Starter Protection Diode K13— Key Cut Relay X75— Cab Harness-to-Pilot F18— Idle Stop 5 A Fuse (marked K19— Battery Relay V11— Accessory Cut Diode Shutoff Valve Harness IDLE STOP) V12— Starter Cut Diode K34— Starter Relay Connector F45— Starter In-Line 30 A Fuse V20— Pilot Shutoff Switch Diode X175— Machine Harness-toM1—Starter Motor F60— Alternator 65 A Fuse V44— Starter Relay Diode S1— Key Switch Engine Interface Harness F61— Battery 45 A Fuse X47— Cab Harness-to-Key S3— Pilot Shutoff Switch 1 Connector 1 G1—Battery Switch Harness Connector Y10— Pilot Shutoff Solenoid S4— Pilot Shutoff Switch 2 G2—Battery S91— Battery Disconnect Switch G3—Alternator V1— Battery Relay Diode K1—Load Dump Relay Continued on next page
TM13345X19 (23APR18)
9015-10-15
JJ03229,000116D -19-06APR18-2/34
160GLC Excavator 042318 PN=325
System Diagrams
TM13345X19 (23APR18)
9015-10-16
160GLC Excavator 042318 PN=326
System Diagrams
TX1216542 —UN—14JUN16
RED GRN WHT RED/BLK
B27 HYDRAULIC P OIL FILTER RESTRICTION SWITCH
BLK
S24
S26
SE5 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1216542
System Functional Schematic (SE4—SE6) (2 of 12) Continued on next page
9015-10-17
160GLC Excavator 042318 PN=327
E7 SWITCH PANEL BACK LIGHT 3
E6 SWITCH PANEL BACK LIGHT 2
3
E8 SWITCH PANEL BACK LIGHT 4
WHT/VLT GRN/WHT
2
13 14
S10 WORK LIGHT SWITCH
BLK 120
A23
A26
A25
TO SE22 A11 (PINS B7, B17)
X29 CAB HARNESSTO-SWITCH PANEL CONNECTOR 3
BLU (CAN 1 LOW)
1
A24
- +
GRN (CAN 1 HIGH)
15
120
BLK/RED
BLK/GRN
RED/GRN
GRY
CABLE CABLE
+
BLU (CAN 0 LOW)
16
3
RED/YEL YEL GRN BLK/YEL BLU D = X22 G = X24
GRN (CAN 0 HIGH)
X30 CAB HARNESSTO-SWITCH PANEL CONNECTOR 4
1
GRY
A = X20 B = X21 C = X23
0 1 2
S23
BLK
TO SE7 A3 (PIN F16)
SE4
TM13345X19 (23APR18)
BLU/RED
2
A1 A28 A13
BRN/BLK PNK
YEL/RED
S27
7
FROM SE20 K7 (PIN 5)
4
G2 G1
BLU/WHT BLK/PNK LT GRN
5
S22
X2 MPDR 6-PIN CONNECTOR
C3 C2 C6 C5 C1
BLU BRN GRY
2
FROM SE22 A11 (PIN B3)
GRN/RED
1
BLK
BLK
RED
14 16 15
RED/GRN
11 10 12
S21
X19 MONITOR 2-PIN CONNECTOR G
A11 B31 A12
8 13 9
4
G2 G1
D3 D2 D9 D1
B26 YEL/RED
B25 BLU/WHT
A7 B30 A9
3
6
WHT
RED RED
S25
A5 B28 A6
WHT/YEL BRN/YEL GRN/BLU
1
A3 B29 A4
WHT/YEL BRN GRN/BLU
A8 B27 A10
X18 C3 C2 C6 C5 C1 MONITOR 12-PIN CONNECTOR C
X3 CAB HARNESSTO-MACHINE HARNESS 100-PIN CONNECTOR
A4 MONITOR CONTROLLER (DSZ)
D = X22 G = X24
YEL/BLU BLU/RED GRY/RED
A17
X64 MACHINE HARNESS-TOREAR CAMERA HARNESS CONNECTOR
E1 E2 E7 E8
RED RED
B21
GRY
BLK
BRN/BLU
B20
4
WHT
WHT
BRN/YEL
B19
3
WHT
ORG
GRY
B1
BLK
GRY
PNK
B2
2
BLK
PNK
GRN
B3
A10 MONITOR
4
1
BLK/YEL
GRN
LT GRN/YEL
B4
X28 CAB HARNESSTO-SWITCH PANEL CONNECTOR 2
1
YEL
LT BLU
1
5
RED
GRN/RED
12
2
BLK
CAN 1
ORG
10
A12 REAR CAMERA
S60 KEYPAD
CAN 0
YEL
9
B5
FROM SE2 F7
Q B18 FUEL LEVEL SENSOR
8
B6
BLK/YEL
BLK
S40 HYDRAULIC OIL TEMPERATURE SWITCH
7
B22
2
IF EQUIPPED
T
VLT
BRN
WHT/BLU
6
RED/BLU BLU/BLK BLK/YEL
X76
1
5
A = X20 B = X21 C = X23 A18
X90 RED
4
B17
WHT/RED
B13
3
GRN/WHT
4
2
YEL/BLU BLK/RED BLK/WHT
GRN/BLK
B11 YEL/BLU
B36
BLK
BLK
B35
BLK
VLT
ORG
A22
E5 SWITCH PANEL BACK LIGHT 1
9
K3 SECURITY ALARM RELAY
A4 MONITOR CONTROLLER (DSZ) D8 B10
8
YEL
RED/BLU
D15
S59
BLU/YEL
WHT/RED
B18
7
YEL BLK/RED WHT
GRN/WHT
D16 A16 D7
6
S58
11
YEL GRN RED/WHT
YEL/WHT D6
5
S57
RED/GRN
3
5
4
S56
YEL
2
2
3
S55
BRN
RED/BLU PNK/GRN 1
2
S54
BLU/BLK
2
1
H3 MONITOR WARNING ALARM
BLK
1
X17 CAB HARNESS-TOMONITOR HARNESS CONNECTOR
TO SE10 A3 (PIN A1)
RED/BLK
H2 SECURITY ALARM
RED/BLU BLU/BLK WHT
1
S53
TO SE21 A6 (PIN 16)
RED/BLU
RED/BLK
4 3
0
S52
RED/GRN
RED/BLK
S51
YEL/GRN BLU ORG
A21
V2 NOT USED
S50
F14 5A FUSE
RED
F9 10A FUSE
BLK/RED
RED
X3 F17 5A FUSE
RED
RED/BLK
RED GRN WHT RED/BLK
WHT/BLU
RED GRN WHT YEL/BLK GRN/WHT
BLK
SE6 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-3/34
System Diagrams
TM13345X19 (23APR18)
9015-10-18
160GLC Excavator 042318 PN=328
System Diagrams
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 S58— 8 Key X24— Monitor Controller 2-Pin K3—Security Alarm Relay S59— 9 Key Connector G S10— Work Light Switch S60— Keypad X28— Cab Harness-to-Switch S21— Blower Motor Speed V2— Not Used Panel Connector 2 Switch X2— MPDr 6-Pin Connector X29— Cab Harness-to-Switch S22— Temperature Control/Mode X3— Cab Harness-to-Machine Panel Connector 3 Switch Harness 100-Pin Connector X30— Cab Harness-to-Switch S23— Radio Volume and Power X17— Cab Harness-to-Monitor Panel Connector 4 Switch Harness Connector X64— Machine Harness-to-Rear S24— Radio Tuning Switch X18— Monitor 12-Pin Connector Camera Harness S25— Monitor Dial C Connector S26— Back Button X19— Monitor 2-Pin Connector G X76— Cab Harness Connector 1 S27— Home Button X20— Monitor Controller 28-Pin (marked HMST) (not used) S40— Hydraulic Oil Temperature Connector A X90— Machine Harness-toSwitch (if equipped) X21— Monitor Controller 36-Pin Hydraulic Oil Temperature S50— 0 Key Connector B Switch Connector S51— 1 Key X22— Monitor Controller 16-Pin S52— 2 Key Connector D S53— 3 Key X23— Monitor Controller 12-Pin S54— 4 Key Connector C S55— 5 Key S56— 6 Key S57— 7 Key Continued on next page
TM13345X19 (23APR18)
9015-10-19
JJ03229,000116D -19-06APR18-4/34
160GLC Excavator 042318 PN=329
System Diagrams
TM13345X19 (23APR18)
9015-10-20
160GLC Excavator 042318 PN=330
System Diagrams
TX1250089 —UN—29JAN18
B11
C4
C16
10
0 A1
BLK
L H
+
BLK CAN 0 CAN 1
R15 ENGINE SPEED DIAL
17
P
P 2
B30 BOOM UP PRESSURE SENSOR (MARKED PI1)
3
P 2
3
B31 ARM IN PRESSURE SENSOR (MARKED PI2)
14
P 2
3
B32 FRONT ATTACHMENT PRESSURE SENSOR (MARKED FRT)
A = X31
C = X33
E = X35
B = X32
D = X34
F = X36
RED/YEL
WHT/VLT
D17
18
2
3
B33 SWING PRESSURE SENSOR (MARKED S3)
2
3
B34 TRAVEL PRESSURE SENSOR (MARKED TR)
P
TM13345X19 (23APR18)
9015-10-21
160GLC Excavator 042318 PN=331
P
YEL
BLK
RED
ORG
RED
P
B37 B36 B35 2 2 2 3 3 3 PUMP 2 PUMP 1 PUMP 1 DELIVERY CONTROL DELIVERY PRESSURE PRESSURE PRESSURE SENSOR (MARKED PP2) SENSOR (MARKED PC1) SENSOR (MARKED PP1)
P B38 2 3 PUMP 2 CONTROL PRESSURE SENSOR (MARKED PC2)
3
B60 ATTACHMENT PRESSURE SENSOR
C1
1
X46
T BLK/YEL
1
P 2
CAN 0 CAN 1
System Functional Schematic (SE7—SE9) (3 of 12) (S.N. —057099) Continued on next page
1
P
SE8 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1250089
1
P
CAN 0 CAN 1
SE7
1
1
D18
2
3
RED/WHT
1
BLK
1
GRY
1
BLK
1
RED
1
FROM SE10 X574 (PIN 4)
VLT
1
FROM SE10 X574 (PIN 11)
RED
FROM SE4 B18
BLK
6 LT GRN/BLK
4
YEL/GRN
S11 TRAVEL MODE SWITCH
5
LT BLU
S8 AUTO-IDLE SWITCH
12
BLU/WHT
8
ORG
WHT
9
WHT/YEL
BLK
C10
BLK/YEL
YEL/RED
C13
13
1
TO SE20 X26 (PIN 1)
RED/YEL
16
C15
YEL/BLK
BLU/YEL BLK/YEL
20
C8
GRN/YEL
BLU/RED BLK/YEL
X40
C14
WHT/GRN
D9
H4 TRAVEL ALARM
X86
C3
BRN/BLU
D15
RED/YEL
D14
BLK/YEL
D7
BLK/YEL
D6
RED/YEL
F26 F17
RED/YEL
F16
S13 TRAVEL ALARM CANCEL SWITCH
RED/YEL
WHT
WHT/YEL
BLU/BLK V43 X46 2-SPEED ACTIVATION SOLENOID VALVE DIODE
8
WHT/YEL
GRN V41 SECONDARY X46 RELIEF SOLENOID VALVE DIODE
1
WHT/YEL
9
A
X46
LT BLU
B12
BLU/WHT V40 X46 SELECTOR VALVE SOLENOID VALVE DIODE
1
11
2
WHT/RED
YEL/GRN
A13
A
K
WHT/BLU
RED
A12
2
F11 5A FUSE
2
LT GRN/BLK
VLT/WHT
A10
1
F5 5A FUSE
BLU
A D B C
BLK/YEL
YEL
A11
K
GRN/BLK BLK
0 1
PNK/GRN
GRN
A14
BLU
BLU/WHT
2
A
WHT
RED/YEL
2
BLK/WHT
WHT/GRN
BRN/YEL
BRN/BLU
2
BLU K
A15
RED/YEL
ORG
2
Y43 2-SPEED ACTIVATION SOLENOID VALVE
X46
BLK
2
F25
RED/YEL
D16
BLK/BLU
F8
RED/YEL
F = X36
1
BLK/RED
D = X34
BLK/YEL
B = X32
1
Y41 SECONDARY RELIEF SOLENOID VALVE
Y40 SELECTOR VALVE SOLENOID VALVE
A3 MAIN CONTROLLER (MCZ)
RED/YEL
E = X35
BLK/YEL
C = X33
F7
BLK/GRN
F9
A = X31
A26 A27 A16 A17 A19 A18
WHT
A3 MAIN CONTROLLER (MCZ)
X3 CAB HARNESS-TOMACHINE HARNESS 100-PIN CONNECTOR
1
GRN/YEL
BLU/RED A6
GRN/YEL
BLU/BLK A7
RED/GRN
GRN/WHT A2
BLK/YEL
BRN/WHT A3
F14
RED/BLK
BLU E6
F13
Y44 FLOW RATE ADJUSTMENT SOLENOID VALVE 1
RED/YEL
BLU E5
F5
RED/YEL
RED F3
F4
BRN/YEL
RED F2
5
F17
BRN/BLU
RED F1
1
F16
Y24 POWER DIG/ TRAVEL SPEED SOLENOID (MARKED SG)
BLK/YEL
BLU
YEL/GRN C5
6
X40 PUMP HARNESSTO-MACHINE HARNESS CONNECTOR
BLK/YEL
BRN
2
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
RED/YEL
2
2
S12 POWER MODE BUTTON
2 YEL
1
BLK/YEL
1
TO SE23 A5 BLU (PIN C1,C2)
X29 CAB HARNESS-TOSWITCH PANEL CONNECTOR 3
X40
X40
BLU
BLU
GRY
FROM SE1 K11 (PIN 2)
3
7
PNK
RED
TO SE22 A11 (PIN A4)
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
Y26 PUMP 1 FLOW RATE LIMIT SOLENOID (MARKED SA)
1
BLK/YEL
FROM SE3 F4
LT GRN
ORG/RED
Y21 Y20 PUMP 2 FLOW F10 TORQUE CONTROL SOLENOID RATE LIMIT SOLENOID 5A (MARKED SB) FUSE (MARKED ST)
RED GRN WHT RED/BLK WHT
RED GRN WHT RED/BLK
GRY/BLK
RED GRN WHT RED/BLK
2
B40 HYDRAULIC OIL TEMPERATURE SENSOR
3
B61 ARM OUT PRESSURE SENSOR CAN 0 CAN 1
SE9 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-5/34
System Diagrams
TM13345X19 (23APR18)
9015-10-22
160GLC Excavator 042318 PN=332
System Diagrams
A3—Main Controller (MCZ) B61— Arm Out Pressure Sensor X3— Cab Harness-to-Machine B30— Boom Up Pressure Sensor F5— Optional and Attachment Harness 100-Pin Connector (marked PI1) Connector 5 A Fuse (marked X29— Cab Harness-to-Switch B31— Arm In Pressure Sensor OPT. 1 ALT) Panel Connector 3 (marked PI2) F10— Data Converter and X31— Cab Harness-to-Main B32— Front Attachment Pressure Main Controller Battery Controller 31-Pin Sensor (marked FRT) Power 5 A Fuse (marked Connector A B33— Swing Pressure Sensor CONTROLLER) X32— Cab Harness-to-Main (marked S3) F11— Travel Alarm 5 A Fuse Controller 24-Pin B34— Travel Pressure Sensor (marked TRAVEL ALARM) Connector B (marked TR) H4—Travel Alarm X33— Cab Harness-to-Main B35— Pump 1 Delivery Pressure R15— Engine Speed Dial Controller 17-Pin Sensor (marked PP1) S8— Auto-Idle Switch Connector C B36— Pump 1 Control Pressure S11— Travel Mode Switch X34— Cab Harness-to-Main Sensor (marked PC1) S12— Power Mode Button Controller 30-Pin B37— Pump 2 Delivery Pressure S13— Travel Alarm Cancel Connector D Sensor (marked PP2) Switch X35— Cab Harness-to-Main B38— Pump 2 Control Pressure V40— Selector Valve Solenoid Controller 24-Pin Sensor (marked PC2) Valve Diode Connector E B40— Hydraulic Oil Temperature V41— Secondary Relief Solenoid X36— Cab Harness-to-Main Sensor Valve Diode Controller 26-Pin B60— Attachment Pressure V43— 2-Speed Activation Connector F Sensor Solenoid Valve Diode X40— Pump Harness-to-Machine Harness Connector X46— Attachment Connector Continued on next page
TM13345X19 (23APR18)
9015-10-23
X86— Machine Harness-to-Travel Alarm Harness 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) Y26— Pump 1 Flow Rate Limit Solenoid (marked SA) Y40— Selector Valve Solenoid Valve Y41— Secondary Relief Solenoid Valve Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve
JJ03229,000116D -19-06APR18-6/34
160GLC Excavator 042318 PN=333
System Diagrams
TM13345X19 (23APR18)
9015-10-24
160GLC Excavator 042318 PN=334
System Diagrams
TX1249800 —UN—29JAN18
+
BLK
B11
2
3
P 2
3
2
3
B32 B33 FRONT B30 B31 SWING ATTACHMENT BOOM UP ARM IN PRESSURE PRESSURE SENSOR PRESSURE SENSOR PRESSURE SENSOR SENSOR (MARKED FRT) (MARKED PI1) (MARKED PI2) (MARKED S3)
2
3
B34 TRAVEL PRESSURE SENSOR (MARKED TR)
P 3
B56 BUCKET CURL PRESSURE SENSOR (MARKED BKC)
2
B57 BUCKET DUMP PRESSURE SENSOR
3
WHT
System Functional Schematic (SE7—SE9) (3 of 12) (S.N. 057100— ) Continued on next page
160GLC Excavator 042318 PN=335
BRN/BLU
WHT/GRN
GRN/YEL
YEL/BLK
13
17
14
WHT/YEL E = X35
B = X32
D = X34
F = X36
D17
RED/YEL
C13
C = X33
WHT/VLT
C15
A = X31
BLK/YEL
RED/YEL
C8
RED/YEL
BLK/YEL
BLK
C10
C14
18
3
YEL
BLK
RED
ORG
1
1
1
P
P
P
B37 B36 B35 2 2 2 3 3 3 PUMP 2 PUMP 1 PUMP 1 DELIVERY CONTROL DELIVERY PRESSURE PRESSURE PRESSURE SENSOR (MARKED PP2) SENSOR (MARKED PC1) SENSOR (MARKED PP1)
P B38 2 3 PUMP 2 CONTROL PRESSURE SENSOR (MARKED PC2)
3
B60 ATTACHMENT PRESSURE SENSOR
C1
1
BLK/YEL 1
P 2
D18
T
RED/WHT
1
RED
BLK
GRY
BLK
RED
VLT
RED
1
RED/YEL
WHT
C3
CAN 0 CAN 1
SE8 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1249800
16
1
TO SE20 X26 (PIN 1)
P
P 2
20
BLK
1
CAN 0 CAN 1
SE7
BLK/YEL
YEL/GRN
1
X40
H4 TRAVEL ALARM
X86
X46 BLU/GRN
1
P
A16
X3 BRN/WHT
BLK/YEL
BLK/YEL
P 2
3
1
RED/YEL
YEL/RED
P
1
GRY/RED
BLU/YEL
P
1
FROM SE10 X574 (PIN 4)
E13
X3
S13 TRAVEL ALARM CANCEL SWITCH
WHT/YEL
10
WHT/YEL
BLU/BLK V43 X46 2-SPEED ACTIVATION SOLENOID VALVE DIODE
8
WHT/YEL
1
C16
D25
BLK/YEL
BLU/RED
1
FROM SE10 X574 (PIN 11)
RED/YEL
BLK/RED
R15 ENGINE SPEED DIAL
FROM SE4 B18
RED/YEL
BLK/YEL 6
BLK
9015-10-25
GRN V41 SECONDARY X46 RELIEF SOLENOID VALVE DIODE
9
C4
D8
BLK/YEL
D9
RED/YEL
D15
RED/YEL
D14
RED/YEL
D7
CAN 0 CAN 1
TM13345X19 (23APR18)
A
X46
LT BLU
YEL/GRN
B12
1
11
2
WHT/RED
RED
A13
BLU/WHT V40 X46 SELECTOR VALVE SOLENOID VALVE DIODE
K
F11 5A FUSE
WHT/BLU
VLT/WHT
A12
A
F5 5A FUSE
A D B C
BLK/YEL
YEL
A10
1
2
PNK/GRN
GRN
A11
K
GRN/BLK BLK
0 1
BLU
BLU/WHT
WHT
A14
BLU
2
A
A15
Y43 2-SPEED ACTIVATION SOLENOID VALVE
BLU K
BLK/WHT
BRN/YEL
2
D6
BLK
2
F26 F17
4
L H
2
F16
RED/YEL
5
2
F25
LT GRN/BLK
LT BLU
12
1
Y41 SECONDARY RELIEF SOLENOID VALVE
Y40 SELECTOR VALVE SOLENOID VALVE
A3 MAIN CONTROLLER (MCZ)
YEL/GRN
ORG 0 A1
ORG
8
D16
WHT
F8
1
GRN/YEL
F = X36
RED GRN WHT RED/BLK
Y44 FLOW RATE ADJUSTMENT SOLENOID VALVE
1
RED/YEL
D = X34
Y24 POWER DIG/ TRAVEL SPEED SOLENOID (MARKED SG)
1
BLK/YEL
B = X32
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
RED/YEL
E = X35
BLK/BLU
BLK/GRN WHT
S12 POWER MODE BUTTON
C = X33
F7
S11 TRAVEL MODE SWITCH
A26 A27 A16 A17 A19 A18
A = X31
BLU/WHT
A3 MAIN CONTROLLER (MCZ)
RED/YEL
A6
X3 CAB HARNESS-TOMACHINE HARNESS 100-PIN CONNECTOR
BLK/YEL
BLU/RED
A7
RED/YEL
BLU/BLK
A2
WHT/GRN
GRN/WHT
A3
F14
RED/GRN
BRN/WHT
E6
F13
RED/BLK
BLU
E5
F5
GRN/YEL
BLU
F3
F4
BRN/YEL
RED
F2
5
F17
BLK/YEL
RED
F1
1
F16
BLK/YEL
RED
C5
6
X40 PUMP HARNESSTO-MACHINE HARNESS CONNECTOR
RED/YEL
BLU
YEL/GRN
BLU
BRN
2
BLK/YEL
2
BRN/BLU
1
2
S8 AUTO-IDLE SWITCH
2 YEL
BRN/BLU
1
TO SE23 A5 BLU (PIN C1,C2)
X29 CAB HARNESS-TOSWITCH PANEL CONNECTOR 3 9
3
X40
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
Y26 PUMP 1 FLOW RATE LIMIT SOLENOID (MARKED SA)
1
7
BLU
F9
LT GRN
ORG/RED
Y20 PUMP 2 FLOW RATE LIMIT SOLENOID X40 (MARKED SB)
GRY
FROM SE1 K11 (PIN 2)
TO SE22 A11 (PIN A4)
PNK
RED
FROM SE3 F4
Y21 TORQUE CONTROL SOLENOID (MARKED ST)
BLK/YEL
F10 5A FUSE
RED GRN WHT RED/BLK
GRY/BLK
RED GRN WHT RED/BLK
2
2
B40 HYDRAULIC OIL TEMPERATURE SENSOR
3
B61 ARM OUT PRESSURE SENSOR CAN 0 CAN 1
SE9 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-7/34
System Diagrams
TM13345X19 (23APR18)
9015-10-26
160GLC Excavator 042318 PN=336
System Diagrams B57— Bucket Dump Pressure A3—Main Controller (MCZ) V43— 2-Speed Activation Sensor B30— Boom Up Pressure Sensor Solenoid Valve Diode B60— Attachment Pressure (marked PI1) X3— Cab Harness-to-Machine Sensor B31— Arm In Pressure Sensor Harness 100-Pin Connector B61— Arm Out Pressure Sensor X29— Cab Harness-to-Switch (marked PI2) B32— Front Attachment Pressure F5— Optional and Attachment Panel Connector 3 Connector 5 A Fuse (marked X31— Cab Harness-to-Main Sensor (marked FRT) OPT. 1 ALT) B33— Swing Pressure Sensor Controller 31-Pin F10— Data Converter and (marked S3) Connector A Main Controller Battery B34— Travel Pressure Sensor X32— Cab Harness-to-Main Power 5 A Fuse (marked (marked TR) Controller 24-Pin CONTROLLER) B35— Pump 1 Delivery Pressure Connector B F11— Travel Alarm 5 A Fuse Sensor (marked PP1) X33— Cab Harness-to-Main (marked TRAVEL ALARM) B36— Pump 1 Control Pressure Controller 17-Pin H4—Travel Alarm Sensor (marked PC1) Connector C B37— Pump 2 Delivery Pressure R15— Engine Speed Dial X34— Cab Harness-to-Main S8— Auto-Idle Switch Sensor (marked PP2) Controller 30-Pin B38— Pump 2 Control Pressure S11— Travel Mode Switch Connector D S12— Power Mode Button Sensor (marked PC2) X35— Cab Harness-to-Main B40— Hydraulic Oil Temperature S13— Travel Alarm Cancel Controller 24-Pin Switch Sensor Connector E V40— Selector Valve Solenoid B56— Bucket Curl Pressure X36— Cab Harness-to-Main Valve Diode Sensor (marked BKC) Controller 26-Pin V41— Secondary Relief Solenoid Connector F Valve Diode X40— Pump Harness-to-Machine Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-10-27
X46— Attachment Connector X86— Machine Harness-to-Travel Alarm Harness 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) Y26— Pump 1 Flow Rate Limit Solenoid (marked SA) Y40— Selector Valve Solenoid Valve Y41— Secondary Relief Solenoid Valve Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve
JJ03229,000116D -19-06APR18-8/34
160GLC Excavator 042318 PN=337
System Diagrams
TM13345X19 (23APR18)
9015-10-28
160GLC Excavator 042318 PN=338
System Diagrams
TX1250416 —UN—18JAN18
RED GRN WHT RED/BLK
X W U
FROM SE14 F38
1
RED
5 3
TO SE24 F6003
RED
7
10
RED/BLK
2
4
GRN/WHT BLK/YEL YEL/BLK WHT/GRN
X5018 MACHINE HARNESSTO-ENGINE INTERFACE HARNESS CONNECTOR 2
PN=339
GRY GRN
GRY
BRN
PUR
WHT
1
BRN
SIGNAL
TO SE24 A6000 (PINS H1, H2)
15
16
48
17
14
R5601 X5018 CAN 0 TERMINATION RESISTOR TO SE24 A6000 (PINS G1, G2)
K
GRY (CAN 0 SHLD)
E
BLU GRN
J H
BLK
A
LT GRN/RED
B
TO SE23 R10 N CAN FROM SE20 F35
BRN
36
18
27
X5015
X5015
D C
BRN 6
ORG
BRN
1
1
4 2
1
P
YEL
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
J
12
GRY
17
WHT
41
BLU
26
ORG
BLU
YEL
52
VLT
08
BRN
27
GRN
11
10
GRN
07
ORG
44
B
SE11
160GLC Excavator 042318
1
BLK LO
160GLC SYSTEM FUNCTIONAL SCHEMATIC
9015-10-29
27
A
System Functional Schematic (SE10—SE12) (4 of 12) (S.N. —056599)
TM13345X19 (23APR18)
49
1
B5209 T FUEL TEMPERATURE SENSOR
3
2
LT BLU
HI
CAN 0 CAN 1
Continued on next page
Q B5600 WATERIN-FUEL (WIF) SENSOR
2
ORG
RETURN GRY
D2
CAN 0 CAN 1
TX1250416
GRY
+5V
GRY
GRN YEL
BLU (CAN 0 LOW) GRN (CAN 0 HIGH)
SE10
GRN
GRN
GRY
YEL
16
YEL GRN BLK
C2
V
B5208 ENGINE T COOLANT TEMPERATURE SENSOR
25
43
LT BLU
S18 SERVICE ADVISOR™ REMOTE (SAR) SWITCH
F2
24
DK GRN
RED
RED
A
E3
M1
X5018
A1
17 21
01
B1
F3
1 2
53 02
= X5503
C1
39
BLK
RED
BLK
RED/BLK
RED/BLK
BLU (CAN 0 LOW)
BLK
BLK
YEL/GRN
YEL/WHT
GRN (CAN 0 HIGH)
L2
GRY
B5102 EXHAUST MANIFOLD PRESSURE SENSOR YEL
Y5400 EXHAUST GAS RECIRCULATION (EGR) VALVE
6 4
3 2 1
P
3
3
Y5402 EXHAUST THROTTLE ACTUATOR
ORG
WITH AFL
L1
F5004 10A FUSE
X42 CAN 1 CONNECTOR
BLU (CAN 1 LOW)
WITHOUT AFL
BLU (CAN 1 LOW)
GRN (CAN 1 HIGH)
GRN/BLK BLK TO SE32
FROM SE4 A4 (PIN D6)
2
GRN (CAN 1 HIGH)
BLK
X544
1
RED
50
= X5502
A15 FLEX POWER CONTROLLER (FPC)
M3
37
-
2 1
FROM SE3 V9
M2
36
+
RIGHT PILOT CONTROL LEVER S7 POWER 0 1 DIG SWITCH
GRN/BLK
22
05
BLK
07
2
GRY 2
BLK
D3
B5107 INLET FUEL PRESSURE SENSOR
3
P
BLK
D2
C
BLK
F6
B
BLK
F5
A
1
GRY
BLK
F4
B5009 ENGINE COOLANT LOSS LEVEL SENSOR
YEL
YEL
E2
1
GRN (CAN 0 HIGH)
E1
P
GRN
A1 F13
= X5501
120
D5
24
YEL
D4
3
B5104 INTAKE MANIFOLD PRESSURE SENSOR
BRN
A1 ENGINE CONTROL UNIT (ECU)
GRN
27 50
F11
1
BLU
12
PUR PUR
F = X36
P
3
2
YEL
BLU
E = X35
D = X34
B5103 EXHAUST GAS RECIRCULATION (EGR) DELTA PRESSURE SENSOR
2
FROM SE16 B5204 (PIN 2) ORG
C = X33
B = X32
X5016 ENGINE INTERFACE HARNESS-TOENGINE HARNESS CONNECTOR 2
RED GRN WHT RED/BLK GRN
B5303 FAN SPEED SENSOR
DK GRN
10
GRN
RED/BLK
RED/BLK
ORG/BLK
BLU/WHT
WHT/BLU
GRY
A = X31
1
X5018
A25 C2 C12 F22 B2 C6 C7 A22 A23 A24 E4
A3 MAIN CONTROLLER (MCZ)
T
B
DK GRN
B5207 EXHAUST GAS RECIRCULATION (EGR) TEMPERATURE SENSOR
2
RED RED
A4 A5 A20 A21 D29 D28
DK GRN
BLU
ORG/BLK BLU/WHT WHT/BLU GRY BLK/BLU BLU/YEL RED/BLU BLK/GRN GRN/BLU YEL/BLU
F8 20A FUSE
GRN
BLK/YEL
BLU/YEL
4
TO SE8 A3 (PIN F25, F26) TO SE7 A3 (PIN F16, F17)
RED/YEL
BLK/BLU
5
10 7 2 6 5 8 12 9 1 3
GRN/RED
6
ORG/BLU
2
YEL/RED
3
BLU/RED
WHT/RED
1
BLU/BLK
X575 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR 2
X574 AUXILIARY 4 FUNCTION LEVER (AFL) 11 CONNECTOR 1
RED GRN WHT RED/BLK GRN
BLU (CAN 0 LOW)
RED GRN WHT RED/BLK
2
B5101 ENGINE OIL PRESSURE SENSOR CAN 1
SE12 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-9/34
System Diagrams
TM13345X19 (23APR18)
9015-10-30
160GLC Excavator 042318 PN=340
System Diagrams
A1—Engine Control Unit (ECU) B5303—Fan Speed Sensor A3—Main Controller (MCZ) B5600—Water-in-Fuel (WIF) A15— Flex Power Controller Sensor (FPC) F8— Engine Control Unit (ECU) B5009—Engine Coolant Loss 20 A Fuse (marked ECU P1) Level Sensor F5004—Flex Power Controller B5101—Engine Oil Pressure (FPC) In-Line 10 A Fuse Sensor R5601—CAN 0 Termination B5102—Exhaust Manifold Resistor Pressure Sensor S7— Power Dig Switch B5103—Exhaust Gas S18— Service ADVISOR™ Recirculation (EGR) Delta Remote (SAR) Switch Pressure Sensor X1— Service ADVISOR™ B5104—Intake Manifold Pressure Diagnostic Connector Sensor X31— Cab Harness-to-Main B5107—Inlet Fuel Pressure Controller 31-Pin Sensor Connector A B5207—Exhaust Gas X32— Cab Harness-to-Main Recirculation (EGR) Controller 24-Pin Temperature Sensor Connector B B5208—Engine Coolant Temperature Sensor B5209—Fuel Temperature Sensor
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 X42— CAN 1 Connector X544— Power Dig Switch Connector X574— Auxiliary Function Lever (AFL) Connector 1 X575— Auxiliary Function Lever (AFL) Connector 2 X5015—Engine Interface Harness-to-Engine Harness Connector 1 X5016—Engine Interface Harness-to-Engine Harness Connector 2
X5018—Machine Harness-toEngine Interface Harness Connector 2 X5501—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 1 X5502—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 2 X5503—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 3 Y5400—Exhaust Gas Recirculation (EGR) Valve Y5402—Exhaust Throttle Actuator
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-31
JJ03229,000116D -19-06APR18-10/34
160GLC Excavator 042318 PN=341
System Diagrams
TM13345X19 (23APR18)
9015-10-32
160GLC Excavator 042318 PN=342
System Diagrams
TX1250417 —UN—18JAN18
RED GRN WHT RED/BLK
TO SE24 F6003
1
3 7
10
2
4
GRN/WHT BLK/YEL YEL/BLK
1
2
TO SE24 A6000 (PINS G1, G2)
E15 ENGINE COMPARTMENT LIGHT
GRY
SIGNAL
16
48
17
14
TO SE24 A6000 (PINS H1, H2)
17
R5601 CAN 0 TERMINATION RESISTOR
X5018 K
J
ORG
BRN
X5015
GRY (CAN 0 SHLD) TO SE23 R10 N CAN FROM SE20 F35
WHT/GRN
BRN 6
PN=343
ORG
BRN
YEL
LT BLU
DK GRN
1
4 2
J H
BLK
A
LT GRN/RED
B
BLU (CAN 0 LOW) GRN (CAN 0 HIGH)
D C
1
2
1
P
3
2
B5102 EXHAUST MANIFOLD PRESSURE SENSOR
6 4
3
E
BLU GRN
LT BLU
BLK
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
36
18
27
X5015
BLK LO
12
GRY
41
WHT
26
BLU
52
VLT
08
10
GRN
27
ORG
YEL
BLK
GRN
11
BRN
07
BLU
44
BLK
BLK
BLK
27
B
System Functional Schematic (SE10—SE12) (4 of 12) (S.N. 056600— )
160GLC Excavator 042318
GRY GRN
15
25
43
A
SE11 160G SYSTEM FUNCTIONAL SCHEMATIC
Continued on next page
1
PUR
GRY
1
BRN
BRN
49
2
ORG
WHT
24
GRN
GRY
39
B5600 WATERIN-FUEL (WIF) SENSOR
B5209 T FUEL TEMPERATURE SENSOR
B5208 T ENGINE 1 COOLANT TEMPERATURE SENSOR
Q
Y5400 EXHAUST GAS RECIRCULATION (EGR) VALVE
1
P
3
3
Y5402 EXHAUST THROTTLE ACTUATOR
2
B5101 ENGINE OIL PRESSURE SENSOR
YEL
CAN 1
TX1250417
9015-10-33
RETURN
GRY HI
CAN 0 CAN 1
SE10
TM13345X19 (23APR18)
+5V
YEL
16
GRN YEL
C2
1 2
2
GRY BRN
GRN 5
01
YEL GRN BLK
J4
S18 SERVICE ADVISOR™ REMOTE X5018 X W U V (SAR) SWITCH
RED/BLK CAN 0 CAN 1
F3 F2
RED
X5018 RED MACHINE HARNESS-TO-ENGINE INTERFACE CONNECTOR 2
17 21
D2
BLU
RED
RED A
FROM SE14 F38
02
A1
C1
GRY
53
B1
E3
M1
50
BLK
RED
BLK
RED/BLK
RED/BLK
BLU (CAN 0 LOW)
BLK
BLK
YEL/GRN
YEL/WHT
GRN (CAN 0 HIGH)
L2
3
P
GRY
ORG
WITH AFL
L1
F5004 10A FUSE
X42 CAN 1 CONNECTOR
BLU (CAN 1 LOW)
WITHOUT AFL
BLU (CAN 1 LOW)
GRN (CAN 1 HIGH)
GRN/BLK BLK TO SE32
FROM SE4 A4 (PIN D6)
2
GRN (CAN 1 HIGH)
BLK
X544
1
M3 RED
B5107 INLET FUEL PRESSURE SENSOR
GRY
37
= X5503
A15 FLEX POWER CONTROLLER (FPC)
M2
C
36
= X5502
D1
B
05
-
2 1
FROM SE3 V9
P023 RED
= X5501
+
RIGHT PILOT CONTROL LEVER S7 POWER 0 1 DIG SWITCH
GRN/BLK
22
24
A
1
2
BLK
GRN
07
1
YEL
D3
B5104 INTAKE MANIFOLD PRESSURE SENSOR
3
P
GRN (CAN 0 HIGH)
D2
2
B5009 ENGINE COOLANT LOSS LEVEL SENSOR
YEL
GRN
F6
A1 ENGINE CONTROL UNIT (ECU)
120
F5
1
YEL
F4
27 50
GRN
E2
12
L055 BRN
E1
P
3
YEL
G001 BLK
A1 F13
ORG
F = X36
X5016 ENGINE INTERFACE HARNESS-TOENGINE HARNESS CONNECTOR 2
FROM SE16 B5204 (PIN 2)
P023 RED
E = X35
D = X34
X5018
B
B5103 EXHAUST GAS RECIRCULATION (EGR) DELTA PRESSURE SENSOR
BLU (CAN 0 LOW)
BLU B022 RED A
0 1
2
RED GRN WHT RED/BLK GRN
B5303 FAN SPEED SENSOR
DK GRN
10
BLU
D5
C = X33
B = X32
T
DK GRN
VLT VLT
D4
F11
A = X31
B5207 EXHAUST GAS RECIRCULATION (EGR) TEMPERATURE SENSOR
2
1
A25 C2 C12 F22 B2 C6 C7 A22 A23 A24 E4
A3 MAIN CONTROLLER (MCZ)
DK GRN
RED RED
RED/BLK
S90 ENGINE COMPARTMENT LIGHT SWITCH
B A4 A5 A20 A21 D29 D28
F8 20A FUSE
F46 7.5A FUSE
RED/BLK
ORG/BLK BLU/WHT WHT/BLU GRY BLK/BLU BLU/YEL RED/BLU BLK/GRN GRN/BLU YEL/BLU
ORG/BLK
10 7 2 6 5 8 12 9 1 3
BLU/WHT
BLK/YEL
WHT/BLU
11
BLK/BLU
4
FROM SE1 K19 (PIN B)
TO SE8 A3 (PIN F25, F26) TO SE7 A3 (PIN F16, F17)
RED/YEL
GRY
YEL/RED
5
4
BLU/YEL
6
GRN/RED
2
ORG/BLU
3
BLU/RED
WHT/RED
1
BLU/BLK
X575 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR 2
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR 1
RED GRN WHT RED/BLK GRN
GRN
RED GRN WHT RED/BLK
CAN 1
SE12 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-11/34
System Diagrams
TM13345X19 (23APR18)
9015-10-34
160GLC Excavator 042318 PN=344
System Diagrams
A1—Engine Control Unit (ECU) B5600—Water-in-Fuel (WIF) X32— Cab Harness-to-Main A3—Main Controller (MCZ) Sensor Controller 24-Pin A15— Flex Power Controller E15— Engine Compartment Light Connector B (FPC) F8— Engine Control Unit (ECU) X33— Cab Harness-to-Main B5009—Engine Coolant Loss 20 A Fuse (marked ECU P1) Controller 17-Pin Level Sensor F46— Engine Light In-Line 7.5 A Connector C B5101—Engine Oil Pressure Fuse X34— Cab Harness-to-Main Sensor F5004—Flex Power Controller Controller 30-Pin B5102—Exhaust Manifold (FPC) In-Line 10 A Fuse Connector D Pressure Sensor R5601—CAN 0 Termination X35— Cab Harness-to-Main B5103—Exhaust Gas Resistor Controller 24-Pin Recirculation (EGR) Delta S7— Power Dig Switch Connector E Pressure Sensor S18— Service ADVISOR™ X36— Cab Harness-to-Main B5104—Intake Manifold Pressure Remote (SAR) Switch Controller 26-Pin Sensor S90— Engine Compartment Light Connector F B5107—Inlet Fuel Pressure Switch X42— CAN 1 Connector Sensor X1— Service ADVISOR™ X544— Power Dig Switch B5207—Exhaust Gas Diagnostic Connector Connector Recirculation (EGR) X31— Cab Harness-to-Main X574— Auxiliary Function Lever Temperature Sensor Controller 31-Pin (AFL) Connector 1 B5208—Engine Coolant Connector A X575— Auxiliary Function Lever Temperature Sensor (AFL) Connector 2 B5209—Fuel Temperature Sensor X5015—Engine Interface B5303—Fan Speed Sensor Harness-to-Engine Harness Connector 1
X5016—Engine Interface Harness-to-Engine Harness Connector 2 X5018—Machine Harness-toEngine Interface Harness Connector 2 X5501—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 1 X5502—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 2 X5503—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 3 Y5400—Exhaust Gas Recirculation (EGR) Valve Y5402—Exhaust Throttle Actuator
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-35
JJ03229,000116D -19-06APR18-12/34
160GLC Excavator 042318 PN=345
System Diagrams
TM13345X19 (23APR18)
9015-10-36
160GLC Excavator 042318 PN=346
System Diagrams
TX1234111 —UN—15FEB17
CAN 1
7
BRN
1
Y3 ELECTRONIC INJECTOR (CYLINDER 3)
Y2 ELECTRONIC INJECTOR (CYLINDER 2)
PUR
BRN
BRN
52
31 54
25 21
6
1
4
16
40
44 35
26
1
T
1
2
Y5024 FUEL RAIL PRESSURE RELIEF VALVE (PRV)
18
System Functional Schematic (SE13—SE15) (5 of 12) (S.N. —056599) Continued on next page
160GLC Excavator 042318 PN=347
= X5501 = X5502 = X5503
05
C
X5016
1
B5206 MANIFOLD AIR TEMPERATURE (MAT) SENSOR
T 2
ORG
SE14 160GLC SYSTEM FUNCTIONAL SCHEMATIC (S.N. —056599)
A1 ENGINE CONTROL UNIT (ECU)
BRN
37
ORG
51
BRN
09
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
6
24
X5016
FROM SE3 G3 (PIN D+)
2
29
C
1
P
2
3
X5018
B5113 FUEL RAIL PRESSURE SENSOR
VLT/GRN
12
X5016 FROM SE2 E22
09
45
1
B5205 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
3
2
FROM SE1 K4 (PIN 2)
B5105 CRANK CASE PRESSURE SENSOR
ORG
CAN 1
TX1234111
5
SHLD
BLK
BLK
50
53
GRN
15
LO
B
GRN (AT CAN LOW)
5
-
HI
YEL (AT CAN HIGH)
4
RED BLU BLU GRN YEL BLK
3
RED BLU GRN YEL BLK
1
9 10 11 12
ORG
34
CAN 1
9015-10-37
8
GRN
WHT
SHD
WHT
3
SE13
TM13345X19 (23APR18)
6
+ 120
GRN
GRY YEL RED
X
LT BLU
SHD
BLK
C
PUR
ORG
J
LT BLU
BLU
W
E
Y4 ELECTRONIC INJECTOR (CYLINDER 4) PUR
06 46
F
23
RED BRN PUR
GRY
BLU
PUR
49
30
34
B
Y1 ELECTRONIC INJECTOR (CYLINDER 1)
20
06
03
A
8
= X5503
02
33
2
5
= X5502
YEL
X5000 4 ENGINE HARNESS-TOFUEL INJECTOR HARNESS CONNECTOR
19 51
GRN
D
= X5501
04
DK GRN
43
ORG
X5068 ENGINE INTERFACE HARNESS-TOENGINE HARNESS CONNECTOR 3
44
BRN
28
A1 ENGINE CONTROL UNIT (ECU)
4
1
TO SE24 F6001
YEL
45
TO SE10 F5004
GRY
46
RED
RED
YEL
30
FROM SE16 X5502 (PIN 28)
GRY
DK GRN
38
GRY
GRY
29
ORG
PUR
35
BLU/RED
G
ORG
DK GRN
SHD
X5018
B5601 DIESEL EXHAUST FLUID (DEF) TANK LEVEL SENSOR
3
B5218 AFTERTREATMENT OUTLET NOX SENSOR B5503 SCR OUTLET NOX SENSOR
RED GRN WHT RED/BLK
A
YEL WHT GRN ORG BRN GRN YEL BLU GRY PUR
Y5019 COOLANT CONTROL VALVE
2
DK GRN
2
B5211 DIESEL EXHAUST FLUID (DEF) TANK TEMPERATURE SENSOR
WHT
1
B5500 INTAKE AIR SENSOR
GRN
4
T/U
F38 20A FUSE
A5507 DIESEL EXHAUST FLUID (DEF) TANK HEADER ASSEMBLY
BLU
N2
3
R5603 ENGINE CAN TERMINATION RESISTOR
B5502 SCR INLET NOX SENSOR
B5501 DIESEL EXHAUST FLUID (DEF) DOSING UNIT
3
5 4
LT BLU
1
2 GRN (ENG CAN LOW) YEL (ENG CAN HIGH)
ORG
N1
B5217 AFTERTREATMENT INLET NOX SENSOR
BLK
BLU
B5301 CRANKSHAFT POSITION SENSOR
120
2
RED GRN WHT RED/BLK GRN BLK
LT BLU
B5302 CAMSHAFT POSITION SENSOR
RED GRN WHT RED/BLK GRN BLK
GRN
RED GRN WHT RED/BLK GRN GRY BLK
CAN 1
SE15 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-13/34
System Diagrams
TM13345X19 (23APR18)
9015-10-38
160GLC Excavator 042318 PN=348
System Diagrams
A1—Engine Control Unit (ECU) B5301—Crankshaft Position A5507—Diesel Exhaust Fluid Sensor (DEF) Tank Header B5302—Camshaft Position Assembly Sensor B5105—Crankcase Pressure B5500—Intake Air Sensor Sensor B5501—Diesel Exhaust Fluid B5113—Fuel Rail Pressure (DEF) Dosing Unit Sensor B5502—Selective Catalytic B5205—Charge Air Cooler Outlet Reduction (SCR) Inlet Temperature Sensor NOx Sensor B5206—Manifold Air Temperature B5503—Selective Catalytic (MAT) Sensor Reduction (SCR) Outlet B5211—Diesel Exhaust Fluid NOx Sensor (DEF) Tank Temperature B5601—Diesel Exhaust Fluid Sensor (DEF) Tank Level Sensor B5217—Aftertreatment Inlet NOx F38— Fuel Transfer Pump and Sensor Controllers 20 A Fuse B5218—Aftertreatment Outlet (marked ECU P4) NOx Sensor R5603—Engine CAN Termination Resistor
R5605—Aftertreatment CAN X5503—Engine Control Unit Termination Resistor (ECU)-to-Engine Interface X5000—Engine Harness-to-Fuel Harness Connector 3 Injector Harness Y1— Electronic Injector (cylinder Connector 1) X5016—Engine Interface Y2— Electronic Injector (cylinder Harness-to-Engine 2) Harness Connector 2 Y3— Electronic Injector (cylinder X5018—Machine Harness-to3) Engine Interface Harness Y4— Electronic Injector (cylinder Connector 2 4) X5068—Engine Interface Y5019—Coolant Control Valve Harness-to-Engine Y5024—Fuel Rail Pressure Relief Harness Connector 3 Valve (PRV) X5501—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 1 X5502—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 2
Continued on next page
TM13345X19 (23APR18)
9015-10-39
JJ03229,000116D -19-06APR18-14/34
160GLC Excavator 042318 PN=349
System Diagrams
TM13345X19 (23APR18)
9015-10-40
160GLC Excavator 042318 PN=350
System Diagrams
TX1234116 —UN—23FEB17
PUR CAN 1
6
1
4
5
1
7
Y3 ELECTRONIC INJECTOR (CYLINDER 3)
Y2 ELECTRONIC INJECTOR (CYLINDER 2)
PUR
B
GRN (AT CAN LOW)
5
LO
A
YEL (AT CAN HIGH)
4
50
BRN
SHLD
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
C
6
31 54
25 21
53
16
40
44 35
2 FROM SE3 G3 (PIN D+)
1
Y5024 FUEL RAIL PRESSURE RELIEF VALVE (PRV)
1
T 2
18
TX1234116
System Functional Schematic (SE13—SE15) (5 of 12) (S.N. 056600— ) Continued on next page
160GLC Excavator 042318 PN=351
= X5503
05
24
C
DK GRN
1
1
B5206 MANIFOLD AIR TEMPERATURE (MAT) SENSOR
T 2
P
2
3
X5018
B5113 FUEL RAIL PRESSURE SENSOR
VLT/GRN
X5016
1
B5205 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
3
2
FROM SE1 K4 (PIN 2)
B5105 CRANKCASE PRESSURE SENSOR
ORG
CAN 1
SE14 160GLC SYSTEM FUNCTIONAL SCHEMATIC (S.N. 056600— )
= X5501 = X5502
BRN
GRN
37
ORG
51
BRN
09
ORG
GRN
26
X5016 LT BLU
FROM SE2 E22
BLU
12
X5016
45
29
A1 ENGINE CONTROL UNIT (ECU)
WHT
43
09
ORG
WHT
15
CAN 1
9015-10-41
3
7
LT BLU
WHT
3
34
BLU
RED
X
LT BLU
BLK
C LT BLU
ORG
W
BLU
F
J
SE13
TM13345X19 (23APR18)
1
9 10 11 12
-
HI
RED BLU GRN YEL
4
30
E
RED PUR
1
06
23
Y4 ELECTRONIC INJECTOR (CYLINDER 4)
8
RED BLU BLU GRN YEL
YEL
RED
GRY = X5503
BRN
BLU
GRY
8
6
52 34
B
Y1 ELECTRONIC INJECTOR (CYLINDER 1)
2
46
03
A
2
3
20
YEL
X5000 ENGINE HARNESS-TO- 4 FUEL INJECTOR HARNESS CONNECTOR
51
02
GRN
D
5
+ 120
Q
= X5502 33
4
B5218 B5503 AFTERTREATMENT SELECTIVE OUTLET NOx SENSOR CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
GRN YEL
= X5501
04
DK GRN
43
ORG
X5068 ENGINE INTERFACE HARNESS-TOENGINE HARNESS CONNECTOR 3
44
BRN
28
A1 ENGINE CONTROL UNIT (ECU)
T
3
RED GRN WHT RED/BLK
GRN RED
YEL
45
GRY
GRY
ORG
YEL
DK GRN 46
RED
30
2
B5601
B5506
TO SE24 F6001
TO SE10 F5004
BRN
GRN
38
FROM SE16 X5502 (PIN 28)
1
B5211
BRN WHT BLU ORG BRN GRN YEL BLU GRY VLT
G
PUR
YEL
29
Y5019 COOLANT CONTROL VALVE
B5502 B5217 SELECTIVE AFTERTREATMENT CATALYTIC INLET NOx SENSOR REDUCTION (SCR) INLET NOx SENSOR
B5501 DIESEL EXHAUST FLUID (DEF) DOSING UNIT
SHD
2
4
X5018
YEL
GRN
1
B5500 INTAKE AIR SENSOR
SHD
9
4
PUR
GRY
8
3
R5603 ENGINE CAN TERMINATION RESISTOR
A5507B DIESEL EXHAUST FLUID (DEF) TANK HEADER B
BRN
PUR
2
SHD
X5015 3
35
GRN (ENG CAN LOW) YEL (ENG CAN HIGH)
N2
ORG
1
DK GRN
N1
F38 20A FUSE
120
2
B5301 CRANKSHAFT POSITION SENSOR
RED GRN WHT RED/BLK GRN
BLU/RED
B5302 CAMSHAFT POSITION SENSOR
RED GRN WHT RED/BLK GRN
GRN
RED GRN WHT RED/BLK GRN GRY
CAN 1
SE15 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-15/34
System Diagrams
TM13345X19 (23APR18)
9015-10-42
160GLC Excavator 042318 PN=352
System Diagrams
A1—Engine Control Unit (ECU) B5302—Camshaft Position R5605—Aftertreatment CAN X5502—Engine Control Unit A5507B—Diesel Exhaust Fluid Sensor Termination Resistor (ECU)-to-Engine Interface (DEF) Tank Header B B5500—Intake Air Sensor X5000—Engine Harness-to-Fuel Harness Connector 2 B5105—Crankcase Pressure B5501—Diesel Exhaust Fluid Injector Harness X5503—Engine Control Unit Sensor (DEF) Dosing Unit Connector (ECU)-to-Engine Interface B5113—Fuel Rail Pressure B5502—Selective Catalytic X5015—Engine Interface Harness Connector 3 Sensor Reduction (SCR) Inlet Harness-to-Engine Y1— Electronic Injector (cylinder B5205—Charge Air Cooler Outlet NOx Sensor Harness Connector 1 1) Temperature Sensor B5503—Selective Catalytic X5016—Engine Interface Y2— Electronic Injector (cylinder B5206—Manifold Air Temperature Reduction (SCR) Outlet Harness-to-Engine 2) (MAT) Sensor NOx Sensor Harness Connector 2 Y3— Electronic Injector (cylinder B5211—Diesel Exhaust Fluid B5506—Diesel Exhaust Fluid X5018—Machine Harness-to3) (DEF) Tank Temperature (DEF) Tank Concentration Engine Interface Harness Y4— Electronic Injector (cylinder Sensor Sensor Connector 2 4) B5217—Aftertreatment Inlet NOx B5601—Diesel Exhaust Fluid X5068—Engine Interface Y5019—Coolant Control Valve Sensor (DEF) Tank Level Sensor Harness-to-Engine Y5024—Fuel Rail Pressure Relief B5218—Aftertreatment Outlet F38— Fuel Transfer Pump and Harness Connector 3 Valve (PRV) NOx Sensor Controllers 20 A Fuse X5501—Engine Control Unit B5301—Crankshaft Position (marked ECU P4) (ECU)-to-Engine Interface Sensor R5603—Engine CAN Termination Harness Connector 1 Resistor Continued on next page
TM13345X19 (23APR18)
9015-10-43
JJ03229,000116D -19-06APR18-16/34
160GLC Excavator 042318 PN=353
System Diagrams
TM13345X19 (23APR18)
9015-10-44
160GLC Excavator 042318 PN=354
System Diagrams
TX1234117 —UN—15FEB17
RED GRN WHT RED/BLK
RED GRN WHT RED/BLK FROM SE3 G3 (PIN B1+)
19
35
= X5501
14
18
22
26
38
2
21
32
54
B5202 DIESEL OXIDATION CATALYST (DOC) OUTLET TEMPERATURE SENSOR
40
01
39
ORG
A1 ENGINE CONTROL UNIT (ECU)
D
E
24
= X5501
F37 20A FUSE
23
X5018 MACHINE HARNESSTO-ENGINE INTERFACE HARNESS CONNECTOR 2
13 14
= X5502 = X5503
11
12
42
41
1
B5213 DIESEL PARTICULATE FILTER (DPF) OUTLET PRESSURE SENSOR
1 2 3 4
B5204 EXHAUST FILTER B5216 SELECTIVE CATALYTIC TEMPERATURE MODULE REDUCTION (SCR) INLET TEMPERATURE SENSOR
B5214 DIESEL PARTICULATE FILTER (DPF) INLET PRESSURE SENSOR
CAN 1
2 1
1 2 3
Y5002 SUCTION CONTROL VALVE (SCR)
BRN ORG
B5109 EXHAUST FILTER DELTA PRESSURE SENSOR
CAN 1
SE16
System Functional Schematic (SE16—SE18) (6 of 12) (S.N. —056599) Continued on next page
160GLC Excavator 042318 PN=355
1 2
1
2
PUR
GRY
E5602 DIESEL EXHAUST FLUID (DEF) DOSING UNIT SUPPLY LINE HEATER
1
2
E5603 DIESEL EXHAUST FLUID (DEF) DOSING UNIT RETURN LINE HEATER
Y5020 DIESEL EXHAUST FLUID (DEF) DOSING INJECTOR
CAN 1
SE17 160GLC SYSTEM FUNCTIONAL SCHEMATIC (S.N. —056599)
TX1234117
9015-10-45
2
E5601 DIESEL EXHAUST FLUID (DEF) DOSING UNIT PRESSURE LINE HEATER
YEL
BRN
GRN YEL
GRN
TO SE13 B5500 (PIN 1)
YEL GRN ORG BLU
B5201 DIESEL OXIDATION CATALYST (DOC) INLET TEMPERATURE SENSOR
42
ORG BRN
47
WHT
28
10
YEL
13
YEL GRN GRN
= X5503
F63 50A FUSE
X5604 ENGINE HARNESS-TOGLOW PLUG HARNESS CONNECTOR
32
16 06
R4
RED
1
= X5502
TO SE11 A1 (PIN 24)
TM13345X19 (23APR18)
3
ORG
FROM SE20 F6
A1 ENGINE CONTROL UNIT (ECU)
2
R3
F36 20A FUSE
RED
ORG
2
PUR
RED
TAN
X83 CAB HARNESS-TOREVERSING FAN SWITCH HARNESS
RED
3
TAN
PUR
BLU
X5018 S16 EXHAUST FILTER PARKED CLEANING SWITCH
WHT
2
1
R2
R19 GLOW PLUG RESISTOR YEL
1
2
T
Y5014 VARIABLE SPEED FAN SOLENOID
BRN
ORG/BLK
Y5015 REVERSING FAN SOLENOID
DK GRN
5
Y5501 FUEL TRANSFER PUMP
1
ORG
RED/BLK
1
ORG
1
M GRN
S
X5018
2
1
S15 REVERSING FAN SWITCH
ORG YEL
M O A
ORG/GRN
YEL
9
LT GRN
8
BLK
4
RED/BLU
2
K16 GLOW PLUG RELAY R1
RED
3
RED
1 3
RED
RED
RED
RED GRN WHT RED/BLK
RED
RED GRN WHT RED/BLK
CAN 1
SE18 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-17/34
System Diagrams
TM13345X19 (23APR18)
9015-10-46
160GLC Excavator 042318 PN=356
System Diagrams E5601—Diesel Exhaust Fluid A1—Engine Control Unit (ECU) R3—Glow Plug 3 X5503—Engine Control Unit (DEF) Dosing Unit B5109—Exhaust Filter Delta R4—Glow Plug 4 (ECU)-to-Engine Interface Pressure Line Heater Pressure Sensor R19— Glow Plug Resistor Harness Connector 3 B5201—Diesel Oxidation Catalyst E5602—Diesel Exhaust Fluid S15— Reversing Fan Switch X5604—Engine Harness-to-Glow (DEF) Dosing Unit Supply S16— Exhaust Filter Parked (DOC) Inlet Temperature Plug Harness Connector Line Heater Sensor Cleaning Switch Y5002—Suction Control Valve B5202—Diesel Oxidation Catalyst E5603—Diesel Exhaust Fluid X83— Cab Harness-to-Reversing (SCR) (DEF) Dosing Unit Return (DOC) Outlet Temperature Fan Switch Harness Y5014—Variable Speed Fan Line Heater Sensor (marked VSF-SW) Solenoid F36— Engine Control Unit (ECU) X5018—Machine Harness-toB5204—Exhaust Filter Y5015—Reversing Fan Solenoid 20 A Fuse (marked ECU P2) Temperature Module Engine Interface Harness Y5020—Diesel Exhaust Fluid B5213—Diesel Particulate Filter F37— Engine Control Unit (ECU) Connector 2 (DEF) Dosing Injector 20 A Fuse (marked ECU P3) X5501—Engine Control Unit (DPF) Outlet Pressure Y5501—Fuel Transfer Pump F63— Glow Plug 50 A Fuse Sensor (ECU)-to-Engine Interface B5214—Diesel Particulate Filter K16— Glow Plug Relay Harness Connector 1 R1—Glow Plug 1 (DPF) Inlet Pressure X5502—Engine Control Unit R2—Glow Plug 2 Sensor (ECU)-to-Engine Interface B5216—Selective Catalytic Harness Connector 2 Reduction (SCR) Inlet Temperature Sensor Continued on next page
TM13345X19 (23APR18)
9015-10-47
JJ03229,000116D -19-06APR18-18/34
160GLC Excavator 042318 PN=357
System Diagrams
TM13345X19 (23APR18)
9015-10-48
160GLC Excavator 042318 PN=358
System Diagrams
TX1234119 —UN—15FEB17
RED GRN WHT RED/BLK
RED GRN WHT RED/BLK FROM SE3 G3 (PIN B1+)
54
32
TO SE13 B5500 (PIN 1) GRN YEL
B5202 DIESEL OXIDATION CATALYST (DOC) OUTLET TEMPERATURE SENSOR
40
01
39
1
B5213 DIESEL PARTICULATE FILTER (DPF) OUTLET PRESSURE SENSOR
YEL GRN ORG BLU
B5201 DIESEL OXIDATION CATALYST (DOC) INLET TEMPERATURE SENSOR
42
1 2 3 4
B5204 EXHAUST FILTER B5216 SELECTIVE CATALYTIC TEMPERATURE MODULE REDUCTION (SCR) INLET TEMPERATURE SENSOR
B5214 DIESEL PARTICULATE FILTER (DPF) INLET PRESSURE SENSOR
CAN 1
2 1
1 2 3
Y5002 SUCTION CONTROL VALVE (SCR)
BRN ORG
B5109 EXHAUST FILTER DELTA PRESSURE SENSOR
CAN 1
SE16
System Functional Schematic (SE16—SE18) (6 of 12) (S.N. 056600— ) Continued on next page
160GLC Excavator 042318 PN=359
= X5503
E5601 DIESEL EXHAUST FLUID (DEF) DOSING UNIT PRESSURE LINE HEATER
1 2
RED
RED/BLU
RED
23
X5018 MACHINE HARNESSTO-ENGINE INTERFACE HARNESS CONNECTOR 2
13 14
= X5502 11
12
42
41
1
2
E5602 DIESEL EXHAUST FLUID (DEF) DOSING UNIT SUPPLY LINE HEATER
1
2
E5603 DIESEL EXHAUST FLUID (DEF) DOSING UNIT RETURN LINE HEATER
Y5020 DIESEL EXHAUST FLUID (DEF) DOSING INJECTOR
CAN 1
SE17 160GLC SYSTEM FUNCTIONAL SCHEMATIC (S.N. 056600— )
TX1234119
9015-10-49
2
E
24
= X5501
BRN
47
ORG
28
ORG BRN
= X5503
10
WHT
06
13
YEL
16
A1 ENGINE CONTROL UNIT (ECU)
D
RED
32
X5604 ENGINE HARNESS-TOGLOW PLUG HARNESS CONNECTOR
= X5502
TO SE11 A1 (PIN 24)
TM13345X19 (23APR18)
2
F37 20A FUSE
VLT
21
26
1
F63 50A FUSE
RED
ORG 22
R4
F36 20A FUSE
GRY
14
18
38
R3
GRN
19
35
= X5501
23
BLK
YEL GRN GRN
A1 ENGINE CONTROL UNIT (ECU)
2
X5016
FROM SE20 F6
R2
R19 GLOW PLUG RESISTOR RED
2
VLT
RED
TAN
TAN
VLT
BLU
X83 CAB HARNESS-TOREVERSING FAN SWITCH HARNESS
K16 GLOW PLUG RELAY R1
X5604
WHT
3
Y5014 VARIABLE SPEED FAN SOLENOID
YEL
2
1
Y5015 REVERSING FAN SOLENOID
BRN
1
2
T
X5018 S16 EXHAUST FILTER PARKED CLEANING SWITCH
4
LT BLU
ORG/BLK
2
BLK
5
Y5501 FUEL TRANSFER PUMP
1
BLK
RED/BLK
1
BLK
1
M GRN
S
X5018
3
3
2
1
S15 REVERSING FAN SWITCH
ORG YEL
M O A
ORG/GRN
YEL
9
LT GRN
8
BLK
1
RED
3
RED
DK GRN
RED
RED
RED GRN WHT RED/BLK
YEL
RED GRN WHT RED/BLK
CAN 1
SE18 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-19/34
System Diagrams
TM13345X19 (23APR18)
9015-10-50
160GLC Excavator 042318 PN=360
System Diagrams E5601—Diesel Exhaust Fluid A1—Engine Control Unit (ECU) R4—Glow Plug 4 X5503—Engine Control Unit (DEF) Dosing Unit B5109—Exhaust Filter Delta R19— Glow Plug Resistor (ECU)-to-Engine Interface Pressure Line Heater Pressure Sensor S15— Reversing Fan Switch Harness Connector 3 B5201—Diesel Oxidation Catalyst E5602—Diesel Exhaust Fluid S16— Exhaust Filter Parked X5604—Engine Harness-to-Glow (DEF) Dosing Unit Supply (DOC) Inlet Temperature Cleaning Switch Plug Harness Connector Line Heater Sensor X83— Cab Harness-to-Reversing Y5002—Suction Control Valve B5202—Diesel Oxidation Catalyst E5603—Diesel Exhaust Fluid Fan Switch Harness (SCR) (DEF) Dosing Unit Return (DOC) Outlet Temperature (marked VSF-SW) Y5014—Variable Speed Fan Line Heater Sensor X5016—Engine Interface Solenoid F36— Engine Control Unit (ECU) B5204—Exhaust Filter Harness-to-Engine Y5015—Reversing Fan Solenoid 20 A Fuse (marked ECU P2) Temperature Module Harness Connector 2 Y5020—Diesel Exhaust Fluid B5213—Diesel Particulate Filter F37— Engine Control Unit (ECU) X5018—Machine Harness-to(DEF) Dosing Injector 20 A Fuse (marked ECU P3) (DPF) Outlet Pressure Engine Interface Harness Y5501—Fuel Transfer Pump F63— Glow Plug 50 A Fuse Sensor Connector 2 B5214—Diesel Particulate Filter K16— Glow Plug Relay X5501—Engine Control Unit R1—Glow Plug 1 (DPF) Inlet Pressure (ECU)-to-Engine Interface R2—Glow Plug 2 Sensor Harness Connector 1 R3—Glow Plug 3 B5216—Selective Catalytic X5502—Engine Control Unit Reduction (SCR) Inlet (ECU)-to-Engine Interface Temperature Sensor Harness Connector 2 Continued on next page
TM13345X19 (23APR18)
9015-10-51
JJ03229,000116D -19-06APR18-20/34
160GLC Excavator 042318 PN=361
System Diagrams
TM13345X19 (23APR18)
9015-10-52
160GLC Excavator 042318 PN=362
System Diagrams
TX1231171 —UN—22DEC16
RED GRN WHT RED/BLK
RED WHT RED/BLK
(S.N. —056599)
TO SE1 K19 (PIN B)
G22 BRN 0 1
RED
B22 RED
WHT
WHT/BLK
RED
GRN
YEL/RED
RED/BLU
GRN
BLK
BLK
GRN
GRN
FROM SE9 F5
B25 RIGHT SPEAKER
8 ACCESSORY RED/BLU
16
(B+) (+)
A6 RADIO
FROM SE5 F9
(-)
2 10
ORG BRN
2 4
GRN/RED WHT
B26 LEFT SPEAKER
E1 WORK LIGHT
E2 BOOM LIGHT
TO SE29 X55 (PIN 1)
SE20 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1231171
System Functional Schematic (SE19—SE21) (7 of 12) (S.N. —057099) Continued on next page
160GLC Excavator 042318 PN=363
3 6
GRN
X25 CAB HARNESS AUXILIARY POWER CONNECTOR 1 (AUX +/-)
1 2 6 4 5
WHT BLK GRY YEL/BLU BLK
14 6 5 7
X77 RADIO AUXILIARY CONNECTOR
X26 OPTIONAL CONNECTOR
CAN 1
SE19
4 5 1 2
BLK
BLK
(+) (-)
15
4
12
BLU (CAN 1 LOW)
TO SE6 X29 (PIN 16)
BLU/RED
9015-10-53
-
W60 RADIO ANTENNA
BLU/RED
CAN 1
TM13345X19 (23APR18)
+
B
S90 ENGINE COMPARTMENT LIGHT SWITCH
YEL/RED RED/BLU
GRN (CAN 1 HIGH)
WHT
F46 7.5A FUSE
BLK
E
BLU/RED
1
F15 10A FUSE
V6 AUXILIARY POWER CONNECTOR DIODE
BLK
BLK
4
R9 LIGHTER
LT GRN/RED
L
5
K8 BOOM LIGHT RELAY
BLU/RED RED/BLU WHT/YEL RED
RED
LB
2
3
BLK
B
M6 WINDSHIELD WASHER MOTOR L
FROM SE22 A11 (PIN A5)
4
1
2
FROM SE22 A11 (PIN A2)
BLK
BLU
VLT
M5 WINDSHIELD WIPER MOTOR
5
K7 WORK LIGHT RELAY
TO SE16 X83 (PIN 3)
RED/BLU
TO SE23 X27 (PIN 8)
X3 BLK/BLU
S28 WINDOW SWITCH
3
FROM SE22 A11 (PIN A6) B11
A8 12-VOLT POWER CONVERTER 4
F13 10A FUSE
1
F12 5A FUSE
E15 ENGINE COMPARTMENT LIGHT
BLU/YEL
3
F20 5A FUSE
RED/BLU
4
VLT
5
2
K9 WINDSHIELD WASHER RELAY
3
2
1
F6 20A FUSE
RED BLU
ORG
RED/BLU
BLK WHT
BLU RED
1
GRN
RED/BLK
3
RED/YEL
4
BLU/RED
2
BLU/RED
FROM SE22 A11 (PIN B9)
1
YEL
BLK
LT GRN/RED
G5 12-VOLT POWER OUTLET 1
BLK/RED BLK
X39 CAB HARNESSTO-WINDOW SWITCH
F62 WIPER MOTOR ASSEMBLY CIRCUIT BREAKER
TO SE11 X1 (PIN B)
F16 10A FUSE
2
BLK/PNK
S
F35 5A FUSE
GRN
RED/BLK
BLK/RED
4
K6 WINDSHIELD WIPER RELAY
F1 20A FUSE
BLK/RED
5
GRY/RED
2
3
RED/BLK
1
BLK/YEL
BLK/YEL
RED/BLK
2
F2 10A FUSE
A
G01 BLK
FROM SE1 X47 (PIN 5)
GRN
FROM SE1 K12 (PIN 4)
RED
WHT
WHT
WHT
WHT
BLK/YEL
WHT
RED GRN WHT RED/BLK
1 9
GRY/BLK WHT/BLK
1 3
GRY/BLK WHT/BLK
X73 CAB HARNESSTO-SPEAKERS CONNECTOR
TO SE29, SE31
CAN 1
SE21 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-21/34
System Diagrams
TM13345X19 (23APR18)
9015-10-54
160GLC Excavator 042318 PN=364
System Diagrams A6—Radio W60—Radio Antenna F13— Lighter 10 A Fuse (marked F62— Wiper Motor Assembly A8—12-Volt Power Converter Circuit Breaker X3— Cab Harness-to-Machine LIGHTER) B25— Right Speaker G5—12-Volt Power Outlet Harness 100-Pin Connector F15— Cab Auxiliary Power B26— Left Speaker K6—Windshield Wiper Relay X25— Cab Harness Auxiliary Connector 1 10 A Fuse E1— Work Light K7—Work Light Relay Power Connector 1 (marked AUX) E2— Boom Light K8—Boom Light Relay (marked AUX +/-) F16— 12-Volt Power Unit 10 A E15— Engine Compartment Light K9—Windshield Washer Relay X26— Optional Connector Fuse (marked 12V UNIT) F1— Work and Boom Lights 20 A F20— Optional Connector 5 A M5—Windshield Wiper Motor X39— Cab Harness-to-Window Fuse (marked LAMP) Switch Fuse (marked OPT. 3 BATT) M6—Windshield Washer Motor F2— Windshield Wiper and R9—Lighter X73— Cab Harness-to-Speakers F35— Service ADVISOR™ Washer 10 A Fuse (marked Connector Diagnostic Connector 5 A S28— Window Switch WIPER) S90— Engine Compartment Light X77— Radio Auxiliary Connector Fuse (marked DIAG) F6— Optional Connector and Switch F46— Engine Light In-Line 7.5 A Reversing Fan 20 A Fuse V6— Auxiliary Power Connector Fuse (marked OPT. 2 ALT) Diode F12— Radio and Dome 5 A Fuse (marked RADIO) Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-55
JJ03229,000116D -19-06APR18-22/34
160GLC Excavator 042318 PN=365
System Diagrams
TM13345X19 (23APR18)
9015-10-56
160GLC Excavator 042318 PN=366
System Diagrams
TX1250512 —UN—08FEB18
RED GRN WHT RED/BLK
RED
CAN 1
SE19
SE20 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1250512
System Functional Schematic (SE19—SE21) (7 of 12) (S.N. 057100— ) Continued on next page
160GLC Excavator 042318 PN=367
WHT
WHT/BLK
GRN
RED
WHT WHT/YEL
TO SE29 X55 (PIN 1)
4 5 1 2
X25 CAB HARNESS AUXILIARY POWER CONNECTOR 1 (AUX +/-)
YEL/RED
RED/BLU
GRN GRN
8 ACCESSORY RED/BLU
16
(B+) (+)
A6 RADIO
FROM SE5 F9
1 2 6 4 5
WHT BLK GRY YEL/BLU BLK
(-)
ORG BRN
2 4
GRN/RED WHT
B26 LEFT SPEAKER
14 6 5 7
X77 RADIO AUXILIARY CONNECTOR
2 10
(+) (-)
15
4
12
BLU (CAN 1 LOW)
RED/BLU
E2 BOOM LIGHT
BLK
GRN
GRN
E1 WORK LIGHT
CAN 1
9015-10-57
BLK
BLK
VLT
FROM SE9 F5
BLU/RED
TM13345X19 (23APR18)
GRN
B25 RIGHT SPEAKER
GRN (CAN 1 HIGH)
WHT
BLU/RED
-
V6 AUXILIARY POWER CONNECTOR DIODE
3 1
+
W60 RADIO ANTENNA
BLK
E
R9 LIGHTER
G6 USB CONNECTOR
TO SE6 X29 (PIN 16)
F15 10A FUSE
BLK
BLK
4
2
BLK
L
FROM SE22 A11 (PIN A5)
LB
5
K8 BOOM LIGHT RELAY
F12 5A FUSE
YEL/RED RED/BLU
BLU/RED RED/BLU WHT/YEL RED
RED
L
BLU/RED
BLK
B
M6 WINDSHIELD WASHER MOTOR
2
3
FROM SE22 A11 (PIN A2)
BLK
BLU
4
1
4
TO SE16 X83 (PIN 3)
RED/BLU
TO SE23 X27 (PIN 8)
X3 BLK/BLU
M5 WINDSHIELD WIPER MOTOR
5
K7 WORK LIGHT RELAY
FROM SE22 A11 (PIN A6) B11
S28 WINDOW SWITCH
2
3
RED/BLU
4
VLT
5
1
K9 WINDSHIELD WASHER RELAY
3
2
ORG
RED/YEL
BLK WHT
BLU RED
1
GRN
RED/BLK
3
BLU/RED
4
F13 10A FUSE
1
A8 12-VOLT POWER CONVERTER
FROM SE1 X47 (PIN 5)
BLU/YEL
3
F20 5A FUSE
BLU/RED
2
F6 20A FUSE
LT GRN/RED BLK
BLU
FROM SE1 K12 (PIN 4)
RED
GRN
BLK/RED
FROM SE22 A11 (PIN B9)
1
YEL
BLK
G5 12-VOLT POWER OUTLET 1
BLK/RED BLK
X39 CAB HARNESSTO-WINDOW SWITCH
F62 WIPER MOTOR ASSEMBLY CIRCUIT BREAKER
TO SE11 X1 (PIN B)
LT GRN/RED
F16 10A FUSE
2
BLK/PNK
S
F35 5A FUSE
RED
WHT
WHT RED/BLK
K6 WINDSHIELD WIPER RELAY
F1 20A FUSE
BLK/RED
4
F2 10A FUSE
RED/BLK
5
GRY/RED
2
3
BLK/YEL
BLK/YEL
RED/BLK 1
WHT
BLK/YEL
WHT
WHT RED/BLK
BLK
RED GRN WHT RED/BLK
1 9
GRY/BLK WHT/BLK
1 3
GRY/BLK WHT/BLK
X73 CAB HARNESSTO-SPEAKERS CONNECTOR
3 6
X26 OPTIONAL CONNECTOR TO SE29, SE31 CAN 1
SE21 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-23/34
System Diagrams
TM13345X19 (23APR18)
9015-10-58
160GLC Excavator 042318 PN=368
System Diagrams 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— Optional Connector and Reversing Fan 20 A Fuse (marked OPT. 2 ALT) F12— Radio and Dome 5 A Fuse (marked RADIO)
F13— Lighter 10 A Fuse (marked F62— Wiper Motor Assembly Circuit Breaker LIGHTER) G5—12-Volt Power Outlet F15— Cab Auxiliary Power G6—USB Connector Connector 1 10 A Fuse K6—Windshield Wiper Relay (marked AUX) K7—Work Light Relay F16— 12-Volt Power Unit 10 A K8—Boom Light Relay Fuse (marked 12V UNIT) K9—Windshield Washer Relay F20— Optional Connector 5 A Fuse (marked OPT. 3 BATT) M5—Windshield Wiper Motor M6—Windshield Washer Motor F35— Service ADVISOR™ Diagnostic Connector 5 A R9—Lighter S28— Window Switch Fuse (marked DIAG) V6— Auxiliary Power Connector Diode
W60—Radio Antenna X3— Cab Harness-to-Machine Harness 100-Pin Connector X25— Cab Harness Auxiliary Power Connector 1 (marked AUX +/-) X26— Optional Connector X39— Cab Harness-to-Window Switch X73— Cab Harness-to-Speakers Connector X77— Radio Auxiliary Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-59
JJ03229,000116D -19-06APR18-24/34
160GLC Excavator 042318 PN=369
System Diagrams
TM13345X19 (23APR18)
9015-10-60
160GLC Excavator 042318 PN=370
System Diagrams
TX1222912 —UN—08SEP16
RED
RED
RED
RED
WHT RED/BLK
WHT RED/BLK
WHT RED/BLK
WHT RED/BLK
FROM SE11 X1 (PIN J,H) (N CAN)
X27 CAB HARNESSTO-SWITCH PANEL CONNECTOR 1 YEL/RED RED/BLU
GRN/WHT
GRN/WHT
B17
3
BLK/WHT
FROM BLU/RED SE17 K7 (PIN 5) B18
BLK
A8
8
C7
BLU
E10 SWITCH PANEL BACK LIGHT 5
BLU/YEL
B1 B11
C1
A5 DATA CONVERTER C5 C11
S14 DOOR SWITCH
C12
GRN
C6
BLU
A
System Functional Schematic (SE22—SE24) (8 of 12) Continued on next page
160GLC Excavator 042318 PN=371
YEL
B
GRN
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
GRN YEL
YEL (N CAN HIGH)
G1
FROM SE10 A15 (PIN M1)
GRN (N CAN LOW)
G2
GRN
H2
YEL
H1
RED
L1
FROM SE11 A1 (PIN 01, 02)
F6003 7.5A FUSE
F6001 7.5A FUSE
RED
A6002 SATELLITE (SAT) MODULE CONTROL UNIT (IF EQUIPPED)
X6016 ENGINE INTERFACE HARNESS-TOSATELLITE (SAT) HARNESS CONNECTOR
B LO
+
120
R10 INTERFACE CAN RESISTOR 1
-
M1
BLK
4
BLK
BLK
M1
M2
RED
5
RED
RED
M2
J3
TAN
3
TAN
M3
A1
PUR
1
PUR
A1
A2
PUR
2
PUR
A2
X6007 JDLINK™ HARNESS GROUND 1
6 = X6015
BLK
= X6014
F3
CAN 1
SE23 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1222912
9015-10-61
LO
A
C14 C15
CAN 1
SE22
A6003 SATELLITE (SAT) ANTENNA
C2
HI
CAN 1
TM13345X19 (23APR18)
HI
BLK
B7
GRN
FROM SE14 X5018 (PIN G)
BLU (N CAN LOW)
BLK/WHT
GRN (N CAN HIGH)
B13
BLU
GRN/BLU
RED/BLK
2
BLU
BLK/BLU
RED/BLK
BLK
WHT/VLT
FROM SE7 A3 (PINS E5, E6)
BLU (CAN 1 LOW)
WHT/VLT
2 1 0
YEL/GRN YEL/RED
B4
A = X10 B = X11
R
FROM SE11 A15 (PINS C2, D2)
GRN (GRN 1 HIGH)
V13 WORK LIGHT 1 DIODE
A11 MACHINE CONTROLLER (BCZ)
4 1
BLK
2
A6
GRN/BLK RED
BLU (CAN 1 LOW)
YEL 1
3
TO SE6 X29 (PINS 13, 14)
YEL
S9 WINDSHEILD WIPER AND WASHER SWITCH
TO SE5 X30 (PIN 5)
B6 B3
BLU (N CAN LOW)
R11 INTERFACE CAN RESISTOR 2
A5
A2
YEL
V14 WORK LIGHT 2 DIODE
B9
GRN (GRN 1 HIGH)
TO SE20 K7 (PIN 2)
WHT/YEL
BLK
RED/YEL
A4
10
TO SE19 K9 (PIN 2)
TO SE19 K6 (PIN 2)
GRY/RED
BLK
BLK
B10 A7 B19
RED/YEL
TO SE20 K8 (PIN 2)
FROM SE7 F10
BLU
3
E3 CAB DOME LIGHT
ORG/BLU
YEL/RED
1
ORG/BLU
E9 KEY SWITCH LIGHT
YEL
-
YEL/RED RED/BLU
ORG/BLU
RED/BLU
2
BLK/RED
P
120
DOOR OFF ON
9
GRN (N CAN HIGH)
+
S2 CAB DOME LIGHT SWITCH
RED/BLU
A6001 GPS/CELLULAR ANTENNA
X5018 MACHINE HARNESS-TOENGINE INTERFACE HARNESS CONNECTOR 2
SE24 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-25/34
System Diagrams
TM13345X19 (23APR18)
9015-10-62
160GLC Excavator 042318 PN=372
System Diagrams
A5—Data Converter E10— Switch Panel Back Light 5 A11— Machine Controller (BCZ) F6001—JDLink™ Unswitched A6000—Modular Telematics Power 7.5 A Fuse Gateway (MTG) F6003—JDLink™ Switched Controller Power 7.5 A Fuse A6001—GPS/Cellular Antenna R10— Interface CAN Resistor 1 A6002—Satellite (SAT) Module R11— Interface CAN Resistor 2 Control Unit (if equipped) S2— Cab Dome Light Switch A6003—Satellite (SAT) Antenna S9— Windshield Wiper and E3— Cab Dome Light Washer Switch E9— Key Switch Light
X6007— JDLink™ Harness S14— Door Switch Ground 1 V13— Work Light 1 Diode X6014—Modular Telematics V14— Work Light 2 Diode Gateway (MTG) Control X10— Machine Controller 8-Pin Unit 48-Pin Connector Connector A X11— Machine Controller 20-Pin X6015—Satellite (SAT) Module Control Unit 48-Pin Connector B Connector X27— Cab Harness-to-Switch X6016—Engine Interface Panel Connector 1 Harness-to-Satellite X5018—Machine Harness-to(SAT) Harness Connector Engine Interface Harness Connector 2
JDLink is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-63
JJ03229,000116D -19-06APR18-26/34
160GLC Excavator 042318 PN=373
System Diagrams
TM13345X19 (23APR18)
9015-10-64
160GLC Excavator 042318 PN=374
System Diagrams
TX1250453 —UN—17JAN18
RED WHT
WHT
4
2
WHT YEL/BLU
4 6
1
RED/YEL
1
10
BLK/YEL
6
21
BLU/YEL
2
13 11
WHT/BLU BLK/RED
5 4
M11 AIR CONDITIONER AND HEATER MIXER SERVO MOTOR
BLU/BLK
1
BLK/YEL
6
23
LT GRN
2
12
WHT BLK/RED
5 4
RED
24
M10 AIR CONDITIONER AND HEATER BLOWER PORT CHANGE SERVO MOTOR
R17 BLOWER MOTOR RESISTOR
4
2
M7 AIR CONDITIONER AND HEATER BLOWER MOTOR
BLK
BLK BLK
4 9
BLK/YEL
X17 14
ORG
15 17 16
BRN/BLU GRN/BLU GRN/BLK
BRN/BLK RED/BLK
BRN/BLK
2
RED/GRN
3
5
4
25
K15 AIR CONDITIONER BLOWER MOTOR RELAY BRN/RED PNK
31
GRN
20
BLU
40
32
CAN 1
CAN 1
SE25
2
B41 AIR CONDITIONER FREEZE CONTROL SWITCH
2
TX1250453
System Functional Schematic (SE25—SE27) (9 of 12) Continued on next page
160GLC Excavator 042318 PN=375
1
T
1
B55 AIR RECIRCULATION SENSOR
B21 SOLAR SENSOR
T
B22 AMBIENT AIR TEMPERATURE SENSOR
1
BLK/YEL
SE26 160GLC SYSTEM FUNCTIONAL SCHEMATIC
T
BRN/RED
T
RED/GRN
PNK
9015-10-65
1
X3
CAN 1
TM13345X19 (23APR18)
RED/BLK
1
BLK/YEL
2
2
X17
2
BLK/YEL
1
YEL/RED
RED
BLK/YEL
WITH AFL BLK
WITHOUT AFL
BLK
RED
33 34
BLK/YEL
BLK
B24 LOW NOTE HORN
TO SE20
3
1
M9 AIR CONDITIONER AND HEATER INTERNAL AND EXTERNAL SERVO MOTOR
BLK/YEL
5
B23 HIGH NOTE HORN
PNK/WHT
YEL/BLK
RED/BLK
3
1
X543
A7 AIR CONDITIONER CONTROLLER (ACF)
RED
BLU
PNK/WHT
PNK/WHT
2
1
RED
K17 MAX-HI RELAY
RED
1
2
R16 BLOWER MOTOR TRANSISTOR
WHT
RED
5
BRN/BLK
2
3
BLK
1
RED/BLK
K18 AIR CONDITIONER COMPRESSOR CLUTCH RELAY
3
7
BLK
RED/BLK
BLK
WHT
4
WHT
BLK 1 2
RED/BLK
BLK
K10 HORN RELAY
WHT/VLT BLK
2 1
4
WHT/VLT
S5 HORN SWITCH
B20 AIR CONDITIONER HIGH/LOWPRESSURE SWITCH
WHT
WHT 5
WHT/VLT
2
2
V8 AIR CONDITIONER COMPRESSOR CLUTCH DIODE
RED/GRN
WHT 1
3
RED/BLK
F3 20A FUSE
WHT/RED
1
RED/BLK
RED/BLK
Y11 AIR CONDITIONER COMPRESSOR CLUTCH
WHT
F19 10A FUSE
WHT
RED
WHT RED/BLK
BLK/YEL
SE27 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-27/34
System Diagrams
TM13345X19 (23APR18)
9015-10-66
160GLC Excavator 042318 PN=376
System Diagrams
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 M9—Air Conditioner and Heater V8— Air Conditioner Compressor 20 A Fuse (marked HEATER) Internal and External Servo Clutch Diode F19— Horn 10 A Fuse (marked Motor X3— Cab Harness-to-Machine HORN) M10— Air Conditioner and Heater Harness 100-Pin Connector K10— Horn Relay Blower Port Change Servo X17— Cab Harness-to-Monitor K15— Air Conditioner Blower Motor Harness Connector Motor Relay M11— Air Conditioner and Heater X543— Horn Switch Connector K17— Max-Hi Relay Mixer Servo Motor Y11— Air Conditioner K18— Air Conditioner R16— Blower Motor Transistor Compressor Clutch Compressor Clutch Relay R17— Blower Motor Resistor M7—Air Conditioner and Heater S5— Horn Switch Blower Motor Continued on next page
TM13345X19 (23APR18)
9015-10-67
JJ03229,000116D -19-06APR18-28/34
160GLC Excavator 042318 PN=377
System Diagrams
TM13345X19 (23APR18)
9015-10-68
160GLC Excavator 042318 PN=378
System Diagrams
TX1251270 —UN—14FEB18
3 4 2 1
X582 BLK/GRN RED/GRN RED BLK
1 2 1 2
RED BLK
T
T
B81 SEAT TEMPERATURE SWITCH 2
1
3
2 2
5
4
K21 CAB ROOF LIGHT 1 RELAY
R18 SEAT HEATER BLK
1 RED/BLK
SE29 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1251270
System Functional Schematic (SE28—SE30) (10 of 12) Continued on next page
160GLC Excavator 042318 PN=379
RED
YEL/RED
RED
GRN
5
2
4
K33 LEFT SOLENOID RELAY A RED/BLU
1 X535 LEFT AUXILIARY SOLENOID CONNECTOR (MARKED SL/H)
3
RED/BLU
2
3 BLK
BLK
BLK
GRN
GRN
A
5
V32 LEFT SOLENOID DIODE B B
Y35 LEFT SOLENOID (MARKED SL/H)
4
1 X534 RIGHT AUXILIARY SOLENOID CONNECTOR (MARKED SR/H)
2
K31 RIGHT SOLENOID RELAY A GRN
1
3
RED/BLU
V33 LEFT SOLENOID DIODE A
4
YEL/RED
YEL
2
5
RED/BLU
3 BLK GRN
2
B80 SEAT TEMPERATURE SWITCH 1
2
RED/YEL
1
3
RED
2
S33 LEFT PILOT 1 CONTROL LEVER SWITCH A (MARKED C)
1
BLK
1
4
GRN
2
BLK
K22 CAB ROOF LIGHT 2 RELAY
RED BLK
1
5
K30 RIGHT SOLENOID RELAY B
BLK
4
M12 SEAT AIR COMPRESSOR MOTOR
RED/GRN
BLK/RED
5
SE28
9015-10-69
2
1
BLK
K20 SEAT HEATER RELAY
K32 LEFT SOLENOID RELAY B
3
2
BLK
BLK
4
1
1
S30 RIGHT PILOT CONTROL LEVER SWITCH B (MARKED B)
RED/YEL
5
YEL
2
GRN
3
X581
TM13345X19 (23APR18)
1
RED/WHT
1
2
RED
GRN
RED/GRN
1
YEL/RED
S31 RIGHT PILOT CONTROL LEVER SWITCH A (MARKED C)
BLK
BLK/RED
1 0
BLK
BLK
3
RED
1
2
X580
S62 SEAT HEATER SWITCH
BLU/YEL
BLU
2
RED/BLU
BLK
E12 + CAB ROOF LIGHT 2
X55 FRONT CAB LIGHT 1 CONNECTOR (MARKED CAB LAMP FRONT)
1
X26 OPTIONAL CONNECTOR
RED/BLK
X62 CAB AUXILIARY POWER CONNECTOR 2 (MARKED AUX_2)
BLK
RED/GRN
BLK/RED
BLK
2
2
RED/BLU
WITHOUT AFL
S34 RIGHT ENABLE SWITCH BLU/YEL
BLU/YEL
S32 LEFT PILOT CONTROL LEVER SWITCH B (MARKED B)
BLK
BLK BLK
RED/BLU
BLK
BLK
BLK -
1
3 X56 FRONT CAB LIGHT 2 CONNECTOR (MARKED CAB LAMP FRONT +2)
1
RED
-
E14 + CAB ROOF LIGHT 4
RED/GRN
-
BLK/WHT
E11 CAB ROOF LIGHT 1
E13 + CAB ROOF LIGHT 3
2
RED/GRN
1
X63 CAB AUXILIARY POWER CONNECTOR 3 (MARKED AUX_3)
2
BLK
BLK
RED
+
-
2
RED
1
X59 SATELLITE COMMUNICATION CONNECTOR (MARKED IMOBI)
3
RED/BLK
S61 SEAT COMPRESSOR SWITCH
2
X58 WARNING LIGHT CONNECTOR (MARKED WARNING LAMP)
BLK
2
1
2
X61 QUICK HITCH CONNECTOR (MARKED QUICK HITCH)
RED/GRN
1 TO X57 SE35
BLK/WHT
X57
BLK
BLK
BLK
BLK
BLK
BLU/YEL
BLU/YEL
IF EQUIPPED
2
BLU/YEL
BLU
BLK
TO X630 SE34
RED/BLU
1
WHT 3
0 1
BLU
2
RED
1
1
BLU
RED/BLU
X630
2
X54 HEATED AIR SEAT HARNESS 3-PIN CONNECTOR (MARKED SEAT HEATER)
RED/BLK
RED/BLU
RED
RED
RED
RED
RED
RED
RED
RED
SE20 K8 (PIN 5)
RED
F22 10A FUSE FROM
RED/GRN
F32 10A FUSE
RED/BLK
WHT
WHT
F34 10A FUSE
1 2 3 4 5 6
F21 10A FUSE
F31 10A FUSE BLK
F33 10A FUSE
TO SE20 X26
BLK
F26 5A FUSE
WHT
WHT
WHT
F25 5A FUSE
BLK
F24 5A FUSE
F27 20A FUSE
RED
F23 10A FUSE
WHT
WHT
WHT
WHT
WHT
0 1
S35 LEFT ENABLE SWITCH
LT GRN/YEL
WHT
RED
WHT
BLK
BLK
GRN
GRN
V31 RIGHT SOLENOID DIODE A
A
V30 RIGHT SOLENOID DIODE B B
Y34 RIGHT SOLENOID (MARKED SR/H)
SE30 CONTINUE NEXT PAGE
JJ03229,000116D -19-06APR18-29/34
System Diagrams
TM13345X19 (23APR18)
9015-10-70
160GLC Excavator 042318 PN=380
System Diagrams B80— Seat Temperature Switch 1 F33— Warning Lamp 10 A Fuse S35— Left Enable Switch X62— Cab Auxiliary Power (marked WARNING LAMP) S61— Seat Compressor Switch B81— Seat Temperature Switch 2 Connector 2 (marked F34— Cab Auxiliary Power E11— Cab Roof Light 1 S62— Seat Heater Switch AUX_2) Connector 2 10 A Fuse E12— Cab Roof Light 2 V30— Right Solenoid Diode B X63— Cab Auxiliary Power (marked AUX_2) E13— Cab Roof Light 3 V31— Right Solenoid Diode A Connector 3 (marked K20— Seat Heater Relay E14— Cab Roof Light 4 V32— Left Solenoid Diode B AUX_3) F21— Heated Air Seat 10 A Fuse K21— Cab Roof Light 1 Relay V33— Left Solenoid Diode A X534— Right Auxiliary Solenoid K22— Cab Roof Light 2 Relay (marked SEAT HEATER) X26— Optional Connector Connector (marked SR/H) K30— Right Solenoid Relay B F22— Front Cab Light 1 10 A X54— Heated Air Seat Harness X535— Left Auxiliary Solenoid Fuse (marked CAB LAMP K31— Right Solenoid Relay A 3-Pin Connector (marked Connector (marked SL/H) K32— Left Solenoid Relay B FRONT) SEAT HEATER) X580— Cab Roof Light Harness F23— Rear Cab Light 10 A Fuse K33— Left Solenoid Relay A X55— Front Cab Light 1 Connector (marked CAB LAMP REAR) M12— Seat Air Compressor Motor Connector (marked CAB X581— Cab Roof Light Jumper F24— IMMOBI 5 A Fuse (marked R18— Seat Heater LAMP FRONT) Harness Connector 1 S30— Right Pilot Control Lever X56— Front Cab Light 2 IMOBI) X582— Cab Roof Light Jumper Switch B (marked B) F25— Quick Hitch 5 A Fuse Connector (marked CAB Harness Connector 2 S31— Right Pilot Control Lever (marked QUICK HITCH) LAMP FRONT +2) X630— Premium Seat Harness Switch A (marked A) F26— Cab Auxiliary Power X57— Rear Cab Light Connector Connector (marked 24V S32— Left Pilot Control Lever Connector 3 5 A Fuse (marked CAB LAMP REAR) POWER) Switch B (marked B) (marked AUX_3) X58— Warning Light Connector Y34— Right Solenoid (marked S33— Left Pilot Control Lever F27— Seat Heat/Cool 20 (marked WARNING LAMP) SR/H) Switch A (marked A) A Fuse (marked X59— Satellite Communication Y35— Left Solenoid (marked S34— Right Enable Switch SEAT_HEAT/COOL) Connector (marked SL/H) F31— Seat Compressor 10 IMMOBI) A Fuse (marked SEAT X61— Quick Hitch Connector COMPR) (marked QUICK HITCH) F32— Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) Continued on next page
TM13345X19 (23APR18)
9015-10-71
JJ03229,000116D -19-06APR18-30/34
160GLC Excavator 042318 PN=381
System Diagrams
TM13345X19 (23APR18)
9015-10-72
160GLC Excavator 042318 PN=382
System Diagrams
TX1250473 —UN—17JAN18
FROM SE20 X26
WITH AFL
5
WHT/YEL
BLK
WHT/YEL
RED
BLK
RED
2
5
4
GRN BLK/YEL RED/YEL WHT RED/YEL
BLK/BLU
X577 AUXILIARY FUNCTION LEVER (AFL) HARNESSTO-AUXILIARY FUNCTION LEVER (AFL) SOLENOID HARNESS CONNECTOR
WHT/YEL
K33 LEFT SOLENOID RELAY A (MARKED LSW3)
WHT/YEL
3
BLK/BLU
1
B85 AUXILIARY FUNCTION LEVER (AFL) SOLENOID PRESSURE SENSOR (MARKED PS1)
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
BLK/YEL RED/YEL
12 11 14 6 13 1 2 3 4 5
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
B68 SECONDARY HYDRAULIC OIL TEMPERATURE SENSOR 1
1
P
BLK RED/YEL RED/WHT
X536 RIGHT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR (MARKED R_GRIP)
4
K32 LEFT SOLENOID RELAY B (MARKED LSW1)
V22 PILOT SHUTOFF SOLENOID DIODE
2
T 2
3
BLK/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
Y61 AUXILIARY FUNCTION LEVER (AFL) SOLENOID A (MARKED 1A) 1
2 1
2
RED/YEL BLK/YEL
2
TO SE22 X543
X543 HORN SWITCH CONNECTOR
TO SE10 X544
GRN/BLK GRN/BLU
BLK
1
GRN/BLK
2
WHT YEL
SE31
1 9 12 11 4 5 6 2 7 3 10 8
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR
X544 POWER DIG SWITCH CONNECTOR SE32 160GLC SYSTEM FUNCTIONAL SCHEMATIC System Functional Schematic (SE31—SE33) (11 of 12)
Continued on next page
9015-10-73
Y62 AUXILIARY FUNCTION LEVER (AFL) SOLENOID B (MARKED 1B)
GRN/BLU
TX1250473
TM13345X19 (23APR18)
TO SE30 X535
X535 LEFT AUXILIARY SOLENOID CONNECTOR (MARKED SL/H)
TO SE10 X574
LT GRN/YEL WHT YEL
1
3 2 1
GRN/BLU BLK/GRN RED/BLU BLK/YEL RED/YEL BLK/BLU GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLU/YEL
X534 2 1 3 RIGHT AUXILIARY SOLENOID TO SE30 X534 CONNECTOR (MARKED SR/H)
160GLC Excavator 042318 PN=383
1 2 3 4 5 6
X26 OPTIONAL CONNECTOR
GRY
2
3
BLK
6
5
RED/YEL
4
1
YEL WHT
1
1
Y66 SECONDARY PILOT SHUTOFF SOLENOID (MARKED PiC)
2
1
GRN/BLU
5
K31 RIGHT SOLENOID RELAY A (MARKED RSW1)
LT GRN/YEL BLK/YEL RED/YEL
BLK/YEL
GRN
2
BLK
BLK 3
9
WHT
3
GRN
2
8
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
WHT/YEL
RED/YEL
1
WHT
BLU 4
RED
GRN/BLU
BRN 5
GRN/BLK
X537 LEFT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR (MARKED L_GRIP)
LT GRN/YEL
6
BLK
WHT
YEL
WHT/VLT
7
BLU/YEL
S29 AUXILIARY FUNCTION LEVER (AFL) PROPORTIONAL CONTROL SWITCH
S45 AUXILIARY FUNCTION ENABLE SWITCH (MARKED AFL_SW)
BLU
WHT
S32 LEFT PILOT CONTROL LEVER SWITCH B
5
BLU
S7 POWER DIG SWITCH
S33 LEFT PILOT CONTROL LEVER SWITCH A
4
WHT
0 1
GRN
BRN
0 1
S35 LEFT ENABLE SWITCH (MARKED ON/OFF)
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
BLU
S5 HORN SWITCH
LEFT PILOT CONTROL LEVER
S31 RIGHT PILOT CONTROL LEVER SWITCH A
S34 RIGHT ENABLE SWITCH (MARKED ON/OFF)
RED
RIGHT PILOT CONTROL LEVER
RED
X26 OPTIONAL CONNECTOR
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
RED
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
RED/YEL
1 2 3 4 5 6
SE33
JJ03229,000116D -19-06APR18-31/34
System Diagrams
TM13345X19 (23APR18)
9015-10-74
160GLC Excavator 042318 PN=384
System Diagrams Y61— Auxiliary Function Lever B68— Secondary Hydraulic Oil S31— Right Pilot Control Lever X535— Left Auxiliary Solenoid (AFL) Solenoid A (marked Temperature Sensor Switch A Connector (marked SL/H) 1A) B85— Auxiliary Function Lever S32— Left Pilot Control Lever X536— Right Auxiliary Function Y62— Auxiliary Function Lever (AFL) Solenoid Pressure Switch B Lever (AFL) Connector (AFL) Solenoid B (marked Sensor (marked PS1) S33— Left Pilot Control Lever (marked R_GRIP) 1B) K31— Right Solenoid Relay A Switch A X537— Left Auxiliary Function Y66— Secondary Pilot Shutoff (marked RSW1) S34— Right Enable Switch Lever (AFL) Connector Solenoid Valve (marked K32— Left Solenoid Relay B (marked ON/OFF) (marked L_GRIP) PiC) (marked LSW1) S35— Left Enable Switch X543— Horn Switch Connector K33— Left Solenoid Relay A (marked ON/OFF) X544— Power Dig Switch (marked LSW3) S45— Auxiliary Function Enable Connector S5— Horn Switch Switch (marked AFL_SW) X574— Auxiliary Function Lever S7— Power Dig Switch V22— Pilot Shutoff Solenoid (AFL) Connector 1 S29— Auxiliary Function Lever Diode X577— Auxiliary Function (AFL) Proportional Control X26— Optional Connector Lever (AFL) Harness-toSwitch X534— Right Auxiliary Solenoid Auxiliary Function Lever Connector (marked SR/H) (AFL) Solenoid Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-10-75
JJ03229,000116D -19-06APR18-32/34
160GLC Excavator 042318 PN=385
System Diagrams
TM13345X19 (23APR18)
9015-10-76
160GLC Excavator 042318 PN=386
System Diagrams
TX1251237 —UN—14FEB18
BLK
OPTIONAL
X636 RED BLK BLU BLK
1
RED
BLK
A24 B5 B3 A1 A7 A13 A14 A15 A16 A17 A18 A= X641 B= X642
0 1
8
S36 REAR CAB LIGHT SWITCH
2
3
4
BLK
A25 PREMIUM SEAT POWER CONVERTER
YEL
1 2 3 4 5 6 7 8 9
LT BRN RED ORG YEL GRN LT BLU VLT GRY WHT
S37 HEATED/ COOLED SEAT SWITCH
A26 PREMIUM SEAT CONTROLLER (PSC) X640
BRN
BLU
BRN
GRN
YEL
BLU
RED
X638
2
BLK
A12 A4 A20 B2 B4 A22 A3 B1 B6 A21 A2
RED
WHT
YEL/RED
4
K23 REAR CAB LIGHT RELAY
RED
1
RED/GRN
X633
5
YEL/RED
BLK/YEL
2
3
WHT
1
RED BLK WHT BLK
GRN
YEL
ORG
BRN
BLK
WHT
2
M12 SEAT AIR COMPRESSOR MOTOR
BLU
RED
BLK
RED PNK BLU WHT BLK BRN ORG YEL GRN PNK
X632
1 2 3 4
X635
S61 SEAT COMPRESSOR SWITCH
BLK
1
1 BLK
RED/GRN
RED/GRN
2
4
ORG
4 BLK/YEL
3
RED
RED
BLK
RED/GRN BLK
-
X637
RED
E18 REAR + CAB LIGHT
RED
X634
2
BLK
1
2
BLK
FROM SE28 X57
X57
1
RED
X630
RED
FROM SE28 X630
GRN BRN YEL BLU
4 3 2 1
LT GRN LT GRN YEL BLU
R21 LOWER THERMAL DUCT MODULE
LT GRN LT GRN YEL BLU
R20 UPPER THERMAL DUCT MODULE
X639
M15 PREMIUM SEAT BLOWER
9
SE34
GRN BRN YEL BLU
4 3 2 1
SE35 160GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1251237
System Functional Schematic (SE34—SE36) (12 of 12) Continued on next page
TM13345X19 (23APR18)
9015-10-77
160GLC Excavator 042318 PN=387
SE36
JJ03229,000116D -19-06APR18-33/34
System Diagrams
TM13345X19 (23APR18)
9015-10-78
160GLC Excavator 042318 PN=388
System Diagrams
A25— Premium Seat Power S37— Heated/Cooled Seat Switch X634— Premium Seat Converter S61— Seat Compressor Switch Compressor Harness A26— Premium Seat Controller X57— Rear Cab Light Connector Connector (marked (PSC) (marked CAB LAMP REAR) COMPRESSOR) E18— Rear Cab Light X630— Premium Seat Harness X635— Heated/Cooled Seat K23— Rear Cab Light Relay Connector (marked 24V Switch Connector M12— Seat Air Compressor Motor POWER) X636— Premium Seat Power M15— Premium Seat Blower X632— Rear Cab Light Harness Converter Connector R20— Upper Thermal Duct Connector (marked INVERTER) Module X633— Rear Cab Light Switch X637— Heat Cool Lumbar R21— Lower Thermal Duct Harness Connector Connector (marked Module (marked CAB LAMP HEAT/COOL LUMBAR) S36— Rear Cab Light Switch REAR) X638— Premium Seat Blower Connector
X639— Upper Thermal Module Connector X640— Lower Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A X642— Premium Seat Controller (PSC) Connector B
JJ03229,000116D -19-06APR18-34/34
Cab Harness (W1) Component Location IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
Specification Cab Harness-toMachine Harness 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
NOTE: Switch configuration may vary. Continued on next page
TM13345X19 (23APR18)
9015-10-79
JA92389,000015D -19-13FEB18-1/5
160GLC Excavator 042318 PN=389
System Diagrams
TM13345X19 (23APR18)
9015-10-80
160GLC Excavator 042318 PN=390
System Diagrams
TX1251188 —UN—29JAN18
S7 A3 X34
A6
S21
W37
X35 X36 W1 X26 X25
X33
S60
X32 X31 A8 K12
X73 X99
K8 K9
A11
X51 X52
K10 K4 X54
X61
X57
X63
A3
X573 V2 H2
V3 V5
V12 V11 V9 V10 V1 V4 V8
K6
X28 X30
F50 X27
X81
K1 K7 A5
X75
X3
X62
V14 V13
X45
X55 X56
A6
W37
S14 X50 X83
X52
A4
X51
A4
X543
A8 A11
X22 W1
X76
W3
W36 W1
W35
W23
S13
W16
S34 S16
W10 W35
S5
S15
X65 S7
S18
X24
X23
S11
W22
X47
X11
X20
R15 S8
X37 X29
X2 F51
X58 V6
K3
X10
X21
S23
W9
X1
X77
X59 K2
S24
S12 S10
X74
X39 K13
V7
W29
G5
R9
S26 S27
S1
W10
K5
R10
S9
S16 S34 S18
E3
K11
S25 S22
X42 X17 X574
X575
X78 W22 W9
X544
TX1251188 Cab Harness (W1) Component Location (S.N. —057099) Continued on next page
TM13345X19 (23APR18)
9015-10-81
160GLC Excavator 042318 PN=391
JA92389,000015D -19-13FEB18-2/5
System Diagrams
TM13345X19 (23APR18)
9015-10-82
160GLC Excavator 042318 PN=392
System Diagrams
A3—Main Controller (MCZ) S27— Home Button X23— Monitor Controller 12-Pin X57— Rear Cab Light Connector A4—Monitor Controller (DSZ) S34— Right Enable Switch Connector C (marked CAB LAMP REAR) A5—Data Converter (marked ON/OFF) X24— Monitor Controller 2-Pin X58— Warning Light Connector A6—Radio S60— Keypad Connector G (marked WARNING LAMP) A8—12-Volt Power Converter V1— Battery Relay Diode X25— Cab Harness Auxiliary X59— Satellite Communication A11— Machine Controller (BCZ) V2— Not Used Power Connector 1 Connector (marked E3— Cab Dome Light V3— Load Dump Relay Diode (marked AUX +/-) IMMOBI) F50— Fuse Box 1 V4— Security Diode X26— Optional Connector X61— Quick Hitch Connector F51— Fuse Box 2 V5— Starter Cut Relay Diode X27— Cab Harness-to-Switch (marked QUICK HITCH) G5—12-Volt Power Outlet V6— Auxiliary Power Connector Panel Connector 1 X62— Cab Auxiliary Power H2—Security Alarm Diode X28— Cab Harness-to-Switch Connector 2 (marked K1—Load Dump Relay V7— Start Relay Diode Panel Connector 2 AUX_2) K2—Pilot Shutoff Solenoid Relay V8— Air Conditioner Clutch Diode X29— Cab Harness-to-Switch X63— Cab Auxiliary Power K3—Security Alarm Relay V9— Pilot Shutoff Diode Panel Connector 3 Connector 3 (marked K4—Starter Cut Relay V10— Starter Protection Diode X30— Cab Harness-to-Switch AUX_3) K5—Security Relay V11— Accessory Cut Diode Panel Connector 4 X65— Cab Harness-to-Pilot K6—Windshield Wiper Relay V12— Starter Cut Diode X31— Cab Harness-to-Main Shutoff Switch Harness K7—Work Light Relay V13— Work Light 1 Diode Controller 31-Pin Connector K8—Boom Light Relay V14— Work Light 2 Diode Connector A X73— Cab Harness-to-Speakers K9—Windshield Washer Relay W1—Cab Harness X32— Cab Harness-to-Main Connector K10— Horn Relay W3—Monitor Harness Controller 24-Pin X74— Cab Harness-to-Service K11— Idle Stop Relay W9—Exhaust Filter Parked Connector B ADVISOR™ Remote (SAR) K12— Accessory Cut Relay Cleaning Switch Harness X33— Cab Harness-to-Main Switch Harness Connector K13— Key Cut Relay W10—Service ADVISOR™ Controller 17-Pin (marked ADV-SW) R9—Lighter Remote (SAR) Switch Connector C X75— Cab Harness-to-Pilot R10— Interface CAN Resistor 1 Harness X34— Cab Harness-to-Main Shutoff Valve Harness R15— Engine Speed Dial W16—Travel Alarm Cancel Controller 30-Pin Connector S1— Key Switch Switch Harness Connector D X76— Cab Harness Connector 1 S5— Horn Switch W22—Auxiliary 3-Button Cancel X35— Cab Harness-to-Main (marked HMST) (not used) S7— Power Dig Switch Switch Harness Controller 24-Pin X77— Radio Auxiliary Connector S8— Auto-Idle Switch W23—Reversing Fan Switch Connector E X78— Optional Switch Connector S9— Windshield Wiper and Harness X36— Cab Harness-to-Main X81— Multi-Function Washer Switch W29—Starter Switch Harness Controller 26-Pin Pilot Control Lever S10— Work Light Switch W35—Cab Harness Ground 1 Connector F Harness-to-Auxiliary S11— Travel Speed Switch W36—Cab Harness Ground 2 X37— Cab Harness-to-Exhaust 3-Button Cancel Switch S12— Power Mode Button W37—Cab Harness Ground 3 Filter Switch Harness Harness Connector S13— Travel Alarm Cancel X1— Service ADVISOR™ Connector X83— Cab Harness-to-Reversing Switch Diagnostic Connector X39— Cab Harness-to-Window Fan Switch Harness S14— Door Switch X2— MPDr 6-Pin Connector Switch Connector Connector (marked S15— Reversing Fan Switch X3— Cab Harness-to-Machine X42— CAN 1 Connector VSF-SW) S16— Exhaust Filter Parked Harness 100-Pin Connector X45— Option 2 12-Pin Connector X99— Cab Ground Splice Cleaning Switch X10— Machine Controller (BCZ) (not used) X543— Horn Switch Connector S18— Service ADVISOR™ 8-Pin Connector A X47— Cab Harness-to-Key X544— Power Dig Switch Remote (SAR) Switch X11— Machine Controller (BCZ) Switch Harness Connector Connector S21— Blower Motor Speed 20-Pin Connector B X50— Cab Harness-to-Travel X573— Exhaust Solenoid Switch X17— Cab Harness-to-Monitor Alarm Cancel Switch Harness Connector (not S22— Temperature Control/Mode Harness Connector Harness Connector used) Switch X20— Monitor Controller 28-Pin X51— Air Conditioner 4-Pin X574— Auxiliary Function Lever S23— Radio Volume and Power Connector A Connector (AFL) Connector 1 Switch X21— Monitor Controller 36-Pin X52— Air Conditioner 10-Pin X575— Auxiliary Function Lever S24— Radio Tuning Switch Connector B Connector (AFL) Connector 2 S25— Monitor Dial X22— Monitor Controller 16-Pin X54— Heated Air Seat Harness S26— Back Button Connector D 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) Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-83
JA92389,000015D -19-13FEB18-3/5
160GLC Excavator 042318 PN=393
System Diagrams
TM13345X19 (23APR18)
9015-10-84
160GLC Excavator 042318 PN=394
System Diagrams
TX1251189 —UN—30JAN18
S7 A3
X34
A6
X35 X26 X25 W82
X33
S21
W37
X36
W1
S60
X26 E3
S24 S23 R15 S8
G6 A8 K12
K8 K9
K11
A11
X51 X52
K10 K4
K2
V3 V5
V12 V11 V9 V10 V1 V4 V8
K6
X603 X77 X61 X54 X58 V6 X63 X57
X28 X30
X37 X47
K1
X81
X27
K7 A5
X75 X45
X59 X55 X62
V14 V13
A6 X56
X52
A4
X51
A4
X630
A8 A11
X22
W1 G6
W35 X76 W36
W35
W10
X42 X17 X574 X575 X78
W37
S14 X50 X83
X543
S5
S15 W23
S13
X65 S7
S18
X24
W3
W22 W10
X29
F50
X3
X23
X74
X2 F51
X11
X20
W9
W82
X1
K3
X10
X21
S12 S10
X631
X39
A3 V7
W29
G5
R9 K5
R10
S11
W83
K13
X573 V2 H2
S1
S9
S18
X31 X73
S26 S27
S34 S16
X32
X99
S25 S22
W16
S34 S16
X623
W1
W22 W9 X544
TX1251189 Cab Harness (W1) Component Location (S.N. 057100— ) Continued on next page
TM13345X19 (23APR18)
9015-10-85
160GLC Excavator 042318 PN=395
JA92389,000015D -19-13FEB18-4/5
System Diagrams
TM13345X19 (23APR18)
9015-10-86
160GLC Excavator 042318 PN=396
System Diagrams V1— Battery Relay Diode A3—Main Controller (MCZ) X25— Cab Harness Auxiliary X59— Satellite Communication V2— Not Used A4—Monitor Controller (DSZ) Power Connector 1 Connector (marked V3— Load Dump Relay Diode A5—Data Converter (marked AUX +/-) IMMOBI) V4— Security Diode A6—Radio X26— Optional Connector X61— Quick Hitch Connector V5— Starter Cut Relay Diode A8—12-Volt Power Converter X27— Cab Harness-to-Switch (marked QUICK HITCH) A11— Machine Controller (BCZ) V6— Auxiliary Power Connector Panel Connector 1 X62— Cab Auxiliary Power Diode E3— Cab Dome Light X28— Cab Harness-to-Switch Connector 2 (marked V7— Start Relay Diode F50— Fuse Box 1 Panel Connector 2 AUX_2) V8— Air Conditioner Clutch Diode X29— Cab Harness-to-Switch F51— Fuse Box 2 X63— Cab Auxiliary Power V9— Pilot Shutoff Diode G5—12-Volt Power Outlet Panel Connector 3 Connector 3 (marked V10— Starter Protection Diode G6—USB Connector X30— Cab Harness-to-Switch AUX_3) V11— Accessory Cut Diode H2—Security Alarm Panel Connector 4 X65— Cab Harness-to-Pilot V12— Starter Cut Diode K1—Load Dump Relay X31— Cab Harness-to-Main Shutoff Switch Harness K2—Pilot Shutoff Solenoid Relay V13— Work Light 1 Diode Controller 31-Pin Connector V14— Work Light 2 Diode K3—Security Alarm Relay Connector A X73— Cab Harness-to-Speakers W1—Cab Harness K4—Starter Cut Relay X32— Cab Harness-to-Main Connector W3—Monitor Harness K5—Security Relay Controller 24-Pin X74— Cab Harness-to-Service W9—Exhaust Filter Parked K6—Windshield Wiper Relay Connector B ADVISOR™ Remote (SAR) Cleaning Switch Harness K7—Work Light Relay X33— Cab Harness-to-Main Switch Harness Connector W10—Service ADVISOR™ K8—Boom Light Relay Controller 17-Pin (marked ADV-SW) Remote (SAR) Switch K9—Windshield Washer Relay Connector C X75— Cab Harness-to-Pilot Harness K10— Horn Relay X34— Cab Harness-to-Main Shutoff Valve Harness W16—Travel Alarm Cancel K11— Idle Stop Relay Controller 30-Pin Connector Switch Harness K12— Accessory Cut Relay Connector D X76— Cab Harness Connector 1 W22—Auxiliary 3-Button Cancel X35— Cab Harness-to-Main K13— Key Cut Relay (marked HMST) (not used) Switch Harness R9—Lighter Controller 24-Pin X77— Radio Auxiliary Connector W23—Reversing Fan Switch R10— Interface CAN Resistor 1 Connector E X78— Optional Switch Connector Harness R15— Engine Speed Dial X36— Cab Harness-to-Main X81— Multi-Function W29—Starter Switch Harness S1— Key Switch Controller 26-Pin Pilot Control Lever W35—Cab Harness Ground 1 S5— Horn Switch Connector F Harness-to-Auxiliary W36—Cab Harness Ground 2 S7— Power Dig Switch X37— Cab Harness-to-Exhaust 3-Button Cancel Switch W37—Cab Harness Ground 3 S8— Auto-Idle Switch Filter Switch Harness Harness Connector W82—USB Harness S9— Windshield Wiper and Connector X83— Cab Harness-to-Reversing W83—USB Jumper Harness Washer Switch X39— Cab Harness-to-Window Fan Switch Harness X1— Service ADVISOR™ S10— Work Light Switch Switch Connector Connector (marked Diagnostic Connector S11— Travel Speed Switch X42— CAN 1 Connector VSF-SW) X2— MPDr 6-Pin Connector S12— Power Mode Button X45— Option 2 12-Pin Connector X99— Cab Ground Splice X3— Cab Harness-to-Machine S13— Travel Alarm Cancel (not used) X543— Horn Switch Connector Harness 100-Pin Connector X47— Cab Harness-to-Key Switch X544— Power Dig Switch X10— Machine Controller (BCZ) S14— Door Switch Switch Harness Connector Connector 8-Pin Connector A S15— Reversing Fan Switch X50— Cab Harness-to-Travel X573— Exhaust Solenoid X11— Machine Controller (BCZ) S16— Exhaust Filter Parked Alarm Cancel Switch Harness Connector (not 20-Pin Connector B Cleaning Switch Harness Connector used) X17— Cab Harness-to-Monitor S18— Service ADVISOR™ X51— Air Conditioner 4-Pin X574— Auxiliary Function Lever Harness Connector Remote (SAR) Switch Connector (AFL) Connector 1 X20— Monitor Controller 28-Pin X52— Air Conditioner 10-Pin S21— Blower Motor Speed X575— Auxiliary Function Lever Connector A Switch Connector (AFL) Connector 2 S22— Temperature Control/Mode X21— Monitor Controller 36-Pin X54— Heated Air Seat Harness X603— Not Used Connector B Switch 3-Pin Connector (marked X623— Cab Harness CAN S23— Radio Volume and Power X22— Monitor Controller 16-Pin SEAT HEATER) Connector Connector D Switch X55— Front Cab Light 1 X630— Premium Seat Harness X23— Monitor Controller 12-Pin S24— Radio Tuning Switch Connector (marked CAB Connector (marked 24V Connector C S25— Monitor Dial LAMP FRONT) POWER) X24— Monitor Controller 2-Pin S26— Back Button X56— Front Cab Light 2 X631— USB Harness Connector Connector G S27— Home Button Connector (marked CAB (marked USB) S34— Right Enable Switch LAMP FRONT +2) (marked ON/OFF) X57— Rear Cab Light Connector S60— Keypad (marked CAB LAMP REAR) X58— Warning Light Connector (marked WARNING LAMP) JA92389,000015D -19-13FEB18-5/5
Cab Harness (W1) Wiring Diagram IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
Specification Cab Harness-toMachine Harness 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Continued on next page
TM13345X19 (23APR18)
9015-10-87
JA92389,000015E -19-14FEB18-1/19
160GLC Excavator 042318 PN=397
System Diagrams
TM13345X19 (23APR18)
9015-10-88
160GLC Excavator 042318 PN=398
System Diagrams
Cab Harness (W1) Wiring Diagram (S.N. —057099) TX1248636 —UN—13DEC17
NUMBER 1 2 3 4 26 39 88 138 139 141 155 235 250 301 302 303 304 305 306 307 400 401 402 500 501 502 503 505 506 507 508 509 510 511 517 518 519 520 522 523 524 525 527 528 529 530 531 532 533 534 535 536 537 540 541 542 544 545 546 548 TX1248636
COLOR RED RED RED RED WHT/RED BLU RED/BLK GRN/BLK BLK WHT/YEL ORG BRN WHT/BLU BLU BLU RED/BLK BLK BLK GRN BLU WHT/RED GRN/RED RED BLK BLK RED/BLK BLK WHT/BLK WHT BLK/RED WHT BLK WHT RED VLT/GRN BLK RED RED BLU RED WHT VLT VLT/RED VLT/GRN VLT/WHT ORG PNK/BLK RED RED WHT/BLK BLK RED/BLU BLU/RED BLK PNK/GRN PNK/WHT RED/BLU WHT/VLT VLT BLK
END #2 END #1 F4 (518) X36 (518) (518) X36 (518) X36 X33 X3 F10 X35 (764) X35 X50 X3 W37 X50 (610) X45 V9 (530) X20 X3 X21 X3 A5 (39) A5 (39) A5 (764) W36 A5 A5 (304) A5 (1251) A5 (1252) X83 X3 X83 X3 X83 (611) W35 X99 X3 (1579)-(1588) V2 (764) X45 W37 X3 K4 X3 F50 V2 X3 V3 X3 X99 W37 V1 (508) X47 X3 K4 V4 X99 W36 (511) K1 (511) K1 X47 F18 K5 (1) K1 (508) K5 K2 K5 V4 V5 (517) K2 V5 X65 V5 K2 X75 X75 (1) K2 (1) V7 (505) W36 V7 K8 X3 K7 X3 W36 K3 H2 K3 K10 X3 H2 (552) K10 S5/X543 K9 X3 V1 W36
END #2 NUMBER COLOR END #1 550 BLK W36 K5 552 RED/BLU F9 K3 560 RED (511) F50 561 WHT (1590)-(1595) (506) 562 BLK X99 (501) 566 YEL/RED F12 A6 568 RED/BLU A6 (552) 569 ORG A6 X73 570 BRN A6 X73 571 GRY/BLK A6 X73 572 WHT/BLK A6 X73 573 BLK W37 A6 589 BLK/PNK X39 K6 590 BLK/YEL K6 X39 591 BLK/RED F2 X39 592 BLK X39 W37 593 RED/BLK (764) K6 594 BLK W36 K6 595 RED/BLK (764) K9 596 BLK/RED (591) K9 598 GRN F1 K7 599 RED/BLK K7 (764) 600 GRN K8 (598) 601 GRN K8 (598) 602 WHT K10 (603) 603 WHT F19 K10 604 BLK W37 X65 605 BLK W37 S5/X543 606 YEL/BLK V3 (1312) 607 WHT X47 F15 609 RED/GRN F3 X51 610 WHT/YEL F5 X26 611 RED X26 F6 612 LT GRN/RED F20 X26 615 BLK W37 X26 616 BLU/RED X26 (537) 617 RED/BLU X26 (536) 618 RED/BLU X55 (536) 632 BLU/YEL F13 R9 633 BLK W37 R9 651 BLU/WHT X33 X3 655 ORG/WHT X3 X33 660 RED (611) X3 661 GRN F15 X25 662 BLK X25 W37 664 WHT/YEL (610) X3 665 WHT/YEL F11 X3 666 BLK V6 (662) 667 GRN (661) V6 745 VLT/GRN X3 (517) 754 BLK W37 X1 762 BLK/GRN X3 X22 764 RED/BLK F17 X3 771 BLU/BLK F14 X22 772 BLU (39) X10 800 GRN X20 X3 801 BLU X20 X3 802 GRY X20 SHIELD X3 810 BLU F8 X3 824 RED/BLK (764) X20
NUMBER 825 850 851 852 854 855 856 870 876 877 881 890 891 892 893 900 910 1002 1003 1004 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1020 1022 1023 1025 1026 1027 1028 1029 1030 1031 1033 1039 1045 1061 1062 1067 1069 1071 1074 1076 1082 1083 1084 1085 1086 1087 1089
COLOR VLT YEL GRY/RED GRN/BLK RED/YEL BLK/BLU ORG BLU/RED ORG/BLK ORG/GRN WHT RED BLK BLU ORG WHT/RED WHT/RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN/YEL RED BLK/YEL RED/YEL WHT/RED RED/GRN GRN BLK/RED ORG/BLU BLK/GRN GRN/WHT SK BLU GRN/BLK BLU/RED YEL/BLK BLU BLU/BLK GRN/WHT GRN/ORG LT GRN RED/BLK GRN/RED GRN/ORG YEL BLU BLK/WHT WHT BLK
END #2 END #1 X65 X21 K7 X10 K6 X11 K3 X22 K8 X10 K9 X10 K1 X22 X29 (616) X37 X3 X37 X3 (506) F50 A8 F16 W37 A8 A8 G5 A8 G5 X47 K4 K4 (900) (501) X20 X21 W36 X21 W36 W36 X30 W36 S7/X544 W37 X35 W37 (1015)-(1017) X10 W37 X51 W36 X77 W37 W36 V8 X11 E3 X36 (1009) (1009) X36 (1009) X36 X31 X3 X3 X22 X22 X3 X3 X29 X17 X22 X2 X20 X20 X11 X2 X20 X36 X45 X2 X20 V4 X22 X3 X33 X36 S7/X544 X3 X34 X33 X3 X35 (39) X3 X31 X31 X3 X31 X3 X36 X78 X17 (764) X3 X31 X3 (1071) X3 X31 A6 (1155) X31 X3 X3 X31 X2 (1004)
NUMBER 1090 1092 1093 1096 1097 1100 1101 1104 1105 1110 1111 1112 1113 1116 1117 1118 1119 1120 1121 1122 1124 1125 1132 1133 1135 1136 1138 1139 1140 1141 1145 1148 1150 1152 1153 1154 1155 1156 1157 1158 1159 1160 1161 1163 1164 1167 1168 1169 1171 1173 1175 1176 1177 1179 1180 1181 1182 1183 1184 1185
COLOR BRN/BLU BLU/YEL GRN/YEL BLK GRN/BLK WHT/GRN YEL/RED BRN/BLU WHT GRN/YEL ORG RED/YEL RED/GRN RED WHT/VLT GRY RED/YEL GRN BLK GRN GRN BLU GRY GRN WHT BLU GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK RED/BLU YEL/BLU BLK BLK/YEL RED/BLU BLU ORG/BLU YEL/WHT YEL/BLU WHT/RED ORG YEL/RED ORG/BLK GRY GRN/RED YEL/GRN BLU ORG YEL BLU/RED RED/BLK WHT YEL/BLU BLU/WHT BLK/RED WHT GRY/RED WHT/YEL RED/GRN
END #1 END #2 X3 X33 X3 X34 X3 X34 (1011) X3 X3 X52 X31 X3 (566) X11 X3 X52 X3 X52 X3 X33 X17 X52 X3 X52 X51 (609) X3 X32 X34 X3 X45 X36 X36 (1023) (800) X34 X35 (1008) A6 (1027) X52 (1027) X52 (1155) X1 (802) X1 (800) X3 X22 X1 (801) X33 X574 X31 X574 X31 X574 X574 (1023) (1003) X76 X21 (552) X76 X21 X77 A6 X3 X29 E3 (552) X20 X11 E3 (1215) X31 X22 A6 X77 F7 X20 X29 X36 X21 X30 X31 X574 X33 X574 X3 (1082) X30 X20 X30 X21 X30 X20 X30 X20 X30 X21 X51 (764) X30 X20 X30 X20 X31 X574 X30 X21 X34 X29 X30 X20 X30 X20 X31 X3
END #1 X30 X29 X29 V9 X29 X574 X31 X30 A6 X28 X28 X28 X28 (1027) X28 (801) X28 X3 X28 X28 X28 X28 X31 X27 X27 X29 X3 X29 (1155) X30 X31 X29 X3 X36 X31 X29 X29 X17 X27 X27 X30 V8 A6 X31 X27 X27 X27 R10 R10 X34 X33 (1153) (1023) (1153) X28 X33 X32 (1023) X27 X3
END #2 X20 X20 X21 X36 X20 (1153) X3 X21 X77 X21 X21 X21 X21 X34 X21 X34 X21 X31 X21 X21 X21 (1020) X3 (552) X10 (1020) X34 X36 X34 (1278) X3 X36 X33 (1153) X3 X11 X11 X52 X11 X11 X21 (1105) X77 X3 X11 X11 X11 X3 X3 X3 X3 X36 X3 X3 X21 X3 X3 X36 X11 X34
NUMBER COLOR END #1 1291 GRN (1251) 1292 BLU (1252) 1293 BLK/RED X3 1295 BRN/WHT X3 1297 BRN/BLU X3 1298 GRN/RED X36 1303 GRY X3 1310 BLU/YEL X11 1311 WHT/BLK K12 1312 YEL/BLK K13 1314 WHT X47 1315 BLU (522) 1320 YEL/GRN K11 1321 BLK W36 1322 YEL/GRN (1320) 1323 BLU K12 1324 BLU K13 1325 YEL/GRN K12 1326 YEL/GRN K13 1327 BLU F18 1332 WHT/RED (900) 1340 RED/BLU X36 1341 BLK/BLU X33 1342 BLK/GRN X33 1343 BLU/YEL X32 1353 BLK X28 1354 BLU/RED X27 1355 BLK W36 1356 GRN A5 1357 BLU A5 1358 GRN X42 1359 BLU X42 1360 RED/BLK X37 1363 BLK W36 1364 GRN/WHT X37 1365 GRN X37 1370 WHT K12 1371 WHT/BLK V11 1372 GRN V11 1373 YEL/BLK V12 1374 GRN V12 1375 YEL V13 1376 WHT/VLT V13 1377 YEL V14 1378 RED/YEL V14 1379 GRN/WHT V14 1380 LT GRN/RED F35 1381 WHT/GRN X74 1382 YEL/BLK X74 1383 BLK/YEL X74 1384 GRN/WHT X74 1385 RED/BLK X74 1386 VLT/GRN V10 1387 YEL/GRN V10 1400 RED/BLK (1213) 1401 RED/GRN (1185) 1402 WHT/GRN (1100) 1403 RED/YEL (1245) 1502 RED F36 1503 RED/BLU F37
END #2 X1 X1 X34 X31 X31 X78 X22 S14 F13 F17 (607) K13 X33 K11 K11 (1327) (1327) (1320) (1320) K11 F7 X574 X574 X574 X574 W36 (616) X78 (1027) (1155) (1027) (1155) (764) X37 X3 X3 (607) (1311) F50 (1312) (1372) (850) (1234) (850) (854) (1236) X1 X3 X3 X3 X3 (764) (517) (1320) X573 X573 X573 X573 X3 X3
NUMBER 1504 1550 1551 1567 1568 1569 1570 1571 1572 1573 1574 1576 1577 1578 1579 1580 1581 1582 1583 1584 1586 1587 1588 1589 1590 1591 1592 1593 1594 1595 1816 1817 1818 1819 1821 1830
COLOR BLU/RED BLK/GRN BLK RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK RED/BLU WHT WHT WHT WHT WHT WHT WHT/RED BLU/RED YEL/RED ORG/BLU BLU/BLK GRN/RED
END #1 X3 X3 X3 (511) X62 X58 X59 X61 X63 X54 X54 X57 X56 X55 X62 X58 X59 X61 X63 X54 X57 X56 X55 (618) F35 F51 F51 F23 F51 F51 X31 X31 X31 X31 X34 X575
END #2 F38 (1030) (1002) F51 F34 F33 F24 F25 F26 F31 F21 F23 F32 F22 (501) (501) (501) (501) (501) (501) (501) (501) (501) X56 (561) (561) (561) (561) (561) (561) X575 X575 X575 X575 X575 X34
SHEET 1 OF 5 Cab Harness (W1) Wiring Diagram (1 of 5) (S.N. —057099) Continued on next page
TM13345X19 (23APR18)
NUMBER COLOR 1186 GRN/BLU 1187 BLU/WHT 1189 BLK/PNK 1190 YEL/GRN 1191 LT GRN 1192 BLK/YEL 1194 VLT/WHT 1196 BLU/WHT 1197 GRY 1198 RED/GRN 1199 BLU/YEL 1200 YEL 1202 GRN/WHT 1203 GRN 1204 LT GRN/YEL 1205 BLU 1206 GRN 1207 ORG/RED 1208 GRY 1210 BRN/YEL 1211 BRN/BLU 1212 RED 1213 RED/BLK 1214 RED/BLU 1215 ORG/BLU 1219 RED 1220 ORG 1221 BLK/GRN 1222 BLU 1223 RED 1224 GRN 1225 BLK/BLU 1227 GRY/BLK 1228 BLK/YEL 1229 BLU/RED 1234 WHT/VLT 1236 GRN/WHT 1237 YEL/RED 1238 GRN/BLK 1240 GRN/YEL 1241 BRN 1242 WHT 1244 WHT 1245 RED/YEL 1246 RED/BLK 1248 BLK/WHT 1250 WHT/BLK 1251 GRN 1252 BLU 1253 WHT/BLU 1254 PNK/GRN 1255 BLK/YEL 1256 RED/YEL 1257 BLK/YEL 1258 PNK 1264 WHT/GRN 1268 YEL/GRN 1276 RED/YEL 1278 RED 1285 YEL/RED
9015-10-89
160GLC Excavator 042318 PN=399
JA92389,000015E -19-14FEB18-2/19
System Diagrams
TX1248637 —UN—13DEC17
X1
F50 F10
F9 552
X2 1 2 3 4 5 6
(1028) (1026) (1089) (1030) — —
BLK/RED RED/GRN BLK BLK/GRN
X20 X20 (1004) X20
F8 810 F7 1159 F6 611 F5 610
S14 1
(1310)
BLU/YEL
X11
F4
X83 1 2 3
(400) (401) (402)
WHT/RED GRN/RED RED
F2 591 F1 598
S14
(545) (605)
WHT/VLT BLK
K10 W37
1
F3 609
X3 X3 (611)
S5/X543 1 2
39
5A
5A
560
10A
10A
20A
5A
5A
522 1312
1332
20A
10A
5A 20A
607
10A 5A
506
20A 10A
5A
1311 1372
20A
881
10A 5A 5A
612 F20 603 F19 1327 F18
F51
764 F17 F30
F40
F29
F39
661 F15 20A
S5/X543
F28 1567
F27 5A
20A
754 A
1502 F36
G
566 F12 F25 1571
5A
1592
5A
1590
1380 F35
F23 1576
10A
10A 1591 1593
10A
F22 1578 F21 1574
6
10A 10A
10A 1595
1594
10A
X1
1380 B
(139) (503) (509) (573) (592) (604) (605) (615) (633) (662) (754) (891) (1008) (1009) (1010) (1012)
BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
X50 X45 X99 A6 X39 X65 S5/X543 X26 R9 X25 X1 A8 X35 (1015)-(1017) X10 X77
1292 J
A6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
MB
1568 F34
9
571 569
1122 1197 1152 1158 566
572 570
1085
2
X73 X73
GRN GRY BLK YEL/BLU YEL/RED WHT/BLK BRN
(1027) X77 X77 X77 F12 X73 X73
BLU
(1155)
WHT BLK RED/BLU
X77 W37 (552)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1244 573 568 16
X35 — (1120) (1205) (1203) (1222) (1093) (1293) — (1285) — — — — (1045) (1092)
A8
X25
1577 F32 890
891
2
GRN BLK
1 2 3 4 5 6 7 8 9 10 11 12 13
F15 W37
3
892
893
4
(666) (667)
BLK GRN
(662) (661)
+
+
1
-
1 2 3 4
FVS
(890) (891) (892) (893)
RED BLK BLU ORG
X-
F16 W37 G5 G5
V6
AU
A 666 667
(800) (801) (1027) (1155) X3 X3
YEL/RED
X3
BLU/RED BLU/YEL
X3 X3
(1182) (1117) (1253) — — — — — — — (1220) — (1830) (1821) —
WHT WHT/VLT WHT/BLU
X29 X3 X3
ORG
X3
GRN/RED BLU/BLK
X575 X575
1 2 3 4 5 6 7 8 9 10 11 12
(1008) (1121) — (88) (39) (1062) — — — — — —
BLK BLK
W37 (1008)
RED/BLK BLU BLU
(764) F10 (39)
13 14 15 16 17 18 19 20 21 22 23 24
— — — — — — — — — — — —
X36 (661) (662)
V6 A K
GRN BLU GRN BLU GRN/YEL BLK/RED
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
X36
A8
3
SW
1
+ -
8
1569 F33
1573 F31
GRY/BLK ORG
X25
AU 400 401 402
X34 (571) (569) — (1122) (1197) (1152) (1158) (566) (572) (570) — (1085) — (1244) (573) (568)
A6
W37
1291 H
665 F11 5A
1133 C
1503 F37
X83
2
(1251) (1252)
1132 E
3
4
GRN BLU
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X
1
20A
F F26 1572
1030 605
W37 F35 (800) (801) (802)
1504 F38
632 F13
1028 1026 1089
545
BLK LT GRN/RED GRN BLU GRY
1136 D
771 F14
X2 1
(754) (1380) (1133) (1136) (1132) PLUG PLUG (1291) (1292)
890 F16
F24 1570 1310
W37
A B C D E F G H J
(4) (3) (2) (1015) (1016) (1017) (1160) (1225) (1221) — (1039) (1074) (1190)
RED RED RED BLK BLK BLK ORG BLK/BLU BLK/GRN
(518) (518) (518) (1009) (1009) (1009) X29 X29 X29
GRN/BLK LT GRN YEL/GRN
S7/X544 X78 V9
14 15 16 17 18 19 20 21 22 23 24 25 26
— — (1255) (1228) (1118) (1298) — (1029) (1340) — — (1276) (1119)
1
BLK/YEL BLK/YEL GRY GRN/RED
(1153) (1153) X45 X78
ORG/BLU RED/BLU
X45 X574
RED/YEL RED/YEL
(1023) (1023)
4
1017
6
1039 1074 1190
1255 1228
17
1340
1276 1119
26
3
7
1160 1225 1221
18
1118 1298
2
1015
1029
1016
K
1
3
1118 1029
141
503
X50 1 2
(138) (139)
GRN/BLK BLK
X3 W37
X65 1 2 3
(530) (825) (604)
ORG VLT BLK
V5 X21 W37
X75 1 2
(532) (531)
TX1248637
RED PNK/BLK
(1) K2
6
X45 1 2 3 4 5 6 7 8 9 10 11 12
(141) — — (1118) (1029) — — — — — — (503)
12
WHT/YEL
GRY ORG/BLU
(610)
X36 X36
X45
1 2 3 4 5 6
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
F5 F6 F20 (537) (536) W37
X26 1
610
611
612
3
4
616
617
615
6
-
1
(632) (633)
BLU/YEL BLK
F13 W37
G5 BLK
W37
1
1580
2
4
R9
893 2
(892) (893)
BLU ORG
A8 A8
G5
(589) (591) (592) (590)
BLK/PNK BLK/RED BLK BLK/YEL
1576
1
1586
2
(618) (1588) (1578)
RED/BLU BLK RED
(536) (501) F22
F23 (501)
X59
X55 1 2 3
1 2
(1576) (1586)
RED BLK
X35
1
X61
2
1571 1582
1
X63
2
1572 1583
1 2
X62
1568 1579
1
1
(1573) (1584) (1574)
RED BLK RED
F31 (501) F21
X58 1 2
X59 1 2
X63 (1570) (1581)
RED BLK
F24 (501)
X61 (1569) (1580)
RED BLK
F33 (501)
1 2
1 2
RED BLK
F25 (501)
1 2
1121
88
39
1062
6 16
17
24
X34 (1572) (1583)
RED BLK
F26 (501)
X62 (1571) (1582)
1008
7 2
X54 1 2 3
K6 F2 W37 K6
1570 1581
2 1584 1574 3
X39 1 2 3 4
2 1588 1578 3
X57
1573 1
X58 1 892
1 2
X39
1569
618 1
(618) (501) F32
X57
X54
R9 + -
589 591 592 590
X55
RED/BLU BLK RED
2
2
X26
2 1587 1577 3 CA B FR LAM ON P T
6
(1589) (1587) (1577)
QUICK HITCH
2
3
A6 W37 A6
1 2 3
X AU
1
YEL/BLU BLK GRY
X56
1589 1
3 AUX
X50
5
1158 1012 1197
AT SE ER AT HE
1
139
1
2 1152
WARNING LAMP
138
2
532 531
X77
1 1244
I
530 825 604
A6 A6
P M LA B AR CA RE
1
WHT BLK
X56
B
X75
(1244) (1152) — (1158) (1012) (1197)
+
X65
1 2 3 4 5 6
CA B FRO LAM NT P +2
IM MO
X77
(1568) (1579)
RED BLK
F34 (501)
1
1120 1205 1203 1222 1093 1293
11
1045 1092 1182 1117 1253
23
1220
1285
10 22
1830 1821
30
SHEET 2 OF 5
Cab Harness (W1) Wiring Diagram (2 of 5) (S.N. —057099)
JA92389,000015E -19-14FEB18-3/19
Continued on next page
TM13345X19 (23APR18)
9015-10-90
160GLC Excavator 042318 PN=400
System Diagrams F16— 12-Volt Power Unit 10 A 1— Continued on Sheet 3 F36— Engine Control Unit (ECU) X54— Heated Air Seat Harness Fuse (marked 12V UNIT) A6—Radio 20 A Fuse (marked ECU P2) 3-Pin Connector (marked F17— Power On 5 A Fuse A8—12-Volt Power Converter F37— Engine Control Unit (ECU) SEAT HEATER) (marked POWER ON) F1— Work and Boom Lights 20 A 20 A Fuse (marked ECU P3) X55— Front Cab Light 1 F18— Idle Stop 5 A Fuse (marked F38— Fuel Transfer Pump and Fuse (marked LAMP) Connector (marked CAB IDLE STOP) F2— Windshield Wiper and Controllers 20 A Fuse LAMP FRONT) Washer 10 A Fuse (marked F19— Horn 10 A Fuse (marked (marked ECU P4) X56— Front Cab Light 2 HORN) WIPER) F39— Not Used Connector (marked CAB F3— Air Conditioner and Heater F20— Optional Connector 5 A F40— Not Used LAMP FRONT +2) Fuse (marked OPT. 3 BATT) F50— Fuse Box 20 A Fuse (marked HEATER) X57— Rear Cab Light Connector F4— Solenoid 20 A Fuse (marked F21— Heated Air Seat 10 A Fuse F51— Fuse Box 2 (marked CAB LAMP REAR) (marked SEAT HEATER) SOLENOID) G5—12-Volt Power Outlet X58— Warning Light Connector F22— Front Cab Light 1 10 A F5— Optional and Attachment R9—Lighter (marked WARNING LAMP) Fuse (marked CAB LAMP S5— Horn Switch Connector 5 A Fuse (marked X59— Satellite Communication FRONT) OPT. 1 ALT) S14— Door Switch Connector (marked IMOBI) F23— Rear Cab Light 10 A Fuse V6— Auxiliary Power Connector X61— Quick Hitch Connector F6— Optional Connector and (marked CAB LAMP REAR) Reversing Fan 20 A Fuse Diode (marked QUICK HITCH) F24— IMMOBI 5 A Fuse (marked W37—Cab Harness Ground 3 (marked OPT. 2 ALT) X62— Cab Auxiliary Power IMOBI) F7— Start Position Signal 5 A X1— Service ADVISOR™ Connector 2 (marked F25— Quick Hitch 5 A Fuse Fuse (marked START) Diagnostic Connector AUX_2) (marked QUICK HITCH) F8— Engine Control Unit (ECU) X2— MPDr 6-Pin Connector X63— Cab Auxiliary Power 20 A Fuse (marked ECU P1) F26— Cab Auxiliary Power X25— Cab Harness Auxiliary Connector 3 (marked Connector 3 5 A Fuse F9— Radio Backup 10 A Fuse Power Connector 1 AUX_3) (marked AUX_3) (marked BACK UP) (marked AUX+/-) X65— Cab Harness-to-Pilot F27— Not Used F10— Data Converter and X26— Optional Connector Shutoff Switch Harness F28— Not Used Main Controller Battery X34— Cab Harness-to-Main Connector F29— Not Used Power 5 A Fuse (marked Controller 30-Pin X75— Cab Harness-to-Pilot F30— Not Used CONTROLLER) Connector D Shutoff Valve Harness F31— Seat Compressor 10 F11— Travel Alarm 5 A Fuse X35— Cab Harness-to-Main Connector A Fuse (marked SEAT (marked TRAVEL ALARM) Controller 24-Pin X77— Radio Auxiliary Connector COMPR) F12— Radio and Dome 5 A Fuse Connector E X83— Cab Harness-to-Reversing F32— Front Cab Light 2 10 A (marked RADIO) X36— Cab Harness-to-Main Fan Switch Harness Fuse (marked CAB LAMP F13— Lighter 10 A Fuse (marked Controller 26-Pin (marked VSF-SW) FRONT +2) LIGHTER) Connector F X543— Horn Switch Connector F14— Monitor 5 A Fuse (marked F33— Warning Lamp 10 A Fuse X39— Cab Harness-to-Window (marked WARNING LAMP) MONITOR) Switch F34— Cab Auxiliary Power F15— Cab Auxiliary Power X45— Option 2 12-Pin Connector Connector 2 10 A Fuse Connector 1 10 A Fuse (not used) (marked AUX_2) (marked AUX) X50— Cab Harness-to-Travel F35— Service ADVISOR™ Alarm Cancel Switch Diagnostic Connector 5 A Harness Connector Fuse (marked DIAG) Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-91
JA92389,000015E -19-14FEB18-4/19
160GLC Excavator 042318 PN=401
System Diagrams
TM13345X19 (23APR18)
9015-10-92
160GLC Excavator 042318 PN=402
System Diagrams
TX1159483 —UN—27MAY14
X51
X3 A1 (1067) A2 (1229) A3 PLUG A4 (1227) A5 (655) A6 (651) A7 PLUG A8 (745) A9 PLUG A10 (26) A11 PLUG A12 (1254) A13 PLUG A14 (1033) A15 (764) A16 PLUG A17 (876) A18 (877) A19 (1365) A20 (1364) A21 (507) B1 (1295) B2 (1069) B3 (1071) B4 (1082) B5 (1381) B6 (1382) B7 (665) B8 (1097) B9 (1096) B10 (542) B11 (546) B12 (1383) B13 (1550) B14 (1384)
X33 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
(1033) (1138) (1254) (1227) (1320) (1341) (1164) (1264) — (26) — (1342) (1061) (1090) (1110) (651) (655)
SK BLU GRN/BLU PNK/GRN GRY/BLK YEL/GRN BLK/BLU GRY WHT/GRN
X3 X574 X3 X3 K11 X574 X574 X3
WHT/RED
X3
BLK/GRN YEL/BLK BRN/BLU GRN/YEL BLU/WHT ORG/WHT
X574 X3 X3 X3 X3 X3
X32 1 2 3 4 5 6 7 8 9 10 11 12
— (1343) — — — — — — — — (1268) (1116)
BLU/YEL
YEL/GRN RED
X574
X3 X3
13 14 15 16 17 18 19 20 21 22 23 24
— — — — — — — — — — — —
BLU/BLK BLU/RED
X31 X31
GRY/BLK ORG/WHT BLU/WHT
X33 X33 X33
VLT/GRN
(517)
WHT/RED
X33
PNK/GRN
X33
SK BLU RED/BLK
X33 F17
ORG/BLK ORG/GRN GRN GRN/WHT BLK/RED BRN/WHT GRN/WHT GRN/ORG GRN/RED WHT/GRN YEL/BLK WHT/YEL GRN/BLK BLK PNK/WHT VLT BLK/YEL BLK/GRN GRN/WHT
X37 X37 X37 X37 V2 X31 X31 X31 X31 X74 X74 F11 X52 (1011) K10 K9 X74 (1030) X74
B15 (1551) B16 (235) B17 (1104) B18 (1112) B19 (1257) B20 (1256) B21 (138) C1 (511) C2 (508) C3 (505) C4 (810) C5 (660) C6 (664) C7 (537) C8 (536) D1 (1105) D2 (1023) D3 (506) D4 (1502) D5 (1503) D6 (501) D7 (1504) D8 (1153) E1 (1020) E2 (1022) E3 (800) E4 (1264) E5 (1117) E6 (1061) E7 (1135) E8 (1303) E9 (801) E10 (1090) E11 (1220) E12 (1110)
BLK BRN BRN/BLU RED/YEL BLK/YEL RED/YEL GRN/BLK RED WHT WHT/BLK BLU RED WHT/YEL BLU/RED RED/BLU WHT RED/YEL WHT RED RED/BLU BLK BLU/RED BLK/YEL RED BLK/YEL GRN WHT/GRN WHT/VLT YEL/BLK WHT GRY BLU BRN/BLU ORG GRN/YEL
(1002) X20 X52 X52 (1153) (1023) X50 X47 V3 K4 F8 (611) (610) K7 K8 X52 X29 F50 F36 F37 (1579)-(1588) F38 X29 X22 X22 X20 X33 X34 X33 X22 X22 X20 X33 X34 X33
E13 PLUG E14 (802) E15 (1251) E16 (1252) E17 (1116) E18 (1268) E19 (1083) E20 (1167) E21 (1084) F1 (1285) F2 (1045) F3 (1093) F4 (1213) F5 (1185) F6 (250) F7 (1092) F8 (1253) F9 (1293) F10 (400) F11 (401) F12 (762) F13 (1100) F14 (1245) F15 (1194) F16 (1297) F17 (1018) F18 (1207) F19 (1086) F20 (1087) F21 (1224)
GRY GRN BLU RED YEL/GRN GRN/ORG GRN/RED YEL YEL/RED BLU/RED GRN/YEL RED/BLK RED/GRN WHT/BLU BLU/YEL WHT/BLU BLK/RED WHT/RED GRN/RED BLK/GRN WHT/GRN RED/YEL VLT/WHT BRN/BLU BRN/YEL ORG/RED BLK/WHT WHT GRN
1 2 3 4
H2
— R10 R10 X32 X32 (1071) (1082) X31 X34 X34 X34 X31 X31 X21 X34 X34 X34 X83 X83 X22 X31 X31 X31 X31 X31 X31 X31 X31 X31
1 2 15 1251 1252 1116 1268 1083 1167 1084 21 E
(544) (541)
RED/BLU PNK/GRN
(552) K3
1100 1092 1253 1293
400 401 762
1 1020 1022 800
1264 1117 1061 6
1 1285 1045 1093
1213 1185 250 6
1 2 3
(1154) (1156) (1014)
RED/BLU ORG/BLU BLK
1 2 3 4 5 6 7 8 9 10
(552) (1215) X11
X51
810
8
7
1504 1153
8
H2
X3
5
660 664
6
4
1502 1503
5
2
508 505
3
1
1105 1023
2
501
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
2
C
D
2
3 1113 1176 4
(1111) (1237) (1112) (1104) (1097) (1105) — — (1124) (1125)
ORG YEL/RED RED/YEL BRN/BLU GRN/BLK WHT
X17 X17 X3 X3 X3 X3
GRN BLU
(1027) (1155)
544 541
(301) (302) — — (1356) (307) (303) — — — (1357) (306) — (304) (305) — —
BLU BLU
(39) (39)
GRN BLU RED/BLK
(1027) (1252) (764)
BLU GRN
(1155) (1251)
BLK BLK
W36 (304)
X52 506
511
1 1011 609
1
6
4
1
W36 F3 (609) (764)
X52
E3
1245
F
1090 1220 1110
537 536
BLK RED/GRN RED/GRN RED/BLK
15 1194 1297 1018 1207 1086 1087 1224 21
802
1135 1303 801
7
A5 (1011) (609) (1113) (1176)
E3
3
1 1111 1237
1112 1104 4
5 1097 1105
1124 1125 10
A5
1154 1156 1014 1
15
764
876
877 1365 1364 507 21 A
745 1 1067 1229
26
3
15 1551 235 1104 1112 1257 1256 138 21
1033
1550
1254
665 1097 1096
1227 655 651 6
2
1 1295 1069 1071
301
7
303
13
1384
B
1
302
1356 307
6
1357 306
12 17
304 305
542 546 1383
X573
1082 1381 1382 6
2 4
1401 1400
1
1403 1402
3
1
2 X99 1
X31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(1157) (1069) (1295) (1816) (1817) (1229) (1067) (1071) (1082) (1224) (1087) (1084) (1194) (1086) (1207) (1213)
YEL/WHT GRN/WHT BRN/WHT WHT/RED BLU/RED BLU/RED BLU/BLK GRN/ORG GRN/RED GRN WHT YEL VLT/WHT BLK/WHT ORG/RED RED/BLK
X22 X3 X3 X575 X575 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(1185) (1245) (1100) (1818) (1819) (1139) (1180) (1163) (1140) (1297) (1018) — — — —
RED/GRN RED/YEL WHT/GRN YEL/RED ORG/BLU WHT/BLU BLU/WHT ORG/BLK YEL/BLU BRN/BLU BRN/YEL
X3 X3 X3 X575 X575 X574 X574 X574 X574 X3 X3
1 2 3 4 5 6
1
500
BLK BLK BLK BLK
W37 W36 W35
562
4
6
3
1 A 502 507
2
571 569
K
A K
1
1157
1082
9
1
1033 1138 1254 1227 1320 1341
10
1224 1087 1084 1194 1086 1207 1213 1185 1245 1100 1818 1819
21
7
1164 1264
22
1139 1180 1163 1140 1297
31
13
1061 1090 1110
1069
1295
1816
1817 1229
1018
1067
1071
1
7
1343 1268 1116
26
12
V3
651 655
17
A K
16
160GLC Excavator 042318 PN=403
(606) (508)
YEL/BLK WHT
(1312) X3
V12
V3 A 606 508
K
V5
A 1371 1372 K
2
3
A 1190 155
V9
V5 (528) (530) (529)
VLT/GRN ORG VLT/WHT
(517) X65 K2
RED/BLK RED/GRN WHT/GRN RED/YEL
(1213) (1185) (1100) (1245)
4
1 2 3
(1251) (1252) PLUG
GRN BLU
X3 X3
(571) (569) (572) (570)
GRY/BLK ORG WHT/BLK BRN
A6 A6 A6 A6
(1373) (1374)
YEL/BLK GRN
(1312) (1372)
(1371) (1372)
WHT/BLK GRN
(1311) F50
X73 1 2 3 4
V12 528 530 529 1
1 2 3
V11
A 1373 1374 K
3
(1400) (1401) (1402) (1403)
V9 A K
(1190) (155)
YEL/GRN ORG
X36 (530)
K
A K
V11 A K
SHEET 3 OF 5 Cab Harness (W1) Wiring Diagram (3 of 5) (S.N. —057099)
Continued on next page
(764) X3
X33
X32
TX1159483
RED/BLK BLK/RED
6
1342
24
17
(502) (507)
1 2 3 4
R10
X73
V2
(501)
2
1251 1252
572 570
X31
9015-10-93
— (509) (518) (500) — (562)
V2
8
TM13345X19 (23APR18)
3 509 518
X99
X573
R10
JA92389,000015E -19-14FEB18-5/19
System Diagrams
TM13345X19 (23APR18)
9015-10-94
160GLC Excavator 042318 PN=404
System Diagrams
1— Continued on Sheet 2 2— Continued on Sheet 4 A5—Data Converter E3— Cab Dome Light H2—Security Alarm R10— N CAN Resistor 1 V2— Not Used 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
Continued on next page
TM13345X19 (23APR18)
9015-10-95
X73— Cab Harness-to-Speakers Connector X99— Cab Ground Splice X573— Exhaust Solenoid Harness Connector (not used)
JA92389,000015E -19-14FEB18-6/19
160GLC Excavator 042318 PN=405
System Diagrams
TM13345X19 (23APR18)
9015-10-96
160GLC Excavator 042318 PN=406
System Diagrams
TX1248638 —UN—18DEC17
K1 A1 A2 A3 A4 A5
K2 (519) (856) (520) — (524)
RED ORG RED
(511) X22 (511)
WHT
(508)
K4 D1 D2 D3 D4 D5
(533) (529) (531) — (525)
RED VLT/WHT PNK/BLK
(1) V5 X75
VLT
K5
C1 C2 C3 C4 C5
K5 (910) (517) (900) (505) —
WHT/RED VLT/GRN WHT/RED WHT/BLK
(900) V4 X47 X3
K7 G1 G2 G3 G4 G5
B1 B2 B3 B4 B5
K3
E1 E2 E3 E4 E5
RED/BLK YEL GRN
(764) X10 F1
BLU/RED
X3
H1 H2 H3 H4 H5
(552) (852) (541) — (540)
RED/BLU GRN/BLK PNK/GRN
F9 X22 H2
BLK
W36
(523) (527) (550) (525) —
RED VLT/RED BLK VLT
(1) V4 W36 K2
F1 F2 F3 F4 F5
K6 (593) (851) (590) (589) (594)
RED/BLK GRY/RED BLK/YEL BLK/PNK BLK
(764) X11 X39 X39 W36
R6
GRN RED/YEL GRN
(598) X10 (598)
RED/BLU
X3
I1 I2 I3 I4 I5
RED/BLK BLK/BLU BLK/RED
(764) X10 (591)
VLT
X3
590
F3 F5
R7
1321 5
1370 3
1322 3
K8
598 G3
R8
850
601
G1
G2
H1
520 A3
R2
A1
A4
531 B3
R3
525 B5
524 A5 519
G4
856
533
A2
B1
K1
B4
600 H3
529
552
B2
C1
K2
H4
R9
854
595
H2
I1
541 C3
R4
596
I3
546
I5
I4
J1 J2 J3 J4 J5
K11 (602) (545) (603) — (542)
WHT WHT/VLT WHT
(603) S5/X543 F19
PNK/WHT
X3
1 2 3 4 5
855
602
I2
J1
900 D3
BLU YEL/GRN YEL/GRN
F18 X33 (1320)
BLK
W36
1 2 3 4 5
(1323) (1325) (1370) (1311) —
BLU YEL/GRN WHT WHT/BLK
R5
603
J3
542
J5 545 J2
J4
550 E3
D5
E5
852
910 505 517
523 525 527
C2
D1
K3
K12 (1327) (1320) (1322) — (1321)
R10
540 C5
C4
D4
D2
E1
K4
K5 1
X10
5 1 1315 3
5
854
772
4
855 850 1215 1010
8
K13 1 2 3 4 5
(1324) (1326) (1315) (1312) —
BLU YEL/GRN BLU YEL/BLK
(1327) (1320) (522) F17
— (854) — (772) (855) (850) (1215) (1010)
RED/YEL
K8
BLU BLK/BLU YEL ORG/BLU BLK
(39) K9 K7 X27 W37
GRN
X20
RED RED/BLK
X27 X27
GRN/BLK WHT/VLT
X27 X29
GRY/RED BLK BLU
K6 E3 X20
BLK/WHT WHT/BLK
X27 X27
W36 1 2 3 4 5 6 7 8 9
X11
E2
E4
K13 1326 1312 1324
(1327) (1320) (607) F13
1 2 3 4 5 6 7 8
K10
2
K10
X10
K9
536 H5
537 G5 599
F4
1 1327
5
K7
594
4
K11 1320
F2
R1 (595) (855) (596) — (546)
2
1
593 589 851 F1
K9 (601) (854) (600) — (536)
4
K12 1325 1311 1323
K6
K8 (599) (850) (598) — (537)
2
X11 1 1027
1278 1246
1238 1234
851 1014 10
11 1155
1248 1250
1240 1236 1310 1101
20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(1027) — (1278) (1246) — (1238) (1234) — (851) (1014) (1155) — (1248) (1250) — (1240) (1236) (1310) (1101) —
(304) (518) (535) (540) (548) (550) (594) (1003) (1004)
BLK BLK BLK BLK BLK BLK BLK BLK BLK
A5 X99 V7 K3 V1 K5 K6 X21 X21
(1111) (1237) (1025) (1076)
ORG YEL/RED WHT/RED RED/BLK
X52 X52 X22 (764)
10 11 12 13 14 15 16 17
(1006) (1007) (1011) (1013) (1321) (1353) (1355) (1363)
X30 S7/X544 X51 V8 K11 X28 X78 X37
W36
X17 1 2 3 4
MB
X17
4
1
X42 1 2
1111 1237 1025 1076
(1358) (1359)
GRN BLU
(1027) (1155)
X42 1
GRN/YEL GRN/WHT BLU/YEL YEL/RED
BLK BLK BLK BLK BLK BLK BLK BLK
X27 X29 S14 (566)
2
1358 1359
2
3 V14
V14 1 2 3
(1377) (1379) (1378)
YEL GRN/WHT RED/YEL
(850) (1236) (854)
V13 A K
(1375) (1376)
YEL WHT/VLT
(850) (1234)
1
2
V13
V10
(1013) (1242)
BLK WHT
W36 (1105)
A 1386 1387 K
BLK BLK/WHT
W36 (505)
VLT/GRN YEL/GRN
V1 A 548 510
A 535 534
K
517 1031 527 1
2
BLK WHT
K
1 2 3
(517) (1031) (527)
VLT/GRN GRN/WHT VLT/RED
V4
3
K4 X22 K5
1 2 3 4 5 6 7 8 9 10 11 12
(1138) (1139) (1140) (1141) (1341) (1164) (1180) (1343) (1342) (1163) (1192) (1340)
12
X575 GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK/BLU GRY BLU/WHT BLU/YEL BLK/GRN ORG/BLK BLK/YEL RED/BLU
X33 X31 X31 (1023) X33 X33 X31 X32 X33 X31 (1153) X36
1 2 3 4 5 6
(1816) (1818) (1817) (1830) (1821) (1819)
WHT/RED YEL/RED BLU/RED GRN/RED BLU/BLK ORG/BLU
X31 X31 X31 X34 X34 X31
1 1816
X575
2 1818
1817 1830 1821 1819 3
X78
6
1074 1355 1298 1
2
3
X78 1 2 3
(1074) (1355) (1298)
LT GRN BLK GRN/RED
X36 W36 X36
SHEET 4 OF 5
TX1248638 Cab Harness (W1) Wiring Diagram (4 of 5) (S.N. —057099) Continued on next page
TM13345X19 (23APR18)
W36 (508)
V4
A 1013 1242 K
6
X574 (548) (510)
5
1140 1141 1341
1164 1180 1343 1342 1163 1192 1340
(517) (1320)
V1 A K
V7 (535) (534)
(1386) (1387)
A 1375 1376 K
V7 A K
A K
X574
1138 1139
V10
3
V8
V8 A K
1 1377 1379 1378
9015-10-97
160GLC Excavator 042318 PN=407
JA92389,000015E -19-14FEB18-7/19
System Diagrams
TM13345X19 (23APR18)
9015-10-98
160GLC Excavator 042318 PN=408
System Diagrams K8—Boom Light Relay 2— Continued on Sheet 3 V10— Starter Protection Diode K9—Windshield Washer Relay 3— Continued on Sheet 5 V13— Work Light 1 Diode K10— Horn Relay K1—Load Dump Relay V14— Work Light 2 Diode K2—Pilot Shutoff Solenoid Relay K11— Idle Stop Relay W36—Cab Harness Ground 2 K12— Accessory Cut Relay K3—Security Alarm Relay X10— Machine Controller 8-Pin K13— Key Cut Relay K4—Starter Cut Relay Connector A V1— Battery Relay Diode K5—Security Relay X11— Machine Controller 20-Pin V4— Security Diode K6—Windshield Wiper Relay Connector B V7— Start Relay Diode K7—Work Light Relay X17— Cab Harness-to-Monitor V8— Air Conditioner Clutch Diode Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-10-99
X42— CAN 1 Connector X78— Optional Switch X574— Auxiliary Function Lever (AFL) Connector 1 X575— Auxiliary Function Lever (AFL) Connector 2 (not used)
JA92389,000015E -19-14FEB18-8/19
160GLC Excavator 042318 PN=409
System Diagrams
TM13345X19 (23APR18)
9015-10-100
160GLC Excavator 042318 PN=410
System Diagrams
TX1248639 —UN—13DEC17
X74
X27
1
1
X37
1360
1
X74
2
1 2 3 4 5 6
4
1278 1246
1248 1238
1250 1240
1354 1214 1215
5
10
1363
X28
1 1212 1199 1200
5
1206 1258 1208 1210 1211 1198 1353
3
6
6
X29
1
1385
1381
1187 1191 1189
1382 1383
1384
1160 1221
3
6
AD
1 2 3 4 5 6
12
2
7
(764) X3 X3 X3
GRN/WHT
X3
1 2 3 4 5 6 7 8 9 10
(1360) (1363) (877) (876) (1365) (1364)
RED/BLK BLK ORG/GRN ORG/ BLK GRN GRN/WHT
(764) W36 X3 X3 X3 X3
1 2 3 4 5 6 7 8 9 10 11 12
1023 1182 1153
16
X30
1 1196 1161 1168 1171
X29 (1278) (1246) (1248) (1238) (1250) (1240)
RED RED/BLK BLK/WHT GRN/BLK WHT/BLK GRN/YEL
X11 X11 X11 X11 X11 X11
(1354) (1214) (1215)
BLU/RED RED/BLU ORG/BLU
(616) (552) X10
1 2 3 4 5 6 7 8
7 1223 1169 1006
(1212) (1199) (1200) (1202) (1204) (1206) (1258) (1208) (1210) (1211) (1198) (1353)
RED BLU/YEL YEL GRN/WHT LT GRN/YEL GRN PNK GRY BRN/YEL BRN/BLU RED/GRN BLK
(1187) (1191) (1189) (1023) (1182) (1153) — (1160)
BLU/WHT LT GRN BLK/PNK RED/YEL WHT BLK/YEL
X20 X20 X21 X3 X34 X3
(1221) — — (1225) (1234) (1236) (1219) (870)
BLK/GRN
X36
X36
9 10 11 12 13 14 15 16
BLK/BLU WHT/VLT GRN/WHT RED BLU/RED
X36 X11 X11 (1020) (616)
ORG
(1196) (1161) (1168) (1171) (1223) (1169) (1006) (1173)
BLU/WHT YEL/RED YEL/GRN ORG RED BLU BLK YEL
X21 X21 X20 X20 (1278) X21 W36 X20
9 10 11 12 13 14 15 16
(1177) (1175) (1179) (1183) (1181) (1184) (1186) (1241)
WHT BLU/RED YEL/BLU GRY/RED BLK/RED WHT/YEL GRN/BLU BRN
X20 X21 X20 X20 X21 X20 X20 X21
X30 1 2 3 4 5 6 7 8
X28
1225 1234 1236 1219 870
8
VSW
RED/BLK WHT/GRN YEL/BLK BLK/YEL
X37
1202 1204
877 876 1365 1364
X27 (1385) (1381) (1382) (1383) — (1384)
(1020) X21 X21 X21 X21 X21 X21 X21 X21 X21 X21 W36
X21
1173 1177 1175 1179 1183 1181 1184 1186 1241 8
16
W35 MB
S7/X544 3
S7/X544 1
1 2
BLK GRN/BLK
W36 X36
(500)
BLK
X99
(1150) (1145)
YEL/BLU BLK
X21 (1003)
X76
607
900
762 1157 1025 856 852 1031
8 16
F
BLK/GRN YEL/WHT WHT/RED ORG
X3 X31 X17 K1
9 10 11 12 13 14 15 16
(1135) — — — — — (852) (1031)
WHT
F15
WHT/RED BLU WHT RED
K4 F50 (607) X3
1258 1206 1204 1202 1200 1199 1208 1210 1211 1198
X20 1 15
1030
1173 1177 1179 1183 1184 1168 1186 1171 1187 1191 1028
824 1159 235
1002 801 800 1155 1027
TX1248639 Cab Harness (W1) Wiring Diagram (5 of 5) (S.N. —057099)
9015-10-101
160GLC Excavator 042318 PN=411
1026
825 1150
250
1196 1161 1169 1175 1181 1241 1189
802
Continued on next page
WHT
X3
GRN/BLK GRN/WHT
K3 V4
VLT YEL/BLU
X65 X76
(250) — — — (771) (1148)
WHT/BLU
X3
BLU/BLK RED/BLU
F14 (552)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
(1208) (1210) (1211) (1198) — — (1196) (1161) (1169) (1175) (1181) (1241) (1189) — — — (1004) (1003)
GRY BRN/YEL BRN/BLU RED/GRN
X28 X28 X28 X28
BLU/WHT YEL/RED BLU BLU/RED BLK/RED BRN BLK/PNK
X30 X30 X30 X30 X30 X30 X29
BLK BLK
W36 W36
X20 1
X47
TM13345X19 (23APR18)
X3 X3 X3
X28 X28 X28 X28 X28 X28
X21
19
(607) — (900) (522) (1314) (511)
GRY BLK/YEL RED
M
6
X47
1 2 3 4 5 6
(1303) (1022) (1020) — (762) (1157) (1025) (856)
PNK GRN LT GRN/YEL GRN/WHT YEL BLU/YEL
X76 ST
F M
522 1314 511
1303 1022 1020 1135
1 2 3 4 5 6 7 8
(1258) (1206) (1204) (1202) (1200) (1199) — — — (825) (1150)
HM
3
9
W35 1
1
1
2
1007 1039
4
(1007) (1039)
X22
X22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
14 28
771 1148 1004 1003
18 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14
(1030) — (1173) (1177) (1179) (1183) (1184) (1168) (1186) (1171) (1187) (1191) (1028) —
BLK/GRN
X2
YYEL WHT YEL/BLU GRY/RED WHT/YEL YEL/GRN GRN/BLU ORG BLU/WHT LT GRN BLK/RED
X30 X30 X30 X30 X30 X30 X30 X30 X29 X29 X2
15 16 17 18 19 20 21 22 23 24 25 26 27 28
— (824) (1159) (235) — — — (1002) (801) (800) (1155) (1027) — (1026)
RED/BLK WHT/RED BRN
(764) F7 X3
BLK BLU GRN BLU GRN
(501) X3 X3 X11 X11
RED/GRN
X2
SHEET 5 OF 5
JA92389,000015E -19-14FEB18-9/19
System Diagrams
TM13345X19 (23APR18)
9015-10-102
160GLC Excavator 042318 PN=412
System Diagrams
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 X76— Cab Harness Connector 1 Filter Switch Harness (marked HMST) (not used) Connector X544— Power Dig Switch X47— Cab Harness-to-Key Connector Switch Harness Connector X74— Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness (marked SDV-SW)
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-103
JA92389,000015E -19-14FEB18-10/19
160GLC Excavator 042318 PN=413
System Diagrams
TM13345X19 (23APR18)
9015-10-104
160GLC Excavator 042318 PN=414
System Diagrams
Cab Harness (W1) Wiring Diagram (S.N. 057100— ) TX1247486 —UN—14DEC17
NUMBER 1 2 3 4 26 39 88 138 139 141 155 235 250 301 302 303 304 305 306 307 400 401 402 500 501 502 503 505 506 507 508 509 510 511 517 518 519 520 522 523 524 525 527 528 529 530 531 532 533 534 535 536 537 540 541 542 544 545 546 548 TX1247486
COLOR RED RED RED RED WHT/RED BLU RED/BLK GRN/BLK BLK WHT/YEL ORG BRN WHT/BLU BLU BLU RED/BLK BLK BLK GRN BLU WHT/RED GRN/RED RED BLK BLK RED/BLK BLK WHT/BLK WHT BLK/RED WHT BLK WHT RED VLT/GRN BLK RED RED BLU RED WHT VLT VLT/RED VLT/GRN VLT/WHT ORG PNK/BLK RED RED WHT/BLK BLK RED/BLU BLU/RED BLK PNK/GRN PNK/WHT RED/BLU WHT/VLT VLT BLK
END #1 F4 X36 (518) (518) X33 F10 (764) X50 W37 (610) V9 X20 X21 A5 A5 A5 W36 A5 A5 A5 X83 X83 X83 W35 X3 V2 X45 X3 X3 V2 V3 X99 V1 X47 K4 X99 (511) (511) X47 K5 K1 K5 K5 V5 K2 X65 K2 X75 K2 V7 W36 K8 K7 W36 H2 K10 H2 K10 K9 V1
END #2 (518) (518) X36 X36 X3 X35 X35 X3 X50 X45 (530) X3 X3 (39) (39) (764) A5 (304) (1251) (1252) X3 X3 (611) X99 (1579—1588) (764) W37 K4 F50 X3 X3 W37 (508) X3 V4 W36 K1 K1 F18 (1) (508) K2 V4 (517) V5 V5 X75 (1) (1) (505) V7 X3 X3 K3 K3 X3 (552) S5/X543 X3 W36
NUMBER COLOR 550 BLK 552 RED/BLU 560 RED 561 WHT 562 BLK 566 YEL/RED 568 RED/BLU 569 ORG 570 BRN 571 GRY/BLK 572 WHT/BLK 573 BLK 589 BLK/PNK 590 BLK/YEL 591 BLK/RED 592 BLK 593 RED/BLK 594 BLK 595 RED/BLK 596 BLK/RED 598 GRN 599 RED/BLK 600 GRN 601 GRN 602 WHT 603 WHT 604 BLK 605 BLK 606 YEL/BLK 607 WHT 609 RED/GRN 610 WHT/YEL 611 RED 612 LT GRN/RED 615 BLK 616 BLU/RED 617 RED/BLU 618 RED/BLU 632 BLU/YEL 633 BLK 651 BLU/WHT 655 ORG/WHT 660 RED 661 GRN 662 BLK 664 WHT/YEL 665 WHT/YEL 666 BLK 667 GRN 745 VLT/GRN 754 BLK 762 BLK/GRN 764 RED/BLK 771 BLU/BLK 772 BLU 800 GRN 801 BLU 802 GRY 810 BLU 824 RED/BLK
END #2 END #1 W36 K5 F9 K3 (511) F50 (1590—1596) (506) X99 (501) F12 A6 A6 (552) A6 X73 A6 X73 A6 X73 A6 X73 W37 A6 X39 K6 K6 X39 F2 X39 X39 W37 (764) K6 W36 K6 (764) K9 (591) K9 F1 K7 K7 (764) K8 (598) K8 (598) K10 (603) F19 K10 W37 X65 W37 S5/X543 V3 (1312) X47 F15 F3 X51 F5 X26 X26 F6 F20 X26 W37 X26 X26 (537) X26 (536) X55 (536) F13 R9 W37 R9 X33 X3 X3 X33 (611) X3 F15 X25 X25 W37 (610) X3 F11 X3 V6 (662) (661) V6 X3 (517) W37 X1 X3 X22 F17 X3 F14 X21 (39) X10 X20 X3 X20 X3 X20 SHIELD X3 F8 X3 (764) X20
NUMBER 825 850 851 852 854 855 856 870 876 877 881 890 891 892 893 900 910 1002 1003 1004 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1020 1022 1023 1025 1026 1027 1028 1029 1030 1031 1033 1039 1045 1047 1061 1062 1067 1069 1071 1074 1076 1082 1083 1084 1085 1086 1087
COLOR VLT YEL GRY/RED GRN/BLK RED/YEL BLK/BLU ORG BLU/RED ORG/BLK ORG/GRN WHT RED BLK BLU ORG WHT/RED WHT/RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BRN/YEL RED BLK/YEL RED/YEL WHT/RED RED/GRN GRN BLK/RED ORG/BLU BLK/GRN GRN/WHT SK BLU GRN/BLK BLU/RED GRY/RED YEL/BLK BLU BLU/BLK GRN/WHT GRN/ORG LT GRN RED/BLK GRN/RED GRN/ORG YEL BLU BLK/WHT WHT
END #2 END #1 X65 X21 K7 X10 K6 X11 K3 X22 K8 X10 K9 X10 K1 X22 X29 (616) X37 X3 X37 X3 (506) F50 A8 F16 W37 A8 A8 G5 A8 G5 X47 K4 K4 (900) (501) X20 X21 W36 X21 W36 W36 X30 W36 S7/X544 W37 X35 W37 (1015—1017) X10 W37 X51 W36 X77 W37 W36 V8 X11 E3 X36 (1009) (1009) X36 (1009) X36 X31 X3 X3 X22 X22 X3 X3 X29 X17 X22 X2 X20 X623B X11 X2 X20 X36 X45 X2 X20 V4 X22 X3 X33 X36 S7/X544 X3 X34 X34 X3 X33 X3 X35 (39) X3 X31 X31 X3 X31 X3 X36 X78 X17 (764) X3 X31 X3 (1071) X3 X31 A6 (1155) X31 X3 X3 X31
NUMBER 1089 1090 1092 1093 1094 1096 1097 1100 1101 1104 1105 1110 1111 1112 1113 1115 1116 1117 1118 1119 1120 1121 1122 1124 1125 1132 1133 1135 1136 1138 1139 1140 1141 1142 1143 1145 1148 1150 1152 1153 1154 1155 1156 1157 1158 1159 1160 1161 1163 1164 1167 1168 1169 1171 1173 1175 1176 1177 1178 1179
COLOR BLK BRN/BLU BLU/YEL GRN/YEL YEL/GRN BLK GRN/BLK WHT/GRN YEL/RED BRN/BLU WHT GRN/YEL ORG RED/YEL RED/GRN YEL/RED RED WHT/VLT GRY RED/YEL GRN BLK GRN GRN BLU GRY GRN WHT BLU GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK/RED RED BLK RED/BLU YEL/BLU BLK BLK/YEL RED/BLU BLU ORG/BLU YEL/WHT YEL/BLU WHT/RED ORG YEL/RED ORG/BLK GRY GRN/RED YEL/GRN BLU ORG YEL BLU/RED RED/BLK WHT BLK/YEL YEL/BLU
END #1 END #2 X2 (1004) X3 X33 X3 X34 X3 X34 X34 X3 (1011) X3 X3 X52 X31 X3 (566) X11 X3 X52 X3 X52 X3 X33 X17 X52 X3 X52 X51 (609) X32 X3 X3 X32 X34 X3 X45 X36 X36 (1023) (800) X34 X35 (1008) A6 (1027) X52 (1027) X52 (1155) X1 (802) X1 (800) X3 X22 X1 (801) X33 X574 X31 X574 X31 X574 X574 (1023) X603 X11 X603 (611) (1003) X76 X21 (552) X76 X21 X77 A6 X3 X29 E3 (552) X623B X11 E3 (1215) X31 X22 A6 X77 F7 X20 X29 X36 X21 X30 X31 X574 X33 X574 X3 (1082) X30 X20 X30 X21 X30 X20 X30 X20 X30 X21 X51 (764) X30 X20 X603 X10 X30 X20
END #1 X31 X30 X34 X30 X30 X31 X30 X29 X29 V9 X29 X574 X31 X30 A6 X28 X28 X28 X28 (1027) X28 (801) X28 X3 X28 X28 X28 X28 X31 X27 X27 X29 X3 X29 (1155) X30 X31 X29 X3 X36 X31 X32 X29 X29 X17 X27 X27 X30 V8 A6 X31 X27 X27 X27 R10 R10 X34 X33 (1153) (1023)
END #2 X574 X21 X29 X20 X20 X3 X20 X20 X21 X36 X20 (1153) X3 X21 X77 X21 X21 X21 X21 X34 X21 X34 X21 X31 X21 X21 X21 (1020) X3 (552) X10 (1020) X34 X36 X34 (1278) X3 X36 X33 (1153) X3 X3 X11 X11 X52 X11 X11 X21 (1105) X77 X3 X11 X11 X11 X3 X3 X3 X3 X36 X3
NUMBER COLOR END #1 1257 BLK/YEL (1153) 1258 PNK X28 1261 BRN X32 1263 GRY X32 1264 WHT/GRN X33 1268 YEL/GRN X32 1276 RED/YEL (1023) 1278 RED X27 1285 YEL/RED X3 1291 GRN (1251) 1292 BLU (1252) 1293 BLK/RED X3 1295 BRN/WHT X3 1297 BRN/BLU X3 1298 GRN/RED X36 1303 GRY X3 1310 BLU/YEL X11 1311 WHT/BLK K12 1312 YEL/BLK K13 1314 WHT X47 1315 BLU (522) 1320 YEL/GRN K11 1321 BLK W36 1322 YEL/GRN (1320) 1323 BLU K12 1324 BLU K13 1325 YEL/GRN K12 1326 YEL/GRN K13 1327 BLU F18 1330 BLU/YEL X32 1331 LT GRN/BLK X32 1332 WHT/RED (900) 1340 RED/BLU X36 1341 BLK/BLU X33 1342 BLK/GRN X33 1343 BLU/YEL X32 1352 BLK X603 1353 BLK X28 1354 BLU/RED X27 1355 BLK W36 1356 GRN A5 1357 BLU A5 1358 GRN X42 1359 BLU X42 1360 RED/BLK X37 1362 RED/BLK X603 1363 BLK W36 1364 GRN/WHT X37 1365 GRN X37 1370 WHT K12 1371 WHT/BLK V11 1372 GRN V11 1373 YEL/BLK V12 1374 GRN V12 1375 YEL V13 1376 WHT/VLT V13 1377 YEL V14 1378 RED/YEL V14 1379 GRN/WHT V14 1380 LT GRN/RED F35
END #2 X3 X21 X3 X3 X3 X3 X36 X11 X34 X1 X1 X34 X31 X31 X78 X22 S14 F13 F17 (607) K13 X33 K11 K11 (1327) (1327) (1320) (1320) K11 X3 X3 F7 X574 X574 X574 X574 W37 W36 (616) X78 (1027) (1155) (1027) (1155) (764) (764) X37 X3 X3 (607) (1311) F50 (1312) (1372) (850) (1234) (850) (854) (1236) X1
NUMBER 1381 1382 1383 1384 1385 1386 1387 1400 1401 1402 1403 1502 1503 1504 1567 1568 1569 1570 1571 1572 1573 1574 1575 1576 1577 1578 1579 1580 1581 1582 1583 1584 1585 1586 1587 1588 1589 1590 1591 1592 1593 1594 1595 1596 1816 1817 1818 1819 1821 1830 1850 1851
COLOR WHT/GRN YEL/BLK BLK/YEL GRN/WHT RED/BLK VLT/GRN YEL/GRN RED/BLK RED/GRN WHT/GRN RED/YEL RED RED/BLU BLU/RED RED RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK RED/BLU WHT WHT WHT WHT WHT WHT WHT WHT/RED BLU/RED YEL/RED ORG/BLU BLU/BLK GRN/RED GRN BLU
END #1 X74 X74 X74 X74 X74 V10 V10 (1213) (1185) (1100) (1245) F36 F37 X3 (511) X62 X58 X59 X61 X63 X54 X54 X630 X57 X56 X55 X62 X58 X59 X61 X63 X54 X630 X57 X56 X55 (618) F35 F51 F51 F23 F51 F51 F27 X31 X31 X31 X31 X34 X575 X623A X623A
END #2 X3 X3 X3 X3 (764) (517) (1320) X573 X573 X573 X573 X3 X3 F38 F51 F34 F33 F24 F25 F26 F31 F21 F27 F23 F32 F22 (501) (501) (501) (501) (501) (501) (501) (501) (501) (501) X56 (561) (561) (561) (561) (561) (561) (561) X575 X575 X575 X575 X575 X34 X20 X20
SHEET 1 OF 5 Cab Harness (W1) Wiring Diagram (1 of 5) (S.N. 057100— ) Continued on next page
TM13345X19 (23APR18)
NUMBER COLOR 1180 BLU/WHT 1181 BLK/RED 1182 WHT 1183 GRY/RED 1184 WHT/YEL 1185 RED/GRN 1186 GRN/BLU 1187 BLU/WHT 1189 BLK/PNK 1190 YEL/GRN 1191 LT GRN 1192 BLK/YEL 1194 VLT/WHT 1196 BLU/WHT 1197 GRY 1198 RED/GRN 1199 BLU/YEL 1200 YEL 1202 GRN/WHT 1203 GRN 1204 LT GRN/YEL 1205 BLU 1206 GRN 1207 ORG/RED 1208 GRY 1210 BRN/YEL 1211 BRN/BLU 1212 RED 1213 RED/BLK 1214 RED/BLU 1215 ORG/BLU 1219 RED 1220 ORG 1221 BLK/GRN 1222 BLU 1223 RED 1224 GRN 1225 BLK/BLU 1227 GRY/BLK 1228 BLK/YEL 1229 BLU/RED 1230 ORG/BLU 1234 WHT/VLT 1236 GRN/WHT 1237 YEL/RED 1238 GRN/BLK 1240 GRN/YEL 1241 BRN 1242 WHT 1244 WHT 1245 RED/YEL 1246 RED/BLK 1248 BLK/WHT 1250 WHT/BLK 1251 GRN 1252 BLU 1253 WHT/BLU 1254 PNK/GRN 1255 BLK/YEL 1256 RED/YEL
9015-10-105
160GLC Excavator 042318 PN=415
JA92389,000015E -19-14FEB18-11/19
System Diagrams
TX1247498 —UN—24JAN18
X1
F50 F10
F9 552
X2 1 2 3 4 5 6
(1028) (1026) (1089) (1030) — —
BLK/RED RED/GRN BLK BLK/GRN
X20 X20 (1004) X20
F8 810 F7 1159 F6 611 F5 610
S14 1
(1310)
BLU/YEL
X11
F4
X83 1 2 3
(400) (401) (402)
WHT/RED GRN/RED RED
F2 591 F1 598
S14
(545) (605)
WHT/VLT BLK
1
F3 609
X3 X3 (611)
S5/X543 1 2
39
5A
5A
560
10A
10A
20A
5A
5A
522
5A
1312
1332
20A
10A
5A 20A
10A
607
5A
506
20A
1311
10A
10A 5A
1372
20A
5A
881
612 F20 603 F19 1327 F18
F51
764 F17 F30
F40
F29
F39
1310
661 F15 20A
F28
S5/X543
F27 1575
1596
1567
20A
5A
20A
(1251) (1252)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
754 A
1502 F36
G
566 F12 F25 1571
5A
1592
5A
1590
1380 F35
F23 1576
10A
10A 1591 1593
10A
F22 1578 F21 1574
6
10A 10A
10A 1595
1594
10A
1380 B
X1
(139) (503) (509) (573) (592) (604) (605) (615) (633) (662) (754) (891) (1008) (1009) (1010) (1012) (1352)
BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
X50 X45 X99 A6 X39 X65 S5/X543 X26 R9 X25 X1 A8 X35 (1015—1017) X10 X77 X603
1292 J
A6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
MB
1568 F34
9
571 569
1122 1197 1152 1158 566
572 570
1085
1244 573 568 16
A8
1 2 3 4
SW FVS
530 825 604 2
GRN GRY BLK YEL/BLU YEL/RED WHT/BLK BRN
(1027) X77 X77 X77 F12 X73 X73
BLU
(1155)
WHT BLK RED/BLU
X77 W37 (552)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1
890
891
2
3
892
893
4
(890) (891) (892) (893)
RED BLK BLU ORG
F16 W37 G5 G5
GRN BLK
F15 W37
(666) (667)
BLK GRN
(662) (661)
-
V6
AU
A 666 667
GRN BLU GRN BLU GRN/YEL BLK/RED GRY/RED YEL/RED
BLU/RED BLU/YEL
(800) (801) (1027) (1155) X3 X3 X3 X3
X3 X3
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(1182) (1117) (1253) — — — — — — (1094) (1220) — (1830) (1821) —
WHT WHT/VLT WHT/BLU
X29 X3 X3
YEL/GRN ORG
X3 X3
GRN/RED BLU/BLK
X575 X575
1 2 3 4 5 6 7 8 9 10 11 12
(1008) (1121) — (88) (39) (1062) — — — — — —
BLK BLK
W37 (1008)
RED/BLK BLU BLU
(764) F10 (39)
13 14 15 16 17 18 19 20 21 22 23 24
— — — — — — — — — — — —
X36 (661) (662)
+
X-
X35 — (1120) (1205) (1203) (1222) (1093) (1293) (1047) (1285) — — — — (1045) (1092)
X36
A8
3
X65 1
A K
X25
1577 F32
+
2
X73 X73
V6
X 1
+ -
8
1569 F33
1573 F31
GRY/BLK ORG
X25
AU 400 401 402
X34 (571) (569) — (1122) (1197) (1152) (1158) (566) (572) (570) — (1085) — (1244) (573) (568)
A6
W37
1291 H
665 F11 5A
1133 C
1503 F37
X83
2
1
20A
3
4
GRN BLU
1132 E F
F26 1572
1030 605
W37 F35 (800) (801) (802)
1136 D
632 F13
1028 1026 1089
545
BLK LT GRN/RED GRN BLU GRY
1504 F38
771 F14
X2 1
(754) (1380) (1133) (1136) (1132) PLUG PLUG (1291) (1292)
890 F16
F24 1570
K10 W37
W37
A B C D E F G H J
1 2 3 4 5 6 7 8 9 10 11 12 13
(4) (3) (2) (1015) (1016) (1017) (1160) (1225) (1221) — (1039) (1074) (1190)
RED RED RED BLK BLK BLK ORG BLK/BLU BLK/GRN
(518) (518) (518) (1009) (1009) (1009) X29 X29 X29
GRN/BLK LT GRN YEL/GRN
S7/X544 X78 V9
14 15 16 17 18 19 20 21 22 23 24 25 26
— — (1255) (1228) (1118) (1298) — (1029) (1340) — — (1276) (1119)
1
BLK/YEL BLK/YEL GRY GRN/RED
(1153) (1153) X45 X78
ORG/BLU RED/BLU
X45 X574
RED/YEL RED/YEL
(1023) (1023)
4
1017
6
1039 1074 1190
1255 1228
17
1340
1276 1119
26
3
7
1160 1225 1221
18
1118 1298
2
1015
1029
1016
K
3
1
1
X630
X630 1 2 3
(1575) (1585) PLUG
RED BLK
F27 (501)
1
2
1575 1585 3
X50 1 2
(138) (139)
GRN/BLK BLK
X3 W37
X65 TX1247498
1 2 3
(530) (825) (604)
ORG VLT BLK
V5 X21 W37
(141) — — (1118) (1029) — — — — — — (503)
WHT/YEL
GRY ORG/BLU
(610)
X26
X36 X36
1 2 3 4 5 6
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
F5 F6 F20 (537) (536) W37
BLK
W37
+ -
RED PNK/BLK
(1) K2
1 2
1
610
611
612
3
4
616
617
615
6
-
(632) (633)
BLU/YEL BLK
F13 W37
(892) (893)
BLU ORG
A8 A8
1569
1
1573 1
1580
2
2 1584 1574 3
589 591 592 590 1
R9
G5 (532) (531)
X26
R9
X75 1 2
(610) (611) (612) (616) (617) (615)
2 1587 1577 3 CA B FR LAM ON P T
6
893 2
(1143) (1352) (1178) (1142) — (1362)
RED/BLK
(611) W37 X10 X11 (764)
X39
618 1 2 1588 1578 3
X57 1576
1
1586
2
X603
(618) (501) F32
(618) (1588) (1578)
RED/BLU BLK RED
(536) (501) F22
F23 (501)
X59
X55 1 2 3
1 2
(1576) (1586)
RED BLK
1570 1581
2
1143
1352
1178 1142
1362
3
RED/BLU BLK RED
X35
X57
X54 1
G5 RED BLK BLK/YEL BLK/RED
4
X58
1 892
X603 1 2 3 4 5 6
X39
X55
(1589) (1587) (1577)
2
VERSION B
1 2 3 4 5 6 7 8 9 10 11 12
3
A6 W37 A6
1 2 3
X AU
F27 (501)
YEL/BLU BLK GRY
X56
1589 1
3 AUX
RED BLK
X45
1158 1012 1197
P M LA B AR CA RE
(1575) (1585)
12
2 1152
1244
AT SE TER A HE
1585 1575
X630 1 2
6
1
X77
1
A6 A6
WARNING LAMP
2
503
532 531
X630
VERSION A
1118 1029
141
2
WHT BLK
QUICK HITCH
2
(1244) (1152) — (1158) (1012) (1197)
I
1
X75
1 2 3 4 5 6
B
139
5
X56
IM MO
138
X45
1
CA B FRO LAM NT P +2
+
X50
X77
1
X61
2
1571 1582
1
X63
2
1572 1583
1 2
X62
1568 1579
1
1
(1573) (1584) (1574)
RED BLK RED
F31 (501) F21
X59 1 2
X63 (1570) (1581)
RED BLK
F24 (501)
1 2
RED BLK
F33 (501)
1 2
X62 (1571) (1582)
RED BLK
F25 (501)
1 2
39
1062
6 16
17
24
F26 (501) 1
X61
88
X34 (1572) (1583)
6
1 (589) BLK/PNK K6 X58 2 (591) BLK/RED F2 1 (1569) RED 3 (592) BLK W37 2 (1580) BLK 4 (590) BLK/YEL K6 Cab Harness (W1) Wiring Diagram (2 of 5) (S.N. 057100— )
1121
2
X54 1 2 3
1008
7
1120 1205 1203 1222 1093 1293 1047 1285
11
(1568) (1579)
RED BLK
F34 (501)
23
1094 1220
10 22
1045 1092 1182 1117 1253 1830 1821
30
SHEET 2 OF 5 JA92389,000015E -19-14FEB18-12/19
Continued on next page
TM13345X19 (23APR18)
9015-10-106
160GLC Excavator 042318 PN=416
System Diagrams
1— Continued on Sheet 3 F17— Power On 5 A Fuse F36— Engine Control Unit (ECU) X54— Heated Air Seat Harness A6—Radio (marked POWER ON) 20 A Fuse (marked ECU P2) 3-Pin Connector (marked A8—12-Volt Power Converter F18— Idle Stop 5 A Fuse (marked F37— Engine Control Unit (ECU) SEAT HEATER) F1— Work and Boom Lights 20 A IDLE STOP) 20 A Fuse (marked ECU P3) X55— Front Cab Light 1 Fuse (marked LAMP) F19— Horn 10 A Fuse (marked F38— Fuel Transfer Pump and Connector (marked CAB F2— Windshield Wiper and HORN) Controllers 20 A Fuse LAMP FRONT) Washer 10 A Fuse (marked F20— Optional Equipment 5 A (marked ECU P4) X56— Front Cab Light 2 WIPER) Fuse (marked OPT. 3 BATT) F39— Not Used Connector (marked CAB F3— Air Conditioner and Heater F21— Heated Air Seat 10 A Fuse F40— Not Used LAMP FRONT +2) 20 A Fuse (marked HEATER) (marked SEAT HEATER) F50— Fuse Box X57— Rear Cab Light Connector F4— Solenoid 20 A Fuse (marked F22— Front Cab Light 1 10 A F51— Fuse Box 2 (marked CAB LAMP REAR) SOLENOID) Fuse (marked CAB LAMP G5—12-Volt Power Outlet X58— Warning Light Connector F5— Optional and Attachment FRONT) R9—Lighter (marked WARNING LAMP) Connector 5 A Fuse (marked F23— Rear Cab Light 10 A Fuse S5— Horn Switch X59— Satellite Communication OPT. 1 ALT) (marked CAB LAMP REAR) S14— Door Switch Connector (marked F6— Optional Connector and F24— IMOBI 5 A Fuse (marked V6— Auxiliary Power Connector IMMOBI) Reversing Fan 20 A Fuse IMOBI) Diode X61— Quick Hitch Connector (marked OPT. 2 ALT) F25— Quick Hitch 5 A Fuse W37—Cab Harness Ground 3 (marked QUICK HITCH) F7— Start Position Signal 5 A (marked QUICK HITCH) X1— Service ADVISOR™ X62— Cab Auxiliary Power Fuse (marked START) F26— Cab Auxiliary Power Diagnostic Connector Connector 2 (marked AUX F8— Engine Control Unit (ECU) Connector 3 5 A Fuse X2— WinDr 6-Pin Connector 2) 20 A Fuse (marked ECU P1) (marked AUX. 3) X25— Cab Harness Auxiliary X63— Cab Auxiliary Power F9— Radio Backup 10 A Fuse F27— Seat Heat/Cool 20 Power Connector 1 Connector 3 (marked AUX (marked BACK UP) A Fuse (marked (marked AUX+/-) 3) F10— Data Converter and SEAT_HEAT/COOL) X26— Optional Connector X65— Cab Harness-to-Pilot Main Controller Battery F28— Not Used X34— Cab Harness-to-Main Shutoff Switch Harness Power 5 A Fuse (marked F29— Not Used Controller 30-Pin Connector CONTROLLER) F30— Not Used Connector D X75— Cab Harness-to-Pilot F11— Travel Alarm 5 A Fuse F31— Seat Compressor 10 X35— Cab Harness-to-Main Shutoff Valve Harness (marked TRAVEL ALARM) A Fuse (marked SEAT Controller 24-Pin Connector F12— Radio and Dome 5 A Fuse COMPR) Connector E X77— Radio Auxiliary Connector (marked RADIO) F32— Front Cab Light 2 10 A X36— Cab Harness-to-Main X83— Cab Harness-to-Reversing F13— Lighter 10 A Fuse (marked Fuse (marked CAB LAMP Controller 26-Pin Fan Switch Harness LIGHTER) FRONT +2) Connector F (marked VSF-SW) F14— Monitor 5 A Fuse (marked F33— Warning Lamp 10 A Fuse X39— Cab Harness-to-Window X543— Horn Switch Connector MONITOR) (marked WARNING LAMP) Switch X603— Not Used F15— Cab Auxiliary Power F34— Cab Auxiliary Power X45— Option 2 12-Pin Connector X630— Premium Seat Harness Connector 1 10 A Fuse Connector 2 10 A Fuse (not used) Connector (marked AUX) (marked AUX. 2) X50— Cab Harness-to-Travel F16— 12-Volt Power Unit 10 A F35— Service ADVISOR™ Alarm Cancel Switch Fuse (marked 12V UNIT) Diagnostic Connector 5 A Harness Connector Fuse (marked DIAG) Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-107
JA92389,000015E -19-14FEB18-13/19
160GLC Excavator 042318 PN=417
System Diagrams
TM13345X19 (23APR18)
9015-10-108
160GLC Excavator 042318 PN=418
System Diagrams
TX1247503 —UN—11DEC17
X51
X3 X33 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
(1033) (1138) (1254) (1227) (1320) (1341) (1164) (1264) — (26) — (1342) (1061) (1090) (1110) (651) (655)
SK BLU GRN/BLU PNK/GRN GRY/BLK YEL/GRN BLK/BLU GRY WHT/GRN
X3 X574 X3 X3 K11 X574 X574 X3
WHT/RED
X3
BLK/GRN YEL/BLK BRN/BLU GRN/YEL BLU/WHT ORG/WHT
X574 X3 X3 X3 X3 X3
X32 1 2 3 4 5 6 7 8 9 10 11 12
— (1343) — — — — — — — — (1268) (1116)
BLU/YEL
YEL/GRN RED
X574
X3 X3
13 14 15 16 17 18 19 20 21 22 23 24
— — (1261) (1115) — — — — (1263) (1230) (1330) (1331)
BRN YEL/RED
GRY ORG/BLU BLU/YEL LT GRN/BLK
X3 X3
X3 X3 X3 X3
A1 (1067) A2 (1229) A3 (1115) A4 (1227) A5 (655) A6 (651) A7 (1230) A8 (745) A9 (1261) A10 (26) A11 PLUG A12 (1254) A13 (1263) A14 (1033) A15 (764) A16 (1094) A17 (876) A18 (877) A19 (1365) A20 (1364) A21 (507) B1 (1295) B2 (1069) B3 (1071) B4 (1082) B5 (1381) B6 (1382) B7 (665) B8 (1097) B9 (1096) B10 (542) B11 (546) B12 (1383) B13 (1330) B14 (1384)
BLU/BLK BLU/RED YEL/RED GRY/BLK ORG/WHT BLU/WHT ORG/BLU VLT/GRN BRN WHT/RED
X31 X31 X32 X33 X33 X33 X32 (517) X32 X33
PNK/GRN GRY SK BLU RED/BLK YEL/GRN ORG/BLK ORG/GRN GRN GRN/WHT BLK/RED BRN/WHT GRN/WHT GRN/ORG GRN/RED WHT/GRN YEL/BLK WHT/YEL GRN/BLK BLK PNK/WHT VLT BLK/YEL BLU/YEL GRN/WHT
X33 X32 X33 F17 X34 X37 X37 X37 X37 V2 X31 X31 X31 X31 X74 X74 F11 X52 (1011) K10 K9 X74 X32 X74
B15 (1331) B16 (235) B17 (1104) B18 (1112) B19 (1257) B20 (1256) B21 (138) C1 (511) C2 (508) C3 (505) C4 (810) C5 (660) C6 (664) C7 (537) C8 (536) D1 (1105) D2 (1023) D3 (506) D4 (1502) D5 (1503) D6 (501) D7 (1504) D8 (1153) E1 (1020) E2 (1022) E3 (800) E4 (1264) E5 (1117) E6 (1061) E7 (1135) E8 (1303) E9 (801) E10 (1090) E11 (1220) E12 (1110)
LT GRN/BLK X32 BRN X20 BRN/BLU X52 RED/YEL X52 BLK/YEL (1153) RED/YEL (1023) GRN/BLK X50 RED X47 WHT V3 WHT/BLK K4 BLU F8 RED (611) WHT/YEL (610) BLU/RED K7 RED/BLU K8 WHT X52 RED/YEL X29 WHT F50 RED F36 RED/BLU F37 BLK (1579—1588) BLU/RED F38 BLK/YEL X29 RED X22 BLK/YEL X22 GRN X20 WHT/GRN X33 WHT/VLT X34 YEL/BLK X33 WHT X22 GRY X22 BLU X20 BRN/BLU X33 ORG X34 GRN/YEL X33
E13 (1047) E14 (802) E15 (1251) E16 (1252) E17 (1116) E18 (1268) E19 (1083) E20 (1167) E21 (1084) F1 (1285) F2 (1045) F3 (1093) F4 (1213) F5 (1185) F6 (250) F7 (1092) F8 (1253) F9 (1293) F10 (400) F11 (401) F12 (762) F13 (1100) F14 (1245) F15 (1194) F16 (1297) F17 (1018) F18 (1207) F19 (1086) F20 (1087) F21 (1224)
GRY/RED GRY GRN BLU RED YEL/GRN GRN/ORG GRN/RED YEL YEL/RED BLU/RED GRN/YEL RED/BLK RED/GRN WHT/BLU BLU/YEL WHT/BLU BLK/RED WHT/RED GRN/RED BLK/GRN WHT/GRN RED/YEL VLT/WHT BRN/BLU BRN/YEL ORG/RED BLK/WHT WHT GRN
X34 X20 SHIELD R10 R10 X32 X32 (1071) (1082) X31 X34 X34 X34 X31 X31 X21 X34 X34 X34 X83 X83 X22 X31 X31 X31 X31 X31 X31 X31 X31 X31
1 2 3 4
H2 1 2 15 1251 1252 1116 1268 1083 1167 1084 21 1047
E
802
(544) (541)
RED/BLU PNK/GRN
(552) K3
1100 1092 1253 1293
400 401 762
1 1020 1022 800
1264 1117 1061 6
1 1285 1045 1093
1213 1185 250 6
1 2 3
(1154) (1156) (1014)
RED/BLU ORG/BLU BLK
(552) (1215) X11
X51
810
8
7
1504 1153
8
H2
X3
5
660 664
6
4
1502 1503
5
2
508 505
3
1
1105 1023
2
501
2
C
D
2
3 1113 1176 4
1 2 3 4 5 6 7 8 9 10
(1111) (1237) (1112) (1104) (1097) (1105) — — (1124) (1125)
ORG YEL/RED RED/YEL BRN/BLU GRN/BLK WHT
X17 X17 X3 X3 X3 X3
GRN BLU
(1027) (1155)
544 541
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
(301) (302) — — (1356) (307) (303) — — — (1357) (306) — (304) (305) — —
BLU BLU
(39) (39)
GRN BLU RED/BLK
(1027) (1252) (764)
BLU GRN
(1155) (1251)
BLK BLK
W36 (304)
X52 506
511
1 1011 609
1
6
4
1
W36 F3 (609) (764)
X52
E3
1245
F
1090 1220 1110
537 536
BLK RED/GRN RED/GRN RED/BLK
15 1194 1297 1018 1207 1086 1087 1224 21
1135 1303 801
7
A5 (1011) (609) (1113) (1176)
E3
3
1 1111 1237
1112 1104 4
5 1097 1105
1124 1125 10
A5
1154 1156 1014 1
15
764 1094 876
877 1365 1364 507 21
1263
A
1230 745 1261 1 1067 1229 1115
26
3
15 1331 235 1104 1112 1257 1256 138 21
1033
1330
1254
665 1097 1096
1227 655 651 6
2
1 1295 1069 1071
301
7
303
13
1384
B
1
302
1356 307
6
1357 306
12 17
304 305
542 546 1383
X573
1082 1381 1382 6
2 4
1401 1400
1
1403 1402
3
1
2 X99 1
X31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(1157) (1069) (1295) (1816) (1817) (1229) (1067) (1071) (1082) (1224) (1087) (1084) (1194) (1086) (1207) (1213)
YEL/WHT GRN/WHT BRN/WHT WHT/RED BLU/RED BLU/RED BLU/BLK GRN/ORG GRN/RED GRN WHT YEL VLT/WHT BLK/WHT ORG/RED RED/BLK
X22 X3 X3 X575 X575 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(1185) (1245) (1100) (1818) (1819) (1139) (1180) (1163) (1140) (1297) (1018) — — — —
RED/GRN RED/YEL WHT/GRN YEL/RED ORG/BLU WHT/BLU BLU/WHT ORG/BLK YEL/BLU BRN/BLU BRN/YEL
X3 X3 X3 X575 X575 X574 X574 X574 X574 X3 X3
1 2 3 4 5 6
1
500
BLK BLK BLK BLK
W37 W36 W35
562
4
6
3
1 A 502 507
2
571 569
K
A K
1
1157
1082
9
1
1033 1138 1254 1227 1320 1341
10
1224 1087 1084 1194 1086 1207 1213 1185 1245 1100 1818 1819
21
7
1164 1264
22
1139 1180 1163 1140 1297
31
13
1061 1090 1110
1069
1295
1816
1817 1229
1018
1067
1071
1
7
1343
8
1268 1116
1261 1115
16
17
1263
1230 1330 1331
24
26
12
V3
651 655
17
A K
PN=419
(764) X3
(606) (508)
YEL/BLK WHT
(1312) X3
V12
V3 A 606 508
K
A 1371 1372 K
2
3
A 1190 155
V9
V5 (528) (530) (529)
VLT/GRN ORG VLT/WHT
(517) X65 K2
A 1373 1374 K
3
(1400) (1401) (1402) (1403)
RED/BLK RED/GRN WHT/GRN RED/YEL
(1213) (1185) (1100) (1245)
4
1 2 3
(1251) (1252) PLUG
GRN BLU
X3 X3
(571) (569) (572) (570)
GRY/BLK ORG WHT/BLK BRN
A6 A6 A6 A6
(1373) (1374)
YEL/BLK GRN
(1312) (1372)
(1371) (1372)
WHT/BLK GRN
(1311) F50
X73 1 2 3 4
V12 528 530 529 1
1 2 3
V11 V5
X33 V9 A K
(1190) (155)
YEL/GRN ORG
X36 (530)
K
A K
V11 A K
SHEET 3 OF 5 Cab Harness (W1) Wiring Diagram (3 of 5) (S.N. 057100— )
160GLC Excavator 042318
RED/BLK BLK/RED
6
1342
X32 Continued on next page
(502) (507)
1 2 3 4
R10
X73
V2
(501)
2
1251 1252
572 570
X31
9015-10-109
— (509) (518) (500) — (562)
V2
TX1247503
TM13345X19 (23APR18)
3 509 518
X99
X573
R10
JA92389,000015E -19-14FEB18-14/19
System Diagrams
TM13345X19 (23APR18)
9015-10-110
160GLC Excavator 042318 PN=420
System Diagrams
1— Continued on Sheet 2 2— Continued on Sheet 4 A5—Data Converter E3— Cab Dome Light H2—Security Alarm R10— N 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
Continued on next page
TM13345X19 (23APR18)
9015-10-111
X73— Cab Harness-to-Speakers Connector X99— Cab Ground Splice X573— Exhaust Solenoid Harness Connector (not used)
JA92389,000015E -19-14FEB18-15/19
160GLC Excavator 042318 PN=421
System Diagrams
TM13345X19 (23APR18)
9015-10-112
160GLC Excavator 042318 PN=422
System Diagrams
TX1247505 —UN—14DEC17
K1 A1 A2 A3 A4 A5
K2 (519) (856) (520) — (524)
RED ORG RED
(511) X22 (511)
WHT
(508)
K4 D1 D2 D3 D4 D5
(533) (529) (531) — (525)
RED VLT/WHT PNK/BLK
(1) V5 X75
VLT
K5
C1 C2 C3 C4 C5
K5 (910) (517) (900) (505) —
WHT/RED VLT/GRN WHT/RED WHT/BLK
(900) V4 X47 X3
K7 G1 G2 G3 G4 G5
B1 B2 B3 B4 B5
K3
E1 E2 E3 E4 E5
RED/BLK YEL GRN
(764) X10 F1
BLU/RED
X3
H1 H2 H3 H4 H5
(552) (852) (541) — (540)
RED/BLU GRN/BLK PNK/GRN
F9 X22 H2
BLK
W36
(523) (527) (550) (525) —
RED VLT/RED BLK VLT
(1) V4 W36 K2
F1 F2 F3 F4 F5
K6 (593) (851) (590) (589) (594)
RED/BLK GRY/RED BLK/YEL BLK/PNK BLK
(764) X11 X39 X39 W36
R6
GRN RED/YEL GRN
(598) X10 (598)
RED/BLU
X3
I1 I2 I3 I4 I5
RED/BLK BLK/BLU BLK/RED
(764) X10 (591)
VLT
X3
590
F3 F5
R7
1321 5
1370 3
1322 3
K8
598 G3
R8
850
601
G1
G2
H1
520 A3
R2
A1
A4
531 B3
R3
525 B5
524 A5 519
G4
856
533
A2
B1
K1
B4
600 H3
529
552
B2
C1
K2
H4
R9
854
595
H2
I1
541 C3
R4
596
I3
546
I5
I4
J1 J2 J3 J4 J5
K11 (602) (545) (603) — (542)
WHT WHT/VLT WHT
(603) S5/X543 F19
PNK/WHT
X3
1 2 3 4 5
855
602
I2
J1
900 D3
BLU YEL/GRN YEL/GRN
F18 X33 (1320)
BLK
W36
1 2 3 4 5
(1323) (1325) (1370) (1311) —
BLU YEL/GRN WHT WHT/BLK
R5
603
J3
542
J5 545 J2
J4
550 E3
D5
E5
852
910 505 517
523 525 527
C2
D1
K3
K12 (1327) (1320) (1322) — (1321)
R10
540 C5
C4
D4
D2
E1
K4
K5 1
X10
5 1 1178 854 1315 3
5
772
4
855 850 1215 1010
8
K13 1 2 3 4 5
(1324) (1326) (1315) (1312) —
BLU YEL/GRN BLU YEL/BLK
(1327) (1320) (522) F17
(1178) (854) — (772) (855) (850) (1215) (1010)
BLK/YEL RED/YEL
X603 K8
BLU BLK/BLU YEL ORG/BLU BLK
(39) K9 K7 X27 W37
GRN
X623B
RED RED/BLK
X27 X27
GRN/BLK WHT/VLT
X27 X29
GRY/RED BLK BLU
K6 E3 X623B
BLK/WHT WHT/BLK
X27 X27
W36 1 2 3 4 5 6 7 8 9
X11
E2
E4
K13 1326 1312 1324
(1327) (1320) (607) F13
1 2 3 4 5 6 7 8
K10
2
K10
X10
K9
536 H5
537 G5 599
F4
1 1327
5
K7
594
4
K11 1320
F2
R1 (595) (855) (596) — (546)
2
1
593 589 851 F1
K9 (601) (854) (600) — (536)
4
K12 1325 1311 1323
K6
K8 (599) (850) (598) — (537)
2
X11 1 1027
1278 1246
1238 1234
851 1014 10
11 1155
1248 1250
1240 1236 1310 1101 1142 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(1027) — (1278) (1246) — (1238) (1234) — (851) (1014) (1155) — (1248) (1250) — (1240) (1236) (1310) (1101) (1142)
(304) (518) (535) (540) (548) (550) (594) (1003) (1004)
BLK BLK BLK BLK BLK BLK BLK BLK BLK
A5 X99 V7 K3 V1 K5 K6 X21 X21
(1111) (1237) (1025) (1076)
ORG YEL/RED WHT/RED RED/BLK
X52 X52 X22 (764)
10 11 12 13 14 15 16 17
(1006) (1007) (1011) (1013) (1321) (1353) (1355) (1363)
X30 S7/X544 X51 V8 K11 X28 X78 X37
W36
X17 1 2 3 4
MB
X17
4
1
X42 1 2
1111 1237 1025 1076
(1358) (1359)
GRN BLU
(1027) (1155)
X42 1
GRN/YEL GRN/WHT BLU/YEL YEL/RED BLK/RED
BLK BLK BLK BLK BLK BLK BLK BLK
X27 X29 S14 (566) X603
2
1358 1359
2
3 YEL GRN/WHT RED/YEL
(850) (1236) (854)
V13 A K
(1375) (1376)
YEL WHT/VLT
(850) (1234)
1
2
V13
V10
(1013) (1242)
BLK WHT
W36 (1105)
A 1386 1387 K
BLK WHT/BLK
W36 (505)
(1386) (1387)
VLT/GRN YEL/GRN
(517) (1320)
(548) (510)
BLK WHT
W36 (508)
V1 A K
V1
V4
A 1013 1242 K A 548 510
V7 (535) (534)
A K
A 1375 1376 K
V7 A K
V10
3
V8
V8 A K
1377 1379 1378
A 535 534
K
517 1031 527 1
2
K
1 2 3
(517) (1031) (527)
VLT/GRN GRN/WHT VLT/RED
V4
3
K4 X22 K5
1 2 3 4 5 6 7 8 9 10 11 12
(1138) (1139) (1140) (1141) (1341) (1164) (1180) (1343) (1342) (1163) (1192) (1340)
GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK/BLU GRY BLU/WHT BLU/YEL BLK/GRN ORG/BLK BLK/YEL RED/BLU
X33 X31 X31 (1023) X33 X33 X31 X32 X33 X31 (1153) X36
1 2 3 4 5 6
(1816) (1818) (1817) (1830) (1821) (1819)
WHT/RED YEL/RED BLU/RED GRN/RED BLU/BLK ORG/BLU
X31 X31 X31 X34 X34 X31
1
1164 1180 1343 1342 1163 1192 1340 6
12
X575
1
(1074) (1355) (1298)
LT GRN BLK GRN/RED
5
1140 1141 1341
1138 1139
X78 1 2 3
X574
1816
X36 W36 X36
2 1818
DSZ
(1377) (1379) (1378)
X575
1817 1830 1821 1819 3
6
X623A
X78 1
X623B 1 2
(1027) (1155)
GRN BLU
X11 X11
1
2
3
X623B 2
GRN BLU
X20 X20
SHEET 4 OF 5
TX1247505 Cab Harness (W1) Wiring Diagram (4 of 5) (S.N. 057100— ) Continued on next page
TM13345X19 (23APR18)
(1850) (1851)
1
1155 1027
X623A 1 2
2
1850 1851
1074 1355 1298
BCZ
V14 1 2 3
X574
V14
9015-10-113
160GLC Excavator 042318 PN=423
JA92389,000015E -19-14FEB18-16/19
System Diagrams
TM13345X19 (23APR18)
9015-10-114
160GLC Excavator 042318 PN=424
System Diagrams K9—Windshield Washer Relay V13— Work Light 1 Diode 2— Continued on Sheet 3 K10— Horn Relay V14— Work Light 2 Diode 3— Continued on Sheet 5 K11— Idle Stop Relay W36—Cab Harness Ground 2 K1—Load Dump Relay X10— Machine Controller 8-Pin K2—Pilot Shutoff Solenoid Relay K12— Accessory Cut Relay K13— Key Cut Relay Connector A K3—Security Alarm Relay V1— Battery Relay Diode X11— Machine Controller 20-Pin K4—Starter Cut Relay V4— Security Diode Connector B K5—Security Relay V7— Start Relay Diode X17— Cab Harness-to-Monitor K6—Windshield Wiper Relay V8— Air Conditioner Clutch Diode Harness Connector K7—Work Light Relay V10— Starter Protection Diode X42— CAN 1 Connector K8—Boom Light Relay X78— Optional Switch Continued on next page
TM13345X19 (23APR18)
9015-10-115
X574— Auxiliary Function Lever (AFL) Connector 1 X575— Auxiliary Function Lever (AFL) Connector 2 (not used) X623A—Cab Harness CAN Connector A (marked DSZ) X623B—Cab Harness CAN Connector B (marked BCZ) JA92389,000015E -19-14FEB18-17/19
160GLC Excavator 042318 PN=425
System Diagrams
TM13345X19 (23APR18)
9015-10-116
160GLC Excavator 042318 PN=426
System Diagrams
TX1247506 —UN—15DEC17
X74
X27
1
1
X37
1360
1
X74
2
1 2 3 4 5 6
4
1278 1246
1248 1238
1250 1240
1354 1214 1215
5
10
1363
X28
1 1212 1199 1200
5
1206 1258 1208 1210 1211 1198 1353
3
6
6
X29
1
1385
1381
1187 1191 1189
1382 1383
1384
1160 1221
3
6
AD
1 2 3 4 5 6
12
2
7
(764) X3 X3 X3
GRN/WHT
X3
1 2 3 4 5 6 7 8 9 10
(1360) (1363) (877) (876) (1365) (1364)
RED/BLK BLK ORG/GRN ORG/BLK GRN GRN/WHT
(764) W36 X3 X3 X3 X3
1 2 3 4 5 6 7 8 9 10 11 12
1023 1182 1153
16
X30
1 1196 1161 1168 1171
X29 (1278) (1246) (1248) (1238) (1250) (1240)
RED RED/BLK BLK/WHT GRN/BLK WHT/BLK GRN/YEL
X11 X11 X11 X11 X11 X11
(1354) (1214) (1215)
BLU/RED RED/BLU ORG/BLU
(616) (552) X10
1 2 3 4 5 6 7 8
7 1223 1169 1006
(1212) (1199) (1200) (1202) (1204) (1206) (1258) (1208) (1210) (1211) (1198) (1353)
RED BLU/YEL YEL GRN/WHT LT GRN/YEL GRN PNK GRY BRN/YEL BRN/BLU RED/GRN BLK
(1187) (1191) (1189) (1023) (1182) (1153) — (1160)
BLU/WHT LT GRN BLK/PNK RED/YEL WHT BLK/YEL
X20 X20 X21 X3 X34 X3
(1221) — — (1225) (1234) (1236) (1219) (870)
BLK/GRN
X36
X36
9 10 11 12 13 14 15 16
BLK/BLU WHT/VLT GRN/WHT RED BLU/RED
X36 X11 X11 (1020) (616)
ORG
(1196) (1161) (1168) (1171) (1223) (1169) (1006) (1173)
BLU/WHT YEL/RED YEL/GRN ORG RED BLU BLK YEL
X21 X21 X20 X20 (1278) X21 W36 X20
9 10 11 12 13 14 15 16
(1177) (1175) (1179) (1183) (1181) (1184) (1186) (1241)
WHT BLU/RED YEL/BLU GRY/RED BLK/RED WHT/YEL GRN/BLU BRN
X20 X21 X20 X20 X21 X20 X20 X21
X30 1 2 3 4 5 6 7 8
X28
1225 1234 1236 1219 870
8
VSW
RED/BLK WHT/GRN YEL/BLK BLK/YEL
X37
1202 1204
877 876 1365 1364
X27 (1385) (1381) (1382) (1383) — (1384)
(1020) X21 X21 X21 X21 X21 X21 X21 X21 X21 X21 W36
X21
1173 1177 1175 1179 1183 1181 1184 1186 1241 8
16
W35 MB
S7/X544 3
S7/X544 1
1 2
BLK GRN/BLK
W36 X36
(500)
BLK
X99
(1150) (1145)
YEL/BLU BLK
X21 (1003)
X76
607
900
762 1157 1025 856 852 1031
8 16
F
BLK/GRN YEL/WHT WHT/RED ORG
X3 X31 X17 K1
9 10 11 12 13 14 15 16
(1135) — — — — — (852) (1031)
WHT
F15
WHT/RED BLU WHT RED
K4 F50 (607) X3
1258 1206 1204 1202 1200 1199 1208 1210 1211 1198
X20 1 15
1030
1173 1177 1179 1183 1184 1168 1186 1171 1187 1191 1028
824 1159 235
1002 801 800 1851 1850
TX1247506 Cab Harness (W1) Wiring Diagram (5 of 5) (S.N. 057100— )
9015-10-117
160GLC Excavator 042318 PN=427
1026
825 1150
250
1196 1161 1169 1175 1181 1241 1189
802
Continued on next page
WHT
X3
GRN/BLK GRN/WHT
K3 V4
VLT YEL/BLU
X65 X76
(250) — — — (771) (1148)
WHT/BLU
X3
BLU/BLK RED/BLU
F14 (552)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
(1208) (1210) (1211) (1198) — — (1196) (1161) (1169) (1175) (1181) (1241) (1189) — — — (1004) (1003)
GRY BRN/YEL BRN/BLU RED/GRN
X28 X28 X28 X28
BLU/WHT YEL/RED BLU BLU/RED BLK/RED BRN BLK/PNK
X30 X30 X30 X30 X30 X30 X29
BLK BLK
W36 W36
X20 1
X47
TM13345X19 (23APR18)
X3 X3 X3
X28 X28 X28 X28 X28 X28
X21
19
(607) — (900) (522) (1314) (511)
GRY BLK/YEL RED
M
6
X47
1 2 3 4 5 6
(1303) (1022) (1020) — (762) (1157) (1025) (856)
PNK GRN LT GRN/YEL GRN/WHT YEL BLU/YEL
X76 ST
F M
522 1314 511
1303 1022 1020 1135
1 2 3 4 5 6 7 8
(1258) (1206) (1204) (1202) (1200) (1199) — — — (825) (1150)
HM
3
9
W35 1
1
1
2
1007 1039
4
(1007) (1039)
X22
X22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
14 28
771 1148 1004 1003
18 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14
(1030) — (1173) (1177) (1179) (1183) (1184) (1168) (1186) (1171) (1187) (1191) (1028) —
BLK/GRN
X2
YEL WHT YEL/BLU GRY/RED WHT/YEL YEL/GRN GRN/BLU ORG BLU/WHT LT GRN BLK/RED
X30 X30 X30 X30 X30 X30 X30 X30 X29 X29 X2
15 16 17 18 19 20 21 22 23 24 25 26 27 28
— (824) (1159) (235) — — — (1002) (801) (800) (1851) (1850) — (1026)
RED/BLK WHT/RED BRN
(764) F7 X3
BLK BLU GRN BLU GRN
(501) X3 X3 X623A X623A
RED/GRN
X2
SHEET 5 OF 5
JA92389,000015E -19-14FEB18-18/19
System Diagrams
TM13345X19 (23APR18)
9015-10-118
160GLC Excavator 042318 PN=428
System Diagrams
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 X76— Cab Harness Connector 1 Filter Switch Harness (marked HMST) (not used) Connector X544— Power Dig Switch X47— Cab Harness-to-Key Connector Switch Harness Connector X74— Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness (marked SDV-SW)
Service ADVISOR is a trademark of Deere & Company JA92389,000015E -19-14FEB18-19/19
Machine Harness (W2) Component Location IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
Specification Cab Harness-toMachine Harness 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·ft
Continued on next page
TM13345X19 (23APR18)
9015-10-119
JA92389,0000169 -19-31JAN18-1/3
160GLC Excavator 042318 PN=429
System Diagrams
TM13345X19 (23APR18)
9015-10-120
160GLC Excavator 042318 PN=430
System Diagrams
TX1251051 —UN—26JAN18
A12
W19
G3
Y11 X64 B22 B27
B56
Y24
S40
Y22
X175
Y23 B31 B33 B34 B30
K19 B20
X3 B61
F61
X86 B18
X90 B32
B57
X40 X104
M6
X590 X98
E2 W2 E1
X67
F60
X46 X5018
B23 B24
TX1251051 Machine Harness (W2) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-121
160GLC Excavator 042318 PN=431
JA92389,0000169 -19-31JAN18-2/3
System Diagrams
TM13345X19 (23APR18)
9015-10-122
160GLC Excavator 042318 PN=432
System Diagrams X40— Pump Harness-to-Machine X590— Exhaust Solenoid A12— Rear Camera B56— Bucket Curl Pressure Harness Connector B18— Fuel Level Sensor Sensor (marked BKC) (S.N. Harness Connector (not X46— Attachment Connector B20— Air Conditioner 057100— ) used) X64— Machine Harness-to-Rear X5018—Machine Harness-toHigh/Low-Pressure Switch B57— Bucket Dump Pressure Camera Harness B22— Ambient Air Temperature Sensor (S.N. 057100— ) Engine Interface Harness Connector Sensor B61— Arm Out Pressure Sensor Connector 2 X67— Machine Harness Auxiliary Y11— Air Conditioner B23— High Note Horn (S.N. 057100— ) Power Connector B24— Low Note Horn E1— Work Light Compressor Clutch X86— Machine Harness-to-Travel B27— Hydraulic Oil Filter E2— Boom Light Solenoid Alarm Harness Connector Y22— Dig Regenerative Solenoid Restriction Switch (if F60— Alternator 65 A Fuse X90— Machine Harness-toequipped) F61— Battery 45 A Fuse (marked SF) Hydraulic Oil Temperature Y23— Arm Regenerative B30— Boom Up Pressure Sensor G3—Alternator Switch Connector (marked PI1) K19— Battery Relay Solenoid (marked SC) X98— Machine Harness Power B31— Arm In Pressure Sensor M6—Windshield Washer Motor Y24— Power Dig/Travel Speed Splice (marked PI2) S40— Hydraulic Oil Temperature Solenoid (marked SG) X104— Machine Harness Ground B32— Front Attachment Pressure Switch (if equipped) Splice Sensor (marked FRT) W2—Machine Harness X175— Machine Harness-toB33— Swing Pressure Sensor W19—Rear Camera Harness Engine Interface Harness (marked S3) X3— Cab Harness-to-Machine Connector 1 B34— Travel Pressure Sensor Harness 100-Pin Connector (marked TR) JA92389,0000169 -19-31JAN18-3/3
Machine Harness (W2) Wiring Diagram IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
Specification Cab Harness-toMachine Harness 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Continued on next page
TM13345X19 (23APR18)
9015-10-123
JA92389,0000157 -19-14FEB18-1/9
160GLC Excavator 042318 PN=433
System Diagrams
TM13345X19 (23APR18)
9015-10-124
160GLC Excavator 042318 PN=434
System Diagrams
Machine Harness (W2) Wiring Diagram (S.N. —057099) TX1198939 —UN—26OCT15
501B
BLK
504 505 506 508 511 513 521 536 537 542 543 546 547 549 597 614 619 620 651 655 664 665 745 764 768 800 801 802 810 811 876 877 1000 1001 1018 1020 1022 1033 1045 1049 1051 1053 1055 1056 1061 1067 1069 1084 1086 TX1198939
WHT BLK/WHT WHT WHT RED RED BLK RED/BLU BLU/RED PNK/WHT PNK/WHT VLT BLK BLK BLK/YEL BLK RED WHT BLU/WHT ORG/WHT WHT/YEL WHT/YEL VLT/GRN RED/BLK GRY/RED GRN BLU GRY BLU BLK ORG/BLK ORG/GRN BLK BLK BRN/YEL RED BLK LT BLU BLU/RED BLK/YEL RED/YEL RED/YEL RED/YEL RED/YEL YEL/BLK BLU/BLK GRN/WHT YEL BLK/WHT
END #2 X86 X3 (501) X3 X90 X5018 X5018 (140)(501B)(521)(547)(549) (614)(811)(1000)(1001) (140)(501A)(521)(547)(549) G3 (614)(811)(1000)(1001) F60 G3 X175 X3 G3 X3 K19 X3 X3 F61 X67 (511) K19 (501) X3 E2 X3 E1 X3 B24 B23 (542) X3 M6 M6 (501) X67 (501) (1255) B18 E1 (501) F61 K19 K19 F60 X3 X46 X46 X3 X3 X46 X3 X86 X5018 X3 X3 X5018 X3 X5018 X3 X5018 X3 X5018 X3 X5018 X3 X5018 (501) X5018 X3 X5018 X3 X5018 B23 (501) B24 (501) X3 X40 X64 X3 X3 X64 X3 X40 B32 X3 X104 B30 B31 X98 B32 X98 B33 X98 B34 X98 X3 X40 X40 X3 X3 X40 Y24 X3 X3 Y22 END #1 X3 X86 X86 B18 X3 X3 X3 X3
NUMBER 1087 1090 1091 1092 1093 1096 1100 1104 1105 1110 1112 1116 1117 1135 1147 1170 1185 1194 1207 1213 1220 1224 1227 1229 1245 1251 1252 1253 1254 1255 1256 1257 1264 1268 1270 1272 1276 1277 1279 1285 1293 1295 1297 1298 1299 1300 1303 1381 1382 1383 1384 1502 1503 1504
COLOR WHT BRN/BLU BLK/YEL BLU/YEL GRY WHT/RED WHT/GRN BRN/RED WHT GRY BLK/YEL RED WHT/VLT WHT BLK/YEL BLK/YEL RED/GRN VLT/WHT ORG/RED RED/BLK ORG GRN GRY/BLK BLU/RED RED/YEL GRN BLU WHT/BLU PNK/GRN BLK/YEL RED/YEL BLK/YEL WHT/GRN YEL/GRN BLK/YEL BLK/YEL RED/YEL BLK/YEL RED/YEL YEL/RED BRN BRN/WHT BRN/BLU BRN/BLU RED/YEL BRN/YEL GRY WHT/GRN YEL/BLK BLK/YEL GRN/WHT RED RED/BLU BLU/RED
END #1 Y23 X40 X40 B33 B30 B20 X3 X3 X3 X40 X3 X46 X46 X64 B32 (1255) X3 X3 Y22 X590 X46 X3 X46 X3 X3 X5018 X5018 X3 X3 X104 X3 X3 X3 X3 B34 B33 X98 B31 B30 B34 B31 X40 X3 X46 X40 X46 X3 X3 X3 X3 X3 X3 X3 X5018
END #2 X3 X3 X104 X3 X3 Y11 X590 B22 B20 X3 B22 X3 X3 X3 X104 X40 X590 Y24 X3 X3 X3 Y23 X3 X40 X590 X3 X3 X46 X46 X3 X46 X46 X40 X46 X104 X104 X3 X104 X98 X3 X3 X3 X40 (1297) X98 (1018) X64 X5018 X5018 X5018 X5018 X5018 X5018 X3
E1 1 2
(537) (614)
BLU/RED BLK
B23
B24
1 2
(543) (1000)
PNK/WHT BLK
(250)
(597) (235)
(542) (1001)
PNK/WHT BLK
X3 (501)
B23 1
2 543 1000
1
TM13345X19 (23APR18)
9015-10-125
160GLC Excavator 042318 PN=435
(1053) (1045) (1147)
B24
E2
RED/YEL BLU/RED BLK/YEL
X98 X3 X104
1053
1045
B33 1147
1
1
2
1
542 1001
(536)
RED/BLU
1092
1272
1
2
3
1 2 3
(1055) (1092) (1272)
E2
X67 1
2
513
549
RED BLK
1056
1285
1270
1
2
3
X5018 J
B34
K 800
(1056) (1285) (1270)
RED/YEL YEL/RED BLK/YEL
X98 X3 X104
B
801 L
810
811
C
M
745
802
H
1384 X G 1383 W 1504 A F 1381
764 D
E
N
1502
1503
1382
400
(511) (501)
V
768
401
U
876
P 1251 R
1252 S
877
X90 1
WHT/BLU
BLK/YEL BRN
1 2 3 4
2
597 235
B18
X3
(1255) X3
X3 (1067) (1229) PLUG (1227) (655) (651) PLUG (745) PLUG (26) (768) (1254) PLUG (1033) (764) PLUG (876) (877) PLUG PLUG PLUG (1295) (1069) PLUG PLUG (1381) (1382) (665) PLUG PLUG (542) (546) (1383) PLUG
BLU/BLK BLU/RED
X40 X40
GRY/BLK ORG/WHT BLU/WHT
X46 X46 X46
VLT/GRN
X5018
WHT/RED GRY/RED PNK/GRN
X86 X5018 X46
LT BLU RED/BLK
X40 X5018
ORG/BLK ORG/GRN
X5018 X5018
BRN/WHT GRN/WHT
X40 X40
WHT/GRN YEL/BLK WHT/YEL
X5018 X5018 X86
PNK/WHT VLT BLK/YEL
B24 M6 X5018
B14 B15 B16 B17 B18 B19 B20 B21 C1 C2 C3 C4 C5 C6 C7 C8 D1 D2 D3 D4 D5 D6 D7 D8 E1 E2 E3 E4 E5 E6 E7 E8 E9
(1384) PLUG (235) (1104) (1112) (1257) (1256) (138) (511) (508) (505) (810) PLUG (664) (537) (536) (1105) (1276) (506) (1502) (1503) 501A (1504) (1255) (1020) (1022) (800) (1264) (1117) (1061) (1135) (1303) (801)
GRN/WHT
X5018
BRN BRN/RED BLK/YEL BLK/YEL RED/YEL GRN/BLK RED WHT BLK/WHT BLU
B18 B22 B22 X46 X46 X86 F61 K19 X175 X5018
WHT/YEL BLU/RED RED/BLU WHT RED/YEL WHT RED RED/BLU BLK BLU/RED BLK/YEL RED BLK GRN WHT/GRN WHT/VLT YEL/BLK WHT GRY BLU
X46 E1 E2 B20 X98 G3 X5018 X5018 (501) X5018 X104 X64 X64 X5018 X40 X46 X40 X64 X64 X5018
E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21
(1090) (1220) (1110) PLUG (802) (1251) (1252) (1116) (1268) PLUG PLUG (1084) (1285) (1045) (1093) (1213) (1185) (250) (1092) (1253) (1293) (400) (401) PLUG (1100) (1245) (1194) (1297) (1018) (1207) (1086) (1087) (1224)
BRN/BLU ORG GRY
X40 X46 X40
GRY GRN BLU RED YEL/GRN
X5018 X5018 X5018 X46 X46
21
2
1185
1213
401
4
Y24 B34 B32 B30 X590 X590 X90 B33 X46 B31 X5018 X5018
1245
1100
X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 (501) X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
RED/BLK RED/GRN WHT/GRN RED/YEL
X3 X3 X3 X3
21
1084
1268 1116 1252 1251
802
400
1293 1253 1092
1185 1213
1093 1045 1285
501A
8
1255 1504
7
8
536
6
5
1503 1502
4
6
664
2
1276 1105
1
3
505
1
6
15
E
1110 1220 1090
801
1303 1135
1061 1117 1264
800
1022 1020
1
3
X590
537
508
7
810
5
4
2
506
511
3
21
138
D
1256 1257 1112 1104
1384 1383 6
WHT/GRN RED/YEL VLT/WHT BRN/BLU BRN/YEL ORG/RED BLK/WHT WHT GRN
15
1100
F
(1213) (1185) (1100) (1245)
250
1 6
YEL YEL/RED BLU/RED GRY RED/BLK RED/GRN WHT/BLU BLU/YEL WHT/BLU BRN WHT/RED GRN/RED
1224 1087 1086 1207 1018 1297 1194 1245
RED/BLK BLU VLT/GRN RED RED/BLU GRY/RED BLU/RED GRY GRN BLU BLK GRN/RED WHT/RED GRN BLU ORG/GRN ORG/BLK YEL/BLK WHT/GRN BLK/YEL GRN/WHT
X590
1 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13
(764) (810) (745) (1502) (1503) (768) (1504) (802) (800) (801) (811) (401) (400) (1251) (1252) (877) (876) (1382) (1381) (1383) (1384)
T
X3
1
A B C D E F G H J K L M N P R S T U V W X
X98 X3 X104
TR
X67 (513) (549)
RED/YEL BLU/YEL BLK/YEL
B34
X3
1 2 3
1 2
X5018
B33
1055
3
1
Machine Harness (W2) Wiring Diagram (1 of 2) (S.N. —057099) Continued on next page
1 2 3
2
B18 1 2
1 2
E1
X90 1
(542) (501)
B32
B32
X3 (501)
S3
COLOR WHT/RED GRN/BLK BLK BRN WHT/BLU WHT/RED GRN/RED BLK
FRT
NUMBER 26 138 140 235 250 400 401 501A
235
15
21
546
542
877 1033
B
1382 1381
1
C
665 1069 1295
1
6
876
764
15
1
A
1254
768
26
745
651
655
1227
1229 1067
X590 X590 Y24 X40 X40 Y22 Y22 Y23 Y23
JA92389,0000157 -19-14FEB18-2/9
System Diagrams
TM13345X19 (23APR18)
9015-10-126
160GLC Excavator 042318 PN=436
System Diagrams
1— Continued on Sheet 2 B33— Swing Pressure Sensor B18— Fuel Level Sensor (marked S3) B23— High Note Horn B34— Travel Pressure Sensor B24— Low Note Horn (marked TR) B32— Front Attachment Pressure E1— Work Light Sensor (marked FRT) E2— Boom Light X3— Cab Harness-to-Machine Harness 100-Pin Connector
X67— Machine Harness Auxiliary X5018—Machine Harness-toPower Connector Engine Interface Harness X90— Machine Harness-toConnector 2 Hydraulic Oil Temperature Switch Connector X590— Exhaust Solenoid Harness Connector (not used)
Continued on next page
TM13345X19 (23APR18)
9015-10-127
JA92389,0000157 -19-14FEB18-3/9
160GLC Excavator 042318 PN=437
System Diagrams
TM13345X19 (23APR18)
9015-10-128
160GLC Excavator 042318 PN=438
System Diagrams
TX1198940 —UN—11SEP15
X40 4
1
1033 1297
X104 (1049) (1091) (1147) (1255) (1270) (1272) (1277)
BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL
B30 X40 B32 X3 B34 B33 B31
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 1220 1253 1117 3 1268 1116 1257 1256 651 11
664
1227 1254
1300 1298
655
14
X104
X98 (1051) (1053) (1055) (1056) (1276) (1279) (1299)
X46
X46
RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL
B31 B32 B33 B34 X3 B30 X40
X98
(1220) (1253) (1117) (1268) (1116) (1257) (1256) (651) (1227) (1254) (664) (1300) (1298) (655)
ORG WHT/BLU WHT/VLT YEL/GRN RED BLK/YEL RED/YEL BLU/WHT GRY/BLK PNK/GRN WHT/YEL BRN/YEL BRN/BLU ORG/WHT
X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 (1018) (1297) X3
X40
1295 1067
1170
1018 1069
1229
1299
1110
1090
1091
1061 1264
20
17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(1067) (1295) (1297) (1033) (1229) (1069) (1018) (1170) PLUG PLUG PLUG PLUG (1090) (1110) PLUG (1299) (1264) (1061) PLUG (1091)
BLU/BLK BRN/WHT BRN/BLU LT BLU BLU/RED GRN/WHT BRN/YEL BLK/YEL
F61
X3 X3 X3 X3 X3 X3 X3 (1255)
1 2
B20 1 2
WHT/RED WHT
Y11 X3
1 2
BRN/RED BLK/YEL
2
X98 X3 X3
BLK/YEL
X104
X3 X3
1 2
(504) (620)
WHT WHT
G3 K19
F61 B22 1 1104
RED/YEL WHT/GRN YEL/BLK
X3 K19
F60 (1104) (1112)
B20 1
X3 X3
RED RED
B22 (1096) (1105)
1096 1105
BRN/BLU GRY
(511) (619)
2
511
1
619
2
F60
1112
504
1
620
2
1
B
X175
M6 1 2
BLK VLT
(501) X3
A 505
1
B30
(547) (546)
PI 1279
1093
1049
1
2
3
X175
M6
1
2
2 546
(1279) (1093) (1049)
RED/YEL GRY BLK/YEL
(505)
BLK/WHT
X3
1 547
B30 1 2 3
X98 X3 X104
K19
S
Y23 1 2
(1087) (1224)
WHT GRN
X3 X3
1
665
26
140
138
4
3
B
B B E
E
E
G3 (504) (506) (501B)
WHT WHT BLK
F60 X3 (501)
K19
G3
X86
Y22 1 2
(1207) (1086)
ORG/RED BLK/WHT
X3 X3
X86 1 2 3 4
Y24 1 2
(1084) (1194)
YEL VLT/WHT
Y11
X3 X3
(26) (665) (138) (140)
WHT/RED WHT/YEL GRN/BLK BLK
X3 X3 X3 (501)
1
A
(620)
WHT
F60
B
(619)
RED
F61
E
(521)
BLK
(501)
S
(508)
WHT
X3
1096
Y11 PI 1051
1293
Y23
2
B31
1 1087
1277
Y22 2
1224
1 1207
1
Y24 2
1086
1 1084
2
2
1
1194
3
SG
2
SF
1
SC
1022 1020 1303 1135
B31 1 2 3
(1051) (1293) (1277)
RED/YEL BRN BLK/YEL
4
X98 X3 X104
3
(1096)
WHT/RED
B20
(1020) (1022) (1135) (1303)
RED BLK WHT GRY
X3 X3 X3 X3
X64 1 2 3 4
X64
TX1198940 Machine Harness (W2) Wiring Diagram (2 of 2) (S.N. —057099) Continued on next page
TM13345X19 (23APR18)
9015-10-129
160GLC Excavator 042318 PN=439
JA92389,0000157 -19-14FEB18-4/9
System Diagrams
TM13345X19 (23APR18)
9015-10-130
160GLC Excavator 042318 PN=440
System Diagrams F61— Battery 45 A Fuse 1— Continued on Sheet 1 G3—Alternator B20— Air Conditioner High/Low-Pressure Switch K19— Battery Relay B22— Ambient Air Temperature M6—Windshield Washer Motor X40— Pump Harness-to-Machine Sensor Harness Connector B30— Boom Up Pressure Sensor X46— Attachment Connector (marked PI1) X64— Machine Harness-to-Rear B31— Arm In Pressure Sensor Camera Harness (marked PI2) Connector F60— Alternator 65 A Fuse
X86— Machine Harness-to-Travel Y22— Dig Regenerative Solenoid Alarm Harness Connector (marked SF) X98— Machine Harness Ground Y23— Arm Regenerative Splice Solenoid (marked SC) X104— Machine Harness Power Y24— Power Dig/Travel Speed Splice Solenoid (marked SG) X175— Machine Harness-toEngine Interface Harness Connector 1 Y11— Air Conditioner Compressor Clutch
Continued on next page
TM13345X19 (23APR18)
9015-10-131
JA92389,0000157 -19-14FEB18-5/9
160GLC Excavator 042318 PN=441
System Diagrams
TM13345X19 (23APR18)
9015-10-132
160GLC Excavator 042318 PN=442
System Diagrams
Machine Harness (W2) Wiring Diagram (S.N. 057100— ) TX1247717 —UN—14DEC17
END #1 X3 X86 X86 B18 X3 X3 X3 X3
501B
BLK
504 505 506 508 511 513 521 536 537 542 543 546 547 549 597 614 619 620 651 664 665 745 764 800 801 802 810 811 876 877 1000 1001 1018 1020 1022 1023 1033 1045 1047 1049 1050 1051 1053 1055 1056 1057 1058 1059 1061 TX1247717
WHT BLK/WHT WHT WHT RED RED BLK RED/BLU BLU/RED PNK/WHT PNK/WHT VLT BLK BLK BLK/YEL BLK RED WHT BLU/WHT WHT/YEL WHT/YEL VLT/GRN RED/BLK GRN BLU GRY BLU BLK ORG/BLK ORG/GRN BLK BLK BRN/YEL RED BLK RED/YEL SK BLU BLU/RED BRN/WHT BLK/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL BLK/YEL BLK/YEL YEL/BLK
(140)(501A)(521)(547)(811) (1351) F60 X175 G3 K19 X3 X67 K19 X3 X3 X3 B23 X3 M6 X67 (1153) E1 F61 K19 X3 X3 X3 X5018 X3 X3 X3 X3 X3 (501B) X3 X3 B23 B24 X3 X64 X3 X98 X3 B32 B56 X104 X98 B31 B32 B33 B34 X98 X104 X104 X3
END #2 X86 X3 (501B) X3 X90 X5018 X5018 (501B)(549) (614)(1000)(1001) G3 G3 X3 X3 X3 F61 (511) (501B) E2 E1 B24 (542) M6 (501B) (501A) B18 (501A) K19 F60 X46 X46 X86 X3 X5018 X5018 X5018 X5018 X5018 X5018 X5018 X5018 (501A) (501A) X40 X3 X64 X3 X40 X3 X3 B30 B61 X98 X98 X98 X98 B56 B56 B61 X40
NUMBER 1067 1069 1084 1086 1087 1090 1091 1092 1093 1094 1096 1100 1104 1105 1110 1112 1115 1116 1117 1135 1147 1153 1170 1185 1194 1207 1213 1220 1224 1227 1229 1230 1245 1251 1252 1253 1254 1256 1257 1261 1263 1264 1268 1270 1272 1277 1279 1285 1293 1295 1297 1298 1299 1300 1303 1330 1331 1351 1381 1382
COLOR BLU/BLK GRN/WHT YEL BLK/WHT WHT BRN/BLU BLK/YEL BLU/YEL GRN/YEL BLU/GRN WHT/RED WHT/GRN BRN/RED WHT GRN/YEL BLK/YEL YEL/RED RED WHT/VLT WHT BLK/YEL BLK/YEL BLK/YEL RED/GRN VLT/WHT ORG/RED RED/BLK ORG GRN GRY/BLK BLU/RED ORG/BLU RED/YEL GRN BLU WHT/BLU PNK/GRN RED/YEL BLK/YEL BRN GRY WHT/GRN YEL/GRN BLK/YEL BLK/YEL BLK/YEL RED/YEL YEL/RED BLK/RED BRN/WHT BRN/BLU BRN/BLU RED/YEL BRN/YEL GRY BLU/YEL LT GRN/BLK BLK WHT/GRN YEL/BLK
END #1 X40 X3 Y24 X3 Y23 X40 X40 B33 B30 B57 B20 X3 X3 X3 X40 X3 X46 X46 X46 X64 B32 X104 (1153) X3 X3 Y22 X590 X46 X3 X46 X3 X46 X3 X5018 X5018 X3 X3 X3 X3 X46 X46 X3 X3 B34 B33 B31 B30 B34 B31 X40 X3 X46 X40 X46 X3 X46 X46 X46 X3 X3
END #2 X3 X40 X3 Y22 X3 X3 X104 X3 X3 X3 Y11 X590 B22 B20 X3 B22 X3 X3 X3 X3 X104 X3 X40 X590 Y24 X3 X3 X3 Y23 X3 X40 X3 X590 X3 X3 B61 X46 X46 X46 X3 X3 X40 X46 X104 X104 X104 X98 X3 X3 X3 X40 (1297) X98 (1018) X64 X3 X3 (501B) X5018 X5018
NUMBER 1383 1384 1502 1503 1504 1557 1558
COLOR BLK/YEL GRN/WHT RED RED/BLU BLU/RED RED/YEL BLK/YEL
END #1 X3 X3 X3 X3 X5018 X98 X104
END #2 X5018 X5018 X5018 X5018 X3 B57 B57
1 2 3
TM13345X19 (23APR18)
9015-10-133
160GLC Excavator 042318 PN=443
(1053) (1045) (1147)
RED/YEL BLU/RED BLK/YEL
X98 X3 X104
1053
1045
B33 1147
1
1 2
(542) (1001)
PNK/WHT BLK
X3 (501A)
1092
1272
1
2
3
(536)
RED/BLU
X3
1
1 2 3
(1055) (1092) (1272)
RED/YEL BLU/YEL BLK/YEL
A B C D E F G H J K L M N P R S T U V W X
X98 X3 X104
B34
E2
E1
X5018
B33
1055
3
B24
1056
1285
1270
1
2
3
X5018
TR 1
2
B23
X90 1
1
(250)
WHT/BLU
B24 2
1
543 1000
(597) (235)
BLK/YEL BRN
1 2 3
542 1001
E1
(1153) X3
1 2
X67
X67 1
2
513
549
1 2
(513) (549)
RED BLK
(511) (501A)
(537) (614)
BLU/RED BLK
J
B34
1
B18 1 2
2
E2
X3
K 800
(1056) (1285) (1270)
RED/YEL YEL/RED BLK/YEL
X98 X3 X104
1 2
B
801 L
X3 (501A)
810
811
C
M
745
802
H
1384 X G 1383 W 1504 A F 1381 V
764
401
D
E
N
1502
1503
1382
400
B23 (543) (1000)
PNK/WHT BLK
P 1251
(542) (501A)
U
876
R
1252 S
877
X90 1
1
2
597 235
B18
1 2 3 4
X3 (1067) (1229) (1115) (1227) PLUG (651) (1230) (745) (1261) (26) PLUG (1254) (1263) (1033) (764) (1094) (876) (877) PLUG PLUG PLUG (1295) (1069) PLUG PLUG (1381) (1382) (665) PLUG PLUG (542) (546) (1383) (1330)
BLU/BLK BLU/RED YEL/RED GRY/BLK
X40 X40 X46 X46
BLU/WHT ORG/BLU VLT/GRN BRN WHT/RED
X46 X46 X5018 X46 X86
PNK/GRN GRY SK BLU RED/BLK BLU/GRN ORG/BLK ORG/GRN
X46 X46 X40 X5018 B57 X5018 X5018
BRN/WHT GRN/WHT
X40 X40
WHT/GRN YEL/BLK WHT/YEL
X5018 X5018 X86
PNK/WHT VLT BLK/YEL BLU/YEL
B24 M6 X5018 X46
B14 B15 B16 B17 B18 B19 B20 B21 C1 C2 C3 C4 C5 C6 C7 C8 D1 D2 D3 D4 D5 D6 D7 D8 E1 E2 E3 E4 E5 E6 E7 E8 E9
(1384) (1331) (235) (1104) (1112) (1257) (1256) (138) (511) (508) (505) (810) PLUG (664) (537) (536) (1105) (1023) (506) (1502) (1503) 501A (1504) (1153) (1020) (1022) (800) (1264) (1117) (1061) (1135) (1303) (801)
GRN/WHT LT GRN/BLK BRN BRN/RED BLK/YEL BLK/YEL RED/YEL GRN/BLK RED WHT BLK/WHT BLU
X5018 X46 B18 B22 B22 X46 X46 X86 F61 K19 X175 X5018
WHT/YEL BLU/RED RED/BLU WHT RED/YEL WHT RED RED/BLU BLK BLU/RED BLK/YEL RED BLK GRN WHT/GRN WHT/VLT YEL/BLK WHT GRY BLU
X46 E1 E2 B20 X98 G3 X5018 X5018 (501B) X5018 X104 X64 X64 X5018 X40 X46 X40 X64 X64 X5018
E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21
(1090) (1220) (1110) (1047) (802) (1251) (1252) (1116) (1268) PLUG PLUG (1084) (1285) (1045) (1093) (1213) (1185) (250) (1092) (1253) (1293) (400) (401) PLUG (1100) (1245) (1194) (1297) (1018) (1207) (1086) (1087) (1224)
BRN/BLU ORG GRN/YEL BRN/WHT GRY GRN BLU RED YEL/GRN
X40 X46 X40 B56 X5018 X5018 X5018 X46 X46
21
2
1185
1213
401
4
Y24 B34 B32 B30 X590 X590 X90 B33 B61 B31 X5018 X5018
1245
1100
X3 X3 X3 X3 X3
BLU/RED GRY GRN BLU BLK GRN/RED WHT/RED GRN BLU ORG/GRN ORG/BLK YEL/BLK WHT/GRN BLK/YEL GRN/WHT
X3 X3 X3 X3 (501B) X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
RED/BLK RED/GRN WHT/GRN RED/YEL
X3 X3 X3 X3
21
1084
1268 1116 1252 1251
802
400
1293 1253 1092
1185 1213
1093 1045 1285
501A
8
1153 1504
7
8
536
6
5
1503 1502
4
6
664
2
1023 1105
1
3
505
1
6
15
1047
E
1110 1220 1090
801
1303 1135
1061 1117 1264
800
1022 1020
1
3
X590
537
508
7
810
5
4
2
506
511
3
21
138
D
1256 1257 1112 1104
1384 1383 6
WHT/GRN RED/YEL VLT/WHT BRN/BLU BRN/YEL ORG/RED BLK/WHT WHT GRN
15
1100
F
(1213) (1185) (1100) (1245)
250
1 6
YEL YEL/RED BLU/RED GRN/YEL RED/BLK RED/GRN WHT/BLU BLU/YEL WHT/BLU BLK/RED WHT/RED GRN/RED
1224 1087 1086 1207 1018 1297 1194 1245
RED/BLK BLU VLT/GRN RED RED/BLU
X590
X3 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13
(764) (810) (745) (1502) (1503) PLUG (1504) (802) (800) (801) (811) (401) (400) (1251) (1252) (877) (876) (1382) (1381) (1383) (1384)
T
1
Machine Harness (W2) Wiring Diagram (1 of 2) (S.N. 057100— ) Continued on next page
B32
B32
S3
COLOR WHT/RED GRN/BLK BLK BRN WHT/BLU WHT/RED GRN/RED BLK
FRT
NUMBER 26 138 140 235 250 400 401 501A
B 546
1382 1381
542
1
C
235
1331
15
21
1330 665 1069 1295
877 1033
1
6
876
1094
764
15
1263
A 745
1230
1254
26
1261
651
1227
1115 1229 1067
1
X590 X590 Y24 X40 X40 Y22 Y22 Y23 Y23
SHEET 1 OF 2 JA92389,0000157 -19-14FEB18-6/9
System Diagrams
TM13345X19 (23APR18)
9015-10-134
160GLC Excavator 042318 PN=444
System Diagrams
1— Continued on Sheet 2 B33— Swing Pressure Sensor B18— Fuel Level Sensor (marked S3) B23— High Note Horn B34— Travel Pressure Sensor B24— Low Note Horn (marked TR) B32— Front Attachment Pressure E1— Work Light Sensor (marked FRT) E2— Boom Light X3— Cab Harness-to-Machine Harness 100-Pin Connector
X67— Machine Harness Auxiliary X5018—Machine Harness-toPower Connector Engine Interface Harness X90— Machine Harness-toConnector 2 Hydraulic Oil Temperature Switch Connector X590— Exhaust Solenoid Harness Connector (not used)
Continued on next page
TM13345X19 (23APR18)
9015-10-135
JA92389,0000157 -19-14FEB18-7/9
160GLC Excavator 042318 PN=445
System Diagrams
TM13345X19 (23APR18)
9015-10-136
160GLC Excavator 042318 PN=446
System Diagrams
TX1247718 —UN—15DEC17
X46 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X104 (1049) (1058) (1059) (1091) (1147) (1153) (1270) (1272) (1277) (1558)
BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL
B30 B56 B61 X40 B32 X3 B34 B33 B31 B57
X46 1
1261
RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL
1331
1351 1298
1220
1256
664 1117
1300 1257
17
X3 B61 B31 B32 B33 B34 B56 B30 X40 B57
1116 1330
1263 1268
1227 651 1254
X98 (1023) (1050) (1051) (1053) (1055) (1056) (1057) (1279) (1299) (1557)
4
1115 1230
20
B61
X104 1050
1253
1059
1
2
3
X98
(1115) (1230) (1116) (1330) (1261) (1263) (1268) (1331) (1227) (651) (1351) (1298) (1254) (1220) PLUG (1256) (664) (1117) (1300) (1257)
YEL/RED ORG/BLU RED BLU/YEL BRN GRY YEL/GRN LT GRN/BLK GRY/BLK BLU/WHT BLK BRN/BLU PNK/GRN ORG RED/YEL WHT/YEL WHT/VLT BRN/YEL BLK/YEL
X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 (501B) (1297) X3 X3
X40 4
1
1033 1297
1295 1067
1170
1018 1069
1229
1299
1110
1090
1091
1061 1264
20
17
X3 X3 X3 (1018) X3
B61 1 2 3
(1050) (1253) (1059)
RED/YEL WHT/BLU BLK/YEL
X98 X3 X104
X40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(1067) (1295) (1297) (1033) (1229) (1069) (1018) (1170) PLUG PLUG PLUG PLUG (1090) (1110) PLUG (1299) (1264) (1061) PLUG (1091)
BLU/BLK BRN/WHT BRN/BLU SK BLU BLU/RED GRN/WHT BRN/YEL BLK/YEL
F61
X3 X3 X3 X3 X3 X3 X3 (1153)
1 2
B20 1 2
WHT/RED WHT
Y11 X3
1 2
BRN/RED BLK/YEL
2
X98 X3 X3
BLK/YEL
X104
X3 X3
1 2
(504) (620)
WHT WHT
G3 K19
F61 B22 1 1104
RED/YEL WHT/GRN YEL/BLK
X3 K19
F60 (1104) (1112)
B20 1
X3 X3
RED RED
B22 (1096) (1105)
1096 1105
BRN/BLU GRN/YEL
(511) (619)
2
511
1
619
2
F60
1112
504
1
620
2
1
B
B57
1 2 3
(1557) (1094) (1558)
RED/YEL BLU/GRN BLK/YEL
1557
1094
1558
1
2
3
1 2
A
(501B) X3
505
1093
1049
1
2
3
(1279) (1093) (1049)
RED/YEL GRN/YEL BLK/YEL
2
2 546
Y23 1 2
X98 X3 X104
(1087) (1224)
WHT GRN
X3 X3
1 2
(1207) (1086)
ORG/RED BLK/WHT
X3 X3
(1057) (1047) (1058)
1 2
3
2
RED/YEL BRN/WHT BLK/YEL
X98 X3 X104
X3
665
26
140
138
4
3
504 506
E 501B
E
G3 B B E
(504) (506) (501B)
WHT WHT BLK
F60 X3 (501A)
K19
G3
(1084) (1194)
YEL VLT/WHT
Y11
X86 1 2 3 4
Y24 X3 X3
(26) (665) (138) (140)
WHT/RED WHT/YEL GRN/BLK BLK
X3 X3 X3 (501B)
1
1051
Y23
1293
1 1087
1277
Y22 2
1224
1 1207
1
Y24 2
1086
1
2
1084
2
1
1194
3
SG
2
SF
1
SC
1022 1020 1303 1135
B31 1 2 3
(1051) (1293) (1277)
RED/YEL BLK/RED BLK/YEL
4
X98 X3 X104
(620)
WHT
F60
B
(619)
RED
F61
E
(521)
BLK
(501B)
S
(508)
WHT
X3
1096
3
(1096)
WHT/RED
B20
(1020) (1022) (1135) (1303)
RED BLK WHT GRY
X3 X3 X3 X3
X64 1 2 3 4
X64 SHEET 2 OF 2
TX1247718 Machine Harness (W2) Wiring Diagram (2 of 2) (S.N. 057100— ) Continued on next page
TM13345X19 (23APR18)
A
Y11 B31
PI
1 2 3
1058
2
1
B56
1
X86
BKC 1047
BLK/WHT
Y22
B56 1057
(505)
B
1 547
1279
K19
X175 1
B30 1 2 3
BLK VLT
M6
B30
X98 X3 X104
(547) (546)
S
PI1
B57
X175
M6
9015-10-137
160GLC Excavator 042318 PN=447
JA92389,0000157 -19-14FEB18-8/9
System Diagrams
TM13345X19 (23APR18)
9015-10-138
160GLC Excavator 042318 PN=448
System Diagrams B57— Bucket Dump Pressure 1— Continued on Sheet 1 Sensor B20— Air Conditioner High/Low-Pressure Switch B61— Arm Out Pressure Sensor B22— Ambient Air Temperature F60— Alternator 65 A Fuse F61— Battery 45 A Fuse Sensor B30— Boom Up Pressure Sensor G3—Alternator K19— Battery Relay (marked PI1) M6—Windshield Washer Motor B31— Arm In Pressure Sensor X40— Pump Harness-to-Machine (marked PI2) Harness Connector B56— Bucket Curl Pressure Sensor (marked BKC)
X46— Attachment Connector Y11— Air Conditioner X64— Machine Harness-to-Rear Compressor Clutch Camera Harness Y22— Dig Regenerative Solenoid Connector (marked SF) X86— Machine Harness-to-Travel Y23— Arm Regenerative Alarm Harness Connector Solenoid (marked SC) X98— Machine Harness Ground Y24— Power Dig/Travel Speed Splice Solenoid (marked SG) X104— Machine Harness Power Splice X175— Machine Harness-toEngine Interface Harness Connector 1 JA92389,0000157 -19-14FEB18-9/9
TM13345X19 (23APR18)
9015-10-139
160GLC Excavator 042318 PN=449
System Diagrams
Monitor Harness (W3) Component Location
A10
B21
A4
H3
X18
X19
A10 W3 B21
H3 A4
W3
X17
TX1086763 —UN—13JAN11
X23
X24
W1
TX1086763 Monitor Harness (W3) Component Location 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 Connector
X18— Monitor 12-Pin Connector X24— Monitor Controller 2-Pin C Connector G X19— Monitor 2-Pin Connector G X23— Monitor Controller 12-Pin Connector C BG71862,0000C5F -19-08MAR13-1/1
TM13345X19 (23APR18)
9015-10-140
160GLC Excavator 042318 PN=450
System Diagrams
TM13345X19 (23APR18)
9015-10-141
160GLC Excavator 042318 PN=451
System Diagrams
Monitor Harness (W3) Wiring Diagram NUMBER COLOR END #1 END #2 1042
CABLE
X19
X24
1044
GRN
X23
X18
1046
YEL
X23
X18
1079
CABLE
X19
X24
1081
BLK/YEL
X23
X18
1103
YEL/RED
B21
X17
1107
WHT
H3
X17
1109
BLU/BLK
H3
X17
X24
1188
RED/YEL
X23
X18
1
(1042)
CABLE
X19
1
(1260)
RED/BLK
B21
1195
BLU
X23
X18
2
(1079)
CABLE
X19
2
(1103)
YEL/RED
B21
1260
RED/BLK
B21
X17
3
(1107)
WHT
H3
4
(1109)
BLU/BLK
H3
X17
X24 1
X23 1
1195 1046 1188
2
1042 1079
X17 1109 1107 1103 1260
6
1081 1044
7
4
12
3
2
1
X23 1
(1195)
BLU
X18
2
(1046)
YEL
X18
3
(1188)
RED/YEL
X18
4
—
5
(1081)
BLK/YEL
X18
6
(1044)
GRN
X18
7
—
8
—
9
—
10
—
11
—
12
—
B21 1
(1260)
RED/BLK
X17
2
(1103)
YEL/RED
X17
B21 2
1 1260 1103
X18 1
1195 1046 1188
1081 1044
7
6 12
X18 (1195)
BLU
X23
2
(1046)
YEL
X23
3
(1188)
4
—
5
(1081)
RED/YEL
1
X23
H3
X23 1
1042 1079
2
6
(1044)
7
—
8
—
1
(1042)
CABLE
X24
9
—
2
(1079)
CABLE
X24
10
—
11
—
12
—
GRN
2
1109 1107
X19 BLK/YEL
H3
X23
X19
TX1115351
1
(1109)
BLU/BLK
X17
2
(1107)
WHT
X17
TX1115351 —UN—08JUN12
1
Monitor Harness (W3) Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-10-142
BG71862,0000C60 -19-08MAR13-1/2
160GLC Excavator 042318 PN=452
System Diagrams B21— Solar Sensor H3—Monitor Warning Alarm X17— Cab Harness-to-Monitor Harness Connector
X18— Monitor 12-Pin Connector X23— Monitor Controller 12-Pin C Connector C X19— Monitor 2-Pin Connector G X24— Monitor Controller 2-Pin Connector G BG71862,0000C60 -19-08MAR13-2/2
TM13345X19 (23APR18)
9015-10-143
160GLC Excavator 042318 PN=453
System Diagrams
TM13345X19 (23APR18)
9015-10-144
160GLC Excavator 042318 PN=454
System Diagrams
Engine Harness (W4) Component Location TX1200701 —UN—29SEP15
Y5400
G3
B5205
X5015
B5207 B5205
B5102
W4 B5102
X5068 X5015 X5604
B5103
X5068 B5207
W4
X5016
Y5400
B5206 B5209 B5107
X5016
G3 B5105
X5001
B5101 B5205 X5141
X5040
X5604 G3
W4
X5000 B5104
TX1200701 Engine Harness (W4) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-145
160GLC Excavator 042318 PN=455
JA92389,0000163 -19-04SEP15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-146
160GLC Excavator 042318 PN=456
System Diagrams X5141—Engine Harness-to-Front B5101—Engine Oil Pressure B5205—Charge Air Cooler Outlet X5015—Engine Interface Engine Harness Sensor Temperature Sensor Harness-to-Engine Connector 2 B5102—Exhaust Manifold B5206—Manifold Air Temperature Harness Connector 1 X5604—Engine Harness-to-Glow Pressure Sensor (MAT) Sensor X5016—Engine Interface Plug Interface Harness B5103—Exhaust Gas B5207—Exhaust Gas Harness-to-Engine Connector Recirculation (EGR) Delta Recirculation (EGR) Harness Connector 2 Y5400—Exhaust Gas Pressure Sensor Temperature Sensor X5021—Fuel Injector Harness Recirculation (EGR) Valve B5104—Intake Manifold Pressure B5209—Fuel Temperature Sensor Connector Sensor G3—Alternator X5040—Engine Harness-to-Front B5105—Crankcase Pressure W4—Engine Harness Engine Harness Sensor X5001—Static Ground Connector 1 B5107—Inlet Fuel Pressure X5068—Engine Interface Sensor Harness-to-Engine Harness Connector 3 JA92389,0000163 -19-04SEP15-2/2
TM13345X19 (23APR18)
9015-10-147
160GLC Excavator 042318 PN=457
System Diagrams
Engine Harness (W4) Wiring Diagram NUMBER 5010 5016 5018 5030A 5030B 5030C 5030D 5030E 5030F 5030G 5030H 5051 5053 5246 5410A 5410B 5410C 5410D 5410E 5415 5419 5421 5423 5424 5425 5427 5429 5443 5445 5447 5448 5455 5456 5461 5463 5465 5467 5468 5469 5491 5493 5495 5496 5498 5499 5509 5611 5613 5614A 5614B 5614C 5621 5623A 5623B 5623C 5623D 5624A 5624B 5624C 5625A
COLOR BLK LT BLU GRY BLK BLK CLR BLK BLK CLR BLK CLR BRN ORG LT BLU BLK BLK CLR BLK CLR DK GRN WHT BRN ORG YEL DK GRN PUR WHT ORG DK GRN PUR GRY DK GRN LT BLU BRN ORG DK GRN PUR GRY WHT BRN ORG DK GRN LT BLU GRY WHT WHT BRN ORG YEL YEL YEL BRN ORG ORG ORG ORG YEL YEL YEL DK GRN
END #2 X5016 X5015 X5015 X243 X243 X245 X245 X243 X5040 X262 X262 X5016 X5016 X5016 X5068 X241 X241 X242 X242 X5015 X5068 X5015 X5015 X5068 X5015 B5209 X5016 X5015 X5015 X5015 X5015 X5016 X5016 X5015 X5016 X5015 X5015 B5104 B5107 X5068 X5068 X5068 X5068 X5068 X5068 X5015 X5015 X5015 X253 X253 X253 X5016 X5016 X252 X252 X252 X5016 X255 B5104 X5016
END #1 B5103 X256 B5207 X5015 B5102 Y5400 X5141 X5015 Y5402 B5101 X5015 Y5402 B5101 X5604 X5015 X5604 X5040 X5040 X5141 X5141 X5141 X5015 X5015 X261 X5141
NUMBER 5625B 5625C 5625D 5626A 5626B 5626C 5628 5631A 5631B 5631C 5633A 5633B 5633C 5646 5658 5671 5756 5767 5783 5804 5805 5821 5826A 5826B 5826C
COLOR DK GRN DK GRN DK GRN LT BLU LT BLU LT BLU GRY BRN BRN BRN ORG ORG ORG LT BLU GRY BRN LT BLU PUR ORG YEL DK GRN BRN LT BLU LT BLU LT BLU
END #2 X256 B5104 X256 X254 X254 X254 X5016 X248 X248 X248 X249 X249 X249 X5016 B5107 X5016 X5068 X5068 X5016 X5016 X5016 B5107 X261 B5209 X261
SHEET 1 OF 2
TX1197509 —UN—01OCT15
END #1 X5001 Y5402 Y5402 X5015 X244 X244 X5040 X247 X247 X243 X5141 B5103 B5105 G3 X240 X240 X5000 X240 B5101 X5040 X5141 Y5400 Y5400 X5141 Y5400 X5015 X5604 X5040 X5040 X5040 X5040 B5205 B5206 X5141 B5207 B5102 B5101 X5016 X5015 X5000 X5000 X5000 X5000 X5000 X5000 Y5402 X5040 X5040 X5015 Y5400 B5102 B5105 X252 B5105 B5205 B5206 X255 B5103 X255 X256 TX1197509
Engine Harness (W4) Wiring Diagram (1 of 2) Continued on next page
TM13345X19 (23APR18)
9015-10-148
JA92389,000014B -19-25SEP15-1/3
160GLC Excavator 042318 PN=458
System Diagrams
TX1197605 —UN—28SEP15
X5015 5425 5016 5421 5821 5826A 5658 PLUG PLUG 5467 PLUG 5465 5509 5018 PLUG PLUG
2
1 2
X261 X244
29
7
17 28
8
1
15
12
13
26
X261
3
X5016 20 21
23
4 14
5410D 5410E
D P
X241
W H
X242
G3
B5104
5621 5623B 5053
X254
X5000
E
B5205
5633A 5633B 5633C
2
S
3
2 1
8
7
6 5
X245
2
1
1 2 3
5631C 5633C 5467
50
12 11 10
9
8
7
X245
1
4
3
2
1
8
7
6
5
X5000
B5103
6
5
4
2
Y5402 1 2 3 4 5 6
B5103
B5207
5631B 5633B 5509 5018 PLUG 5016
X248
2
1
1 2 3
1 2 3 4 5 6 7 8
5624B 5625B 5051
B5206 2
B5207 1 2
PLUG PLUG 5495 5493 5498 5499 5496 5491
1
Y5400
5631A 5631B 5631C
5463 5625D
1
B5206 1 2
5456 5623D
X248 3
2
1
6
5
4
X5604 Y5400 1 2 3 4 5 6
E 10
1
5455 5623C
B5205
10
54
2
2
F 30
3
3
B5101 30
4
X5040 4
Y5402
X5141
5804 5783 5419 5826C 5805 5628 5424 5461
1 2
3
R
Q
1
B5101 3
5030C 5030D
5626C 5614B 5425 5423 PLUG 5421
3
2
1
X5604 1 2 3
5671 5429 5646
SHEET 2 OF 2
TX1197605 Engine Harness (W4) Wiring Diagram (2 of 2) Continued on next page
TM13345X19 (23APR18)
1 2 3
X249
X240
T
1 2 3 4 5 6 7 8
5
1
5626A 5626B 5626C
X5001
U
X5141
6
2
X249
G F
PLUG PLUG 5419 5424 PLUG PLUG PLUG PLUG PLUG 5756 5767
5613 5611 5415 5756 5767 PLUG
X253
V
J A
O
7 8 9 10 11 12
X252
5410A 5410B 5410D
50
5030D 5448 5447 5443 5445 PLUG
X242
H
B
5624C 5625C 5468
X254
5614A 5614B 5614C
X240 X241
X
C
1 2 3
28
X5040 1 2 3 4 5 6
X243
X253
5623A 5623B 5623C 5623D
X5068 K
1
X252
5030A 5030B 5030E 5030G
X256
27
5410B 5410C
L
2
16 15 26
25
3
29
5 13
B5104
17 6
12 24
X255
5626B 5614C 5465
18 7
1
M
N O P Q R S T U V W X
30
19
2 3
11
X5068 PLUG 5491 5496 5493 5495 5410A 5498 5499 PLUG PLUG PLUG PLUG
8
10 22
X262
31
9
N
A B C D E F G H J K L M
5030G 5030H
50
PLUG PLUG PLUG PLUG PLUG 5429 5646 5455 5463 5456 5468 PLUG PLUG PLUG PLUG
X243
5625A 5625B 5625C 5625D
5624A 5624B 5624C
1 2 3
B5102
23
X262
1
B5105
B5105
24
25
2
5821 5658 5469
11
14
27
1 2 3
22
4 5
X247
3
B5107
10
3
6
16
X244
21 9
2
1
C
19
18
20
2
B5102
5427 5826B
5826A 5826B 5826C
5030E 5030F
X255 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
3
10
30
X247
5030B 5030C
X5015 31
X5016 5804 5805 PLUG 5783 5010 5621 5623A 5671 5624A 5625A 5628 5246 PLUG 5051 5053 PLUG
B5107
B5209
X256 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
B5209
54
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
46
5614A 5443 5445 5631A 5611 5626A 5423 5447 5448 5030A 5633A 5469 5427 5613 5415 5461
52
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
9015-10-149
160GLC Excavator 042318 PN=459
JA92389,000014B -19-25SEP15-2/3
System Diagrams
TM13345X19 (23APR18)
9015-10-150
160GLC Excavator 042318 PN=460
System Diagrams
B5101—Engine Oil Pressure B5207—Exhaust Gas X253— 5614 YEL Splice Sensor Recirculation (EGR) X254— 5626 LT BLU Splice B5102—Exhaust Manifold Temperature Sensor X255— 5624 YEL Splice Pressure Sensor B5209—Fuel Temperature Sensor X256— 5625 DK GRN Splice B5103—Exhaust Gas G3—Alternator X261— 5826 LT BLU Splice 1 Recirculation (EGR) Delta X240— 5410 BLK Splice 1 X262— 5030 BLK Splice 5 Pressure Sensor X241— 5410 BLK Splice 2 X5000—Engine Harness-to-Fuel B5104—Intake Manifold Pressure X242— 5410 BLK Splice 3 Injector Harness Sensor X243— 5030 BLK Splice 1 Connector B5105—Crankcase Pressure X244— 5030 BLK Splice 2 X5001—Static Ground Sensor X245— 5030 BLK Splice 3 X5015—Engine Interface B5107—Inlet Fuel Pressure X247— 5030 BLK Splice 4 Harness-to-Engine Sensor X248— 5631 BRN Splice Harness Connector 1 B5205—Charge Air Cooler Outlet X249— 5633 ORG Splice X5016—Engine Interface Temperature Sensor X252— 5623 ORG Splice Harness-to-Engine B5206—Manifold Air Temperature Harness Connector 2 (MAT) Sensor
X5040—Engine Harness-to-Front Engine Harness Connector 1 X5068—Engine Interface Harness-to-Engine Harness Connector 3 X5141—Engine Harness-to-Front Engine Harness Connector 2 X5604—Cold Start Aid Interconnect Y5400—Exhaust Gas Recirculation (EGR) Valve Y5402—Exhaust Throttle Actuator
JA92389,000014B -19-25SEP15-3/3
TM13345X19 (23APR18)
9015-10-151
160GLC Excavator 042318 PN=461
System Diagrams
TM13345X19 (23APR18)
9015-10-152
160GLC Excavator 042318 PN=462
System Diagrams
Engine Interface Harness (W5) Component Location Engine Interface Harness (W5) Component Location (S.N. —056599) TX1234452 —UN—21FEB17
A6001 X5015 A6003
W5
X5068 X5016 M1
X5039 X5015
X175 F45 Y5501
V44
X5503 X5502 A6000
B5600
F6003 A1
X5018 R90
X5501
K19
X6014 E22 F5004 A6002 X6015
A15 A1
X5037
W6003 X6016
W39 R92 R93
X5005
W5
K34 F46
F6003 W5 F6001
F5004
X6016 R5601 R11
TX1234452 Engine Interface Harness (W5) Component Location (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-153
160GLC Excavator 042318 PN=463
JL58967,0000733 -19-22FEB17-1/4
System Diagrams
TM13345X19 (23APR18)
9015-10-154
160GLC Excavator 042318 PN=464
System Diagrams
A1—Engine Control Unit (ECU) F6003—JDLink™ Switched A15— Flex Power Controller Power 7.5 A Fuse (FPC) K19— Battery Relay A6000—Modular Telematics K34— Starter Relay Gateway (MTG) M1—Starter Motor Controller R11— Interface CAN Resistor 2 A6001—GPS/Cellular Antenna R90— Diesel Particulate Filter A6002—Satellite (SAT) Module (DPF) Regen Active Lamp Control Unit (if equipped) Resistor A6003—Satellite (SAT) Antenna R92— Service ADVISOR™ B5600—Water-in-Fuel (WIF) Remote (SAR) Switch Sensor Accept LED Resistor E22— Battery Disconnect R93— Service ADVISOR™ Indicator Light Remote (SAR) Switch F45— Starter In-Line 30 A Fuse Decline LED Resistor F46— Engine Light In-Line 7.5 A R5601—CAN 0 Termination Fuse Resistor F5004—Flex Power Controller V44— Starter Relay Diode (FPC) In-Line 10 A Fuse W5—Engine Interface Harness F6001—JDLink™ Unswitched W39—Engine Interface Harness Power 7.5 A Fuse Ground
W6003—Satellite (SAT) Harness X5501—Engine Control Unit X175— Machine Harness-to(ECU) Connector 1 Engine Interface Harness X5502—Engine Control Unit Connector 1 (ECU) Connector 2 X5005—Fan Harness Connector X5503—Engine Control Unit X5015—Engine Interface (ECU) Connector 3 Harness-to-Engine X6014—Modular Telematics Harness Connector 1 Gateway (MTG) Control X5016—Engine Interface Unit 48-Pin Connector Harness-to-Engine X6015—Satellite (SAT) Module Harness Connector 2 Control Unit 48-Pin X5018—Machine Harness-toConnector Engine Interface Harness X6016—Engine Interface Connector 2 Harness-to-Satellite X5037—Engine Interface (SAT) Harness Connector Harness-to-Diesel Y5501—Fuel Transfer Pump Exhaust Fluid (DEF) Harness Connector 1 X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector X5068—Engine Interface Harness-to-Engine Harness Connector 3
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-155
JL58967,0000733 -19-22FEB17-2/4
160GLC Excavator 042318 PN=465
System Diagrams
TM13345X19 (23APR18)
9015-10-156
160GLC Excavator 042318 PN=466
System Diagrams
Engine Interface Harness (W5) Component Location (S.N. 056600— ) TX1234455 —UN—21FEB17
A6001 X5015 A6003
W5
X5068 X5016 M1
X5039 X5015
X175
Y5501
V44
X5503 X5502 A6000
B5600
F6003 A1
X5018 R90
X5501
K34
X6014 E22 F5004 A6002 X6015
A15 A1
X5037
W39 R92 R93 K19
W6003 X6016
X5005
W5
F46
F45 F6003 W5 F6001
F5004
X6016 R5601 R11
TX1234455 Engine Interface Harness (W5) Component Location (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
9015-10-157
160GLC Excavator 042318 PN=467
JL58967,0000733 -19-22FEB17-3/4
System Diagrams
TM13345X19 (23APR18)
9015-10-158
160GLC Excavator 042318 PN=468
System Diagrams
A1—Engine Control Unit (ECU) F6003—JDLink™ Switched A15— Flex Power Controller Power 7.5 A Fuse (FPC) K19— Battery Relay A6000—Modular Telematics K34— Starter Relay Gateway (MTG) M1—Starter Motor Controller R11— Interface CAN Resistor 2 A6001—GPS/Cellular Antenna R90— Diesel Particulate Filter A6002—Satellite (SAT) Module (DPF) Regen Active Lamp Control Unit (if equipped) Resistor A6003—Satellite (SAT) Antenna R92— Service ADVISOR™ B5600—Water-in-Fuel (WIF) Remote (SAR) Switch Sensor Accept LED Resistor E22— Battery Disconnect R93— Service ADVISOR™ Indicator Light Remote (SAR) Switch F45— Starter In-Line 30 A Fuse Decline LED Resistor F46— Engine Light In-Line 7.5 A R5601—CAN 0 Termination Fuse Resistor F5004—Flex Power Controller V44— Starter Relay Diode (FPC) In-Line 10 A Fuse W5—Engine Interface Harness F6001—JDLink™ Unswitched W39—Engine Interface Harness Power 7.5 A Fuse Ground
W6003—Satellite (SAT) Harness X5501—Engine Control Unit X175— Machine Harness-to(ECU) Connector 1 Engine Interface Harness X5502—Engine Control Unit Connector 1 (ECU) Connector 2 X5005—Fan Harness Connector X5503—Engine Control Unit X5015—Engine Interface (ECU) Connector 3 Harness-to-Engine X6014—Modular Telematics Harness Connector 1 Gateway (MTG) Control X5016—Engine Interface Unit 48-Pin Connector Harness-to-Engine X6015—Satellite (SAT) Module Harness Connector 2 Control Unit 48-Pin X5018—Machine Harness-toConnector Engine Interface Harness X6016—Engine Interface Connector 2 Harness-to-Satellite X5037—Engine Interface (SAT) Harness Connector Harness-to-Diesel Y5501—Fuel Transfer Pump Exhaust Fluid (DEF) Harness Connector 1 X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector X5068—Engine Interface Harness-to-Engine Harness Connector 3
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company JL58967,0000733 -19-22FEB17-4/4
TM13345X19 (23APR18)
9015-10-159
160GLC Excavator 042318 PN=469
System Diagrams
TM13345X19 (23APR18)
9015-10-160
160GLC Excavator 042318 PN=470
System Diagrams
Engine Interface Harness (W5) Wiring Diagram Engine Interface Harness (W5) Wiring Diagram (S.N. —056599) TX1222917 —UN—08SEP16
TX1222917
END #1 X5018 A15 X168 X6014 R11 X5018 A15 X167 X6014 R11 Y5501 X5502 X5502 X5501 X5501 X5501 X5018 X5503 X5503 X5502 X140 X140 X5016 X5039 X5501 X156 X5502 X5016 X5018 X5503 X5503 X5005 X5502 X5502 X5502 X5502 X5502 X5037 X5018 X5503 X5503 X5502 X5037 X5502 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5039
NUMBER 1356A 1356B 1356C 1356D 1356E 1357A 1357B 1357C 1357D 1357E 5003 5010 5014 5015 5016 5018 5022A 5022B 5022C 5023 5030A 5030B 5030C 5030D 5030E 5030F 5051 5053 5122A 5122B 5122C 5125 5126 5127 5136 5141 5146 5218 5222A 5222B 5222C 5246 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5321 5324 5329 5331
COLOR YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN ORG BLK YEL GRN BLU GRY RED RED RED ORG CLR CLR CLR BLK BLK BLK BRN ORG RED RED RED GRN BLU PUR BLU BRN BLU GRY RED RED RED BLU BRN ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY BRN YEL WHT BRN
END #2 X152 X152 X152 X168 X168 X153 X153 X153 X167 X167 X5501 X5016 X5005 X5005 X5015 X5015 X176 X176 X176 X5005 X156 X156 X140 X140 X140 X5015 X5016 X5502 X177 X177 X177 X5502 X5005 X5005 X5037 X5037 X5037 X5502 X178 X178 X178 X5016 X5502 X5037 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502
END #1 X5039 X181 X181 X5501 X195 X5501 X5501 X5501 X5501 X5501 X5015 X5016 X5501 X5501 X5501 X5501 B5600 X5502 X5502 X5501 X5502 X5501 X5501 X5502 X5015 X5068 X5068 X5068 X5068 X5068 X5068 X5015 X5502 X5502 X5502 X5501 X5501 X5501 X5502 X5502 X5502 X5016 X5005 X5502 X5016 X5039 X5501 X5502 X5501 X5501 X5039 X5039 X5501 X5016 X5005 X5501 X5015 X5005 X5501 X5068
NUMBER 5333 5410A 5410B 5410C 5410D 5415 5419 5421 5423 5425 5427 5429 5443 5445 5447 5448 5453 5455 5456 5461 5463 5465 5467 5468 5469 5491 5493 5495 5496 5498 5499 5509 5602 5604 5605 5611 5613 5614 5621 5623 5624A 5624B 5624C 5625A 5625B 5625C 5626 5628 5631 5633 5634 5636 5643A 5643B 5643C 5658A 5658B 5658C 5671 5756
COLOR ORG CLR CLR BLK BLK GRN WHT BRN ORG GRN PUR WHT YEL GRN YEL GRN ORG GRN BLU BRN ORG GRN PUR GRY WHT RED BRN GRN ORG YEL BLU WHT RED YEL GRN BRN ORG YEL BRN ORG YEL YEL YEL GRN GRN GRN BLU GRY BRN ORG YEL BLU ORG ORG ORG GRY GRY GRY BRN RED
END #2 X5502 X195 X195 X181 X5068 X5015 X5068 X5015 X5015 X5015 X5501 X5501 X5015 X5015 X5015 X5015 X5501 X5016 X5016 X5015 X5016 X5015 X5015 X5016 X5501 X5501 X5501 X5501 X5501 X5501 X5501 X5501 X5039 X5039 X5039 X5015 X5015 X5015 X5016 X5016 X143 X143 X143 X147 X147 X147 X5015 X5016 X5015 X5015 X5502 X5502 X144 X144 X144 X145 X145 X145 X5016 X5501
END #1 X5501 X5068 X5502 X5016 X5039 X5039 X5039 X5018 R90 X5503 X5501 X5501 X5501 X5501 X5501 X5015 B5600 X5503 K19 X5005 K34 M1 V44 K34 X5018 X5503 X5018 W39 X5018 X5005 X179 A15 A15 X6014 X6014 X6016 X179 X179 X179 X179 X179 M1 K34 E22 M1 X5018 X5018 X6016 X6016 X6014 X5018 A15 X174 X5503 X174 X6014 R5601 X5018 A15 X173
NUMBER 5761 5767 5783A 5783B 5783C 5785 5786 5796A 5796B 5796C 5804 5805 5817 5821 5826A 5826B 5826C 5947 B22A B22B E03A E03B E03C E13 E305 E330 E332 G01A G01B G01C G01E G01F G01G G01H G01K G01L G01M G01N G01P G01R G01S G02A G02B G02C G02D J50 J51 M01 M02 M03 M12A M12B M12C M12D M12E M12F M12G M13A M13B M13C
COLOR YEL BLK ORG ORG ORG GRN BLU BLU BLU BLU YEL GRN PUR BRN BLU BLU BLU PUR RED RED WHT WHT WHT WHT GRN WHT BRN BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK TAN TAN PUR PUR TAN YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN
Engine Interface Harness (W5) Wiring Diagram (S.N. —056599) (1 of 3) Continued on next page
TM13345X19 (23APR18)
9015-10-161
160GLC Excavator 042318 PN=471
END #2 X5068 X5501 X160 X160 X160 X5502 X5502 X169 X169 X169 X5016 X5016 Y5501 X5015 X266 X266 X266 X5018 F46 F46 X149 X149 X149 X175 X5503 E22 X5503 X150 X150 X150 X150 X150 X150 X150 X150 X150 X5503 X5503 X5503 X5503 X5503 X148 X148 X148 V44 X5503 X5503 X6014 X6014 X6016 X164 X164 X164 X174 X187 X187 X187 X165 X165 X165
END #1 X5503 X173 X6014 R5601 X5018 X5018 X5018 F5004 F6001 F5004 F6001 X6014 X6016 X190 X190 M1 F45 X5018 R90 R92 R93 A15 X5503 F6003 F6003 X5018 A15 X172 X5503 X172 X6014 R5601 X5018 R92 A15 X5018 R93 A15
NUMBER M13D M13E M13F M13G M42 M43 P04A P04B P04C P04D P04E P04F P04G P04H P04J P22A P22B P307A P307B P307C P307D P307E P307F P307G P307H R02A R02B R02C R02D R02E R02F R02G W42A W42B W42C W43A W43B W43C
COLOR GRN GRN GRN GRN PUR PUR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU
END #2 X173 X188 X188 X188 A15 A15 X163 X163 X163 X190 X183 X183 X183 A15 A15 F45 K34 X162 X162 X162 X162 X162 X162 X162 X6014 X166 X166 X166 X172 X189 X189 X189 X171 X171 X171 X170 X170 X170
SHEET 1 OF 3 JL58967,0000721 -19-11JAN17-1/10
System Diagrams
TM13345X19 (23APR18)
9015-10-162
160GLC Excavator 042318 PN=472
System Diagrams
TX1230304 —UN—09DEC16
W39 F45 M1
B
A B
B
B22A B22B
A 02 G 02D G
F46
A B
+
-
+ -
1 2
G02D E03C
X175
X148
SIDE A E03B E03C SIDE B E03A
SIDE A G02B G02C SIDE B G02A
E13
X148
X175
B22A
E13
R
SIDE A G01A G01B G01C SIDE B G01E G01F G01G G01H G01K G01L
X166
X164
SIDE A R02A SIDE B R02B R02C
SIDE A M12A SIDE B M12B M12C
M N P
R93
H J K L M N P
R02A M12A M13A G01B J50 J51 1356A
R S T U V W X
1357A 5947 5796A M43 W43A M42 W42A
X150 SIDE A W42B W42C SIDE B W42A
P307B 5796B
2
X170 X171
A
X169
X169
X170
SIDE A 5796B 5796C SIDE B 5796A
SIDE A W43B W43C SIDE B W43A
X150
X166
X164
B
02
G
A
1
X149
K34 1
S 2
1
C D
E
P307A 5022A E305 5222A 5122A E332 P04A
L
A
F
A B C D E F G
K
B
G
V U
R90
A
K19
R92
X5018
T
P307C W42B 2
P307D W43B
W
J
X171
X149 K19
X5018 H
X
R90
V44
A
A
1 2
P22A P22B
1
E03B
1 2
R92
V44
G01A
R93
F45 P22A
A
1 A
F46
W39
1
E03A
P2
2B
X143
X144
X145
X266 30
X143
X144
X145
X266
SIDE A 5624C SIDE B 5624A 5624B
SIDE A 5643C SIDE B 5643A 5643B
SIDE A 5658C SIDE B 5658A 5658B
SIDE A 5826C SIDE B 5826A 5826B
19
6
5
4
12 11 10
3
9
2
8
1
7
1 2 3 4 5 6
5023 5014 5643C 5624C 5658C 5015
7 8 9 10 11 12
1 2
5453 5826C
2
1
16
6 15
1
4
5 13 14
22
12 23
27 26
24 25
X5016 X195
2 1
X5039 8 7
28
5636 5605 5604 5030D 5331 5333
11
SIDE A 5410D SIDE B 5410A 5410B
5003 5817
1 2 3 4 5 6 7 8
Y5501 2
1
Continued on next page
9015-10-163
160GLC Excavator 042318 PN=473
9 10 11 12 13 14 15 16
5624B 5625B 5628 5246 PLUG 5051 5053 PLUG
17 18 19 20 21 22 23 24
PLUG PLUG PLUG PLUG PLUG 5429 5643B 5455
W V H
U
X J A
G F S R
E Q
K L B
M
C N
D O P
X195
5311 9 5146 17 5308 25 5218 5313 10 PLUG 18 5307 26 PLUG 5314 11 PLUG 19 5321 27 PLUG X147 5315 12 5303 20 PLUG 28 PLUG SIDE A 5317 13 5301 21 5324 29 PLUG 5625B 5318 14 5305 22 PLUG 30 PLUG 5625C 5141 15 5304 23 5329 31 PLUG SIDE B 5309 16 5306 24 5136 5625A Engine Interface Harness (W5) Wiring Diagram (S.N. —056599) (2 of 3)
X5015 29
18 17
28
SIDE A 5030F SIDE B 5030A 5030B
16 27
X156
5463 5456 5468 PLUG PLUG PLUG PLUG
X165
X162
X165
SIDE A P307A P307B P307C P307D SIDE B P307E P307F P307G
SIDE A M13A SIDE B M13B M13C
A B C D E F G H
PLUG 5491 5496 5493 5495 5410D 5498 5499
J K L M N O P Q
PLUG PLUG PLUG PLUG PLUG PLUG 5419 5761
R S T U V W X
PLUG PLUG PLUG PLUG PLUG 5756 5767
X5015 30
X156
25 26 27 28 29 30 31
X5068
X5068 T
X5037
TX1230304
TM13345X19 (23APR18)
X160
7 8 9 10 11 12
10 3
X147
Y5501 1 2
31 20 30 21 8 9 19 2 18 10 3 7 1 29 17 11 22 28 23 6 4 16 12 5 15 13 24 27 14 26 25
B5600
B5600
B22B G01C 5127 5126 5125 PLUG
6 5 4 3
12 11 10 9
X5037 X5005
5634 5625C 5783C 5786 5785 5602
21
9
C
X5005
1 2 3 4 5 6
2 7
17
5804 5805 PLUG 5783B 5010 5621 5623 5671
30
SIDE A 5783B 5783C SIDE B 5783A
X5039
8
18
29
1 2 3 4 5 6 7 8
20
50
X160
X162
X5016 31
31 20 8 21 19 9 10 2 3 22 7 11 1 23 4 6 5 12 13 15 24 14 25 26
1 2 3 4 5 6 7 8
5614 5443 5445 5631 5611 5626 5423 5447
9 10 11 12 13 14 15 16
5448 5030F 5633 5469 5427 5613 5415 5461
17 18 19 20 21 22 23 24
5425 5016 5421 5821 5826B 5658B PLUG PLUG
25 26 27 28 29 30 31
5467 PLUG 5465 5509 5018 PLUG PLUG
SHEET 2 OF 3 JL58967,0000721 -19-11JAN17-2/10
System Diagrams
TM13345X19 (23APR18)
9015-10-164
160GLC Excavator 042318 PN=474
System Diagrams
1— Continued on Sheet 3 B5600—Water-in-Fuel (WIF) Sensor F45— Starter In-Line 30 A Fuse F46— Engine Light In-Line 7.5 A Fuse K19— Battery Relay K34— Starter Relay M1—Starter Motor R90— Diesel Particulate Filter (DPF) Regen Active Lamp Resistor R92— Service ADVISOR™ Remote (SAR) Switch Accept LED Resistor
R93— Service ADVISOR™ Remote (SAR) Switch Decline LED Resistor V44— Starter Relay Diode W39—Engine Interface Harness Ground X143— 5624 YEL Splice X144— 5643 ORG Splice X145— 5658 GRY Splice X147— 5625 GRN Splice X148— G02 BLK Splice X149— E03 WHT Splice X150— G01 BLK Splice 1 X156— 5030 BLK Splice 2 X160— 5783 ORG Splice X162— P307 RED Splice X164— M12 YEL Splice 1
X5018—Machine Harness-toX165— M13 GRN Splice 1 Engine Interface Harness X166— R02 BLK Splice 1 Connector 2 X169— 5796 BLU Splice X5037—Engine Interface X170— W43 BLU Splice Harness-to-Diesel X171— W42 BLU Splice Exhaust Fluid (DEF) X175— Machine Harness-toHarness Connector 1 Engine Interface Harness X5039—Engine Interface Connector 1 Harness-to-Exhaust X195— 5410 SHIELD Splice 2 Aftertreatment Harness X266— 5826 BLU Splice Connector X5005—Fan Harness Connector X5068—Engine Interface X5015—Engine Interface Harness-to-Engine Harness-to-Engine Harness Connector 3 Harness Connector 1 Y5501—Fuel Transfer Pump X5016—Engine Interface Harness-to-Engine Harness Connector 2
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-165
JL58967,0000721 -19-11JAN17-3/10
160GLC Excavator 042318 PN=475
System Diagrams
TM13345X19 (23APR18)
9015-10-166
160GLC Excavator 042318 PN=476
System Diagrams
TX1222918 —UN—08SEP16
A15
X153
X152
X163
SIDE A 1357A SIDE B 1357B 1357C
SIDE A 1356A SIDE B 1356B 1356C
SIDE A P04A SIDE B P04B P04C
X153
X152
X163
D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
PLUG 1356B PLUG PLUG PLUG PLUG W42C PLUG PLUG M43 W43C PLUG
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4
PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
PLUG PLUG PLUG PLUG P04H P04J PLUG PLUG P307E G01F G01G PLUG
4 2 1
X5502 X190
12
1
22 32 44
23
54
43
13
33
SIDE A P04H P04J SIDE B P04D
X190
B
F5004 A B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3
F5004 A
X5502
A BC DE FG H J K L M
B
M12B PLUG PLUG PLUG M13B PLUG PLUG PLUG M42 1357B PLUG PLUG
02 R
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4
P04B P04D
5333 PLUG PLUG PLUG 5051 5634 5141 PLUG 5456 5311 5314 5317 5331 5628
15 16 17 18 19 20 21 22 23 24 25 26 27 28
5623 5636 5125 5053 5218 5321 5304 5010 5126 5625A 5306 5014 5463 5783A
29 30 31 32 33 34 35 36 37 38 39 40 41 42
5455 5127 5305 5023 PLUG 5246 5604 5624A 5468 5786 5313 5308 5318 5315
43 44 45 46 47 48 49 50 51 52 53 54
F6001
5146 5605 5621 5309 5785 5136 5329 5602 5324 5303 5307 5301
A B
P04C P04E
X6016
F6003 A B
P307G P307H
X6016 A
A
B
B
1 2
6 5
3
4
1 2 3 4 5 6
M01 M02 M03 G01L P04G PLUG
F6001
F6003
X174
X173
X172
X168
X167
X187
X188
X189
SIDE A M12C M12D SIDE B M12E
SIDE A M13C M13D SIDE B M13E
SIDE A R02C R02D SIDE B R02E
SIDE A 1356C SIDE B 1356D 1356E
SIDE A 1357C SIDE B 1357D 1357E
SIDE A M12E SIDE B M12F M12G
SIDE A M13E SIDE B M13F M13G
SIDE A R02E SIDE B R02F R02G
X174
X173
X172
X168
X167
X187
X188
X189
X183
X183 SIDE A P04E SIDE B P04F P04G
R02F
A15
X6014 A BC DE FG H J K L M 4 3
1
2 1
X176 X140 X181 SIDE A 5410A 5410B SIDE B 5410C
SIDE A 5030A 5030B 5030C 5030D SIDE B 5030E
X177 X178
X140
X179
X176
X177
X178
X179
SIDE A 5022A SIDE B 5022B 5022C
SIDE A 5122A SIDE B 5122B 5122C
SIDE A 5222A SIDE B 5222B 5222C
SIDE A G01E SIDE B G01M G01N G01P G01R G01S
X5503
X181
12
X6014
R5601
A
B
C
1
PLUG 5499 5496 5491 PLUG 5756 5423 5421 5613 5018 5465 5016 PLUG 5817 5453 5461 5631 PLUG
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
PLUG PLUG 5643A 5003 5410C 5821 5614 5467 5626 5445 5443 5448 PLUG 5671 5498 5767 5030E 5509
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
5611 5447 5469 5419 5633 5761 5495 5493 5804 5805 PLUG 5427 5826A 5658A 5415 5425 5015 5429
A B C
33 54
43
A
B
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X5501
12
1
22 32 44
23
54
43
13
33
M13D M12D PLUG PLUG E305 PLUG P307F PLUG PLUG PLUG PLUG 5022B 5122B 5122C
15 16 17 18 19 20 21 22 23 24 25 26 27 28
PLUG G01M G01S J50 J51 PLUG R02D PLUG 5222B 5222C PLUG PLUG G01R PLUG
29 30 31 32 33 34 35 36 37 38 39 40 41 42
PLUG E330 PLUG E332 PLUG PLUG 5796C PLUG PLUG 5947 PLUG PLUG PLUG PLUG
43 44 45 46 47 48 49 50 51 52 53 54
G01N G01P PLUG PLUG PLUG PLUG PLUG 5022C PLUG PLUG PLUG PLUG
Engine Interface Harness (W5) Wiring Diagram (S.N. —056599) (3 of 3) Continued on next page
9015-10-167
R11
X5503
TX1222918
TM13345X19 (23APR18)
M12G M13G R02G
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
R5601
23
E330
22 32 44
X5501
02
G
13
160GLC Excavator 042318 PN=477
R11 A B C
1356E 1357E PLUG
E22
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
M01 M02 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG G01K PLUG
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
1356D 1357D PLUG PLUG M12F M13F PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG P307H PLUG PLUG PLUG G01H P04F M03 PLUG
SHEET 3 OF 3 JL58967,0000721 -19-11JAN17-4/10
System Diagrams
TM13345X19 (23APR18)
9015-10-168
160GLC Excavator 042318 PN=478
System Diagrams
1— Continued on Sheet 2 A15— Flex Power Controller (FPC) E22— Battery Disconnect Indicator Light F5004—Flex Power Controller (FPC) In-Line 10 A Fuse F6001—JDLink™ Unswitched Power 7.5 A Fuse F6003—JDLink™ Switched Power 7.5 A Fuse
R11— Interface CAN Resistor 2 R5601—CAN 0 Termination Resistor X140— 5030 BLK Splice 1 X152— 1356 YEL Splice 1 X153— 1357 GRN Splice 1 X163— P04 RED Splice 1 X167— 1357 GRN Splice 2 X168— 1356 YEL Splice 2 X172— R02 BLK Splice 2 X173— M13 GRN Splice 2 X174— M12 YEL Splice 2
X176— 5022 RED Splice X177— 5122 RED Splice X178— 5222 RED Splice X179— G01 BLK Splice 2 X181— 5410 SHIELD Splice 1 X183— P04 RED Splice 2 X187— M12 YEL Splice 3 X188— M13 GRN Splice 3 X189— R02 BLK Splice 3 X190— P04 RED Splice 3 X5501—Engine Control Unit (ECU) Connector 1
X5502—Engine Control Unit (ECU) Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector
JDLink is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-169
JL58967,0000721 -19-11JAN17-5/10
160GLC Excavator 042318 PN=479
System Diagrams
TM13345X19 (23APR18)
9015-10-170
160GLC Excavator 042318 PN=480
System Diagrams
Engine Interface Harness (W5) Wiring Diagram (S.N. 056600— ) TX1230666 —UN—17JAN17
END #1 X5018 A15 X152 X168 X168 X5018 A15 X153 X167 X167 Y5501 X5502 X5502 X5501 X5501 X5501 X5018 X176 X176 X5502 X140 X140 X5016 X5501 X156 X5502 X5016 X5018 X177 X177 X5005 X5502 X5502 X5502 X5018 X178 X178 X5502 X5037 X5502 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5039 X5039 X181 X181 X5501
NUMBER 1356A 1356B 1356C 1356D 1356E 1357A 1357B 1357C 1357D 1357E 5003 5010 5014 5015 5016 5018 5022A 5022B 5022C 5023 5030A 5030B 5030C 5030E 5030F 5051 5053 5122A 5122B 5122C 5125 5126 5141 5146 5222A 5222B 5222C 5246 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5321 5324 5329 5331 5333 5410A 5410B 5410C
COLOR YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN ORG BLK YEL GRN BLU GRY RED RED RED ORG CLR CLR CLR BLK BLK BRN ORG RED RED RED GRN BLU BRN BLU RED RED RED BLU BRN ORG YEL GRN BLU VLT GRY WHT BRN ORG YEL GRN VLT GRY BRN YEL WHT BRN ORG CLR CLR BLK
END #2 X152 X152 X168 X6014 R11 X153 X153 X167 X6014 R11 X5501 X5016 X5005 X5005 X5015 X5015 X176 X5503 X5503 X5005 X156 X156 X140 X140 X5015 X5016 X5502 X177 X5503 X5503 X5502 X5005 X5037 X5037 X178 X5503 X5503 X5016 X5502 X5037 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X5502 X195 X195 X181
END #1 X195 X5501 X5501 X5501 X5501 X5501 X5015 X5016 X5501 X5501 X5501 X5501 B5600 X5502 X5502 X5501 X5502 X5501 X5501 X5502 X5015 X5068 X5068 X5068 X5068 X5068 X5068 X5015 X5501 X5501 X5501 X5502 X5502 X5502 X5016 X5005 X5502 X147 X147 X5037 X5501 X5502 X5501 X5501 X5039 X5039 X5501 X5502 X5501 X5015 X5005 X5501 X5068 X5501 X5068 X5502 X5016 X5039 X5039 X5039
NUMBER 5410D 5415 5419 5421 5423 5425 5427 5429 5443 5445 5447 5448 5453 5455 5456 5461 5463 5465 5467 5468 5469 5491 5493 5495 5496 5498 5499 5509 5611 5613 5614 5621 5623 5624A 5624B 5624C 5625A 5625B 5625C 5625D 5626 5628 5631 5633 5634 5636 5646 5647 5658A 5658B 5658C 5671 5756 5761 5767 5783A 5783B 5783C 5785 5786
COLOR BLK GRN WHT BRN ORG GRN VLT WHT YEL GRN YEL GRN ORG GRN BLU BRN ORG GRN VLT GRY WHT RED BRN GRN ORG YEL BLU WHT BRN ORG YEL BRN ORG YEL YEL YEL GRN GRN GRN GRN BLU GRY BRN ORG YEL BLU BLK VLT GRY GRY GRY BRN RED YEL BLK ORG ORG ORG GRN BLU
END #2 X5068 X5015 X5068 X5015 X5015 X5015 X5501 X5501 X5015 X5015 X5015 X5015 X5501 X5016 X5016 X5015 X5016 X5015 X5015 X5016 X5501 X5501 X5501 X5501 X5501 X5501 X5501 X5501 X5015 X5015 X5015 X5016 X5016 X143 X143 X143 X147 X5016 X5039 X147 X5015 X5016 X5015 X5015 X5502 X5502 X5016 X5005 X145 X145 X145 X5016 X5501 X5068 X5501 X160 X160 X160 X5502 X5502
END #1 X5018 R90 X5503 X5501 X5501 X5501 X5501 X5501 X5015 B5600 X5503 K19 X5005 K34 M1 V44 K34 X5018 X5503 X5018 W39 X5018 X5005 X150 A15 A15 X150 X150 X150 X179 X179 X179 X179 X179 M1 K34 E22 M1 X5018 X5018 A15 X6016 X6016 X6014 X5018 A15 X174 X5503 X187 X187 X187 X5018 A15 X173 X5503 X173 X188 X188 X5018 X5018
NUMBER 5796A 5796B 5796C 5804 5805 5817 5821 5826A 5826B 5826C 5947 B022A B022B E003A E003B E003C E013 E305 E330 E332 G001A G001B G001C G001E G001F G001G G001H G001K G001L G001M G001N G001P G001R G001S G002A G002B G002C G002D J050 J051 L055 M001 M002 M003 M012A M012B M012C M012D M012E M012F M012G M013A M013B M013C M013D M013E M013F M013G M042 M043
COLOR BLU BLU BLU YEL GRN VLT BRN BLU BLU BLU VLT RED RED WHT WHT WHT WHT GRN WHT BRN BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK TAN TAN BRN VLT VLT TAN YEL YEL YEL YEL YEL YEL YEL GRN GRN GRN GRN GRN GRN GRN VLT VLT
END #1 X5018 X163 X163 F5004 F6001 X183 X6016 X190 X190 K19 F45 A15 X5018 R90 R92 R93 A15 X162 X162 X6014 X5018 A15 X166 X5503 X172 X189 X189 X5018 R92 A15 X5018 R93 A15
NUMBER P004A P004B P004C P004D P004E P004F P004G P004H P004J P022A P022B P023 P307A P307B P307C P307D P307E P307F P307G P307H R002A R002B R002C R002D R002E R002F R002G W042A W042B W042C W043A W043B W043C
COLOR RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU
END #2 X163 F5004 F6001 X190 X183 X6014 X183 A15 A15 F45 K34 X5005 X162 X162 X162 X162 X162 X5503 F6003 F6003 X166 X166 X172 X172 X189 X6014 R5601 X171 X171 X171 X170 X170 X170
SHEET 1 OF 3
TX1230666 Engine Interface Harness (W5) Wiring Diagram (S.N. 056600— ) (1 of 3) Continued on next page
TM13345X19 (23APR18)
END #2 X169 X169 X169 X5016 X5016 Y5501 X5015 X266 X266 X266 X5018 F46 F46 X149 X149 X149 X175 X5503 E22 X5503 X150 X150 X150 X179 X150 X150 X6014 X6014 X6016 X5503 X5503 X5503 X5503 X5503 X148 X148 X148 V44 X5503 X5503 X5005 X6014 X6014 X6016 X164 X164 X164 X174 X174 X6014 R5601 X165 X165 X165 X173 X188 X6014 R5601 A15 A15
9015-10-171
160GLC Excavator 042318 PN=481
JL58967,0000721 -19-11JAN17-6/10
System Diagrams
TM13345X19 (23APR18)
9015-10-172
160GLC Excavator 042318 PN=482
System Diagrams
TX1230667 —UN—12JAN17
W39
W39 1
G001A
X5018
R93 F45 A
A B
B
P022A P022B
1 2
2A 00 D G 002 G
M1
F45
K19
E003B
+
-
+ -
2A P02
B022A
P022B
X175
X148
E0
X175
13
A
E013
S
1 2
G002D E003C
X149
X148
SIDE A E003B E003C SIDE B E003A
SIDE A G002B G002C SIDE B G002A
X166
X164
SIDE A R002A SIDE B R002B R002C
SIDE A M012A SIDE B M012B M012C
M N P
R93
H J K L M N P
R002A M012A M013A G001B J050 J051 1356A
R S T U V W X
1357A 5947 5796A M043 W043A M042 W042A
X150 SIDE A W042B W042C SIDE B W042A
P307B 5796B
R90 1
R
SIDE A G001A G001B G001C SIDE B G001E G001F G001G G001H G001K G001L
C D
E
2
1
L
A
F
P307A 5022A E305 5222A 5122A E332 P004A
K
B
G
V U
A B C D E F G
J
X171
X149 A
R92
X5018
R90
V44
A
2
P307D W043B
W
T
P307C W042B 1
V44
K34
1 2
R92
H
X
2
X170 X171
A
X169
X169
X170
SIDE A 5796B 5796C SIDE B 5796A
SIDE A W043B W043C SIDE B W043A
X150
X166
X164 1
G002B
X225
X143
X145
X266 31 30
X143
X145
X266
SIDE A 5602C SIDE B 5602A 5602B
SIDE A 5624C SIDE B 5624A 5624B
SIDE A 5658C SIDE B 5658A 5658B
SIDE A 5826C SIDE B 5826A 5826B
6
5
4
12 11 10
3
9
2
8
A B
X160 B022A B022B
SIDE A 5783B 5783C SIDE B 5783A
1
7
1 2 3 4 5 6
5023 5014 5647 5624C 5658C 5015
7 8 9 10 11 12
1 2
5453 5826C
2
1
X5039
X160
16
6 15
1
4
5 13 14
11
22
12 23
27 26
24 25
X5016 X195
2 1
8 7
28
5636 5605B 5604B PLUG 5331 5333
10 3
SIDE A 5410D SIDE B 5410A 5410B
5003 5817
1 2 3 4 5 6 7 8
Y5501 2
1
Continued on next page
9015-10-173
160GLC Excavator 042318 PN=483
9 10 11 12 13 14 15 16
5624B 5625B 5628 5246 PLUG 5051 5053 PLUG
17 18 19 20 21 22 23 24
PLUG PLUG PLUG PLUG PLUG 5429 5646 5455
W V H
U
X J A
G F S R
E Q
K L B
M
C N
D O P
X195
5311 9 5146 17 5308 25 PLUG X147 5313 10 PLUG 18 5307 26 5602C SIDE A 5314 11 PLUG 19 PLUG 27 5625D 5625B 5315 12 5303 20 PLUG 28 5604A 5625C 5317 13 5301 21 5321 29 5605A SIDE B 5318 14 5305 22 5324 30 5604B 5625A 5141 15 5304 23 PLUG 31 5605B 5625D 5309 16 5306 24 PLUG Engine Interface Harness (W5) Wiring Diagram (S.N. 056600— ) (2 of 3)
X5015 29
18 17
28
SIDE A 5030F SIDE B 5030A 5030B
16 27
X156
5463 5456 5468 PLUG PLUG PLUG PLUG
X165
X162
X165
SIDE A P307A P307B P307C P307D SIDE B P307E P307F P307G
SIDE A M013A SIDE B M013B M013C
A B C D E F G H
PLUG 5491 5496 5493 5495 5410D 5498 5499
J K L M N O P Q
PLUG PLUG PLUG PLUG PLUG PLUG 5419 5761
R S T U V W X
PLUG PLUG PLUG PLUG PLUG 5756 5767
X5015 30
X156
25 26 27 28 29 30 31
X5068
X5068 T
X5037
TX1230667
TM13345X19 (23APR18)
6 5 4 3
7 8 9 10 11 12
21
9
X147
Y5501 1 2
31 20 30 21 8 9 19 2 18 10 3 7 1 29 17 11 22 28 23 6 4 16 12 5 15 13 24 27 14 26 25
B5600
B5600
5125 5126 P023 L055 B022B G001C
5634 5625C 5783C 5786 5785 5602B
12 11 10 9
X5037 X5005
1 2 3 4 5 6
2 7
17
C
X5005
B
X5039
8
5804 5805 PLUG 5783B 5010 5621 5623 5671
30
F46 A
19 18
29
1 2 3 4 5 6 7 8
20
50
F46
X225
X162
X5016
E0
03
A
A
31 20 8 21 19 9 10 2 3 22 7 11 1 23 4 6 5 12 13 15 24 14 25 26
1 2 3 4 5 6 7 8
5614 5443 5445 5631 5611 5626 5423 5447
9 10 11 12 13 14 15 16
5448 5030F 5633 5469 5427 5613 5415 5461
17 18 19 20 21 22 23 24
5425 5016 5421 5821 5826B 5658B PLUG PLUG
25 26 27 28 29 30 31
5467 PLUG 5465 5509 5018 PLUG PLUG
SHEET 2 OF 3 JL58967,0000721 -19-11JAN17-7/10
System Diagrams
TM13345X19 (23APR18)
9015-10-174
160GLC Excavator 042318 PN=484
System Diagrams
1— Continued on Sheet 3 B5600—Water-in-Fuel (WIF) Sensor F45— Starter In-Line 30 A Fuse F46— Engine Light In-Line 7.5 A Fuse K19— Battery Relay K34— Starter Relay M1—Starter Motor R90— Diesel Particulate Filter (DPF) Regen Active Lamp Resistor R92— Service ADVISOR™ Remote (SAR) Switch Accept LED Resistor
R93— Service ADVISOR™ Remote (SAR) Switch Decline LED Resistor V44— Starter Relay Diode W39—Engine Interface Harness Ground X143— 5624 YEL Splice X145— 5658 GRY Splice X147— 5625 GRN Splice X148— G002 BLK Splice X149— E003 WHT Splice X150— G001 BLK Splice 1 X156— 5030 BLK Splice 2 X160— 5783 ORG Splice X162— P307 RED Splice X164— M012 YEL Splice 1 X165— M013 GRN Splice 1
X5018—Machine Harness-toX166— R002 BLK Splice 1 Engine Interface Harness X169— 5796 BLU Splice Connector 2 X170— W043 BLU Splice X5037—Engine Interface X171— W042 BLU Splice Harness-to-Diesel X175— Machine Harness-toExhaust Fluid (DEF) Engine Interface Harness Harness Connector 1 Connector 1 X5039—Engine Interface X195— 5410 SHIELD Splice 2 Harness-to-Exhaust X225— 5602 RED Splice Aftertreatment Harness X266— 5826 BLU Splice Connector X5005—Fan Harness Connector X5068—Engine Interface X5015—Engine Interface Harness-to-Engine Harness-to-Engine Harness Connector 3 Harness Connector 1 Y5501—Fuel Transfer Pump X5016—Engine Interface Harness-to-Engine Harness Connector 2
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-10-175
JL58967,0000721 -19-11JAN17-8/10
160GLC Excavator 042318 PN=485
System Diagrams
TM13345X19 (23APR18)
9015-10-176
160GLC Excavator 042318 PN=486
System Diagrams
TX1230668 —UN—17JAN17
A15 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
X153
X152
X163
SIDE A 1357A SIDE B 1357B 1357C
SIDE A 1356A SIDE B 1356B 1356C
SIDE A P004A SIDE B P004B P004C
X153
X152
X163
P023 1356B PLUG PLUG PLUG PLUG W042C PLUG PLUG M043 W043C PLUG
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4
PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
PLUG PLUG PLUG L055 P004H P004J PLUG PLUG P307E G001F G001G PLUG
4 2 1
X5502 X190
12
1
22 32 44
23
54
43
13
33
SIDE A P004H P004J SIDE B P004D
X190
B
F5004 A B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3
F5004 A
X5502
A BC DE FG H J K L M
2B
M012B PLUG PLUG PLUG M013B PLUG PLUG PLUG M042 1357B PLUG PLUG
00 R
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4
P004B P004D
5333 PLUG PLUG PLUG 5051 5634 5141 PLUG 5456 5311 5314 5317 5331 5628
15 16 17 18 19 20 21 22 23 24 25 26 27 28
5623 5636 5125 5053 PLUG 5321 5304 5010 5126 5625A 5306 5014 5463 5783A
29 30 31 32 33 34 35 36 37 38 39 40 41 42
5455 PLUG 5305 5023 5647 5246 5604A 5624A 5468 5786 5313 5308 5318 5315
43 44 45 46 47 48 49 50 51 52 53 54
5146 5605A 5621 5309 5785 PLUG PLUG 5602A 5324 5303 5307 5301
F6003 A B
F6001 A B
P307G P307H
X6016
P004C P004E
X6016 A
A
B
B
1 2
6 5
3
4
1 2 3 4 5 6
M001 M002 M003 G001L P004G PLUG
F6003
F6001
X174
X173
X172
X168
X167
X187
X188
X189
SIDE A M012C M012D SIDE B M012E
SIDE A M013C M013D SIDE B M013E
SIDE A R002C R002D SIDE B R002E
SIDE A 1356C SIDE B 1356D 1356E
SIDE A 1357C SIDE B 1357D 1357E
SIDE A M012E SIDE B M012F M012G
SIDE A M013E SIDE B M013F M013G
SIDE A R002E SIDE B R002F R002G
X174
X173
X172
X168
X167
X187
X188
X189
X183
X183 SIDE A P004E SIDE B P004F P004G
R002F
A15
X6014 A BC DE FG H J K L M 4 3
1
2 1
X176 X140 X181 SIDE A 5410A 5410B SIDE B 5410C
SIDE A 5030A 5030B 5030C SIDE B 5030E
X177 X178
X140
X179
X176
X177
X178
X179
SIDE A 5022A SIDE B 5022B 5022C
SIDE A 5122A SIDE B 5122B 5122C
SIDE A 5222A SIDE B 5222B 5222C
SIDE A G001E SIDE B G001M G001N G001P G001R G001S
X5503
X181
12
X6014
R5601
A
B
C
1
PLUG 5499 5496 5491 PLUG 5756 5423 5421 5613 5018 5465 5016 PLUG 5817 5453 5461 5631 PLUG
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
PLUG PLUG 5646 5003 5410C 5821 5614 5467 5626 5445 5443 5448 PLUG 5671 5498 5767 5030E 5509
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
5611 5447 5469 5419 5633 5761 5495 5493 5804 5805 PLUG 5427 5826A 5658A 5415 5425 5015 5429
A B C
33 54
43
A
B
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X5501
12
1
22 32 44
23
54
43
13
33
M013D M012D PLUG PLUG E305 PLUG P307F PLUG PLUG PLUG PLUG 5022B 5122B 5122C
15 16 17 18 19 20 21 22 23 24 25 26 27 28
PLUG G001M G001S J050 J051 PLUG R002D PLUG 5222B 5222C PLUG PLUG G001R PLUG
29 30 31 32 33 34 35 36 37 38 39 40 41 42
PLUG E330 PLUG E332 PLUG PLUG 5796C PLUG PLUG 5947 PLUG PLUG PLUG PLUG
43 44 45 46 47 48 49 50 51 52 53 54
G001N G001P PLUG PLUG PLUG PLUG PLUG 5022C PLUG PLUG PLUG PLUG
Engine Interface Harness (W5) Wiring Diagram (S.N. 056600— ) (3 of 3) Continued on next page
9015-10-177
R11
X5503
TX1230668
TM13345X19 (23APR18)
M012G M013G R002G
2C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
R5601
23
E330
22 32 44
X5501
00
G
13
160GLC Excavator 042318 PN=487
R11 A B C
1356E 1357E PLUG
E22
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4
M001 M002 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG G001K PLUG
G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
1356D 1357D PLUG PLUG M012F M013F PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG P307H PLUG PLUG PLUG G001H P004F M003 PLUG
SHEET 3 OF 3 JL58967,0000721 -19-11JAN17-9/10
System Diagrams
TM13345X19 (23APR18)
9015-10-178
160GLC Excavator 042318 PN=488
System Diagrams
1— Continued on Sheet 2 A15— Flex Power Controller (FPC) E22— Battery Disconnect Indicator Light F5004—Flex Power Controller (FPC) In-Line 10 A Fuse F6001—JDLink™ Unswitched Power 7.5 A Fuse F6003—JDLink™ Switched Power 7.5 A Fuse
R11— Interface CAN Resistor 2 R5601—CAN 0 Termination Resistor X140— 5030 BLK Splice 1 X152— 1356 YEL Splice 1 X153— 1357 GRN Splice 1 X163— P004 RED Splice 1 X167— 1357 GRN Splice 2 X168— 1356 YEL Splice 2 X172— R002 BLK Splice 2 X173— M013 GRN Splice 2 X174— M012 YEL Splice 2
X176— 5022 RED Splice X177— 5122 RED Splice X178— 5222 RED Splice X179— G001 BLK Splice 2 X181— 5410 SHIELD Splice 1 X183— P004 RED Splice 2 X187— M012 YEL Splice 3 X188— M013 GRN Splice 3 X189— R002 BLK Splice 3 X190— P004 RED Splice 3 X5501—Engine Control Unit (ECU) Connector 1
X5502—Engine Control Unit (ECU) Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector
JDLink is a trademark of Deere & Company JL58967,0000721 -19-11JAN17-10/10
TM13345X19 (23APR18)
9015-10-179
160GLC Excavator 042318 PN=489
System Diagrams
TM13345X19 (23APR18)
9015-10-180
160GLC Excavator 042318 PN=490
System Diagrams
Front Engine Harness (W7) Component Location TX1201575 —UN—26OCT15
B5208 B5500 B5113
Y5002 Y5024
Y5002 B5302
X5141
B5302
X5141
X5040
W7
W7 B5301 X5040
TX1201575 Front Engine Harness (W7) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-181
160GLC Excavator 042318 PN=491
JA92389,000016A -19-18SEP15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-182
160GLC Excavator 042318 PN=492
System Diagrams B5113—Fuel Rail Pressure Sensor B5208—Engine Coolant Temperature Sensor B5301—Crankshaft Position Sensor
X5141—Engine Harness-to-Front B5302—Camshaft Position Engine Harness Sensor Connector 2 B5500—Intake Air Sensor Y5002—Suction Control Valve W7—Front Engine Harness (SCV) X5040—Engine Harness-to-Front Y5024—Fuel Rail Pressure Relief Engine Harness Valve (PRV) Connector 1 JA92389,000016A -19-18SEP15-2/2
TM13345X19 (23APR18)
9015-10-183
160GLC Excavator 042318 PN=493
System Diagrams
TM13345X19 (23APR18)
9015-10-184
160GLC Excavator 042318 PN=494
System Diagrams
Front Engine Harness (W7) Wiring Diagram TX1199586 —UN—16OCT15
END #1 X5040 X243 B5302 X243 B5301 X5040 X5141 X5141 X5040 X5040 B5301 B5301 X5141 X5040 X5040 B5500 X5040 X5040 B5500 X5141 X257 X257 X263 X5141 X258 X258 X264 X5141
NUMBER 5030A 5030B 5030C 5030D 5030E 5415 5419 5424 5443 5445 5447 5448 5461 5611 5613 5628 5756 5767 5783 5804A 5804B 5804C 5804CA 5805A 5805B 5805C 5805CA 5826
X5040
COLOR BLK BLK CLR BLK CLR DK GRN WHT YEL ORG DK GRN PUR GRY BRN BRN ORG GRY LT BLU PUR ORG YEL YEL YEL CLR DK GRN DK GRN DK GRN CLR LT BLU
END #2 X243 X244 X244 X245 X245 B5113 Y5002 Y5002 B5302 B5302 X5040 X5040 B5208 B5113 B5113 X5141 Y5024 Y5024 X5141 X257 B5500 X263 R5603 X258 B5500 X264 R5603 B5208
B5500 4
3
2
1 2 3 4
1
B5500
5783 5628 5804B 5805B
B5301
B5301 2
5030E
1 2
1
5447 5448
Y5002
X5141 1 2
3 4
5 6
7 8
X5141
1 2 3 4 5 6 7 8
5804A 5783 5419 5826 5805A 5628 5424 5461
2
1
Y5002 1 2
5424 5419
Y5024 Y5024 2
X244
X245
SIDE A 5030B SIDE B 5030C
SIDE A 5030D SIDE B 5030E
X244
X245
X243
X257
X258
SIDE A 5030B 5030D SIDE B 5030A
SIDE A 5804B 5804C SIDE B 5804A
SIDE A 5805B 5805C SIDE B 5805A
X243
X257
X258
X263
1 2
5756 5767
X264
5804C 5804CA
X263
1
5805C 5805CA
B5208
X264
1 2 3 4 5 6 7 8 9 10 11 12
2
1 2 3 4 5 6
5030A 5448 5447 5443 5445 PLUG
B5208
R5603
X5040 7 8 9 10 11 12
1
1 2
5613 5611 5415 5756 5767 PLUG
5461 5826
B5113 C 30
50
B5302 3
B5302 2
1
1 2
5443 5445
TX1199586 Front Engine Harness (W7) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
9015-10-185
160GLC Excavator 042318 PN=495
2
1
B5113 1 2 3
5611 5415 5613
JA92389,0000161 -19-23SEP15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-186
160GLC Excavator 042318 PN=496
System Diagrams B5113—Fuel Rail Pressure Sensor B5208—Engine Coolant Temperature Sensor B5301—Crankshaft Position Sensor B5302—Camshaft Position Sensor B5500—Intake Air Sensor
R5603—Engine CAN Termination Resistor X243— 5030 BLK Splice 1 X244— 5030 BLK Splice 2 X245— 5030 BLK Splice 3 X257— 5804 YEL Splice 1 X258— 5805 DK GRN Splice 1
X263— 5804 YEL Splice 2 Y5002—Suction Control Valve X264— 5805 DK GRN Splice 2 (SCV) X5040—Engine Harness-to-Front Y5024—Fuel Rail Pressure Relief Engine Harness Valve (PRV) Connector 1 X5141—Engine Harness-to-Front Engine Harness Connector 2 JA92389,0000161 -19-23SEP15-2/2
TM13345X19 (23APR18)
9015-10-187
160GLC Excavator 042318 PN=497
System Diagrams
TM13345X19 (23APR18)
9015-10-188
160GLC Excavator 042318 PN=498
System Diagrams
Pump Harness (W8) Component Location TX1237887 —UN—25APR17
B38 Y20
B38
B36
Y20 Y21 Y26 Y21
B37
B35 W8 B37 W8 W2
X40 B35
B40
TX1237887 Pump Harness (W8) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-189
160GLC Excavator 042318 PN=499
JA92389,0000168 -19-26APR17-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-190
160GLC Excavator 042318 PN=500
System Diagrams B35— Pump 1 Delivery Pressure Sensor (marked PP1) B36— Pump 1 Control Pressure Sensor (marked PC1) B37— Pump 2 Delivery Pressure Sensor (marked PP2)
B38— Pump 2 Control Pressure X40— Pump Harness-to-Machine Y26— Pump 1 Flow Rate Limit Harness Connector Solenoid (marked SA) Sensor (marked PC2) B40— Hydraulic Oil Temperature Y20— Pump 2 Flow Rate Limit Solenoid (marked SB) Sensor Y21— Torque Control Solenoid W2—Machine Harness (marked ST) W8—Pump Harness JA92389,0000168 -19-26APR17-2/2
TM13345X19 (23APR18)
9015-10-191
160GLC Excavator 042318 PN=501
System Diagrams
TM13345X19 (23APR18)
9015-10-192
160GLC Excavator 042318 PN=502
System Diagrams
Pump Harness (W8) Wiring Diagram TX1198874 —UN—04AUG15
END #2 (1099) (1099) (1099) Y20 Y26 Y21 X40 X40 X40 X40 B36 B38 X40 X40 B35 B36 B38 B37 X40 X40
END #1 B36 B37 B38 X40 X40 X40 B35 Y21 Y26 Y20 X40 X40 B37 B35 X40 (1267) (1267) (1267) B40 B40
Y20 Y21
Y21 1 2
(1102) (1080)
BRN PNK/WHT
X40 X40
1
2
1102
1080
1
2
1232
1075
Y20 1 2
(1232) (1075)
1 2
(1106) (1078)
LT GRN YEL
X40 X40
B38 PC2
X40
1075
B35 1
3
1099 1265 1267
B36
2
1367 1368
5
1078
B35 1 2 3
(1099) (1265) (1267)
BLK VLT RED
B37
1301
1247
1066
1
2
3
B38
X40 X40 X40
1 2 3
(1301) (1247) (1066)
RED YEL BLK
(1267) X40 (1099)
PP1
B40
1290
1233
1064
1
2
3
PC1
B36 4
1232 1102
1106
X40 X40
1
1
2
SA
BLU BLK
1
2 PP
B40 (1367) (1368)
X40 X40
Y26
Y26
1 2
GRY BLU
SB
COLOR BLK BLK BLK BLU YEL PNK/WHT BLK BRN LT GRN GRY GRY YEL ORG VLT RED RED RED RED BLU BLK
ST
NUMBER 1064 1065 1066 1075 1078 1080 1099 1102 1106 1232 1233 1247 1262 1265 1267 1290 1301 1302 1367 1368
1 2 3
1106 1367
1080 1078
1368
1262
1267 16
(1290) (1233) (1064)
RED GRY BLK
(1267) X40 (1099)
8
9 13 1265
1233 1247 17
1099 20
X40 1 2 3 4 5 6 7 8 9 10
(1232) (1102) (1106) (1367) (1075) (1080) (1078) (1368) PLUG PLUG
GRY BRN LT GRN BLU BLU PNK/WHT YEL BLK
Y20 Y21 Y26 B40 Y20 Y21 Y26 B40
11 12 13 14 15 16 17 18 19 20
PLUG PLUG (1265) (1262) PLUG (1267) (1233) (1247) PLUG (1099)
1
VLT ORG
B35 B37
RED GRY YEL
B35 B36 B38
BLK
B35
3
1065 1262 1302
B37 1 2 3
(1065) (1262) (1302)
BLK ORG RED
(1099) X40 (1267)
TX1198874 Pump Harness (W8) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
9015-10-193
160GLC Excavator 042318 PN=503
JA92389,0000153 -19-06AUG15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-194
160GLC Excavator 042318 PN=504
System Diagrams B35— Pump 1 Delivery Pressure B38— Pump 2 Control Pressure Y20— Pump 2 Flow Rate Limit Sensor (marked PP1) Solenoid (marked SB) Sensor (marked PC2) B36— Pump 1 Control Pressure B40— Hydraulic Oil Temperature Y21— Torque Control Solenoid Sensor (marked PC1) (marked ST) Sensor B37— Pump 2 Delivery Pressure X40— Pump Harness-to-Machine Y26— Pump 1 Flow Rate Limit Sensor (marked PP2) Solenoid (marked SA) Harness Connector JA92389,0000153 -19-06AUG15-2/2
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location See Cab Harness (W1) Component Location. (Group 9015-10.) JN86345,00002DA -19-08SEP14-1/1
NUMBER 876 877 1360 1363
X37 1 (1360) 2 (1363) (877) 3 (876) 4 5 — 6 —
COLOR ORG/BLK ORG/GRN RED/BLK BLK
END #1 END #2 X37 S16 X37 S16 X37 S16 X37 S16
RED/BLK BLK ORG/GRN ORG/BLK
S16 S16 S16 S16
2
X37
S16 1 (1360) 2 — 3 — — 4 5 (876) — 6 — 7 (1363) 8 9 (877) — 10
6
X37
ORG/BLK
X37
BLK ORG/GRN
X37 X37
4
1
1
1363
RED/BLK
1360
1360
876 877
876
3
5
TX1187554
S16
1363 877
10
TX1187554 —UN—12MAR15
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram
Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram S16— Exhaust Filter Parked Cleaning Switch
X37— Cab Harness-to-Exhaust Filter Switch Harness Connector DP27668,00009E8 -19-10MAR15-1/1
Service ADVISOR™ Remote (SAR) Switch Harness (W10) Component Location See Cab Harness (W1) Component Location. (Group 9015.) CW0833,0000AA9 -19-27JAN15-1/1
TM13345X19 (23APR18)
9015-10-195
160GLC Excavator 042318 PN=505
System Diagrams
Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram END #1 S18 S18 S18 S18 S18 S18 S18
END #2 X74 (1) (1) X74 X74 X74 X74
1 2 3 4 5 6 7 8 9 10
X74 1 2 3 4 5 6
(1) (4) (5) (6) — (7)
2
X74 4 7
RED/BLK WHT/GRN YEL/BLK BLK/YEL
S18 S18 S18 S18
GRN/WHT
S18
S18
1
6
RED/BLK YEL/BLK BLK/YEL WHT/GRN GRN/WHT
(1) X74 X74 X74 X74
RED/BLK
X74
RED/BLK
(1)
3
ADV_SW
5
S18
1
1
6
(3) (5) (6) (4) (7) — (1) — — (2)
7
3
5
TX1174424
5
4 6
1
4 2 10
TX1174424 —UN—22OCT14
COLOR RED/BLK RED/BLK RED/BLK WHT/GRN YEL/BLK BLK/YEL GRN/WHT
NUMBER 1 2 3 4 5 6 7
Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram S18— Service ADVISOR™ Remote (SAR) Switch
X74— Cab Harness-to-Service ADVISOR™ Remote (SAR) Switch Harness (marked ADV-SW)
Service ADVISOR is a trademark of Deere & Company DP27668,00009D4 -19-27JAN15-1/1
TM13345X19 (23APR18)
9015-10-196
160GLC Excavator 042318 PN=506
System Diagrams
Pilot Shutoff Switch Harness (W11) Component Location
V20
S3 W11
X65
TX1087180 —UN—24FEB11
S4
TX1087180 Pilot Shutoff Switch Harness (W11) Component Location S3— Pilot Shutoff Switch 1 S4— Pilot Shutoff Switch 2
V20— Pilot Shutoff Switch Diode X65— Cab Harness-to-Pilot W11— Pilot Shutoff Switch Shutoff Switch Harness Harness Connector BG71862,0000D6C -19-06JAN12-1/1
TM13345X19 (23APR18)
9015-10-197
160GLC Excavator 042318 PN=507
System Diagrams
TM13345X19 (23APR18)
9015-10-198
160GLC Excavator 042318 PN=508
System Diagrams
Pilot Shutoff Switch Harness (W11) Wiring Diagram TX1115335 —UN—08JUN12
NUMBER 10 11 12 13 15 16 17 18 19 20
COLOR BLU RED YEL ORG BLK RED BLU BLU RED BLK
END #1 V20 V20 V20 X65 X65 X136 X136 X137 X135 S3
END #2 X137 X65 X135 X137 X136 S3 S4 S3 S4 S4
S3 1 2 3
(20) (16) (18)
BLK S4 RED X136 BLU X137
2 1
V20 (10) (11) (12)
BLU X137 RED X65 YEL X135
U
ED
1 2 3
3
R
BL
10
11
12
1
BLK
3
3 15
1 11
13
X65 1 2 3
(13) (11) (15)
ORG X137 RED V20 BLK X136
X136
X137
X135
SIDE A (15) SIDE B (16) (17)
SIDE A (10) (13) SIDE B (18)
SIDE A (12) SIDE B (19)
BLK X65 RED S3 BLU S4
BLU V20 ORG X65
YEL V20 RED S4
RE
B
BLU S3
LU
D
2 1 3
S4 1 2 3
(20) (19) (17)
BLK S3 RED X135 BLU X136
TX1115335 Pilot Shutoff Switch Harness (W11) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
9015-10-199
160GLC Excavator 042318 PN=509
BG71862,0000D6D -19-10APR13-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-200
160GLC Excavator 042318 PN=510
System Diagrams
S3— Pilot Shutoff Switch 1 X65— Cab Harness-to-Pilot S4— Pilot Shutoff Switch 2 Shutoff Switch Harness V20— Pilot Shutoff Switch Diode Connector X135— Pilot Shutoff Switch Harness Splice 1
X136— Pilot Shutoff Switch Harness Splice 2 X137— Pilot Shutoff Switch Harness Splice 3 BG71862,0000D6D -19-10APR13-2/2
TM13345X19 (23APR18)
9015-10-201
160GLC Excavator 042318 PN=511
System Diagrams
Heated Air Seat Harness (W14) Component Location
R18
S62
K20
M12 X53
X54
W14
TX1087364 —UN—09MAR11
W24
TX1087364 Heated Air Seat Harness (W14) Component Location
Continued on next page
TM13345X19 (23APR18)
9015-10-202
DP27668,0000869 -19-29MAY14-1/2
160GLC Excavator 042318 PN=512
System Diagrams K20— Seat Heater Relay S62— Seat Heater Switch M12— Seat Air Compressor Motor W14—Heated Air Seat Harness R18— Seat Heater (marked SEAT W24—Seat Heater Switch HEATER) Harness
X53— Seat Heater Switch Harness 3-Pin Connector (marked SEAT HEATER) X54— Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) DP27668,0000869 -19-29MAY14-2/2
Heated Air Seat Harness (W14) Wiring Diagram X53
NUMBER
COLOR
END #1
END #2
2
RED/BLK
X54
K20
1
(6)
4
RED/GRN
X54
M12
2
—
3
(9)
R18 WHT/RED
BLU
5
RED/BLK
K20
R18
6
WHT/RED
X53
K20
7
BLK
K20
(8)
8
BLK
R18
X54
6
9
9
BLU
(2)
X53
1
3
10
BLK
M12
(8)
5
5
2
3
K20
BLK
X54
(2)
2
1
R18
8
SEAT HEATER
M12
X54
K20 1
(6)
WHT/RED
X53
2
(7)
BLK
(8)
3
(2)
RED/BLK
X54
4
—
5
(5)
RED/BLK
TX1115020
R18
2
8
RED/GRN
M12
(8)
BLK
R18
(2)
RED/BLK
K20
(4)
2 3
1
10
4
M12
2
X54 1
2
1
4 3
5
1
(4)
RED/GRN
X54
2
(10)
BLK
(8)
TX1115020 —UN—07JUN12
6
RED/BLK
(8)
SE A HE T AT ER
7
(5)
2
SEAT HEATER
1
1
X53
K20 2
K20
Heated Air Seat Harness (W14) Wiring Diagram K20— Seat Heater Relay X53— Seat Heater Switch M12— Seat Air Compressor Motor Harness 3-Pin Connector R18— Seat Heater (marked SEAT (marked SEAT HEATER) HEATER)
X54— Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) DP27668,000086A -19-29MAY14-1/1
TM13345X19 (23APR18)
9015-10-203
160GLC Excavator 042318 PN=513
System Diagrams
Multi-Function Pilot Control Lever Harness (W15) Component Location
X535
X534
S31
S30 S34
W22 S32
X81
W15
S33 K30
K31 K32 K33
S35
W22 X82
TX1187952 —UN—17AUG15
X26
TX1187952 Multi-Function Pilot Control Lever Harness (W15) Component Location
Continued on next page
TM13345X19 (23APR18)
9015-10-204
DP27668,00009E2 -19-18MAY15-1/2
160GLC Excavator 042318 PN=514
System Diagrams 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 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 W15—Multi-Function Pilot Control Lever Harness W22—Auxiliary 3-Button Cancel Switch Harness X26— Optional Connector (2 used)
X81— Multi-Function X535— Left Auxiliary Solenoid Pilot Control Lever Connector (marked SL/H) Harness-to-Auxiliary (arrow indicates front of 3-Button Cancel Switch machine) Harness Connector X82— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector X534— Right Auxiliary Solenoid Connector (marked SR/H) (arrow indicates front of machine) DP27668,00009E2 -19-18MAY15-2/2
TM13345X19 (23APR18)
9015-10-205
160GLC Excavator 042318 PN=515
System Diagrams
TM13345X19 (23APR18)
9015-10-206
160GLC Excavator 042318 PN=516
System Diagrams
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram TX1185822 —UN—23FEB15
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 610 611 612 615 616 617
COLOR RED RED RED BLU BLU WHT YEL RED RED/WHT RED/YEL BLK GRN BLK BLK RED RED BLK BLK BLK BLU/YEL BLU/YEL LT GRN/YEL YEL/RED RED/BLU BLU/YEL RED LT GRN/RED BLK RED RED/BLU
K30 1 2 3 4 5
(22) (17) (15) — (12)
LT GRN/YEL BLK RED
S30 (11) (1)
GRN
X534
K31 1 2 3 4 5
X26 1 2 3 4 5 6
(610) (611) (612) (616) (617) (615)
BLU/YEL RED LT GRN/RED BLK RED RED/BLU
K31
K30 2
4
3
12
5
24
3
1
15
X26 1 610 616
611 617
4
K32 2
4
5
10
3
16
3
612
611
610
615
615
617
616
6
6
1 2 3 4 5
(7) (13) (16) — (10)
BLU RED
S33 (8)
2
4
1 4
1 2 3 4 5
1 6
14
X82 2
YEL BLK RED
S32 (11) (8)
RED/YEL
X535
K33
K33 (4) (2)
2
X534
4
X82 1 2
RED/BLU
K32 1 7
13
612
S31 (615) (611)
1
1
3
YEL/RED BLK RED
23
11
22
17 5
2 1
4
(23) (11) (1) — (24)
5
9
3
8
(6) (14) (8) — (9)
WHT BLK RED
S33 (11) (1)
RED/WHT
X535
S30 1 2
(22) (21)
LT GRN/YEL BLU/YEL
S32 (7) (5)
YEL BLU
K32 (4)
5
K30 (20)
S30 1
2
B
7
B
1 4
6
(6) (4)
20
WHT BLU
1 22
S31 2
S33 1 2
21
C
S33 2
2
C
S32 1 2
END #2 K31 X82 X81 S33 (4) K33 K32 K33 X535 X535 (615) X534 (11) (11) K30 K32 (11) X534 X535 S31 S30 K30 K31 X534 X26 X26 X26 X26 X26 X26
END #1 (611) (8) (1) X82 S32 S33 S32 (1) K33 K32 K31 K30 K32 K33 (1) (8) K30 (11) (11) X81 (20) S30 S31 K31 X26 X26 X26 X26 X26 X26
1 23
S31
K33 X82
2
1 2
1 3
20
(23) (20)
YEL/RED BLU/YEL
K31 X81
X534
/H
SR
SL
/H
X81
24
12
18
9
10
19
1
2
3
1
2
3
X534 1 2 3
TX1185822
(24) (12) (18)
K31 K30 (11)
1 2 3
(9) (10) (19)
RED/WHT RED/YEL BLK
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram
9015-10-207
1 2
(20) (3)
BLU/YEL RED
S31 (1)
X535 RED/BLU GRN BLK
Continued on next page
TM13345X19 (23APR18)
X81
X535
160GLC Excavator 042318 PN=517
K33 K32 (11)
DP27668,00009E3 -19-19FEB15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-208
160GLC Excavator 042318 PN=518
System Diagrams
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)
X81— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector X82— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector
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) X26— Optional Connector
X534— Right Auxiliary Solenoid Connector (marked SR/H) X535— Left Auxiliary Solenoid Connector (marked SL/H)
DP27668,00009E3 -19-19FEB15-2/2
Travel Alarm Cancel Switch Harness (W16) Component Location For information, see Cab Harness (W1) Component Location. (Group 9015-10.) DS35042,000000F -19-04APR16-1/1
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram COLOR GRN/BLK BLK
END #1 END #2 X50 S13 X50 S13
X50
X50
1 2
1 1 TRAVEL
2 2
4 2
S13
GRN/BLK BLK
S13 S13
S13
1
5
(1) (2)
1 10
1 2 3 4 5 6 7 8 9 10
— — — — — — — (2) (1) —
TX1115334
BLK GRN/BLK
X50 X50
TX1115334 —UN—08JUN12
NUMBER 1 2
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram S13— Travel Alarm Cancel Switch
X50— Cab Harness-to-Travel Alarm Cancel Switch Harness Connector DS35042,0000010 -19-09AUG12-1/1
TM13345X19 (23APR18)
9015-10-209
160GLC Excavator 042318 PN=519
System Diagrams
Attachment Harness (W17) Component Location
B60 V40 Y40 Y41 V43 Y43
W32
V41
Y44
B61
W17
X46
TX1110661 —UN—20MAR12
X87
TX1110661 Attachment Harness (W17) Component Location
Continued on next page
TM13345X19 (23APR18)
9015-10-210
TX03742,0000117 -19-09MAY17-1/2
160GLC Excavator 042318 PN=520
System Diagrams B60— Attachment Pressure Sensor B61— Arm Out Pressure Sensor V40— Selector Valve Solenoid Valve Diode V41— Secondary Relief Solenoid Valve Diode
V43— 2-Speed Activation Solenoid Valve Diode W17—Attachment Harness W32—2-Speed Harness X46— Attachment Connector X87— Attachment Harnessto-Two Speed Harness Connector
Y40— Selector Valve Solenoid Valve Y41— Secondary Relief Solenoid Valve Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve TX03742,0000117 -19-09MAY17-2/2
TM13345X19 (23APR18)
9015-10-211
160GLC Excavator 042318 PN=521
System Diagrams
TM13345X19 (23APR18)
9015-10-212
160GLC Excavator 042318 PN=522
System Diagrams
Attachment Harness (W17) Wiring Diagram TX1237611 —UN—20APR17
NUMBER 2 3 4 5 6 7 12 13 15 17 18 68 69 272 277 650 651 652 664
COLOR BLK RED BLU BLK YEL BLK WHT BLK BLK ORG PNK LT GRN BRN RED BLU YEL WHT GRY BLK
END #1 (664) (272) (277) (664) V40 V40 V41 V41 (664) X46 X46 X46 X46 X46 X46 X46 X46 X46 X46
END #2 Y41 X87 X87 X87 (650) (664) (651) (2) Y40 X87 X87 X87 B60 B60 B60 Y40 Y41 X87 (2)(5)(15)
B60
X46 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PLUG (68) (69) (18) (17) (277) (272) (651) (650) (652) (664) PLUG PLUG PLUG
LT GRN BRN PNK ORG BLU RED WHT YEL GRY BLK
1 2 3
X87 B60 X87 X87 B60 B60 Y41 Y40 X87 (2)(5)(15)
(272) (69) (277)
RED BRN BLU
X46 X46 X46
B60
272
69
277
1
2
3
V40
T AT
A K
V40 7 K
(6) (7)
YEL BLK
(650) (664)
(650) (15)
YEL BLK
X46 (664)
Y40
6 A
1 2
X46 3
69
68
Y40
1 2
7
272
277
17
18
10 652 650 651 14
4
SEL
8
664
15
1 650
11
V41 13 K
12 A
V41 A K 68
3
4
5
5
17
18
652
WHT BLK
(651) (2)
4
HSB
1
(12) (13)
8
X87 2
X87 1 2 3 4 5 6 7 8
(68) (3) (4) (652) (5) (17) (18) PLUG
LT GRN RED BLU GRY BLK ORG PNK
X46 (272) (277) X46 (664) X46 X46
1 2
651
Y41 Y41 1 2
(651) (2)
WHT BLK
X46 (664)
TX1237611 Attachment Harness (W17) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
9015-10-213
160GLC Excavator 042318 PN=523
DP27668,00009DB -19-14DEC17-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-214
160GLC Excavator 042318 PN=524
System Diagrams B60— Attachment Pressure Sensor (marked ATT) V40— Selector Valve Solenoid Valve Diode
V41— Secondary Relief Solenoid Y40— Selector Valve Solenoid Valve Diode Valve (marked SEL) X46— Attachment Connector Y41— Secondary Relief Solenoid X87— Attachment Harness-to-2Valve (marked HSB) Speed Harness Connector DP27668,00009DB -19-14DEC17-2/2
Rear Camera Harness (W19) Component Location
A12
W19
TX1087159 —UN—20JAN11
X64
TX1087159 Rear Camera Harness (W19) Component Location A12— Rear Camera W19—Rear Camera Harness
X64— Machine Harness-to-Rear Camera Harness Connector BG71862,0000C87 -19-10APR13-1/1
TM13345X19 (23APR18)
9015-10-215
160GLC Excavator 042318 PN=525
System Diagrams
Rear Camera Harness (W19) Wiring Diagram NUMBER 1019 1146 1149 1166
COLOR GRY WHT YEL BLK
END #1 A12 A12 A12 A12
END #2 X64 X64 X64 X64
A12
X64 3 1
5 1166 1146 1
1149 2
1149 1166
1019 4
1146 1019 3
4
X64 (1146) (1149) — (1019) (1166)
WHT YEL
X64 X64
GRY BLK
X64 X64
1 2 3 4
TX1174036
(1149) (1166) (1146) (1019)
YEL BLK WHT GRY
A12 A12 A12 A12
TX1174036 —UN—09OCT14
A12 1 2 3 4 5
2
Rear Camera Harness (W19) Wiring Diagram A12— Rear Camera X64— Machine Harness-to-Rear Camera Harness Connector TZ24494,0001603 -19-10OCT14-1/1
TM13345X19 (23APR18)
9015-10-216
160GLC Excavator 042318 PN=526
System Diagrams
Pilot Shutoff Valve Harness (W21) Component Location
X75
W21
TX1087293 —UN—25JAN11
Y10
TX1087293 Pilot Shutoff Valve Harness (W21) Component Location W21—Pilot Shutoff Valve Harness X75— Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10— Pilot Shutoff Solenoid
DS35042,000004C -19-10MAR11-1/1
TM13345X19 (23APR18)
9015-10-217
160GLC Excavator 042318 PN=527
System Diagrams
Pilot Shutoff Valve Harness (W21) Wiring Diagram NUMBER 1 2
COLOR PNK/WHT RED
END #1 END #2 X75 Y10 X75 Y10
Y10
2
A
1
1
2
X75
X75
Y10 PNK/WHT RED
(1) (2)
X75 X75
PNK/WHT RED
Y10 Y10 TX1115337 —UN—08JUN12
(1) (2)
TX1115337 Pilot Shutoff Valve Harness (W21) Wiring Diagram X75— Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10— Pilot Shutoff Solenoid
DS35042,000004D -19-09AUG12-1/1
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location See Multi-Function Pilot Control Lever Harness (W15) Component Location. (Group 9015-10.) DS35042,0000051 -19-20APR11-1/1
TM13345X19 (23APR18)
9015-10-218
160GLC Excavator 042318 PN=528
System Diagrams
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram NUMBER 2 3 4
COLOR
END #1 S34/S35 S34/S35 S34/S35
S34/S35
1
END #2 X81/X82 S34/S35 X81/X82
X81/X82
4
2 3
4
5
4 1
3
2 2
10
S34/S35 — — (2) — — — (3) (4) (3) —
X81/X82 1 2
X81/X82
S34/S35 X81/X82 S34/S35
(4) (2)
S34/S35 S34/S35
TX1115340 —UN—19JUL12
1 2 3 4 5 6 7 8 9 10
TX1115340 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram S34— Right Enable Switch S35— Left Enable Switch X81— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector
X82— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness Connector
BG71862,0000C0E -19-20MAR13-1/1
Reversing Fan Switch Harness (W23) Component Location See Cab Harness (W1) Component Location. (Group 9015.) DS35042,000005B -19-10MAR11-1/1
TM13345X19 (23APR18)
9015-10-219
160GLC Excavator 042318 PN=529
System Diagrams
Reversing Fan Switch Harness (W23) Wiring Diagram NUMBER (1) (2) (3)
COLOR GRN YEL LT GRN
END #1 X83 X83 X83
END #2 S15 S15 S15
X83 (3) (2) (1)
LT GRN YEL GRN
S15 S15 S15
YEL
X83
GRN LT GRN
X83 X83
X83
1
2
3 1
3
VSF SW
1 2 3
S15 — — — — — (2) — (1) (3) —
1
S15
4 2
5
TX1087157
1
3 10
TX1087157 —UN—24FEB11
1 2 3 4 5 6 7 8 9 10
Reversing Fan Switch Harness (W23) Wiring Diagram S15— Reversing Fan Switch
X83— Cab Harness-to-Reversing Fan Switch Harness DS35042,000005C -19-10MAR11-1/1
Seat Heater Switch Harness (W24) Component Location See Heated Air Seat Harness (W14) Component Location. (Group 9015-10.) BG71862,000002F -19-13MAR12-1/1
TM13345X19 (23APR18)
9015-10-220
160GLC Excavator 042318 PN=530
System Diagrams
Seat Heater Switch Harness (W24) Wiring Diagram NUMBER 1 2
COLOR WHT/RED BLU
END #1 END #2 X53 S62 X53 S62 X53 2 3
1 2 3
1 1
(1) — (2)
WHT/RED
S62
BLU
S62
1
4 2
1
5
10
1 2 3 4 5 6 7 8 9 10
— — — — — — — (2) (1) —
TX1115336
BLU WHT/RED
X53 X53
TX1115336 —UN—08JUN12
S62
Seat Heater Switch Harness (W24) Wiring Diagram S62— Seat Heater Switch
X53— Seat Heater Switch Harness 3-Pin Connector (marked SEAT HEATER) DP27668,000086B -19-29MAY14-1/1
TM13345X19 (23APR18)
9015-10-221
160GLC Excavator 042318 PN=531
System Diagrams
Attachment Interface Harness (W25) Component Location—If Equipped
X46A X46
W25
X46
W17 X46B
TX1249062 —UN—20DEC17
W2
TX1249062 Attachment Interface Harness (W25) Component Location (if equipped) W2—Machine Harness W17—Attachment Harness
W25—Attachment Interface Harness X46— Attachment Connector
X46A— Attachment Connector A X46B— Attachment Connector B JN86345,0000037 -19-19DEC17-1/1
TM13345X19 (23APR18)
9015-10-222
160GLC Excavator 042318 PN=532
System Diagrams
Attachment Interface Harness (W25) Wiring Diagram—If Equipped COLOR BLU/WHT WHT/YEL BRN/YEL RED RED WHT/VLT ORG GRY/BLK WHT/BLU PNK/GRN RED/YEL BLK/YEL YEL/GRN BRN/BLU
NUMBER 651 664 1018 1095 1116 1117 1220 1227 1253 1254 1256 1257 1268 1297
END #1 X46A X46A X46B X46A X46B X46B X46B X46B X46A X46A X46A X46A X46A X46B
END #2 X46B X46B X46A X46B X46A X46A X46A X46A X46B X46B X46B X46B X46B X46A
X46A 4
1
X46B
1116 1268 1297
1 1220 1253 1117 3
1095
4 1268 1116 1257 1256 7
651 1227
8 651 1227 1254 10 1256
1253 1220
1254 11 664 1018 1297 1095 14
1257 1018
1117 664 17
X46A
X46B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
PLUG PLUG (1116) PLUG (1095) PLUG (1268) PLUG (1227) (651) PLUG (1297) (1254) (1220) (1253) (1256) (664) (1117) (1018) (1257)
RED
X46B
RED
X46B
YEL/GRN
X46B
GRY/BLK BLU/WHT
X46B X46B
BRN/BLU PNK/GRN ORG WHT/BLU RED/YEL WHT/YEL WHT/VLT BRN/YEL BLK/YEL
X46B X46B X46B X46B X46B X46B X46B X46B X46B
TX1247928
(1220) (1253) (1117) (1268) (1116) (1257) (1256) (651) (1227) (1254) (664) (1018) (1297) (1095)
ORG WHT/BLU WHT/VLT YEL/GRN RED BLK/YEL RED/YEL BLU/WHT GRY/BLK PNK/GRN WHT/YEL BRN/YEL BRN/BLU RED
X46A X46A X46A X46A X46A X46A X46A X46A X46A X46A X46A X46A X46A X46A
TX1247928 —UN—29NOV17
20
Attachment Interface Harness (W25) Wiring Diagram (if equipped) X46A— Attachment Connector A X46B— Attachment Connector B JN86345,0000069 -19-04DEC17-1/1
TM13345X19 (23APR18)
9015-10-223
160GLC Excavator 042318 PN=533
System Diagrams
Travel Alarm Harness (W26) Component Location
W2 W26
X86
TX1202156 —UN—24SEP15
H4
TX1202156 Travel Alarm Harness (W26) Component Location H4—Travel Alarm W2—Machine Harness
W26—Travel Alarm Harness X86— Machine Harness-to-Travel Alarm Harness Connector JA92389,000016E -19-24SEP15-1/1
TM13345X19 (23APR18)
9015-10-224
160GLC Excavator 042318 PN=534
System Diagrams
Travel Alarm Harness (W26) Wiring Diagram NUMBER 26 138 140 141
COLOR RED/YEL GRN/BLK BLK WHT/YEL
END #1 X86 X86 X86 X86
END #2 H4 H4 H4 H4
A
138
141
B
1
26
141
2
D
140
26
C
3
138
140
4
H4 A B C D
X86 (138) (141) (26) (140)
GRN/BLK WHT/YEL RED/YEL BLK
1 2 3 4
X86 X86 X86 X86
TX1241099
(26) (141) (138) (140)
RED/YEL WHT/YEL GRN/BLK BLK
H4 H4 H4 H4
TX1241099 —UN—28JUN17
X86
H4
Travel Alarm Harness (W26) Wiring Diagram H4—Travel Alarm
X86— Machine Harness-to-Travel Alarm Harness JN86345,0000183 -19-28JUN17-1/1
Starter Switch Harness (W29) Component Location See Cab Harness (W1) Component Location. (Group 9015-10.) BG71862,0000BEB -19-10APR13-1/1
TM13345X19 (23APR18)
9015-10-225
160GLC Excavator 042318 PN=535
System Diagrams
Starter Switch Harness (W29) Wiring Diagram NUMBER COLOR (1) WHT/BLU (3) WHT/RED (4) BLU (5) WHT/GRN (6) RED
1
S1
1 4
5
4
END #1 X47 X47 X47 X47 X47
END #2 S1 S1 S1 S1 S1
3
3
3
3
1 1
5
4
6
6
6
6
4
(1) — (3) (4) (5) (6)
WHT/BLU
S1
WHT/RED BLU WHT/GRN RED
S1 S1 S1 S1
X47 (1) — (3) (4) (5) (6)
WHT/BLU
X47
WHT/RED BLU WHT/GRN RED
X47 X47 X47 X47
1 2 3 4 5 6
TX1086912
TX1086912 —UN—22FEB11
S1 1 2 3 4 5 6
X47
Starter Switch Harness (W29) Wiring Diagram S1— Key Switch X47— Cab Harness-to-Starter Switch Harness Connector JN86345,0000276 -19-31OCT17-1/1
2-Speed Harness (W32) Component Location See Attachment Harness (W17) Component Location. (Group 9015-10.) BG71862,0000042 -19-14MAR12-1/1
TM13345X19 (23APR18)
9015-10-226
160GLC Excavator 042318 PN=536
System Diagrams
TM13345X19 (23APR18)
9015-10-227
160GLC Excavator 042318 PN=537
System Diagrams
2-Speed Harness (W32) Wiring Diagram NUMBER COLOR END #1 END #2 3 RED/YEL X87 B61 4 BLK/YEL X87 B61 5 BLU X87 Y43 8 BLU/BLK V43 (652) 9 BLU V43 (5) 17 RED X87 Y44 18 YEL/GRN X87 Y44 68 LT GRN/BLK X87 B61 652 BLU/BLK X87 Y43 1
2
Y43 (652) (5)
1 2
652 5
1
2 17 18
BLU/BLK BLU
X87 X87
Y44 (17) (18)
1 2
RED YEL/GRN
X87 X87
V43 K 9
3
A K
(8) (9)
BLU/BLK BLU
(68) (3) (4) (652) (5) (17) (18) —
LT GRN/BLK RED/YEL BLK/YEL BLU/BLK BLU RED YEL/GRN
(652) (5)
4
1 2 3 (3) (68) (4)
RED/YEL X87 LT GRN/BLK X87 BLK/YEL X87 1
4 652
4
3
68
18
17
5
8
5
TX1237712
X87 1 2 3 4 5 6 7 8
B61 B61 B61 Y43 Y43 Y44 Y44
TX1237712 —UN—20APR17
B61 1 2 3
68
8 A
2-Speed Harness (W32) Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-10-228
DF89619,00B68D7 -19-14FEB18-1/2
160GLC Excavator 042318 PN=538
System Diagrams B61— Arm Out Pressure Sensor (S.N. —057099) B61— Not Used (S.N. 057100— )
V43— 2-Speed Activation Y43— 2-Speed Activation Solenoid Valve Diode Solenoid Valve X87— Attachment Harness-to-2- Y44— Flow Rate Adjustment Speed Harness Connector Solenoid Valve DF89619,00B68D7 -19-14FEB18-2/2
Fuel Injector Harness (W38) Component Location
Y1
X5000
Y2 W38 Y3
TX1202401 —UN—27OCT15
Y4
TX1202401 Fuel Injector Harness (W38) Component Location W38—Fuel Injector Harness X5000—Engine Harness-to-Fuel Injector Harness 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) JA92389,0000171 -19-29SEP15-1/1
TM13345X19 (23APR18)
9015-10-229
160GLC Excavator 042318 PN=539
System Diagrams
TM13345X19 (23APR18)
9015-10-230
160GLC Excavator 042318 PN=540
System Diagrams
Fuel Injector Harness (W38) Wiring Diagram TX1199191 —UN—06AUG15
END #1 X5000 X5000 X5000 X5000 X5000 X335 X335 X5000 X336 X336
NUMBER 3 4 5 6 7A 7B 7C 8A 8B 8C
COLOR GRY BLU RED YEL BRN BRN BRN PUR PUR PUR
END #2 Y4 Y1 Y3 Y2 X335 Y2 Y3 X336 Y1 Y4
X5000
1
2
3
4
5
6
7
8
X5000 — — 3 4 5 6 7A 8A
X336
8C PUR
X335
3 GRY
SIDE A 8A 8B SIDE B 8C
5 RED
X336
SIDE A 7A SIDE B 7B 7C
Y4
Y3
7B BRN
X335
6 YEL
Y2
8B PUR
4 BLU
Y1
7C BRN
1 2 3 4 5 6 7 8
TX1199191 Fuel Injector Harness (W38) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
9015-10-231
160GLC Excavator 042318 PN=541
JA92389,000015A -19-06AUG15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-232
160GLC Excavator 042318 PN=542
System Diagrams
X335— 7 BRN Splice X336— 8 PUR Splice X5000—Engine Harness-to-Fuel Injector Harness 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) JA92389,000015A -19-06AUG15-2/2
TM13345X19 (23APR18)
9015-10-233
160GLC Excavator 042318 PN=543
System Diagrams
TM13345X19 (23APR18)
9015-10-234
160GLC Excavator 042318 PN=544
System Diagrams
Glow Plug Harness (W40) Component Location TX1202429 —UN—19OCT15
G3
X88
W40 X5604
W40
F63 X88 G3
R4 R3 K16 R2 R1
TX1202429 Glow Plug Harness (W40) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-235
160GLC Excavator 042318 PN=545
JA92389,0000172 -19-08OCT15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-236
160GLC Excavator 042318 PN=546
System Diagrams
F63— Glow Plug 50 A Fuse G3—Alternator K16— Glow Plug Relay R1—Glow Plug 1
R2—Glow Plug 2 R3—Glow Plug 3 R4—Glow Plug 4 W40—Glow Plug Harness
X88— Glow Plug Harness-toGlow Plug Connector X5604—Engine Harness-to-Glow Plug Interface Harness Connector JA92389,0000172 -19-08OCT15-2/2
TM13345X19 (23APR18)
9015-10-237
160GLC Excavator 042318 PN=547
System Diagrams
Glow Plug Harness (W40) Wiring Diagram END #1 X5604 X5604 K16 K16 F63 R19 X530 X5604
NUMBER COLOR END #2 DK GRN DK GRN K16 RED 1 RED R19 RED 2 RED X530 RED 3 RED F63 RED 4 RED G3 RED 5 RED X530 RED 6 RED X88 YEL YEL K16
4
1
2 3
K16 1 2 3 4
DK GRN YEL RED 3 RED 2
K16
RED 2
G3
F63 RED 4
R19 RED 3
RED 1
X88 RED 5
RED 6
X530 SIDE A RED 2 RED 5 SIDE B RED 6
X5604
2
3
X5604 1 2 3
YEL RED 1 DK GRN
R4
TX1199440
R3
R2
R1
TX1199440 —UN—07OCT15
1
Glow Plug Harness (W40) Wiring Diagram F63— Glow Plug 50 A Fuse G3—Alternator K16— Glow Plug Relay R1—Glow Plug 1
R2—Glow Plug 2 R3—Glow Plug 3 R4—Glow Plug 4 R19— Glow Plug Resistor
X88— Glow Plug Harness-toGlow Plug Connector X530— RED Splice 1 X5604—Engine Harness-to-Glow Plug Interface Harness Connector JA92389,000015C -19-19OCT15-1/1
TM13345X19 (23APR18)
9015-10-238
160GLC Excavator 042318 PN=548
System Diagrams
Heater and Air Conditioner Harness (W41) Component Location A7 X51
M11 X52
B55
M10 M9
B41 R16 W41 TX1106984 —UN—06FEB12
R17
M7 TX1106984 Heater and Air Conditioner Harness (W41) Component Location 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 R16— Blower Motor Transistor X52— Air Conditioner 10-Pin R17— Blower Motor Resistor Internal and External Connector W41—Heater and Air Conditioner Servomotor Harness M10— Air Conditioner and Heater X51— Air Conditioner 4-Pin Blower Port Change Connector Servomotor M11— Air Conditioner and Heater Mixer Servomotor BG71862,000006A -19-04JUN14-1/1
TM13345X19 (23APR18)
9015-10-239
160GLC Excavator 042318 PN=549
System Diagrams
TM13345X19 (23APR18)
9015-10-240
160GLC Excavator 042318 PN=550
System Diagrams
Heater and Air Conditioner Harness (W41) Wiring Diagram TX1163063 —UN—12JUN14
NUMBER 1 2 3 4 5 6A 6B 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 940A 940B 955 961 972 975 978 979 1104 1111 1112 1124 1125
COLOR BRN/RED WHT/BLU BLK/YEL BLU/YEL RED/YEL BRN/RED BRN/RED WHT LT GRN BLU/BLK WHT YEL/BLU RED YEL/BLK BLK RED BLK/YEL GRN/BLK BLK/YEL GRN/BLU BLK/YEL BLK BLK RED/BLK RED RED/BLK RED/BLK BRN/RED BRN/BLK BLU PNK BLK RED BRN/BLU ORG BLK/YEL GRN BLU
END #1 M9 A7 M10 A7 A7 X419 X419 A7 A7 A7 A7 A7 X421 A7 X418 X421 X420 A7 X420 A7 A7 A7 A7 A7 A7 X422 X422 A7 A7 X51 A7 X51 X51 A7 A7 X52 A7 A7
END #2 M11 M11 M11 M11 M11 A7 M10 M10 M10 M10 M9 M9 R16 R16 R16 R17 B41 B41 B55 B55 X420 X418 X418 X422 X421 X52 M9 X52 X52 M7 X52 R17 M7 X52 X52 X420 X52 X52
A7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A7 (5) (24) (13) (22) — — (23) — (21) (20) (6A) (7) (2) (1111) (1004) (17) (19) — — (1124)
RED/YEL RED/YEL YEL/BLK BLK
M11 (979) R16 (978)
RED/BLK
(940)
BLK BLK/YEL BRN/RED WHT WHT/YEL ORG BRN/BLU GRN/BLK GRN/BLU
(978) (3) M10 M10 M11 X52 X52 B41 B55
GRN
X52
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
M10 (4) — (8) (9) (961) — — — — — (955) (975) (10) (11) — — — — — (1125)
BLU/YEL
M11
LT GRN BLU/BLK BRN/BLK
M10 M10 X52
1 2 3 4 5 6
(9) (8) — (6B) (7) (3)
A7 A7
BRN/RED WHT BLK/YEL
A7 A7 M11
R16
M10 BRN/BLK PNK WHT YEL/BLU
1
1
X52 X52 M9 M9
6B
8
3
7
13
3
6 9
M7
1
972
12
2
14
4
R16 2
1 2 3 4
979
M7 BLU
1 2
A7
X52
(972) (979)
BLU RED
(13) (12) — (14)
YEL/BLK RED
A7 X421
BLK
X418
X51 X51
M9 1
5
21
4
24
13
22
8
9
23
21
20
961
6A
7
2
1111 1104
995
975
10
11
17
19
1124
20
1125
40
R17
1
15
978
1
4
6 11
10
940B
R17 X422
X52
4
SIDE A (23) SIDE B (940A) (940B)
1 955
1124 1111
961
1104 975
940A 1112 1125
1 2 3 4
X422
5
10
X52 1 2 3 4 5 6 7 8 9 10
(995) (961) (1111) (1124) (1125) (1112) (940A) — (975) (1104)
BRN/BLK BRN/BLK ORG GRN BLU BLK/YEL RED/BLK
A7 A7 A7 A7 A7 X420 M9
PNK BRN/BLU
A7 A7
978
4 979
TX1163063
BLK BLU RED
9015-10-241
160GLC Excavator 042318 PN=551
BLK
X51
M9 1 2 3 4 5 6
X420
SIDE A (24) SIDE B (12) (15)
SIDE A (3) (20) (1112) SIDE B (3) (16) (18)
B55
X419
1 2
3
M11 R16 M7 M7
4
1
2
3
M11 (5) (4) — (1) (2) (3)
RED/BLK
X52
WHT/YEL
A7
YEL/BLU
A7
18
19
1
2
(18) (19)
BLK/YEL GRN/BLU
(3) A7
B41 2
1 16
17
6 5
1 2 3 4 5 6
(940B) — — (10) — (11)
B55
SIDE A (1) SIDE B (6A) (6B)
1
RED/YEL BLU/YEL
A7 A7
BLK/RED WHT/BLU BLK/YEL
M9 A7 M10
Heater and Air Conditioner Harness (W41) Wiring Diagram Continued on next page
(979)
X421
1 (978) (972) — (979)
RED
SIDE A (21) SIDE B (14) (22)
X51 1 2 3 4
(15) — — (978)
X418
X51 2 972
TM13345X19 (23APR18)
BLU/BLK LT GRN
B41 1 2
(16) (17)
BLK/YEL GRN/BLK
(3) A7
BG71631,00007C7 -19-16JUN14-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-242
160GLC Excavator 042318 PN=552
System Diagrams
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 R16— Blower Motor Transistor R17— Blower Motor Resistor Internal and External X51— Air Conditioner 4-Pin Servomotor Connector M10— Air Conditioner and Heater X52— Air Conditioner 10-Pin Blower Port Change Connector Servomotor M11— Air Conditioner and Heater X418— 978 BLK Splice Mixer Servomotor
X419— BLK/RED Splice X420— BLK/YEL Splice X421— 979 RED Splice X422— RED/BLK Splice
BG71631,00007C7 -19-16JUN14-2/2
Cab Roof Light Harness (W44) Component Location
W45
X580
W44 E11 K22
E13
X581 E14
X582
K21
W47
W46 X55
X56
TX1173924
TX1173924 —UN—06NOV14
E12
Cab Roof Light Harness (W44) Component Location E11— Cab Roof Light 1 E12— Cab Roof Light 2 E13— Cab Roof Light 3 E14— Cab Roof Light 4 K21— Cab Roof Light 1 Relay K22— Cab Roof Light 2 Relay
W44—Cab Roof Light Harness W45—Cab Roof Light Jumper Harness W46—Cab Roof Light 1 Relay Harness W47—Cab Roof Light 2 Relay Harness
X55— Front Cab Light 1 Connector (marked CAB LAMP FRONT) X56— Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) X580— Cab Roof Light Harness Connector
X581— Cab Roof Light Jumper Harness Connector 1 X582— Cab Roof Light Jumper Harness Connector 2
JN86345,00002E5 -19-03MAR15-1/1
TM13345X19 (23APR18)
9015-10-243
160GLC Excavator 042318 PN=553
System Diagrams
Cab Roof Light Harness (W44) Wiring Diagram NUMBER 1 2 3 4 5 6 7 8
COLOR RED BLK RED/GRN BLK/WHT RED BLK RED/GRN BLK/WHT
END #2 E11 E11 E13 E13 E12 E12 E14 E14
END #1 X580 X580 X580 X580 (1) (2) (3) (4)
E12 + -
(5) (6)
RED BLK
(1) (2)
E12 +
-
X580 2
1
2
1
3
3
4
4
X580 (2) (1) (3) (4)
BLK RED RED/GRN BLK/WHT
E11 E11 E13 E13
-
E13
-
+ -
+ -
+
E11 + -
(1) (2)
RED BLK
TX1173908
X580 X580
(3) (4)
RED/GRN BLK/WHT
X580 X580
E14
E14 E11
E13
+ -
+
(7) (8)
RED/GRN BLK/WHT
(3) (4)
TX1173908 —UN—29OCT14
1 2 3 4
Cab Roof Light Harness (W44) Wiring Diagram E11— Cab Roof Light 1 E12— Cab Roof Light 2
E13— Cab Roof Light 3 E14— Cab Roof Light 4
X580— Cab Roof Light Harness Connector JN86345,00002E6 -19-03MAR15-1/1
Cab Roof Light Jumper Harness (W45) Component Location See Cab Roof Light Harness (W44) Component Location. (Group 9015-10.) JN86345,00002E7 -19-03MAR15-1/1
TM13345X19 (23APR18)
9015-10-244
160GLC Excavator 042318 PN=554
System Diagrams
Cab Roof Light Jumper Harness (W45) Wiring Diagram NUMBER 1 2 3 4
COLOR RED BLK RED/GRN BLK/GRN
END #1 X581 X581 X582 X582
END #2 X580 X580 X580 X580
X582 1 2
(4) (3)
BLK/GRN RED/GRN
X580 X580
RED BLK
X580 X580
X582 1
2 4
3
X580 2
1
2
3
4
3
4
X580 1 2 3 4
(2) (1) (4) (3)
BLK RED BLK/GRN RED/GRN
X581
X581 X581 X582 X582
1
1
2
2
X581 1 2
TX1173912
(1) (2)
TX1173912 —UN—29OCT14
1
Cab Roof Light Jumper Harness (W45) Wiring Diagram X580— Cab Roof Light Harness Connector
X581— Cab Roof Light Jumper Harness Connector 1
X582— Cab Roof Light Jumper Harness Connector 2 JN86345,00002E8 -19-03MAR15-1/1
Cab Roof Light 1 Relay Harness (W46) Component Location See Cab Roof Light Harness (W44) Component Location. (Group 9015-10.) JN86345,00002E9 -19-03MAR15-1/1
TM13345X19 (23APR18)
9015-10-245
160GLC Excavator 042318 PN=555
System Diagrams
Cab Roof Light 1 Relay Harness (W46) Wiring Diagram COLOR RED/GRN BLK/RED BLK BLK RED
END #1 X55 X55 X55 K21 K21
END #2 K21 K21 X581 (3) X581
K21 2
4
1 2
4 5
5
3
1
K21 1 2 3 4 5
(2) (4) (1) — (5)
5
2
3
CAB LAMP FRONT (5) (3)
RED
X581
2 3
1
1 3
2
X55
X581 1 2
X55 (3) X55
X55
X581 1
BLK/RED BLK RED/GRN
RED BLK
1 2 3
K21 X55
TX1173913
(2) (3) (1)
BLK/RED BLK RED/GRN
K21 X581 K21
TX1173913 —UN—06NOV14
NUMBER 1 2 3 4 5
Cab Roof Light 1 Relay Harness (W46) Wiring Diagram K21— Cab Roof Light 1 Relay X55— Front Cab Light 1 Connector (marked CAB LAMP FRONT)
X581— Cab Roof Light Jumper Harness Connector 1
JN86345,00002EA -19-03MAR15-1/1
Cab Roof Light 2 Relay Harness (W47) Component Location See Cab Roof Light Harness (W44) Component Location. (Group 9015-10.) JN86345,00002EB -19-03MAR15-1/1
TM13345X19 (23APR18)
9015-10-246
160GLC Excavator 042318 PN=556
System Diagrams
Cab Roof Light 2 Relay Harness (W47) Wiring Diagram COLOR RED/GRN BLK/RED BLK BLK RED
END #1 X56 X56 X56 K22 K22
END #2 K22 K22 X582 (3) X582
K22 2
4
1 2
4 5
5
3
1
K22 1 2 3 4 5
(2) (4) (1) -(5)
5
2
3
CAB LAMP FRONT +2 (5) (3)
RED
X582
2 3
1
1 3
2
X56
X582 1 2
X56 (3) X56
X56
X582 1
BLK/RED BLK RED/GRN
RED BLK
1 2 3
K22 X56
TX1173914
(2) (3) (1)
BLK/RED BLK RED/GRN
K22 X582 K22
TX1173914 —UN—06NOV14
NUMBER 1 2 3 4 5
Cab Roof Light 2 Relay Harness (W47) Wiring Diagram K22— Cab Roof Light 2 Relay X56— Front Cab Light 2 Connector (marked CAB LAMP FRONT +2)
X582— Cab Roof Light Jumper Harness Connector 2
JN86345,00002EC -19-03MAR15-1/1
TM13345X19 (23APR18)
9015-10-247
160GLC Excavator 042318 PN=557
System Diagrams
Heater and Air Conditioner Relay Harness (W51) Component Location W41 X51 X51B
K18 K15
W51 X52
X52B K17 X52A X51A X52
TX1238741 —UN—11MAY17
X51
W1
TX1238741 Heater and Air Conditioner Relay Harness (W51) Component Location K15— Air Conditioner Blower Motor Relay K17— Max-Hi Relay K18— Air Conditioner Compressor Clutch Relay W1—Cab Harness
W41—Heater and Air Conditioner X51A— Air Conditioner 4-Pin Harness Connector W51—Heater and Air Conditioner X51B— Air Conditioner 4-Pin Relay Harness Connector X51— Air Conditioner 4-Pin X52— Air Conditioner 10-Pin Connector Connector
X52A— Air Conditioner 10-Pin Connector X52B— Air Conditioner 10-Pin Connector
TZ24494,00016A9 -19-11MAY17-1/1
TM13345X19 (23APR18)
9015-10-248
160GLC Excavator 042318 PN=558
System Diagrams
TM13345X19 (23APR18)
9015-10-249
160GLC Excavator 042318 PN=559
System Diagrams
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram COLOR RED/GRN RED/BLK RED/GRN BRN/RED BRN/BLK BLU PNK BLK RED RED/BLK RED/BLK BLK BRN/BLU WHT ORG BLK/YEL GRN BLU RED/BLK BLK/YEL
X52A 1 2 3 4 5 6 7 8 9 10
K18
X51A
(1111) (1237) (1112) (1104) — (1105) — — (1124) (1125)
ORG BLK/YEL BLK/YEL BRN/BLU
X52B (1112) X52B X52B
WHT
K18
GRN BLU
X52B X52B
1 2 3 4
(978) (609) — (1176)
BLK RED/GRN
X51B K18
RED/BLK
K18
2
1104 1112
10 1125 1124
1 2 3 4 5
(1176) (975) (1105) — (609)
RED/BLK PNK WHT
X51A X52B X52A
RED/GRN
X51A
(981) (955) (972) — (941)
RED/BLK BRN/RED BLU
(1176) X52B X51B
RED/GRN
(609)
K15
X51A 609 978
4 1176
X52A 4
END #2 X51A X52B (609) X52B X52B X51B X52B X51B X51B (1176) (1176) (978) X52B X52A X52B X52B X52B X52B X51A (1112)
END #1 K18 (1176) K15 K15 K17 K15 K18 X51A K17 K15 K17 K17 X52A K18 X52A X52A X52A X52A K18 X52A
1 2 3 4 5
K18
1 2
1
975
1176
3
1237 1111
1
5
1105
5
3 1105
609
K15
2
1 981
955
X52B 1 955 961
1111 1124 4
5 1125 1112 940
975 1104 10
(955) (961) (1111) (1124) (1125) (1112) (940) — (975) (1104)
941
3
972
K17 2
1
961
982
X52B 1 2 3 4 5 6 7 8 9 10
5
BRN/RED BRN/BLK ORG GRN BLU BLK/YEL RED/BLK
K15 K17 X52A X52A X52A X52A (1176)
PNK BRN/BLU
K18 X52A
1 978 972 2
979
3
983
979 4
3
X51B
K17
X51B 1 2 3 4
5
(978) (972) — (979)
BLK BLU
X51A K15
RED
K17
1 2 3 4 5
TX1164496
(982) (961) (983) — (979)
RED/BLK BRN/BLK BLK
(1176) X52B (978)
RED
X51B
TX1164496 —UN—21JUL14
NUMBER 609 940 941 955 961 972 975 978 979 981 982 983 1104 1105 1111 1112 1124 1125 1176 1237
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-10-250
TZ24494,00016AA -19-03NOV15-1/2
160GLC Excavator 042318 PN=560
System Diagrams K15— Air Conditioner Blower Motor Relay K17— Max-Hi Relay K18— Air Conditioner Compressor Clutch Relay
X51A— Air Conditioner 4-Pin Connector X51B— Air Conditioner 4-Pin Connector
X52A— Air Conditioner 10-Pin Connector X52B— Air Conditioner 10-Pin Connector TZ24494,00016AA -19-03NOV15-2/2
TM13345X19 (23APR18)
9015-10-251
160GLC Excavator 042318 PN=561
System Diagrams
TM13345X19 (23APR18)
9015-10-252
160GLC Excavator 042318 PN=562
System Diagrams
Exhaust Aftertreatment Harness (W53) Component Location TX1203201 —UN—19OCT15
B5503
Y5020
Y5020
W53 B5503
W53
X5070
X5039
TX1203201 Exhaust Aftertreatment Harness (W53) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-253
160GLC Excavator 042318 PN=563
JA92389,0000174 -19-19OCT15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-254
160GLC Excavator 042318 PN=564
System Diagrams
B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor W53—Exhaust Aftertreatment Harness
X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector X5070—Exhaust Aftertreatment Harness-to-Diesel Particulate Filter (DPF) Harness Connector
Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector
JA92389,0000174 -19-19OCT15-2/2
TM13345X19 (23APR18)
9015-10-255
160GLC Excavator 042318 PN=565
System Diagrams
Exhaust Aftertreatment Harness (W53) Wiring Diagram Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. —056599)
END #2 X202 B5503 X202 Y5020 Y5020 X209 X209 X209 X200 X200 X200 X201 X201 X201 X5070 X5070 X203 X203 X203 X5070 X5070 X5070
B5503 3 2 1 6 5 4
X202 SIDE A 5030A 5030C SIDE B 5030B
X201 SIDE A 5605A 5605C SIDE B 5605B
5
4
3
2
1
12 11 10
9
8
7
B5503 X202 X201
1 2 3 4 5 6
5602B PLUG PLUG 5636B 5605B 5604B
X200 SIDE A 5604A 5604C SIDE B 5604B
X203 SIDE A 5636A 5636C SIDE B 5636B
X209
X200 X203 X209
SIDE A 5602A 5602C SIDE B 5602B
X5070 6
B
COLOR BLK BLK BLK BRN ORG RED RED RED YEL YEL YEL GRN GRN GRN GRN YEL BLU BLU BLU ORG GRN GRN
30
NUMBER 5030A 5030B 5030C 5331 5333 5602A 5602B 5602C 5604A 5604B 5604C 5605A 5605B 5605C 5625 5634 5636A 5636B 5636C 5783 5785 5786
50
END #1 X5039 X202 X5070 X5039 X5039 X5039 B5503 X5070 X5039 B5503 X5070 X5039 B5503 X5070 X5039 X5039 X5039 B5503 X5070 X5039 X5039 X5039
X5070 1 2 3 4 5 6
5634 5625 5783 5786 5785 5602C
7 8 9 10 11 12
5636C 5605C 5604C 5030C PLUG PLUG
X5039
1 2 3 4 5 6 7 8 9 10 11 12
X5039
Y5020
5634 5625 5783 5786 5785 5602A
7 8 9 10 11 12
5636A 5605A 5604A 5030A 5331 5333
1 TX1199156 —UN—14OCT15
2
1 2 3 4 5 6
Y5020 1 2
5331 5333
TX1199156 Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-256
JL58967,0000722 -19-12DEC16-1/4
160GLC Excavator 042318 PN=566
System Diagrams B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor X110— Machine Harness-toExhaust Aftertreatment Harness Connector
X200— 5604 YEL Splice 1 X201— 5605 GRN Splice 1 X202— 5030 BLK Splice X203— 5636 BLU Splice
X209— 5602 RED Splice X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-10-257
Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector
JL58967,0000722 -19-12DEC16-2/4
160GLC Excavator 042318 PN=567
System Diagrams Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. 056600— )
END #1 X5039 X5039 X5039 X209 X5070 X5039 X200 X5070 X5039 X201 X5070 X5039 X5039 X5039 X203 X5070 X5039 X5039 X5039
NUMBER 5331 5333 5602A 5602B 5602C 5604A 5604B 5604C 5605A 5605B 5605C 5625 5634 5636A 5636B 5636C 5783 5785 5786
COLOR BRN ORG RED RED RED YEL YEL YEL GRN GRN GRN GRN YEL BLU BLU BLU ORG GRN GRN
END #2 Y5020 Y5020 X209 B5503 X209 X200 B5503 X200 X201 B5503 X201 X5070 X5070 X203 B5503 X203 X5070 X5070 X5070
B5503 3 2 1 6 5 4
B5503
X201 SIDE A 5605A 5605C SIDE B 5605B
X201
5
4
3
2
1
12 11 10
9
8
7
5602B PLUG PLUG 5636B 5605B 5604B
X200 SIDE A 5604A 5604C SIDE B 5604B
X203 SIDE A 5636A 5636C SIDE B 5636B
X209
X200 X203 X209
SIDE A 5602A 5602C SIDE B 5602B
X5070 6
1 2 3 4 5 6
X5070 1 2 3 4 5 6
5634 5625 5783 5786 5785 5602C
7 8 9 10 11 12
5636C 5605C 5604C PLUG PLUG PLUG
X5039
1 2 3 4 5 6 7 8 9 10 11 12
X5039
Y5020
5634 5625 5783 5786 5785 5602A
7 8 9 10 11 12
5636A 5605A 5604A PLUG 5331 5333
1 TX1230306 —UN—09DEC16
2
1 2 3 4 5 6
Y5020 1 2
5331 5333
TX1230306 Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
9015-10-258
JL58967,0000722 -19-12DEC16-3/4
160GLC Excavator 042318 PN=568
System Diagrams B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor X110— Machine Harness-toExhaust Aftertreatment Harness Connector
X200— 5604 YEL Splice 1 X201— 5605 GRN Splice 1 X203— 5636 BLU Splice X209— 5602 RED Splice
X5039—Engine Interface Harness-to-Exhaust Aftertreatment Harness Connector Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector JL58967,0000722 -19-12DEC16-4/4
TM13345X19 (23APR18)
9015-10-259
160GLC Excavator 042318 PN=569
System Diagrams
TM13345X19 (23APR18)
9015-10-260
160GLC Excavator 042318 PN=570
System Diagrams
Diesel Exhaust Fluid (DEF) Harness (W54) Component Location Diesel Exhaust Fluid (DEF) Harness (W54) Component Location (S.N. —056599) TX1203247 —UN—19OCT15
A5507 E5602 E5603
E5601 B5501
X5037
W54 W54
A5507
TX1203247 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-261
160GLC Excavator 042318 PN=571
JL58967,0000730 -19-15DEC16-1/4
System Diagrams
TM13345X19 (23APR18)
9015-10-262
160GLC Excavator 042318 PN=572
System Diagrams A5507—Diesel Exhaust Fluid (DEF) Tank Header Assembly B5501—Diesel Exhaust Fluid (DEF) Dosing Unit E5601—Diesel Exhaust Fluid (DEF) Dosing Unit Pressure Line Heater
E5602—Diesel Exhaust Fluid W54—Diesel Exhaust Fluid (DEF) (DEF) Dosing Unit Supply Harness Line Heater X5037—Engine Interface E5603—Diesel Exhaust Fluid Harness-to-Diesel (DEF) Dosing Unit Return Exhaust Fluid (DEF) Line Heater Harness Connector 1
Continued on next page
TM13345X19 (23APR18)
9015-10-263
JL58967,0000730 -19-15DEC16-2/4
160GLC Excavator 042318 PN=573
System Diagrams
TM13345X19 (23APR18)
9015-10-264
160GLC Excavator 042318 PN=574
System Diagrams
Diesel Exhaust Fluid (DEF) Harness (W54) Component Location (S.N. 056600— ) TX1230575 —UN—15DEC16
B5601 B5211 B5506
A5507B
X5037
Y5019
E5601 E5602
W54
B5501
E5603
W54
A5507B W54
Y5019
TX1230575 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
9015-10-265
160GLC Excavator 042318 PN=575
JL58967,0000730 -19-15DEC16-3/4
System Diagrams
TM13345X19 (23APR18)
9015-10-266
160GLC Excavator 042318 PN=576
System Diagrams A5507B—Diesel Exhaust Fluid B5601—Diesel Exhaust Fluid E5603—Diesel Exhaust Fluid Y5019—Coolant Control Valve (DEF) Tank Header B (DEF) Tank Level Sensor (DEF) Dosing Unit Return B5211—Diesel Exhaust Fluid E5601—Diesel Exhaust Fluid Line Heater (DEF) Tank Temperature (DEF) Dosing Unit W54—Diesel Exhaust Fluid (DEF) Sensor Pressure Line Heater Harness B5501—Diesel Exhaust Fluid E5602—Diesel Exhaust Fluid X5037—Engine Interface (DEF) Dosing Unit (DEF) Dosing Unit Supply Harness-to-Diesel B5506—Diesel Exhaust Fluid Line Heater Exhaust Fluid (DEF) (DEF) Tank Concentration Harness Connector 1 Sensor JL58967,0000730 -19-15DEC16-4/4
TM13345X19 (23APR18)
9015-10-267
160GLC Excavator 042318 PN=577
System Diagrams
TM13345X19 (23APR18)
9015-10-268
160GLC Excavator 042318 PN=578
System Diagrams
Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram (S.N. —056599) TX1199011 —UN—04AUG15
END #1 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037 X5037
NUMBER 5136 5141 5146 5218 5301 5303 5304 5305 5306 5307 5308 5309 5311 5313 5314 5315 5317 5318 5321 5324 5329
COLOR BLU BRN BLU GRY BRN ORG YEL GRN BLU PUR GRY WHT BRN ORG YEL GRN PUR GRY BRN YEL WHT
END #2 A5507 B5501 B5501 A5507 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 E5601 E5601 E5602 E5602 E5603 E5603 A5507 A5507 A5507
B5501 6
B5501
E5603 2
1
1 2
5317 5318
5
4
3
2
1
12 11 10 9
8
7
1 2 3 4 5 6 7 8 9 10 11 12
PLUG 5141 5309 5146 5303 5301 PLUG 5305 5304 5306 5308 5307
E5603 E5602 2
1
E5602 1 2
5314 5315
X5037 E5601
31 30 29
2
1
28
18 17 16 27
19 7 6 15 26
20 8 2 1 5 14
9 3 4 13 25
21 10 11
22 23
12 24
E5601 1 2
5311 5313
X5037
A5507
A5507 1 2 3 4 5 6
5321 5324 5329 5136 5218 PLUG
1 2 3 4 5 6 7 8 9 10 11
3 2 1 6 5 4
5311 5313 5314 5315 5317 5318 5141 5309 5146 PLUG PLUG
12 13 14 15 16 17 18 19 20 21
5303 5301 5305 5304 5306 5308 5307 5321 PLUG 5324
22 23 24 25 26 27 28 29 30 31
PLUG 5329 5136 5218 PLUG PLUG PLUG PLUG PLUG PLUG
TX1199011 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-269
160GLC Excavator 042318 PN=579
JL58967,000072D -19-12DEC16-1/4
System Diagrams
TM13345X19 (23APR18)
9015-10-270
160GLC Excavator 042318 PN=580
System Diagrams A5507—Diesel Exhaust Fluid (DEF) Tank Header Assembly B5501—Diesel Exhaust Fluid (DEF) Dosing Unit
E5601—Diesel Exhaust Fluid E5603—Diesel Exhaust Fluid (DEF) Dosing Unit (DEF) Dosing Unit Return Pressure Line Heater Line Heater E5602—Diesel Exhaust Fluid X5037—Engine Interface (DEF) Dosing Unit Supply Harness-to-Diesel Line Heater Exhaust Fluid (DEF) Harness Connector 1 Continued on next page
TM13345X19 (23APR18)
9015-10-271
JL58967,000072D -19-12DEC16-2/4
160GLC Excavator 042318 PN=581
System Diagrams
TM13345X19 (23APR18)
9015-10-272
160GLC Excavator 042318 PN=582
System Diagrams
Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram (S.N. 056600— ) TX1230570 —UN—13DEC16
END #1 NUMBER X5037 5141 X5037 5146 X5037 5301 X5037 5303 X5037 5304 X5037 5305 X5037 5306 X5037 5307 X5037 5308 X5037 5309 X5037 5311 X5037 5313 X5037 5314 X5037 5315 X5037 5317 X5037 5318 X5037 5321 X5037 5324 X5037 5602 X5037 5604A X223 5604B A5507B 5604C X5037 5605A X224 5605B A5507B 5605C X5037 5625
COLOR BRN BLU BRN ORG YEL GRN BLU VLT GRY WHT BRN ORG YEL GRN VLT GRY BRN YEL RED YEL YEL YEL GRN GRN GRN GRN
END #2 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 B5501 E5601 E5601 E5602 E5602 E5603 E5603 Y5019 Y5019 A5507B X223 X5037 X223 X224 X5037 X224 A5507B
B5501 6
5
4
3
2
1
12 11 10 9
8
7
1 2 3 4 5 6 7 8 9 10 11 12
B5501
2
1
PLUG 5141 5309 5146 5303 5301 PLUG 5305 5304 5306 5308 5307
4 1
E5602 E5601 2
1
1 2
E5602
1 2
Y5019
5314 5315
5311 5313
2
E5603 1 2
5317 5318
A5507B 1 2 3 4
5602 5605C 5604C 5625
2
Y5019 1 2 3 4
5321 PLUG PLUG 5324
X5037
1
E5603
E5601
2 3
X223
X224
SIDE A 5604C SIDE B 5604A 5604B
SIDE A 5605C SIDE B 5605A 5605B
X223
X224
1 2 3 4 5 6 7 8 9 10 11
5311 5313 5314 5315 5317 5318 5141 5309 5146 PLUG PLUG
12 13 14 15 16 17 18 19 20 21
5303 5301 5305 5304 5306 5308 5307 PLUG PLUG 5321
31 30 29
3
28 4
22 23 24 25 26 27 28 29 30 31
1
18 17 16 27
A5507B
19 7 6 15 26
5324 PLUG PLUG PLUG 5602 5625 5604A 5605A 5604B 5605B
20 8 2 1 5 14
9 3 4 13 25
21 10 11
22 23
12 24
X5037
TX1230570 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
9015-10-273
160GLC Excavator 042318 PN=583
JL58967,000072D -19-12DEC16-3/4
System Diagrams
TM13345X19 (23APR18)
9015-10-274
160GLC Excavator 042318 PN=584
System Diagrams A5507B—Diesel Exhaust Fluid (DEF) Tank Header B B5501—Diesel Exhaust Fluid (DEF) Dosing Unit E5601—Diesel Exhaust Fluid (DEF) Dosing Unit Pressure Line Heater
E5602—Diesel Exhaust Fluid X223— 5604 YEL Splice (DEF) Dosing Unit Supply X224— 5605 GRN Splice Line Heater X5037—Engine Interface E5603—Diesel Exhaust Fluid Harness-to-Diesel (DEF) Dosing Unit Return Exhaust Fluid (DEF) Line Heater Harness Connector 1
Y5019—Coolant Control Valve
JL58967,000072D -19-12DEC16-4/4
TM13345X19 (23APR18)
9015-10-275
160GLC Excavator 042318 PN=585
System Diagrams
TM13345X19 (23APR18)
9015-10-276
160GLC Excavator 042318 PN=586
System Diagrams
Fan Harness (W57) Component Location TX1203413 —UN—28OCT15
S90
E15
B5009 W58
X5041 W57
W58
B5303 Y5015
X5041
Y5014 B5009 W57
Y5015 X5005
Y5014
B5303
W5
TX1203413 Fan Harness (W57) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-277
160GLC Excavator 042318 PN=587
JA92389,0000177 -19-19OCT15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-278
160GLC Excavator 042318 PN=588
System Diagrams
B5009—Engine Coolant Loss S90— Engine Compartment Light X5005—Fan Harness Connector Y5015—Reversing Fan Solenoid Level Sensor Switch X5041—Fan Harness-to-Engine B5303—Fan Speed Sensor W5—Engine Interface Harness Light Harness Connector E15— Engine Compartment Light W57—Fan Harness Y5014—Variable Speed Fan W58—Engine Light Harness Solenoid JA92389,0000177 -19-19OCT15-2/2
TM13345X19 (23APR18)
9015-10-279
160GLC Excavator 042318 PN=589
System Diagrams
Fan Harness (W57) Wiring Diagram Fan Harness (W57) Wiring Diagram (S.N. —056599)
END #1 X5005 X5005 X5005 X5005 X5005 X5005 X5005 Y5014 Y5015 X5005 X5005 X5005
NUMBER 5014 5015 5023 5125 5126 5624 5643A 5643B 5643C 5658 B22 G01
COLOR YEL GRN ORG GRN BLU YEL ORG ORG ORG GRY RED BLK
END #2 Y5015 B5303 Y5014 B5009 B5009 B5303 X144 X144 X144 B5303 X5041 X5041
X5005 1 2 3 4 5 6 7 8 9 10 11 12
X5005
X5041 2
1 2 3 4 5 6 7 8 9 10 11 12
1
X5041 1 2
B22 G01
5023 5014 5643A 5624 5658 5015 B22 G01 PLUG 5126 5125 PLUG
B5009 1 2
5125 5126
B5009 2
1
B5303 A
Y5014 2
B
1 C
B5303 A B C
Y5014 1 2
5023 5643B
5624 5658 5015
2
1
X144 SIDE A 5643A SIDE B 5643B 5643C
Y5015 1 2
5014 5643C
TX1199453
X144
TX1199453 —UN—06OCT15
Y5015
Fan Harness (W57) Wiring Diagram (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-280
JL58967,0000731 -19-13DEC16-1/4
160GLC Excavator 042318 PN=590
System Diagrams B5009—Engine Coolant Loss Level Sensor B5303—Fan Speed Sensor
X144— 5643 ORG Splice Y5014—Variable Speed Fan X5005—Fan Harness Connector Solenoid X5041—Fan Harness-to-Engine Y5015—Reversing Fan Solenoid Light Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-10-281
JL58967,0000731 -19-13DEC16-2/4
160GLC Excavator 042318 PN=591
System Diagrams Fan Harness (W57) Wiring Diagram (S.N. 056600— )
END #1 X5005 X5005 X5005 X5005 X5005 X5005 X5005 Y5014 Y5015 X5005 X5005 X5005 X5005 X5005
NUMBER 5014 5015 5023 5125 5126 5624 5643A 5643B 5643C 5658 B022 G001 L055 P023
COLOR YEL GRN ORG GRN BLU YEL ORG ORG ORG GRY RED BLK BRN RED
END #2 Y5015 B5303 Y5014 B5009 B5009 B5303 X144 X144 X144 B5303 X5041 X5041 X5041 X5041
1 2 3 4 5 6 7 8 9 10 11 12
2
1
4
3
X5041
X5005
X5005
X5041 1 2 3 4
2
1 2 3 4 5 6 7 8 9 10 11 12
B022 P023 L055 G001
1
5023 5014 5643A 5624 5658 5015 5125 5126 P023 L055 B022 G002
B5009
B5009 1 2
2
5125 5126
1
A
B
Y5014
B5303 C
B5303 Y5014 1 2
A B C
5624 5658 5015
5023 5643B
Y5015 1
X144 SIDE A 5643A SIDE B 5643B 5643C
Y5015 1 2
5014 5643C
TX1230620
X144
TX1230620 —UN—12JAN17
2
Fan Harness (W57) Wiring Diagram (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
9015-10-282
JL58967,0000731 -19-13DEC16-3/4
160GLC Excavator 042318 PN=592
System Diagrams B5009—Engine Coolant Loss Level Sensor B5303—Fan Speed Sensor
X144— 5643 ORG Splice Y5014—Variable Speed Fan X5005—Fan Harness Connector Solenoid X5041—Fan Harness-to-Engine Y5015—Reversing Fan Solenoid Light Harness Connector JL58967,0000731 -19-13DEC16-4/4
Engine Light Harness (W58) Component Location See Fan Harness (W57) Component Location. (Group 9015-10.) JA92389,0000178 -19-15OCT15-1/1
Engine Light Harness (W58) Wiring Diagram Engine Light Harness (W58) Wiring Diagram (S.N. —056559)
END #1 X5041 X5041 S90
NUMBER B22 G01 G22
COLOR RED BLK BRN
END #2 E15 S90 E15 E15 2
1
1 2
B22 G22
E15
1
A
2
S90
X5041 1 2
B
A B
B22 G01
TX1156632
G22 G01
TX1156632 —UN—24MAR14
S90
X5041
Engine Light Harness (W58) Wiring Diagram (S.N. —056559) E15— Engine Compartment Light S90— Engine Compartment Light X5041—Fan Harness-to-Engine Light Harness Connector Switch Continued on next page
TM13345X19 (23APR18)
9015-10-283
JL58967,000072B -19-09DEC16-1/2
160GLC Excavator 042318 PN=593
System Diagrams Engine Light Harness (W58) Wiring Diagram (S.N. 056600— )
NUMBER B022 G001 L055 P023
END #2 S90 E15 E15 S90
COLOR RED BLK BRN RED
B
S90
A
S90 A B
B022 P023
X5041
E15 2
1
E15 1 2
1
2
3
4
X5041
L055 G001
1 2 3 4
TX1230510
B022 P023 L055 G001
TX1230510 —UN—12JAN17
END #1 X5041 X5041 X5041 X5041
Engine Light Harness (W58) Wiring Diagram (S.N. 056600— ) E15— Engine Compartment Light S90— Engine Compartment Light X5041—Fan Harness-to-Engine Light Harness Connector Switch JL58967,000072B -19-09DEC16-2/2
TM13345X19 (23APR18)
9015-10-284
160GLC Excavator 042318 PN=594
System Diagrams
Auxiliary Solenoid Harness (W61) Component Location
X535 W15,W75 X534
Y34A,Y35A
V30,V32
W61
Y34B,Y35B
TX1203794 —UN—19OCT15
V31,V33
TX1203794 Auxiliary Solenoid Harness (W61) Component Location 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 X535— Left Auxiliary Solenoid Y35A— Left Solenoid Connector Harness Connector (marked SL/H) A W75—Auxiliary Function Lever Y34A— Right Solenoid Y35B— Left Solenoid Connector (AFL) Harness Connector A B X534— Right Auxiliary Solenoid Y34B— Right Solenoid Connector (marked SR/H) Connector B JA92389,0000176 -19-14FEB18-1/1
TM13345X19 (23APR18)
9015-10-285
160GLC Excavator 042318 PN=595
System Diagrams
Auxiliary Solenoid Harness (W61) Wiring Diagram NUMBER G05 G05A G05B G05C G05D H01 H01A H01B H02 H02A H02B
END #1 X534,X535 X450 X450 X450 X450 X534,X535 X451 X451 X534,X535 X452 X452
COLOR BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN
END #2 X450 Y34A,Y35A Y34B,Y35B V31,V33 V30,V32 X451 Y34A,Y35A V31,V33 X452 Y34B,Y35B V30,V32
X534,X535 1 2 3
1
H02 H01 G05
2 3
X534,X535
V30,V32 F M M
V31,V33 F M
G05D H02B F
V30,V32
G05C H01B M
V31,V33
F
Y34B,Y35B H02A G05B
A
B
SIDE A G05A G05B G05C G05D SIDE B G05
X450
X451
X452
SIDE A H01A H01B SIDE B H01
SIDE A H02A H02B SIDE B H02
X451
X452
B A
A B
X450
B
A
TX1185880 —UN—27FEB15
Y34B,Y35B Y34A,Y35A A
B
Y34A,Y35A
A B
H01A G05A
TX1185880 Auxiliary Solenoid Harness (W61) Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-10-286
DP27668,00009E4 -19-14FEB18-1/2
160GLC Excavator 042318 PN=596
System Diagrams V30— Right Solenoid Diode B V31— Right Solenoid Diode A V32— Left Solenoid Diode B V33— Leftt Solenoid Diode A
X450— G05 BLK Splice X535— Left Auxiliary Solenoid Y35A— Left Solenoid Connector X451— H01 GRN Splice Connector (marked SL/H) A X452— H02 GRN Splice Y34A— Right Solenoid Y35B— Left Solenoid Connector X534— Right Auxiliary Solenoid Connector A B Connector (marked SR/H) Y34B— Right Solenoid Connector B DP27668,00009E4 -19-14FEB18-2/2
TM13345X19 (23APR18)
9015-10-287
160GLC Excavator 042318 PN=597
System Diagrams
Diesel Particulate Filter (DPF) Harness (W62) Component Location
B5201
B5216 B5109 B5204 X5070
W62 B5202 R5605
W62
B5502
TX1203541 —UN—27OCT15
B5201
TX1203541 Diesel Particulate Filter (DPF) Harness (W62) Component Location
Continued on next page
TM13345X19 (23APR18)
9015-10-288
JA92389,0000179 -19-27OCT15-1/2
160GLC Excavator 042318 PN=598
System Diagrams B5109—Exhaust Filter Delta B5204—Exhaust Filter R5605—Aftertreatment CAN Pressure Sensor Temperature Module Termination Resistor B5201—Diesel Oxidation Catalyst B5216—Selective Catalytic W62—Diesel Particulate Filter (DOC) Inlet Temperature Reduction (SCR) Inlet (DPF) Harness Sensor Temperature Sensor X5070—Exhaust Aftertreatment B5202—Diesel Oxidation Catalyst B5502—Aftertreatment Inlet NOx Harness-to-Diesel (DOC) Outlet Temperature Sensor Particulate Filter (DPF) Sensor Harness Connector JA92389,0000179 -19-27OCT15-2/2
TM13345X19 (23APR18)
9015-10-289
160GLC Excavator 042318 PN=599
System Diagrams
Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram (S.N. —056599)
NUMBER 5030A 5030B 5030C 5602 5604A 5604B 5604C 5605A 5605B 5605C 5625A 5625B 5625C 5634A 5634B 5634C 5636A 5636B 5636C 5783 5785 5786
END #1 X5070 B5502 R5605 X5070 X5070 B5502 R5605 X5070 B5502 R5605 X5070 B5204 B5109 X5070 B5204 B5109 X5070 X203 X203 X5070 X5070 X5070
END #2 X202 X202 X202 B5502 X200 X200 X200 X201 X201 X201 X208 X208 X208 X210 X210 X210 X203 B5502 B5502 B5204 B5109 B5204
COLOR BLK BLK BLK RED YEL YEL YEL GRN GRN GRN GRN GRN GRN YEL YEL YEL BLUE BLUE BLUE ORG GRN BLU
B5109 3
1
B5109 A
B
R5605
1 2 3
5634C 5625C 5785
C
R5605 A B C
5604C 5605C 5030C
X203 SIDE A 5636A SIDE B 5636B 5636C
X200
X203
B5502 3 2 1 6 5 4
30
B
X200
SIDE A 5604B 5604C SIDE B 5604A
50
X201
B5502 1 2 3 4 5 6
2
X201
5602 PLUG 5636C 5636B 5605B 5604B
X208
X210
SIDE A 5625C SIDE B 5625A 5625B
SIDE A 5634C SIDE B 5634A 5634B
X5070
X208
X202
X210
1 2 3 4 5 6
SIDE A 5605B 5605C SIDE B 5605A
X202 SIDE A 5030B 5030C SIDE B 5030A
7 8 9 10 11 12
1 2 3 4 5 6
5634A 5625A 5783 5786 5785 5602
B5204 7 8 9 10 11 12
5636A 5605A 5604A 5030A PLUG PLUG
1 2 3 4
5634B 5625B 5783 5786
2
1
3
4
B5204 TX1198785 —UN—14OCT15
X5070
TX1198785 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-10-290
JL58967,0000723 -19-12DEC16-1/4
160GLC Excavator 042318 PN=600
System Diagrams B5109—Exhaust Filter Delta R5605—Aftertreatment CAN Pressure Sensor Termination Resistor B5204—Exhaust Filter X110— Machine Harness-toTemperature Module Exhaust Aftertreatment B5502—Aftertreatment Inlet NOx Harness Connector Sensor
X200— 5604 YEL Splice 1 X201— 5605 GRN Splice 1 X202— 5030 BLK Splice X203— 5636 BLU Splice X208— 5625 GRN Splice Continued on next page
TM13345X19 (23APR18)
9015-10-291
X210— 5634 YEL Splice
JL58967,0000723 -19-12DEC16-2/4
160GLC Excavator 042318 PN=601
System Diagrams Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram (S.N. 056600— )
NUMBER 5602 5604A 5604B 5604C 5605A 5605B 5605C 5625A 5625B 5625C 5634A 5634B 5634C 5636A 5636B 5636C 5783 5785 5786
END #1 X5070 X5070 B5502 R5605 X5070 B5502 R5605 X5070 B5204 B5109 X5070 B5204 B5109 X5070 X203 X203 X5070 X5070 X5070
END #2 B5502 X200 X200 X200 X201 X201 X201 X208 X208 X208 X210 X210 X210 X203 B5502 B5502 B5204 B5109 B5204
COLOR RED YEL YEL YEL GRN GRN GRN GRN GRN GRN YEL YEL YEL BLU BLU BLU ORG GRN BLU
B5109 3
2
1
B5109 A
B
R5605
1 2 3
5634C 5625C 5785
C
R5605 A B C
5604C 5605C PLUG
X203 SIDE A 5636A SIDE B 5636B 5636C
X200
X203
B5502 3 2 1 6 5 4
X200
SIDE A 5604B 5604C SIDE B 5604A
X201 B5502 1 2 3 4 5 6
X201
5602 PLUG 5636C 5636B 5605B 5604B
X208
X210
SIDE A 5625C SIDE B 5625A 5625B
SIDE A 5634C SIDE B 5634A 5634B
X5070
X208
SIDE A 5605B 5605C SIDE B 5605A
X210
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
5634A 5625A 5783 5786 5785 5602
B5204 7 8 9 10 11 12
5636A 5605A 5604A PLUG PLUG PLUG
1 2 3 4
5634B 5625B 5783 5786
2
1
3
4
B5204 TX1230309 —UN—09DEC16
X5070
TX1230309 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
9015-10-292
JL58967,0000723 -19-12DEC16-3/4
160GLC Excavator 042318 PN=602
System Diagrams B5109—Exhaust Filter Delta R5605—Aftertreatment CAN Pressure Sensor Termination Resistor B5204—Exhaust Filter X110— Machine Harness-toTemperature Module Exhaust Aftertreatment B5502—Aftertreatment Inlet NOx Harness Connector Sensor
X200— 5604 YEL Splice 1 X201— 5605 GRN Splice 1 X203— 5636 BLU Splice X208— 5625 GRN Splice
X210— 5634 YEL Splice
JL58967,0000723 -19-12DEC16-4/4
TM13345X19 (23APR18)
9015-10-293
160GLC Excavator 042318 PN=603
System Diagrams
Auxiliary Function Lever (AFL) Harness (W75) Component Location S29
S31 S7 X577
W75
X535
X534
S45
S34
X574
W75
X536 K31 K32 K33 X544
V22
X537 S35
X26 S32
S33
S5
TX1250412 —UN—17JAN18
X543
TX1250412 Auxiliary Function Lever (AFL) Harness (W75) Component Location
Continued on next page
TM13345X19 (23APR18)
9015-10-294
JN86345,0000005 -19-14FEB18-1/2
160GLC Excavator 042318 PN=604
System Diagrams K31— Right Solenoid Relay A S32— Left Pilot Control Lever (marked RSW1) Switch B K32— Left Solenoid Relay B S33— Left Pilot Control Lever (marked LSW1) Switch A K33— Left Solenoid Relay A S34— Right Enable Switch (marked LSW3) (marked ON/OFF) S5— Horn Switch S35— Left Enable Switch S7— Power Dig Switch (marked ON/OFF) S29— Auxiliary Function Lever S45— Auxiliary Function Enable (AFL) Proportional Control Switch (marked AFL_SW) Switch V22— Pilot Shutoff Solenoid S31— Right Pilot Control Lever Diode Switch A W75—Auxiliary Function Lever (AFL) Harness
X26— Optional Connector (2 X543— Horn Switch Connector used) X544— Power Dig Switch X534— Right Auxiliary Solenoid Connector Connector (marked SR/H) X574— Auxiliary Function Lever X535— Left Auxiliary Solenoid (AFL) Connector 1 Connector (marked SL/H) X577— Auxiliary Function X536— Right Auxiliary Function Lever (AFL) Harness-toLever (AFL) Connector Auxiliary Function Lever (marked R_GRIP) (AFL) Solenoid Harness X537— Left Auxiliary Function Connector Lever (AFL) Connector (marked L_GRIP)
JN86345,0000005 -19-14FEB18-2/2
TM13345X19 (23APR18)
9015-10-295
160GLC Excavator 042318 PN=605
System Diagrams
TM13345X19 (23APR18)
9015-10-296
160GLC Excavator 042318 PN=606
System Diagrams
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram TX1250413 —UN—24JAN18
1 2 3
PLUG (64) (74)
GRN BLK
K31 (615)
(68) (72) (73)
64
74
68
72
73
2
3
1
2
3
1 2 3 4 5
(69) (71) (70) — (72)
BLU YEL RED
(65) X537 (611)
RED/YEL
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
4
5 3
X535
1
610
611
612
3
3
612
611
610
1
4
616
617
615
6
6
615
617
616
4
K33
1 69
71
X26
X26 1 2 3 4 5 6
2
2
4
K33
1
72
67
70
5
68
3
66
1
22
10
5
13
20
9 13
11
19
24
4
GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLK/YEL
1 2 3 4 5
12 16
X574 X574 X574 X574 X574 (27)
V22 X574
5 23 45
25 27
13
19
44
A
1 10
12
11
57
58
BLK/BLU WHT/YEL
RED/WHT
X535
1 61
5
64
3
62
605
1 2
X544 S34
1 31
32
2
1
1 2
(32) (31)
75
ON/OFF
BLK GRN/BLK
76
61 10
X536 X536
X574 X574 X574 X544 K31 X544
W
RED/YEL BLK/YEL GRN/BLU GRN/BLK LT GRN/RED BLK
_S
(25) (27) (29) (31) (63) (32) — —
76 5
X536 1 2 3 4 5 6 7 8
4
FL
X536 X577 X577 X536 X577 X577 X577 X577 S45 X577 X536 S45
S45
1
4
46 44 5
1
25
8
2
27
7
3
29
32
6
4
31
63
5
47
45 10
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram Continued on next page
160GLC Excavator 042318 PN=607
(61) (63) (62) — (64)
BLU/YEL LT GRN/RED RED
S34 X536 (611)
GRN
X534
545 1
X543
X536
9015-10-297
(23) (24)
22
A
GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK/BLU GRY BLU/WHT BLU/YEL BLK/GRN ORG/BLK BLK/YEL RED/BLU
(57) (58)
6
X574 (610) (25) X574
X574 (29) (10) (12) (25) (23) (22) (11) (19) (44) (13) (27) (45)
K
A K
2
X544 1 2 3 4 5 6 7 8 9 10 11 12
S35 X537 (611)
X543
V22
29
12
BLK/BLU WHT/YEL RED/YEL BLU/YEL
BLU WHT RED
K31
(545) (605)
WHT/VLT BLK
X537 X537
S34 1 2 3 4 5 6 7 8 9 10
(46) — — — (44) — — (47) (45) —
4 60
RED
ON/OFF
(611)
77
77
65 10
5
S35 WHT/RED WHT/RED BLU/YEL
S34 S34 K31
WHT/YEL
(610)
S45 1 2 3 4 5 6 7 8 9 10
S35
1
— — (75) — — — (76) (76) (61) —
L_GRIP
(22) (10) (11) (12) (13) (20) PLUG PLUG PLUG PLUG (23) (24) (18) (19) PLUG PLUG
4
63
RSW1
X577 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(65) (67) (66) — (68)
K31 2
8 23
18
12
1 2 3 4 5
65
X577
TX1250413
TM13345X19 (23APR18)
K32
K32
K33 K32 (615)
X535
X534 1
RED/WHT RED/YEL BLK
LS W 3
X535
1 2 3
LSW1
X534
R_GRIP
END #2 X574 X574 X574 X574 X577 X574 (27) X577 X577 (610) X574 X574 X574 X544 X544 S45 S45 (610) (615) (23) (24) (611) K31 (611) X536 X534 S35 (611) K33 X535 (65) (611) K32 X535 X535 (615) (611) S34 S35 X543 X537 X26 X26 X26 X26 X26 X26
SL /H
END #1 X577 X577 X577 X577 (25) X577 X577 X574 X574 X577 X536 X536 X536 X536 X536 X574 X574 S45 S45 V22 V22 S35 S34 K31 K31 K31 K33 K33 X537 K33 K32 K32 X537 K32 (615) X534 S34 S34 S35 X537 X543 X26 X26 X26 X26 X26 X26
/H
COLOR WHT/BLU BLU/WHT YEL/BLU ORG/BLK RED/YEL BLU/YEL BLK/YEL GRY BLK/BLU WHT/YEL RED/YEL BLK/YEL GRN/BLU GRN/BLK BLK BLK/GRN RED/BLU WHT/YEL BLK BLK/BLU WHT/YEL RED BLU/YEL RED LT GRN/RED GRN BLU RED WHT RED/WHT BLU RED YEL RED/YEL BLK BLK RED WHT/RED WHT WHT/VLT BLK WHT/YEL RED LT GRN/RED BLK BLU/RED RED/BLU
SR
NUMBER 10 11 12 13 18 19 20 22 23 24 25 27 29 31 32 44 45 46 47 57 58 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 545 605 610 611 612 615 616 617
X537 BLK/GRN
BLK RED/BLU
X574
(615) X574
1 2 3 4 5 6 7 8
— — — (545) (71) (605) (67) —
1
WHT/VLT YEL BLK WHT
X543 K32 X543 K33
8
2
67
7
3
605
6
71
5
4
545
1 2 3 4 5 6 7 8 9 10
— — (60) — — — (77) (77) (65) —
RED
(611)
WHT WHT BLU
S34 S34 K33
X537 JN86345,00002DF -19-17JAN18-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-298
160GLC Excavator 042318 PN=608
System Diagrams
K31— Right Solenoid Relay A (marked RSW1) K32— Left Solenoid Relay B (marked LSW1) K33— Left Solenoid Relay A (marked LSW3) S34— Right Enable Switch (marked ON/OFF) S35— Left Enable Switch (marked ON/OFF)
S45— Auxiliary Function Enable X536— Right Auxiliary Function Lever (AFL) Connector Switch (marked AFL_SW) (marked R_GRIP) V22— Pilot Shutoff Solenoid X537— Left Auxiliary Function Diode Lever (AFL) Connector X26— Optional Connector (marked L_GRIP) X534— Right Auxiliary Solenoid Connector (marked SR/H) X543— Horn Switch Connector X544— Power Dig Switch X535— Left Auxiliary Solenoid Connector Connector (marked SL/H)
X574— Auxiliary Function Lever (AFL) Connector 1 X577— Auxiliary Function Lever (AFL) Harness-toAuxiliary Function Lever (AFL) Solenoid Harness Connector
JN86345,00002DF -19-17JAN18-2/2
TM13345X19 (23APR18)
9015-10-299
160GLC Excavator 042318 PN=609
System Diagrams
TM13345X19 (23APR18)
9015-10-300
160GLC Excavator 042318 PN=610
System Diagrams
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location TX1204169 —UN—27OCT15
X577
W76
Y61
Y62 Y66
Y66
Y62
Y61 B85 B68 W76
W76
TX1204169 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location Continued on next page
TM13345X19 (23APR18)
9015-10-301
160GLC Excavator 042318 PN=611
JA92389,0000180 -19-22OCT15-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-302
160GLC Excavator 042318 PN=612
System Diagrams
B68— Secondary Hydraulic Oil Temperature Sensor B85— Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
W76—Auxiliary Function Lever Y61— Auxiliary Function Lever Y66— Secondary Pilot Shutoff (AFL) Solenoid Harness (AFL) Solenoid A (marked Solenoid Valve (marked X577— Auxiliary Function 1A) PiC) Lever (AFL) Harness-to- Y62— Auxiliary Function Lever Auxiliary Function Lever (AFL) Solenoid B (marked (AFL) Solenoid Harness 1B) Connector JA92389,0000180 -19-22OCT15-2/2
TM13345X19 (23APR18)
9015-10-303
160GLC Excavator 042318 PN=613
System Diagrams
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram NUMBER 10 11 12 13 18 19 20 22 23 24 56
COLOR WHT/BLU BLU/WHT YEL/BLU ORG/BLK RED/YEL BLU/YEL BLK/YEL GRY BLK/BLU WHT/YEL BLK/YEL
END #1 Y61 Y61 Y62 Y62 B85 B85 B68 B68 Y66 Y66 B85
END #2 X577 X577 X577 X577 X577 X577 X577 X577 X577 X577 (20)
B85
B85 18
19
1 2 3
56
1
(18) (19) (56)
RED/YEL BLU/YEL BLK/YEL
X577 X577 (20)
(22) (20)
GRY BLK/YEL
X577 X577
3
PS1
B68 1 2
B68 1 22
2 20
X577 12
11
8 12
10 20
24
22 13
23
16
Y61
1 5
1A
9 19
18
13
1 2 B68 Y61 Y61 Y62 Y62 B68
PiC
GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLK/YEL
1B
(22) (10) (11) (12) (13) (20) PLUG PLUG PLUG PLUG (23) (24) (18) (19) PLUG PLUG
BLK/BLU WHT/YEL RED/YEL BLU/YEL
2
10
11
Y61
X577 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
Y66 Y66 B85 B85
1
2
23
24
Y66
(10) (11)
WHT/BLU BLU/WHT
X577 X577
Y62 1
2
12
13
Y62 1 2
(12) (13)
YEL/BLU ORG/BLK
X577 X577
(23) (24)
BLK/BLU WHT/YEL
X577 X577
Y66 1 2
TX1172670
TX1172670 —UN—24SEP14
4
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram
Continued on next page
TM13345X19 (23APR18)
9015-10-304
JN86345,00002E1 -19-18MAR15-1/2
160GLC Excavator 042318 PN=614
System Diagrams B68— Secondary Hydraulic Oil Temperature Sensor B85— Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
X577— Auxiliary Function Y61— Auxiliary Function Lever Y66— Secondary Pilot Shutoff Lever (AFL) Harness-to(AFL) Solenoid A (marked Solenoid Valve (marked Auxiliary Function Lever 1A) PiC) (AFL) Solenoid Harness Y62— Auxiliary Function Lever Connector (AFL) Solenoid B (marked 1B) JN86345,00002E1 -19-18MAR15-2/2
USB Harness (W82) Component Location For more information, see Cab Harness (W1) Component Location. (Group 9015.) KR46761,0001736 -19-17JAN18-1/1
USB Harness (W82) Wiring Diagram COLOR WHT/YEL BLK WHT/YEL RED LT GRN/RED BLK BLU/RED RED/BLU
END #1 X631 X631 X26 X26 X26 X26 X26 X26
END #2 (610) (615) X26 X26 X26 X26 X26 X26
X631 1 2
(1) (2)
WHT/YEL BLK
(610) (615)
X26 1 2 3 4 5 6
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLK BLU/RED RED/BLU
X26
1
610
611
612
3
4
616
617
615
6
3
612
611
610
1
6
615
617
616
4
X631 1
2
1
2
USB
TX1249924
TX1249924 —UN—09JAN18
NUMBER 1 2 610 611 612 615 616 617
USB Harness (W82) Wiring Diagram X26— Optional Connector (2 used)
X631— USB Harness Connector (marked USB) KR46761,0001737 -19-17JAN18-1/1
USB Jumper Harness (W83) Component Location For more information, see Cab Harness (W1) Component Location. (Group 9015.) KR46761,0001738 -19-17JAN18-1/1
TM13345X19 (23APR18)
9015-10-305
160GLC Excavator 042318 PN=615
System Diagrams
USB Jumper Harness (W83) Wiring Diagram COLOR WHT/YEL BLK
NUMBER 1 2
END #1 X631 X631
END #2 G6 G6
3 1
USB
2
1
2
1
X631
G6 1 2 3
2
(1) — (2)
WHT/YEL
X631
BLK
X631
1 2
TX1249928
(1) (2)
WHT/YEL BLK
G6 G6
TX1249928 —UN—09JAN18
X631
G6 1
USB Jumper Harness (W83) Wiring Diagram G6—USB Connector
X631— USB Harness Connector (marked USB) KR46761,0001739 -19-17JAN18-1/1
TM13345X19 (23APR18)
9015-10-306
160GLC Excavator 042318 PN=616
System Diagrams
Rear Cab Light Switch Harness (W84) Component Location E18
W86
K23
X632
X57 X633
W84
TX1251238
TX1251238 —UN—26JAN18
W85
S36
Rear Cab Light Switch Harness (W84) Component Location E18— Rear Cab Light K23— Rear Cab Light Relay S36— Rear Cab Light Switch W84—Rear Cab Light Switch Harness
W85—Rear Cab Light Relay X632— Rear Cab Light Harness Harness Connector W86—Rear Cab Light Harness X633— Rear Cab Light Switch X57— Rear Cab Light Connector Harness Connector (marked CAB LAMP REAR) (marked CAB LAMP REAR) KR46761,000173A -19-29JAN18-1/1
TM13345X19 (23APR18)
9015-10-307
160GLC Excavator 042318 PN=617
System Diagrams
Rear Cab Light Switch Harness (W84) Wiring Diagram COLOR RED/GRN YEL/RED
END #1 X633 X633
END #2 S36 S36
X633 2
1 1
2
CAB LAMP REAR
(1) (2)
4
2 5
X633 1 2
S36
1
1 10
S36 RED/GRN YEL/RED
S36 S36
1 2 3 4 5 6 7 8 9 10
TX1250124
— — — — — — — (2) (1) —
YEL/RED RED/GRN
X633 X633
TX1250124 —UN—05FEB18
NUMBER 1 2
Rear Cab Light Switch Harness (W84) Wiring Diagram S36— Rear Cab Light Switch
X633— Rear Cab Light Switch Harness Connector (marked CAB LAMP REAR) KR46761,000173B -19-10JAN18-1/1
Rear Cab Light Relay Harness (W85) Component Location For more information, see Rear Cab Light Switch Harness (W84) Component Location. (Group 9015.) KR46761,000173C -19-25JAN18-1/1
TM13345X19 (23APR18)
9015-10-308
160GLC Excavator 042318 PN=618
System Diagrams
Rear Cab Light Relay Harness (W85) Wiring Diagram END #2 K23 K23 (1) X632 X632 (5)
END #1 X57 X633 K23 K23 X57 X633
K23 4
2
1
2
3
5
4
3
1
K23 1 2 3 4 5
(3) (2) (1) — (4)
RED/GRN YEL/RED RED/GRN
(1) X633 X57
RED
X632
X57
4
1
5
2
CAB LAMP REAR
X632
X632 1 2
(4) (5)
RED BLK
K23 X57
CAB LAMP REAR
1
1
5
2
X57 1 2
(1) (5)
RED/GRN BLK
K23 X632
BLK/YEL YEL/RED
(5) K23
X633 X633
6
2
1
2
TX1250126
1 2
(6) (2)
TX1250126 —UN—25JAN18
NUMBER COLOR 1 RED/GRN 2 YEL/RED 3 RED/GRN 4 RED 5 BLK 6 BLK/YEL
Rear Cab Light Relay Harness (W85) Wiring Diagram K23— Rear Cab Light Relay X632— Rear Cab Light Harness X57— Rear Cab Light Connector Connector (marked CAB LAMP REAR) X633— Rear Cab Light Switch Harness Connector (marked CAB LAMP REAR) KR46761,000173D -19-10JAN18-1/1
Rear Cab Light Harness (W86) Component Location For more information, see Rear Cab Light Switch Harness (W84) Component Location. (Group 9015.) KR46761,000173E -19-25JAN18-1/1
TM13345X19 (23APR18)
9015-10-309
160GLC Excavator 042318 PN=619
System Diagrams
Rear Cab Light Harness (W86) Wiring Diagram
NUMBER 1 2
COLOR RED BLK
END #1 X632 X632
END #2 E18 E18
X632 1
2
2
+
E18 -
X632 1 2
(1) (2)
RED BLK
E18 E18
E18 + -
TX1250127
(1) (2)
RED BLK
X632 X632
TX1250127 —UN—11JAN18
1
Rear Cab Light Harness (W86) Wiring Diagram E18— Rear Cab Light
X632— Rear Cab Light Harness Connector KR46761,000173F -19-22JAN18-1/1
TM13345X19 (23APR18)
9015-10-310
160GLC Excavator 042318 PN=620
System Diagrams
Premium Seat Harness (W87) Component Location
A26 X642 R20 S37 X635 R21
X641 X640
S61
X639
A25
X638 X636 TX1251455 —UN—29JAN18
M12 M15 X634 X630A
X637 X630 X630B
TX1251455 Premium Seat Harness (W87) Component Location A25— Premium Seat Power S61— Seat Compressor Switch Converter X630— Premium Seat Harness A26— Premium Seat Controller Connector (marked 24V (PSC) POWER) M12— Seat Air Compressor Motor X630A—Premium Seat Harness M15— Premium Seat Blower Jumper Connector A R20— Upper Thermal Duct X630B—Premium Seat Harness Module Jumper Connector B R21— Lower Thermal Duct X634— Premium Seat Module Compressor Harness S37— Heated/Cooled Seat Switch Connector (marked COMPRESSOR)
X635— Heated/Cooled Seat Switch Connector X636— Premium Seat Power Converter Connector (marked INVERTER) X637— Heat Cool Lumbar Connector (marked HEAT/COOL LUMBAR) X638— Premium Seat Blower Connector X639— Upper Thermal Module Connector
X640— Lower Thermal Module Connector X641— Premium Seat Controller (PSC) Connector A X642— Premium Seat Controller (PSC) Connector B
DF89619,00B68F3 -19-29JAN18-1/1
TM13345X19 (23APR18)
9015-10-311
160GLC Excavator 042318 PN=621
System Diagrams
TM13345X19 (23APR18)
9015-10-312
160GLC Excavator 042318 PN=622
System Diagrams
Premium Seat Harness (W87) Wiring Diagram TX1250940 —UN—29JAN18
END #1 X635 X635 X635 X635 X635 X635 X635 X635 X638 X638 X638 X639 X639 X639 X639 X640 X640 X640 X640 X630 X634 X636 X637 X634 S61 X630A X630 X634 X636 X637 X642 X635 X634 X630A
END #2 X641 X641 X641 X641 X641 X641 X641 X641 X641 X641 X641 X641 X641 X642 X642 X641 X641 X642 X642 X636 (G01) X637 X642 S61 M12 X630B X636 (P01) X637 X641 (P03) (P03) M12 X630B
X637
X636
1 2 3 4
1 2 3 4
— — (P02) (G02)
BLU BLK
X636 X636
2
4
HEAT/COOL LUMBAR
12
3
3
BLU
RED
X635 X640 X639 X638
X635
X638
13 14 15 16 17 18 19 20 21 22 23 24
X637 4
1
3
2
1 2 3 4
— — (P03) (G03)
RED BLK
RED BLK
X630A X630A
X630B
2
2
1
1
X630 1 2
(P01) (G01)
RED BLK
X636 X636
X641 X642
X634 M F
X638 1
2
3
X634
X638 4
1 2 3 4 5
5
— (9) (10) (11) —
RED WHT BLK
X641 X641 X641
RED PNK BLU WHT BLK BRN ORG YEL GRN
(P03) X641 X641 X641 X641 X641 X641 X641 X641
F
F M
(G01A) BLK (P01A) RED
(G01) (P01)
X634 M
F M
(P04) (G04)
BLK RED
M12 S61
X635 X635 1
2
3
4
5
6
7
8
9
WHT BLK BRN ORG YEL GRN
X635 X635 X635 X635 X635 X635
BLK BRN BRN
X638 X640 X639
RED
X637
1 2 3 4 5 6 7 8 9
(P03B) (1) (2) (3) (4) (5) (6) (7) (8)
X630A
X642
1
5
3
1
6
4
2
(18) (14) (G03) (15) (P03A) (19)
1
BLU BLU BLK YEL RED YEL
3
4
X640
X642 1 2 3 4 5 6
2
X640 X639 X637 X639 (P03) X640
2
3
1 2 3 4
(14) (15) (13) (12)
B A C
X630A A B C
(P05) (G06) —
RED BLK
X630B X630B
F
X639 BLU YEL BRN GRN
X642 X642 X641 X641
M12 F
M12
4
F F
(G05) (P04)
(G04) (G05)
RED ORG
ORG BLK
S61 X634
X640 1 2 3 4
(18) (19) (17) (16)
BLU YEL BRN GRN
X642 X642 X641 X641
S61 1
4
1 4
X634 M12
S61
TX1250940 Premium Seat Harness (W87) Wiring Diagram Continued on next page
TM13345X19 (23APR18)
24V POWER
X637
1
(3) (4) (5) (6) (7) (8) — (11) (17) (13) — (P03)
(P05) (G06)
2
X639 PNK GRN GRN WHT
1 2
INVERTER
X641 (1) (16) (12) (10) — — (2) — — — — (9)
X630B
X630
13
24
X630 X630 X637 X637
1
4
X641
1 2 3 4 5 6 7 8 9 10 11 12
RED BLK BLU BLK
X636
X637 1
(P01) (G01) (P02) (G02)
COMPRESSOR
COLOR PNK BLU WHT BLK BRN ORG YEL GRN RED WHT BLK GRN BRN BLU YEL GRN BRN BLU YEL BLK BLK BLK BLK RED ORG BLK RED RED BLU RED RED RED BLK RED
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 G01 G01A G02 G03 G04 G05 G06 P01 P01A P02 P03 P03A P03B P04 P05
9015-10-313
160GLC Excavator 042318 PN=623
DF89619,00B68F4 -19-29JAN18-1/2
System Diagrams
TM13345X19 (23APR18)
9015-10-314
160GLC Excavator 042318 PN=624
System Diagrams
M12— Seat Air Compressor Motor X630B—Premium Seat Harness S61— Seat Compressor Switch Jumper Connector B X630— Premium Seat Harness X634— Premium Seat Connector (marked 24V Compressor Harness POWER) Connector (marked X630A—Premium Seat Harness COMPRESSOR) Jumper Connector A X635— Heated/Cooled Seat Switch Connector X636— Premium Seat Power Converter Connector (marked INVERTER)
X637— Heat Cool Lumbar Connector (marked HEAT/COOL LUMBAR) X638— Premium Seat Blower Connector X639— Upper Thermal Module Connector X640— Lower Thermal Module Connector
X641— Premium Seat Controller (PSC) Connector A X642— Premium Seat Controller (PSC) Connector B
DF89619,00B68F4 -19-29JAN18-2/2
Satellite (SAT) Harness (W6003) Component Location See Engine Interface Harness (W5) Component Location. (Group 9015-10.) RH60123,0000109 -19-10MAR11-1/1
Satellite (SAT) Harness (W6003) Wiring Diagram END #1 X6015 X6015 X6015 X6015 X6015
NUMBER G01 M01 M02 M03 P01
COLOR BLK PUR PUR PUR RED
END #2 X6016 X6016 X6016 X6016 X6016
TX1111520
A1 M01 A2 M02 A3 PLUG A4 PLUG B1 PLUG B2 PLUG B3 PLUG B4 PLUG C1 PLUG C2 PLUG C3 PLUG C4 PLUG
D1 PLUG D2 PLUG D3 PLUG D4 PLUG E1 PLUG E2 PLUG E3 PLUG E4 PLUG F1 PLUG F2 PLUG F3 PLUG F4 PLUG
G1 PLUG G2 PLUG G3 PLUG G4 PLUG H1 PLUG H2 PLUG H3 PLUG H4 PLUG J1 PLUG J2 PLUG J3 M03 J4 PLUG
K1 PLUG K2 PLUG K3 PLUG K4 PLUG L1 PLUG L2 PLUG L3 PLUG L4 PLUG M1 G01 M2 P01 M3 PLUG M4 PLUG
1 2 3 4 5 6
M01 M02 M03 G01 P01 PLUG
TX1111520 —UN—09APR12
X6016 X6015
Satellite (SAT) Harness (W6003) Wiring Diagram X6015—Satellite (SAT) Module Control Unit 48-Pin Connector
X6016—Engine Interface Harness-to-Satellite (SAT) Harness Connector DP27668,00009DC -19-31MAR15-1/1
TM13345X19 (23APR18)
9015-10-315
160GLC Excavator 042318 PN=625
System Diagrams
TM13345X19 (23APR18)
9015-10-316
160GLC Excavator 042318 PN=626
Group 15
Sub-System Diagnostics Controller Area Network (CAN) Theory of Operation Controller Area Network (CAN) Theory of Operation (S.N. —056599) TX1239515 —UN—31MAY17
X52B AIR CONDITIONER 10-PIN CONNECTOR
4
BLU
12
CAN 1
10
BLU
GRN
A6 RADIO
4
9
GRN
GRN
+
GRN
A
YEL
BLU CAN 1
20
W5 ENGINE INTERFACE HARNESS
B1
BLU
B11
CAN 1
INTERFACE CAN
-
A11 MACHINE CONTROLLER (BCZ)
GRN
B
W53 EXHAUST AFTERTREATMENT HARNESS
R11 INTERFACE CAN RESISTOR 2
B = X11
C12
GRN
GRN
D4
BLU
D5
CAN 1
CAN 1
GRN
A3 MAIN CONTROLLER D2 (MCZ)
BLU
D3
BLU
1
A23 -
CAN 0
BLU
A25
120
A26
YEL
A1
GRN
B1
A13
BLK/RED
1
A4 A28 MONITOR CONTROLLER (DSZ)
RED/GRN
2
A15 FLEX POWER CONTROLLER (FPC)
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
X2 MPDr 6-PIN CONNECTOR
YEL
35
GRN
44 -
A = X20 +
-
INTERFACE CAN
-
2
GRN
1
YEL
YEL
H1
CAN 0
BLU
BLU
K
GRN
LT GRN
H2
GRN
E15
GRN
GRN
P
YEL
YEL
G1
BLU
E16
BLU
BLU
R
GRN
LT GRN
G2
INTERFACE CAN
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
8
GRN
GRN
W4 ENGINE HARNESS
B
B5500 INTAKE 4 AIR SENSOR 3
YEL GRN
= X5501 = X5502 = X5503
INTERFACE CAN
YEL
A
= X6014 GRN
B
-
W5 ENGINE INTERFACE HARNESS
YEL
1
YEL
YEL
GRN
2
GRN
GRN
A
ENGINE CAN
CAN 0
J
E9
X3 CAB HARNESS-TO-MACHINE HARNESS 100-PIN CONNECTOR
R10 INTERFACE CAN RESISTOR 1
YEL
120
A
46
CAN 0
BLU
INTERFACE CAN
BLU
GRN
+
+ 120
GRN
GRN
A
R5601 CAN 0 TERMINATION RESISTOR
X5016 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 2
B
-
GRN
GRN CAN 0
B
YEL
120
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR E3
YEL
+
X5018 MACHINE HARNESS-TO-ENGINE INTERFACE HARNESS CONNECTOR 2 GRN
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
9
CAN 0
INTERFACE CAN
INTERFACE CAN
BLU
W2 MACHINE HARNESS CAN 0
J
GRN
-
GRN
GRN
YEL
A1 ENGINE CONTROL UNIT (ECU)
120
H
45
YEL CAN 0
BLU
8
AFTERTREATMENT CAN
120
+
GRN CAN 1
C2
GRN
D
GRN
B5502 SELECTIVE CATALYTIC 5 REDUCTION (SCR) INLET NOx SENSOR 6
-
BLU
GRN
+
A5 DATA CONVERTER
C
YEL
120
A24
120
GRN CAN 0
D2
CAN 0
D = X34
+
BLU
YEL INTERFACE CAN
CAN 0
INTERFACE CAN C6
YEL
B5503 5 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
+
BLU
9
6
ENGINE CAN
GRN
2
CAN 1 C11
YEL
X5070
GRN
C5
GRN
AFTERTREATMENT CAN
X42 CAN 1 CONNECTOR (NOT USED)
YEL
W62 DIESEL PARTICULATE FILTER (DPF) HARNESS
-
GRN
120
A7 AIR CONDITIONER CONTROLLER (ACF)
120
5
W1 CAB HARNESS
+
BLU
40
X52A AIR CONDITIONER 10-PIN CONNECTOR
W51 HEATER AND AIR CONDITIONER RELAY HARNESS
AFTERTREATMENT CAN
W41 HEATER AND AIR CONDITIONER HARNESS
R5603 ENGINE CAN TERMINATION RESISTOR
TX1239515 Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. —056599)
JL58967,0000740 -19-06FEB18-1/6
Continued on next page
TM13345X19 (23APR18)
9015-15-1
160GLC Excavator 042318 PN=627
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-2
160GLC Excavator 042318 PN=628
Sub-System Diagnostics
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) A15— Flex Power Controller (FPC) A6000—Modular Telematics Gateway (MTG) Controller B5500—Intake Air Sensor B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X2— MPDr 6-Pin Connector X5039—Engine Interface R5601—CAN 0 Termination X3— Cab Harness-to-Machine Harness-to-Exhaust Resistor Harness 100-Pin Connector Aftertreatment Harness R5603—Engine CAN Termination X11— Machine Controller 20-Pin Connector Resistor Connector B X5070—Exhaust Aftertreatment R5605—Aftertreatment CAN X20— Monitor Controller 28-Pin Harness-to-Diesel Termination Resistor Connector A Particulate Filter (DPF) W1—Cab Harness X34— Cab Harness-to-Main Harness Connector W2—Machine Harness Controller 30-Pin X5501—Engine Control Unit W4—Engine Harness Connector D (ECU) Connector 1 W5—Engine Interface Harness X42— CAN 1 Connector (not X5502—Engine Control Unit W41—Heater and Air Conditioner used) (ECU) Connector 2 Harness X52A— Air Conditioner 10-Pin X5503—Engine Control Unit W51—Heater and Air Conditioner Connector (ECU) Connector 3 Relay Harness X52B— Air Conditioner 10-Pin X6014—Modular Telematics W53—Exhaust Aftertreatment Connector Gateway (MTG) Control Harness X5016—Engine Interface Unit 48-Pin Connector W62—Diesel Particulate Filter Harness-to-Engine (DPF) Harness Harness Connector 2 X1— Service ADVISOR™ X5018—Machine Harness-toDiagnostic Connector Engine Interface Harness Connector 2
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.
• Engine Control Unit (ECU) (A1) • Main Controller (MCZ) (A3) • Monitor Controller (DSZ) (A4) • Flex Power Controller (FPC) (A15) • Modular Telematics Gateway (MTG) Controller (A6000)
The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite of 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.
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
The 120-ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors. With the key switch in the OFF position, the resistance between the CAN high and CAN low circuits would measure 55—65 ohms. Resistance drops in half because there are two paths for electrical current to flow in a parallel circuit. Total circuit resistance will always be less than any resistors in the circuit. Total circuit resistance can be calculated by using the following equation: R1 x R2 / (R1 + R2) = Total Resistance 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 five CAN circuits: CAN 0, CAN 1, interface CAN, engine CAN, and aftertreatment CAN. CAN 0—The CAN 0 circuit provides the communication link for the following devices:
Theory of Operation. (Group 9015-15.)
CAN 0 also includes the following components:
• CAN 0 Termination Resistor (R5601) • Service ADVISOR™ Diagnostic Connector (X1) CAN 0 utilizes two terminating resistors: CAN 0 termination resistor (R5601) and another located inside monitor controller (DSZ) (A4), which is not accessible. The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application. (Group 9015-20.) CAN 1—The CAN 1 circuit provides the communication link for the following devices:
• Main Controller (MCZ) (A3) • Monitor Controller (DSZ) (A4) • Data Converter (A5) • Radio (A6) • Air Conditioner Controller (ACF) (A7) • Machine Controller (BCZ) (A11) Operations and functions of the individual devices on CAN 1 are covered separately.
• For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM13345X19 (23APR18)
9015-15-3
JL58967,0000740 -19-06FEB18-2/6
160GLC Excavator 042318 PN=629
Sub-System Diagnostics
• For the DSZ, see Monitor Controller (DSZ) Circuit
• Intake Air Sensor (B5500)
Theory of Operation. (Group 9015-15.) • For the BCZ, see Machine Controller (BCZ) Circuit Theory of Operation. (Group 9015-15.)
Engine CAN also includes the following components:
CAN 1 utilizes two terminating resistors: one is located inside monitor controller (DSZ) (A4) and another is located inside machine controller (BCZ) (A11). These resistors are not accessible. Interface CAN—The interface CAN circuit provides the communication link for the following devices:
• Data Converter (A5) • Flex Power Controller (FPC) (A15) • Modular Telematics Gateway (MTG) Controller (A6000) 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).
• Engine Control Unit (ECU) (A1) • Engine CAN Termination Resistor (R5603) The engine CAN utilizes two terminating resistors: engine CAN termination resistor (R5603) and another located inside the ECU, which is not accessible. For information on John Deere PowerTech™ engines and components for engine model 4045HT076, see 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.) Aftertreatment CAN—The aftertreatment CAN circuit provides the communication link for the following devices:
• Selective Catalytic Reduction (SCR) Inlet NOx Sensor (B5502)
• Selective Catalytic Reduction (SCR) Outlet NOx Sensor
Interface CAN also includes the following components:
(B5503)
• Interface CAN Resistor 1 (R10) • Interface CAN Resistor 2 (R11) • Service ADVISOR™ Diagnostic Connector (X1)
Aftertreatment CAN also includes the following components:
Interface CAN utilizes two terminating resistors: interface CAN resistor 1 (R10) and interface CAN resistor 2 (R11). The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application. (Group 9015-20.) Engine CAN—The engine CAN circuit provides the communication link for the following device:
• Engine Control Unit (ECU) (A1) • Aftertreatment CAN Termination Resistor (R5605) The aftertreatment CAN utilizes two terminating resistors: aftertreatment CAN termination resistor (R5605) and another located inside the ECU, which is not accessible. For information on John Deere PowerTech™ engines and components for engine model 4045HT076, see 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
Service ADVISOR is a trademark of Deere & Company PowerTech is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-15-4
JL58967,0000740 -19-06FEB18-3/6
160GLC Excavator 042318 PN=630
Sub-System Diagnostics
Controller Area Network (CAN) Circuit Theory of Operation (S.N. 056600— ) TX1239516 —UN—31MAY17
W1 CAB HARNESS
GRN
4
CAN 1 BLU
5
BLU
10
BLU
20
GRN
4
GRN
9
GRN
A
YEL CAN 1 B1
BLU
B11
CAN 1
INTERFACE CAN
-
A11 MACHINE CONTROLLER (BCZ)
GRN
B
R11 INTERFACE CAN RESISTOR 2
W54 DIESEL EXHAUST FLUID (DEF) HARNESS
-
GRN
+ 120
A7 AIR CONDITIONER CONTROLLER (ACF)
120
BLU
A6 RADIO
+
40
12
W5 ENGINE INTERFACE HARNESS
B = X11
28
29
AFTERTREATMENT CAN AFTERTREATMENT CAN
30
YEL
3
GRN
2
W53 EXHAUST AFTERTREATMENT HARNESS
31
YEL
YEL
GRN
8
GRN
GRN
GRN
CAN 0 D = X34
GRN
A24
BLU
A23
BLK/RED
1
A4 A28 MONITOR CONTROLLER (DSZ)
RED/GRN
2
INTERFACE CAN
E3
GRN
GRN
J
YEL
CAN 0 B
GRN
45
H1
E9
BLU
BLU
K
GRN
LT GRN
H2
GRN
E15
GRN
GRN
P
YEL
YEL
G1
BLU
E16
BLU
BLU
R
GRN
LT GRN
G2
YEL
2
GRN
1
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
8
GRN
GRN
W4 ENGINE HARNESS
INTERFACE CAN
YEL
A
= X6014 GRN
W5 ENGINE INTERFACE HARNESS
YEL GRN
B
B5500 INTAKE 4 AIR SENSOR 3
= X5501 = X5502 = X5503
YEL
1
YEL
YEL
GRN
2
GRN
GRN
A
ENGINE CAN
B
-
X3 CAB HARNESS-TO-MACHINE HARNESS 100-PIN CONNECTOR
R10 INTERFACE CAN RESISTOR 1
YEL CAN 0
INTERFACE CAN
46
CAN 0
BLU
INTERFACE CAN
GRN
120
A
44
+
INTERFACE CAN BLU
GRN
A
R5601 CAN 0 TERMINATION RESISTOR
X5016 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 2
B
-
GRN
YEL
120
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
YEL
+
X5018 MACHINE HARNESS-TO-ENGINE INTERFACE HARNESS CONNECTOR 2
9
A1 ENGINE CONTROL UNIT (ECU)
CAN 0
BLU
YEL
CAN 0
J
W2 MACHINE HARNESS
INTERFACE CAN
GRN
GRN
A = X20
CAN 0
H
35
-
BLU
YEL
120
D
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
AFTERTREATMENT CAN
- +
CAN 0
A13
X2 MPDr 6-PIN CONNECTOR
YEL CAN 0
-
B1
GRN
C
+ 120
GRN
120
A25
-
BLU
120
A26
A1
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
+
- +
GRN CAN 1
YEL
A15 FLEX POWER CONTROLLER (FPC)
-
CAN 0
A5 DATA CONVERTER
120
BLU
C6
C2
120
+
INTERFACE CAN
GRN
GRN
D3
D2
AFTERTREATMENT CAN
C12
BLU
YEL INTERFACE CAN
B5502 SELECTIVE CATALYTIC 5 REDUCTION (SCR) INLET NOx SENSOR 6
+
BLU
GRN
A3 MAIN CONTROLLER D2 (MCZ)
B5503 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
ENGINE CAN
CAN 1 C11
D5
5
9
AFTERTREATMENT CAN
GRN
C5
BLU
CAN 1
CAN 1
GRN
X5070 YEL
BLU
D4
GRN
1
GRN
YEL
GRN
AFTERTREATMENT CAN
2
6
YEL
X5037 X42 CAN 1 CONNECTOR (NOT USED)
YEL
W62 DIESEL PARTICULATE FILTER (DPF) HARNESS
A5507B DIESEL EXHAUST FLUID (DEF) TANK HEADER B
GRN
X52A AIR CONDITIONER 10-PIN CONNECTOR
YEL
W51 HEATER AND AIR CONDITIONER RELAY HARNESS
GRN
X52B AIR CONDITIONER 10-PIN CONNECTOR
YEL
W41 HEATER AND AIR CONDITIONER HARNESS
R5603 ENGINE CAN TERMINATION RESISTOR
TX1239516 Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
9015-15-5
160GLC Excavator 042318 PN=631
JL58967,0000740 -19-06FEB18-4/6
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-6
160GLC Excavator 042318 PN=632
Sub-System Diagnostics
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) A15— Flex Power Controller (FPC) A5507B—Diesel Exhaust Fluid (DEF) Tank Header B A6000—Modular Telematics Gateway (MTG) Controller B5500—Intake Air Sensor B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X2— MPDr 6-Pin Connector X5039—Engine Interface R5601—CAN 0 Termination X3— Cab Harness-to-Machine Harness-to-Exhaust Resistor Harness 100-Pin Connector Aftertreatment Harness R5603—Engine CAN Termination X11— Machine Controller 20-Pin Connector Resistor Connector B X5070—Exhaust Aftertreatment R5605—Aftertreatment CAN X20— Monitor Controller 28-Pin Harness-to-Diesel Termination Resistor Connector A Particulate Filter (DPF) W1—Cab Harness X34— Cab Harness-to-Main Harness Connector W2—Machine Harness Controller 30-Pin X5501—Engine Control Unit W4—Engine Harness Connector D (ECU) Connector 1 W5—Engine Interface Harness X42— CAN 1 Connector (not X5502—Engine Control Unit W41—Heater and Air Conditioner used) (ECU) Connector 2 Harness X52A— Air Conditioner 10-Pin X5503—Engine Control Unit W51—Heater and Air Conditioner Connector (ECU) Connector 3 Relay Harness X52B— Air Conditioner 10-Pin X6014—Modular Telematics W53—Exhaust Aftertreatment Connector Gateway (MTG) Control Harness X5016—Engine Interface Unit 48-Pin Connector W54—Diesel Exhaust Fluid (DEF) Harness-to-Engine Harness Harness Connector 2 W62—Diesel Particulate Filter X5018—Machine Harness-to(DPF) Harness Engine Interface Harness X1— Service ADVISOR™ Connector 2 Diagnostic Connector X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1
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.
CAN 0—The CAN 0 circuit provides the communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Main Controller (MCZ) (A3) • Monitor Controller (DSZ) (A4) • Flex Power Controller (FPC) (A15) • Modular Telematics Gateway (MTG) Controller (A6000)
The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite of 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.
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.)
The 120-ohm termination resistors, usually located at opposite ends of the CAN bus, also help prevent signal errors. With the key switch in the OFF position, the resistance between the CAN high and CAN low circuits would measure 55—65 ohms. Resistance drops in half because there are two paths for electrical current to flow in a parallel circuit. Total circuit resistance will always be less than any resistors in the circuit. Total circuit resistance can be calculated by using the following equation: R1 x R2 / (R1 + R2) = Total Resistance 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 five CAN circuits: CAN 0, CAN 1, interface CAN, engine CAN, and aftertreatment CAN. TM13345X19 (23APR18)
• For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
• For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
CAN 0 also includes the following components:
• CAN 0 Termination Resistor (R5601) • Service ADVISOR™ Diagnostic Connector (X1) CAN 0 utilizes two terminating resistors: CAN 0 termination resistor (R5601) and another located inside monitor controller (DSZ) (A4), which is not accessible. The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application. (Group 9015-20.) CAN 1—The CAN 1 circuit provides the communication link for the following devices:
• Main Controller (MCZ) (A3) • Monitor Controller (DSZ) (A4) • Data Converter (A5) • Radio (A6) • Air Conditioner Controller (ACF) (A7) • Machine Controller (BCZ) (A11)
Continued on next page
9015-15-7
JL58967,0000740 -19-06FEB18-5/6
160GLC Excavator 042318 PN=633
Sub-System Diagnostics
Operations and functions of the individual devices on CAN 1 are covered separately.
• For the MCZ, see Main Controller (MCZ) Circuit Theory
• Intake Air Sensor (B5500) Engine CAN also includes the following components:
• Engine Control Unit (ECU) (A1) • Engine CAN Termination Resistor (R5603)
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.)
The engine CAN utilizes two terminating resistors: engine CAN termination resistor (R5603) and another located inside the ECU, which is not accessible.
CAN 1 utilizes two terminating resistors: one is located inside monitor controller (DSZ) (A4) and another is located inside machine controller (BCZ) (A11). These resistors are not accessible.
For information on John Deere PowerTech™ engines and components for engine model 4045HT076, see 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
Interface CAN—The interface CAN circuit provides the communication link for the following devices:
Aftertreatment CAN—The aftertreatment CAN circuit provides the communication link for the following devices:
• Data Converter (A5) • Flex Power Controller (FPC) (A15) • Modular Telematics Gateway (MTG) Controller (A6000)
• Diesel Exhaust Fluid (DEF) Tank Header B (A5507B) • Selective Catalytic Reduction (SCR) Inlet NOx Sensor
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). Interface CAN also includes the following components:
• Interface CAN Resistor 1 (R10) • Interface CAN Resistor 2 (R11) • Service ADVISOR™ Diagnostic Connector (X1) Interface CAN utilizes two terminating resistors: interface CAN resistor 1 (R10) and interface CAN resistor 2 (R11). The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
(B5502)
• Selective Catalytic Reduction (SCR) Outlet NOx Sensor (B5503)
Aftertreatment CAN also includes the following components:
• Engine Control Unit (ECU) (A1) • Aftertreatment CAN Termination Resistor (R5605) The aftertreatment CAN utilizes two terminating resistors: aftertreatment CAN termination resistor (R5605) and another located inside the ECU, which is not accessible. For information on John Deere PowerTech™ engines and components for engine model 4045HT076, see 4045 PowerTech™ OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120119.)
Engine CAN—The engine CAN circuit provides the communication link for the following device: Service ADVISOR is a trademark of Deere & Company PowerTech is a trademark of Deere & Company JL58967,0000740 -19-06FEB18-6/6
TM13345X19 (23APR18)
9015-15-8
160GLC Excavator 042318 PN=634
Sub-System Diagnostics
Starting and Charging Circuit Theory of Operation TX1254652 —UN—09APR18
G1
G2
ACC
RED
M ST
WHT
F18 5A FUSE
S1 KEY SWITCH
5
YEL/BLK
WHT/BLK
F4 20A FUSE
3
2
1
RED
BLU
YEL/GRN
RED
WHT
4
YEL/GRN
G2
V10 STARTER PROTECTION DIODE
G3 ALTERNATOR
YEL/GRN
G02 BLK
V44 STARTER RELAY DIODE
BLU
BLU ORG
WHT RED WHT
ORG
BLU
YEL 2
X65 V9 PILOT SHUTOFF DIODE
3
4
K1 LOAD DUMP RELAY WHT
X65
3
V20 PILOT SHUTOFF SWITCH DIODE
3
5
BLK
1
1
BLK
M1 STARTER MOTOR
G02 BLK
BLK
1
RED
TX1254652
ORG
X65
2 5246 LT BLU VLT WHT WHT/RED YEL/GRN E330 WHT VLT/GRN
CONTINUE NEXT PAGE Starting and Charging Circuit Theory of Operation Schematic (1 of 2) Continued on next page
TM13345X19 (23APR18)
S4 PILOT SHUTOFF SWITCH 2
2
E03 WHT
BLK
WHT RED WHT
WHT
B
RED
G02 BLK
S
ORG
4
E03 WHT
YEL/GRN
BLK
2
K34 STARTER RELAY
WHT
BLK
F60 65A FUSE
E22 BATTERY DISCONNECT INDICATOR LIGHT
V7 START RELAY DIODE
3
WHT/RED
S91 BATTERY DISCONNECT SWITCH
-
1
BLK
S3 PILOT SHUTOFF SWITCH 1
RED
G2 BATTERY
X175
5246 LT BLU
3
1 2
E03 WHT
+
F45 30A FUSE
E13 WHT
BLK
K19 BATTERY RELAY
RED
A
BLK
WHT
WHT
E
B
4
VLT/GRN
VLT/GRN
S
5
1
-
WHT
V1 BATTERY RELAY DIODE
2
WHT/BLK
RED
+
G1 BATTERY
K4 STARTER CUT RELAY
3
D+
V5 STARTER CUT RELAY DIODE
P22 RED
1
G02 BLK
F61 45A FUSE
F7 5A FUSE
P22 RED
BLK
RED
E03 WHT
RED
P22 RED
VLT/GRN
X47
WHT
VLT/GRN
WHT/RED WHT/RED
3
WHT/RED
WHT/RED
B1+
VLT/GRN WHT/RED
RED
VLT/GRN
ST
V3 LOAD DUMP RELAY DIODE
WHT
BLU
4
WHT
WHT
4
5
V4 SECURITY DIODE
RED
5
5
2
K13 KEY CUT RELAY
3
RED
WHT/GRN
2
BLU
G1
WHT
RED
BAT
K11 IDLE STOP RELAY
ORG
3
RED
1
WHT
WHT
1
1
YEL/BLK
YEL/GRN WHT/BLU
M
4
V11 ACCESSORY CUT DIODE
RED GRN YEL/GRN YEL/BLK GRN/WHT RED
VLT/GRN
ACC
2
K12 ACCESSORY CUT RELAY
YEL/BLK
RED
3
BLU
HEAT OFF ACC ON START
1
V12 STARTER CUT DIODE
BLU
6
BLU
BLU
BLU BLU
RED
RED GRN YEL/GRN YEL/BLK GRN/WHT
GRN
GRN/WHT
B
POSITION HEAT OFF ACC ON START
9015-15-9
160GLC Excavator 042318 PN=635
JJ03229,0001173 -19-06APR18-1/6
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-10
160GLC Excavator 042318 PN=636
Sub-System Diagnostics E22— Battery Disconnect G1—Battery Indicator Light G2—Battery F4— Solenoid 20 A Fuse (marked G3—Alternator SOLENOID) K1—Load Dump Relay F7— Start Position Signal 5 A K4—Starter Cut Relay Fuse (marked START) K11— Idle Stop Relay F18— Idle Stop 5 A Fuse (marked K12— Accessory Cut Relay IDLE STOP) K13— Key Cut Relay F45— Starter In-Line 30 A Fuse K19— Battery Relay F60— Alternator 65 A Fuse K34— Starter Relay F61— Battery 45 A Fuse M1—Starter Motor S1— Key Switch S3— Pilot Shutoff Switch 1 S4— Pilot Shutoff Switch 2
S91— Battery Disconnect Switch 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 V11— Accessory Cut Diode V12— Starter Cut Diode
Continued on next page
TM13345X19 (23APR18)
9015-15-11
V20— Pilot Shutoff Switch Diode V44— Starter Relay Diode X47— Cab Harness-to-Key Switch Harness Connector X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector X175— Machine Harness-toEngine Interface Harness Connector 1
JJ03229,0001173 -19-06APR18-2/6
160GLC Excavator 042318 PN=637
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-12
160GLC Excavator 042318 PN=638
Sub-System Diagnostics
TX1239565 —UN—01JUN17
RED
RED
RED
P01 RED 3
C7
RED/BLK
2
1
2
21
32
54
5022 RED 5022 RED
RED
E6
3
5429 WHT
C5 E5
YEL
F3
RED A
X5604 ENGINE HARNESS-TO-GLOW PLUG HARNESS CONNECTOR
D
E
24
13
X5018 MACHINE HARNESS-TOENGINE INTERFACE HARNESS CONNECTOR 2
12
07
22
14
50
E = X35 F = X36 34
30
12
X5016
05
E330 WHT
F13
A1 ENGINE CONTROL UNIT (ECU)
= X5501
23
14
= X5502 = X5503
E305 GRN
D = X22
R4
X5018
5246 LT BLU
C VLT/GRN
B = X21
C = X33
5246 BLU
WHT/RED
VLT
ORG
D8 B10 A17
A3 MAIN CONTROLLER (MCZ)
A = X20
R3
E4
YEL/GRN
A4 MONITOR CONTROLLER (DSZ)
R2
R19 GLOW PLUG RESISTOR
5671 BRN
F2
PUR
F1
1
4
Y5501 FUEL TRANSFER PUMP DK GRN
2
A = X10
RED/BLK
M
ORG
BLU
B18
YEL/GRN
RED/BLU
B17
RED
BLU/BLK
A16
RED
RED/BLK
D16
A4
B
X5018
RED
GRN/WHT
BLU
X5018
5022 RED
RED/BLK
A11 MACHINE CONTROLLER (BCZ)
K16 GLOW PLUG RELAY R1
5122 RED
1
RED/BLU
C2
F37 20A FUSE
5122 RED
C1
F36 20A FUSE
RED
BLU
A5 DATA CONVERTER
F63 50A FUSE
BLU
F9 10A FUSE
F14 5A FUSE
RED
F17 5A FUSE
F8 20A FUSE
5222 RED
F10 5A FUSE
RED
RED
5222 RED
RED GRN YEL/GRN YEL/BLK GRN/WHT RED
ORG 5246 LT BLU VLT WHT/RED YEL/GRN E330 WHT VLT/GRN
TX1239565 Starting and Charging Circuit Theory of Operation Schematic (2 of 2) Continued on next page
TM13345X19 (23APR18)
9015-15-13
160GLC Excavator 042318 PN=639
JJ03229,0001173 -19-06APR18-3/6
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-14
160GLC Excavator 042318 PN=640
Sub-System Diagnostics
A1—Engine Control Unit (ECU) A3—Main Controller (MCZ) A4—Monitor Controller (DSZ) A5—Data Converter A11— Machine Controller (BCZ) 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) F14— Monitor 5 A Fuse (marked MONITOR)
F17— Power On 5 A Fuse X20— Monitor Controller 28-Pin (marked POWER ON) Connector A F36— Engine Control Unit (ECU) X21— Monitor Controller 36-Pin 20 A Fuse (marked ECU P2) Connector B F37— Engine Control Unit (ECU) X22— Monitor Controller 16-Pin 20 A Fuse (marked ECU P3) Connector D F63— Glow Plug 50 A Fuse X33— Cab Harness-to-Main K16— Glow Plug Relay Controller 17-Pin R1—Glow Plug 1 Connector C R2—Glow Plug 2 X35— Cab Harness-to-Main R3—Glow Plug 3 Controller 24-Pin R4—Glow Plug 4 Connector E R19— Glow Plug Resistor X36— Cab Harness-to-Main X10— Machine Controller 8-Pin Controller 26-Pin Connector A Connector F X5016—Engine Interface Harness-to-Engine Harness Connector 2
Unswitched power is supplied to the following components:
• Battery Relay (K19) • Key Switch (S1) (from battery 45 A fuse [F61]) • Main Controller (MCZ) (A3) (from data converter
and main controller battery power 5 A fuse [marked CONTROLLER] [F10]) • Machine Controller (BCZ) (A11) (from data converter and main controller battery power 5 A fuse [marked CONTROLLER] [F10]) • Data Converter (A5) (from data converter and main controller battery power 5 A fuse [marked CONTROLLER] [F10]) • Engine Control Unit (ECU) (A1) - From Engine Control Unit (ECU) 20 A Fuse (marked ECU P1) (F8) - From Engine Control Unit (ECU) 20 A Fuse (marked ECU P2) (F36) - From Engine Control Unit (ECU) 20 A Fuse (marked ECU P3) (F37) • Monitor Controller (DSZ) (A4) (from radio backup 10 A fuse [marked BACK UP] [F9]) • Load Dump Relay (K1)
relay (K12). Utilizing the normally closed contacts of accessory cut relay, power is supplied through accessory cut diode (V11) and monitor 5 A fuse (F14) to pin B17 of the monitor controller (DSZ) (A4), powering 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. 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). Utilizing the normally closed contacts of the key cut relay, current is passed to pin A16 of monitor controller (A4), indicating the key switch is in the ON/START position. Engine Start
Battery Disconnect Switch The battery disconnect switch (S91) is used to isolate electrical power from batteries (G1 and G2) to ground. The battery disconnect switch has two positions: OFF and ON. Once the machine has been shut down with key switch, the battery disconnect indicator light (E22) stays illuminated until turning the battery disconnect switch to the OFF position is safe. For more information about the battery disconnect switch, see Battery Disconnect Switch. (Operator’s Manual.) For more information about the battery disconnect indicator light, see Engine Control Unit (ECU) Circuit Theory of Operation and see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) Ignition ON When key switch (S1) is placed in the ON position, current flows from key switch pin ACC to pin 3 of accessory cut
When key switch (S1) is moved to the START position, current flows 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 A17 of monitor controller (A4), indicating the key switch is in the START position. Utilizing the normally closed contacts of starter cut relay, power is supplied to pin 1 of starter relay (K34). With battery relay (K19) energized from the ignition ON position, power from battery relay pin A is supplied to pin B of starter motor (M1) and pin 3 of starter relay (K34) through starter in-line 30 A fuse (F45). Starter relay (K34) is a normally open relay, which closes when power is present on pin 1 and ground is present on pin 2. Energized starter relay provides power from battery relay (K19) to pin S of starter motor (M1). 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.
Continued on next page
TM13345X19 (23APR18)
X5018—Machine Harness-toEngine Interface Harness Connector 2 X5501—Engine Control Unit (ECU) Connector 1 X5502—Engine Control Unit (ECU) Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X5604—Engine Harness-to-Glow Plug Harness Connector Y5501—Fuel Transfer Pump
9015-15-15
JJ03229,0001173 -19-06APR18-4/6
160GLC Excavator 042318 PN=641
Sub-System Diagnostics
Starter cut relay (K4) utilizes the normally closed contacts of the relay to continue the start signal to pin 1 of starter relay (K34). Starter cut relay is energized when there is power from the key switch present at pin 1 and ground on pin 2, preventing the starter motor from cranking the engine. The ground on pin 2 is supplied from the monitor controller (DSZ) (A4), pilot shutoff switches (S3 and S4), main controller (MCZ) (A3), or the engine control unit (ECU) (A1). A ground from the monitor controller is the result of a security code violation or machine warning alarm. 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. A ground from the engine control unit is based on the engine run status, which prevents the starter from engaging while the engine is running.
engine control unit (ECU) connector 1 (X5501) to pin 1 of the glow plug relay (K16), current is supplied from pin 32 of ECU connector 1 to pin 2 of the glow plug relay, energizing the relay. Current from pin 3 on glow plug relay is sent to pin 54 of ECU via engine control unit (ECU) connector 1 (X5501) for diagnostics and to glow plugs (R1—R4). With the relay energized, the glow plugs heat the air in the combustion chamber for a set duration. When the ECU determines that coolant temperature is at operating temperature, the ECU stops current to the glow plug relay and glow plugs. The operator may start the engine at any time during the preheat; however, the ECU will de-energize the glow plug relay during cranking. For more information on the glow plugs (cold start) circuit, see Cold Weather Starting Aid. (Group 9010-05.)
When a warning alarm or security code error is detected, pin D16 of monitor controller is connected to ground. When a malfunction in the pilot shutoff circuit is detected, pin B10 of monitor controller is connected to ground. With either pin D16 or pin B10 of the monitor controller connected to ground the starter cut relay (K4) is energized through security diode (V4), removing the start signal from 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. When pilot shutoff switches 1 and 2 (S3 and S4) are closed and pilot shutoff lever is 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 from pin S of starter motor. Removing power from pin S prevents the activation of starter motor when pilot shutoff lever is in the unlocked (DOWN) position. For more information on the pilot shutoff circuit, see Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.)
Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running.
When the engine is running, the engine control unit (ECU) (A1) will ground to pin 2 of starter cut relay (K4), opening the normally closed contacts of the starter cut relay, removing the start signal from starter relay (K34) and preventing the starter from engaging while the engine is running. When the engine is not running, the engine control unit will not ground starter cut 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), and pilot shutoff switch diode (V20) work as logic gates to allow more than one device to control one circuit without backfeeding other circuits.
Charging Circuit
Pin B1+ 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 and engine is running, current flows from pin 34 of engine control unit (ECU) connector 2 (X5502) to pin D+ of the alternator. Current from pin D+ of the alternator flows through the alternator field windings, causing excitation of the windings. Current then flows from pin B1+ of the alternator through pins A and B of battery relay (K19) to battery positive (+) terminal, charging the batteries (G1 and G2). The ECU monitors battery and alternator system voltage. When low voltage is detected, the ECU sends message over the controller area network (CAN) to the monitor controller (DSZ) (A4), the DSZ then activates the alternator alarm indicator on the monitor. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Auto-Shutdown Control The auto-shutdown feature allows the main controller (MCZ) to automatically turn off ignition power and stop the engine in order to reduce fuel consumption if no operation is active for set amount of 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:
Glow Plugs (Cold Start) Circuit The engine control unit (ECU) determines when glow plugs are needed. The ECU provides ground to pin 21 of
• Pilot shutoff lever is in the locked (UP) position • Auto-shutdown enabled • Engine coolant temperature is greater than 60°C (140°F) and less than 100°C (212°F)
• Manual exhaust filter cleaning not active
Continued on next page
TM13345X19 (23APR18)
9015-15-16
JJ03229,0001173 -19-06APR18-5/6
160GLC Excavator 042318 PN=642
Sub-System Diagnostics
When auto-shutdown timer expires, the main controller (MCZ) reduces demand engine speed to slow idle, and provides ground to the idle stop relay (K11) via pin C5. With idle stop relay energized, accessory cut relay (K12) and key cut relay (K13) are energized via ground at idle stop relay pin 5 and MCZ pin C5. With accessory cut and key cut relays energized, power is removed from 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 time duration is selectable by accessing the SETTINGS MENU >> AUTO SHUTDOWN menu in the monitor service menu. See Main Menu—Setting Menu—Auto-Shutdown. (Operator’s Manual.) Load Dump Circuit The load dump circuit consists of load dump relay (K1) and load dump relay diode (V3).
When the alternator (G3) is generating electricity, voltage is detected by the engine control unit (ECU) and the ECU sends a message over the controller area network (CAN) to the monitor controller (DSZ) (A4), causing the monitor controller to put pin D8 of monitor controller to ground and 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 D8 retains a ground path for load dump relay (K1) until alternator (G3) stops producing output voltage, keeping the battery relay (K19) energized and providing a path to the batteries (G1 and G2) for any power produced by the alternator (G3) as the engine slows to a stop. Therefore, 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.) JJ03229,0001173 -19-06APR18-6/6
TM13345X19 (23APR18)
9015-15-17
160GLC Excavator 042318 PN=643
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-18
160GLC Excavator 042318 PN=644
Sub-System Diagnostics
Monitor Controller (DSZ) Circuit Theory of Operation TX1254799 —UN—09APR18
RED
V12 STARTER CUT DIODE
G1
WHT/GRN
5
V10 STARTER PROTECTION DIODE
YEL/GRN
WHT
G2 M
BLU
4
BLU
1
2
5
4
1
2
V5 STARTER CUT RELAY DIODE
WHT
S
BLK
D5 D4
A = X31 D = X34
WHT WHT
X5018 M12 YEL (CAN 0 HIGH) M13 GRN (CAN 0 LOW)
160GLC Excavator 042318 PN=645
S3 PILOT SHUTOFF SWITCH 1
S4 PILOT SHUTOFF SWITCH 2
K
YEL/BLK
1
3
1
1 ORG
BLU
YEL
BLU
A25
GRN
A24
J 02 01
A1 ENGINE CONTROL UNIT (ECU)
34 = X5502 = X5503
2
5
2
X65
X65
WHT/RED A26 A17
3
V20 PILOT SHUTOFF SWITCH DIODE
4
K1 LOAD DUMP RELAY
WHT
X65
3
D16
D8
2
B10
A4 MONITOR CONTROLLER (DSZ)
A23 D6
A22
B35
B36
A = X20
C = X23
B = X21
D = X22
G = X24
B11
X76 BLK
YEL/BLU
GRN/BLK
Monitor Controller (DSZ) Circuit Schematic (1 of 2) Continued on next page
BLK
RED
A3 MAIN CONTROLLER (MCZ)
A15 FLEX POWER CONTROLLER A1 B1 (FPC)
WHT
9015-15-19
5246 LT BLU
GRN
BLU
GRN
BLU D2 D3
A1
RED
G3 ALTERNATOR
RED ORG
CAN 0
TX1254799
TM13345X19 (23APR18)
GRN
BLU
BLU
E03 WHT
M1 STARTER MOTOR
D+
B1+
12
BLU
G02 BLK RED
F7 5A FUSE
CAN 1
CAN 0
BLK
G02 BLK
X5016
CAN 1
B
E03 WHT
V44 STARTER RELAY DIODE
2
5246 BLU
E03 WHT E03 WHT
4
K34 STARTER RELAY
RED
BLK
2
G02 BLK
BLK
S91 BATTERY DISCONNECT SWITCH
V7 START RELAY DIODE
3
4
20
P22 RED
P22 RED
E13 WHT 1
BLK
F60 65A FUSE
WHT
G2 BATTERY
K19 BATTERY RELAY
F45 30A FUSE
1
X175
WHT/BLK
RED B
BLK
B11 B1
P22 RED
+
A
4
-
WHT S
5
12
40
B = X11
GRN
2
C11 C5
4
K2 PILOT SHUTOFF SOLENOID RELAY
GRN
G1 BATTERY
K4 STARTER CUT RELAY
3
GRN
1
+
A6 RADIO
BLU
RED
F61 45A FUSE
A5 DATA CONVERTER
5
3
1
A7 AIR CONDITIONER CONTROLLER (ACF) GRN
A11 MACHINE CONTROLLER (BCZ)
BLU
RED
WHT WHT
WHT/RED
WHT/RED WHT/RED
3
WHT/RED
WHT/RED
X47
V1 BATTERY RELAY DIODE
VLT/GRN
VLT/GRN
WHT/RED
ST
E
VLT/GRN
3
VLT
VLT/RED
VLT/GRN
RED
5246 LT BLU
K5 SECURITY RELAY
3
V3 LOAD DUMP RELAY DIODE
RED
WHT
YEL/GRN
WHT
4
RED
5
RED
2
ORG
BAT
X75
RED BLK
GRN/WHT
K11 IDLE STOP RELAY
PNK/WHT
BLU
3
1
RED
WHT
V4 SECURITY DIODE
BLK
1
4
BLK
WHT/BLU
5
WHT WHT
ACC
2
3
VLT
YEL/GRN 1
2
1
F4 20A FUSE
BLK
K13 KEY CUT RELAY
3
Y10 PILOT SHUTOFF SOLENOID
BLK
1
WHT/BLK
RED
BLK
4
2
BLU
5
YEL/BLK
PNK/BLK
PNK/BLK
2
K12 ACCESSORY CUT RELAY
VLT/GRN
3
BLU
1
YEL/BLK GRN/WHT
WHT
YEL/BLK
BLU
RED
HEAT OFF ACC ON START
F18 5A FUSE
BLU
RED
WHT
6
V11 ACCESSORY CUT DIODE
WHT YEL/BLK GRN/WHT
RED
BLU
RED GRN
VLT/WHT
BLU
RED
S1 KEY SWITCH
RED GRN
GRN
ORG
WHT
GRN/BLK
M ST
RED
ACC
VLT/RED
G2
GRN/WHT
G1
WHT
B
POSITION HEAT OFF ACC ON START
WHT
CONTINUE NEXT PAGE
JJ03229,0000ED1 -19-06APR18-1/6
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-20
160GLC Excavator 042318 PN=646
Sub-System Diagnostics
A1—Engine Control Unit (ECU) K2—Pilot Shutoff Solenoid Relay V20— Pilot Shutoff Switch Diode X75— Cab Harness-to-Pilot A3—Main Controller (MCZ) K4—Starter Cut Relay V44— Starter Relay Diode Shutoff Valve Harness A4—Monitor Controller (DSZ) K5—Security Relay X11— Machine Controller 20-Pin Connector A5—Data Converter K11— Idle Stop Relay Connector B X76— Cab Harness Connector 1 A6—Radio K12— Accessory Cut Relay X20— Monitor Controller 28-Pin (marked HMST) (not used) A7—Air Conditioner Controller K13— Key Cut Relay Connector A X175— Machine Harness-to(ACF) K19— Battery Relay X21— Monitor Controller 36-Pin Engine Interface Harness A11— Machine Controller (BCZ) K34— Starter Relay Connector B Connector 1 A15— Flex Power Controller M1—Starter Motor X22— Monitor Controller 16-Pin X5016—Engine Interface (FPC) S1— Key Switch Connector D Harness-to-Engine F4— Solenoid 20 A Fuse (marked S3— Pilot Shutoff Switch 1 X23— Monitor Controller 12-Pin Harness Connector 2 SOLENOID) S4— Pilot Shutoff Switch 2 Connector C X5018—Machine Harness-toF7— Start Position Signal 5 A S91— Battery Disconnect Switch X24— Monitor Controller 2-Pin Engine Interface Harness Fuse (marked START) V1— Battery Relay Diode Connector G Connector 2 F18— Idle Stop 5 A Fuse (marked V3— Load Dump Relay Diode X31— Cab Harness-to-Main X5502—Engine Control Unit IDLE STOP) V4— Security Diode Controller 31-Pin (ECU) Connector 2 F45— Starter In-Line 30 A Fuse V5— Starter Cut Relay Diode Connector A X5503—Engine Control Unit F60— Alternator 65 A Fuse V7— Start Relay Diode X34— Cab Harness-to-Main (ECU) Connector 3 F61— Battery 45 A Fuse V10— Starter Protection Diode Controller 30-Pin Y10— Pilot Shutoff Solenoid G1—Battery V11— Accessory Cut Diode Connector D G2—Battery V12— Starter Cut Diode X47— Cab Harness-to-Key G3—Alternator Switch Harness Connector K1—Load Dump Relay X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector Continued on next page
TM13345X19 (23APR18)
9015-15-21
JJ03229,0000ED1 -19-06APR18-2/6
160GLC Excavator 042318 PN=647
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-22
160GLC Excavator 042318 PN=648
Sub-System Diagnostics
TX1191176 —UN—22APR15
RED GRN YEL/BLK
4
3
4
1
2
A10 MONITOR
B21
3 BLK
GRY
WHT
D3 D2 D9 D1
C3 C2 C6 C5 C1
G2 G1
A1 A28 A13
14 16 15
1
2
BLK
5
7
X30 CAB HARNESSTO-SWITCH PANEL CONNECTOR 4
16
1
S25
S21
S22
S24
S26
S27
BLK
E6 SWITCH PANEL BACK LIGHT 2
E7 SWITCH PANEL BACK LIGHT 3
E8 SWITCH PANEL BACK LIGHT 4
C = X23 D = X22
G = X24
A12
15
1
S23
A = X20 B = X21
3
2
13 14
S10 WORK LIGHT SWITCH
X29 CAB HARNESSTO-SWITCH PANEL CONNECTOR 3
BRN/BLK PNK
11 10 12
A11
BLU/WHT BLK/PNK LT GRN
B26
BLU BRN GRY
B25
RED
A9
RED
A7
GRN/RED
A6
BLK
RED/BLU BLU/BLK BLK/YEL
Q
A5
YEL GRN RED/WHT
4
A4
RED/GRN
8 13 9
6
A3
YEL/RED
3
A10
B31
B30
YEL/RED
A8
BLU/YEL
BLK/GRN
B20
CABLE CABLE
B19
BLU/WHT
A18
YEL BLK/RED WHT
B28
YEL/GRN BLU ORG
B29
BRN RED
B1
1
A4 MONITOR CONTROLLER (DSZ)
2
B18 FUEL LEVEL SENSOR
B2
2
E1 E2 E7 E8
G = X24
RED
IF EQUIPPED
B3
WHT/BLU
D = X22
B4
WHT/YEL BRN GRN/BLU
B = X21
B5
WHT/YEL BRN/YEL GRN/BLU
C = X23
B6
YEL/BLU BLU/RED GRY/RED
A = X20
B22
4
RED/YEL YEL GRN BLU/YEL BLU
B17
X19
G2 G1
GRY
RED
BRN/BLU
BRN/YEL
GRY
PNK
GRN
LT GRN/YEL
GRN/WHT
X3
RED
D15
B13
YEL
X18 C3 C2 C6 C5 C1
X28 CAB HARNESSTO-SWITCH PANEL CONNECTOR 2
WHT
1
BLK
9
RED
8
BLK/YEL
7
X2 MPDr 6-PIN CONNECTOR
BLK/RED
1
RED/GRN
5
GRY
X64
2
WHT
A12 REAR CAMERA
YEL 12
RED
BLK
10
S60 KEYPAD
BLK
E5 SWITCH PANEL BACK LIGHT 1
9
WHT
6
S59
8
ORG
5
S58
7
GRY
4
6
PNK
5
S57
RED
B27
B27 HYDRAULIC P OIL FILTER RESTRICTION SWITCH
YEL
BLU/YEL
RED/GRN
4
A4 MONITOR CONTROLLER (DSZ)
S40 T HYDRAULIC OIL TEMPERATURE SWITCH
3
YEL/BLU BLK/RED BLK/WHT
B18
1
S56
BLK
GRN/BLK
5
K3 SECURITY ALARM RELAY
BLU/BLK
3
2
X90
4
GRN
2
3
S55
LT BLU
11
2
S54
2
WHT/RED
RED/BLK
1
S53
1 RED/BLU PNK/GRN
D7
WHT/BLU
S52
GRN/RED
H2 SECURITY ALARM
1
A16
0
BRN
X17 CAB HARNESSTO-MONITORHARNESS CONNECTOR
S51
RED/GRN
2
RED/BLU
BLU/BLK WHT
RED/BLU
H3 MONITOR WARNING ALARM
1 4 3
S50
F14 5A FUSE
YEL
F9 10A FUSE
F17 5A FUSE
0 1 2
TX1191176 Monitor Controller (DSZ) Circuit Schematic (2 of 2) Continued on next page
TM13345X19 (23APR18)
9015-15-23
160GLC Excavator 042318 PN=649
JJ03229,0000ED1 -19-06APR18-3/6
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-24
160GLC Excavator 042318 PN=650
Sub-System Diagnostics
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 S55— 5 Key X23— Monitor Controller 12-Pin H3—Monitor Warning Alarm S56— 6 Key Connector C K3—Security Alarm Relay S57— 7 Key X24— Monitor Controller 2-Pin S10— Work Light Switch S58— 8 Key Connector G S21— Blower Motor Speed S59— 9 Key X28— Cab Harness-to-Switch Switch S60— Keypad Panel Connector 2 S22— Temperature Control/Mode X2— MPDr 6-Pin Connector X29— Cab Harness-to-Switch Switch X3— Cab Harness-to-Machine Panel Connector 3 S23— Radio Volume and Power Harness 100-Pin Connector X30— Cab Harness-to-Switch Switch X17— Cab Harness-to-Machine Panel Connector 4 S24— Radio Tuning Switch Harness Connector X64— Machine Harness-to-Rear S25— Monitor Dial X18— Monitor 12-Pin Connector Camera Harness S26— Back Button C Connector S27— Home Button X19— Monitor 2-Pin Connector G X90— Machine Harness-toS40— Hydraulic Oil Temperature X20— Monitor Controller 28-Pin Hydraulic Oil Temperature Switch (if equipped) Connector A Switch Connector S50— 0 Key X21— Monitor Controller 36-Pin S51— 1 Key Connector B S52— 2 Key X22— Monitor Controller 16-Pin S53— 3 Key Connector D S54— 4 Key
NOTE: The information controller (ICZ) is an internal controller of the monitor controller (DSZ). 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 information 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), machine controller (BCZ) (A11), and main controller (MCZ) (A3) through pins A25 and A26 of DSZ. The DSZ also communicates on CAN 0 with the engine control unit (ECU) (A1), flex power controller (FPC) (A15), 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) and through monitor 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, pin 1 of idle stop 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) and 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 voltage is monitored by the engine control unit (ECU) (A1). When the alternator voltage is below charging level or the battery voltage is low, the ECU sends a message over the controller area network (CAN) to the monitor controller (DSZ) (A4), the DSZ then illuminates the alternator alarm indicator on the monitor. The monitor controller also uses this signal from the ECU to activate the load dump circuit.
Continued on next page
TM13345X19 (23APR18)
9015-15-25
JJ03229,0000ED1 -19-06APR18-4/6
160GLC Excavator 042318 PN=651
Sub-System Diagnostics
For more information, see Starting and Charging Circuit Theory of Operation or see Controller Area Network (CAN) 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.) Preheat Indicator—The preheat indicator comes on when the engine control unit (ECU) (A1) activates the glow plugs for cold starting. The ECU sends a message over the controller area network (CAN) to the monitor controller (DSZ) (A4), the DSZ then illuminates the preheat indicator. For more information, see Cold Weather Starting Aid. (Group 9010-05.) Monitor (A10)—The monitor (A10) communicates directly with the monitor controller (DSZ). 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. NOTE: When work light switch is in position 2, the monitor screen will change to nighttime mode screen. Daytime mode screen can be returned by pressing 0 on the keypad.
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 D3 and ground is provided from pin D2 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.
For more information on MPDr, see MPDr Application. (Group 9015-20.) TM13345X19 (23APR18)
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 will activate, indicating a low level of fuel. Specification Fuel Level Indicator Light—Resistance................................. Illuminates Above 82—88 ohms
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) (A7) via the controller area network (CAN). For more information, see Cab Heater and Air Conditioner. (Operator’s Manual.)
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 DSZ provides MPDr with 5 V power from pin A1 and serial communication from pins A13 and A28.
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.
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).
Continued on next page
9015-15-26
JJ03229,0000ED1 -19-06APR18-5/6
160GLC Excavator 042318 PN=652
Sub-System Diagnostics
For more information, see Operating the AM/FM Radio. (Operator’s Manual.)
For more information, see Switch Panel Functions. (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.
Back Button (S26)—The back button (S26) grounds pin B25 of monitor controller (DSZ), returning the monitor to the previous menu.
The monitor controller communicates these inputs to the radio (A6) via the controller area network (CAN). For more information, see Operating the AM/FM Radio. (Operator’s Manual.) Monitor Dial (S25)—The monitor dial (S25) is a Hall effect sensor, which offers infinite 360-degree rotation. Pressing the monitor dial grounds pin B27 of monitor controller (DSZ), selecting the highlighted option on the monitor (A10). Rotating the monitor dial left or right moves the current selection on the monitor up and down by sending a pulse width modulated (PWM) signal to pins A8 and A10 of the DSZ.
For more information, see Switch Panel Functions. (Operator’s Manual.) Home Button (S27)—The home button (S27) grounds pin B26 of monitor controller (DSZ), returning the monitor to the default screen. For more information, see Switch Panel Functions. (Operator’s Manual.) Keypad (S60)—Keypad (S60) contains numerical keys 0—9 (S50—S59) respectively. Keypad also contains switch panel back light 1 (E5), which provides backlighting for the individual keys. The keypad is used to input the anti-theft security code and other various parameters into the monitor controller (DSZ). For more information, see Switch Panel Functions. (Operator’s Manual.) JJ03229,0000ED1 -19-06APR18-6/6
TM13345X19 (23APR18)
9015-15-27
160GLC Excavator 042318 PN=653
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-28
160GLC Excavator 042318 PN=654
Sub-System Diagnostics
Engine Control Unit (ECU) Circuit Theory of Operation Engine Control Unit (ECU) Circuit Theory of Operation (S.N. —056599) TX1239519 —UN—02JUN17
RED/BLK
RED/BLK
BLU
D5
RED
LT BLU
WHT
RED
BLK
WHT
V44 STARTER RELAY DIODE
E22 BATTERY DISCONNECT INDICATOR LIGHT
M1 STARTER MOTOR
H2
M12 YEL
M13 GRN
LT BLU
BLK/YEL
RED/YEL
WHT
L1
4
6
R15 ENGINE SPEED DIAL
+
BLU (CAN 1 LOW)
B40 HYDRAULIC OIL TEMPERATURE SENSOR
F6003 7.5A FUSE
RED
5
B
2
GRN (CAN 0 HIGH)
BLK/YEL
X29 S
H1
N CAN
WHT BLK
RED
-
N CAN
RED WHT WHT VLT/GRN
WHT
CAN 0
CAN 0
WHT VLT/GRN
WHT VLT/GRN
WHT
Engine Control Unit (ECU) Circuit Schematic (S.N. —056599) (1 of 3) Continued on next page
TM13345X19 (23APR18)
D4
CAN 1
4
A23
LT GRN/BLK
5
2
A24 WHT
K34 STARTER RELAY
3
T
BLU/WHT
BLK
RED WHT
D3
CAN 0
BLK
S91 BATTERY DISCONNECT SWITCH BLK
TX1239519
V7 START RELAY DIODE
-
WHT
BLK
BLK
RED 1
BLU (CAN 0 LOW)
F60 65A FUSE
VLT/GRN
RED
G2 BATTERY BLK
V1 BATTERY RELAY DIODE
RED
WHT/RED
+
X175
GRN (CAN 0 HIGH)
VLT/GRN
D2
C1
1
A = X20 D = X22
RED
A
F45 30A FUSE
WHT
VLT/GRN
-
K19 BATTERY RELAY
4
D = X34 F = X36
F16
RED
B
5
F25
M2 A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER = X6014
BLK
WHT
E
2
G1 BATTERY
D16
A4 MONITOR CONTROLLER (DSZ)
K4 STARTER CUT RELAY
3
40
C = X33
A3 MAIN CONTROLLER (MCZ)
WHT
RED
+
WHT S
G
D8
G01 BLK
RED
1
F6001 7.5A FUSE
15 20
F17 5A FUSE
G3 ALTERNATOR
X5018
WHT
BRN/BLU B17
WHT/RED
VLT/GRN
WHT/RED
F61 45A FUSE
4
V10 STARTER PROTECTION DIODE
WHT/BLK
ST
5
A7 AIR CONDITIONER CONTROLLER (ACF)
X3
BRN/RED
YEL/GRN
BLU
WHT/RED
M
2
1
B22 AMBIENT AIR TEMPERATURE SENSOR
WHT
G2
4
WHT
YEL/GRN
G1
5
K1 LOAD DUMP RELAY
ORG
2
K13 KEY CUT RELAY
3
D+
RED
BAT
1
10
2
T B1+
BLU/RED
3
F38 20A FUSE
ORG
1
RED RED/BLK RED WHT RED LT BLU
BLK/YEL
WHT
ACC
RED
YEL/BLK
RED RED
YEL/BLK
BLU
S1 KEY SWITCH
BLU
HEAT OFF ACC ON START
V3 LOAD DUMP RELAY DIODE
F18 5A FUSE
RED
WHT
RED YEL/BLK RED WHT RED LT BLU
RED
RED YEL/BLK
GRN
RED YEL/BLK
M ST
GRN (CAN 1 HIGH)
ACC
CAN 1
G2
BLU
G1
BLU (CAN 0 LOW)
B
POSITION HEAT OFF ACC ON START
9015-15-29
160GLC Excavator 042318 PN=655
JL58967,0000742 -19-01JUN17-1/28
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-30
160GLC Excavator 042318 PN=656
Sub-System Diagnostics
A3—Main Controller (MCZ) F45— Starter In-Line 30 A Fuse A4—Monitor Controller (DSZ) F60— Alternator 65 A Fuse A7—Air Conditioner Controller F61— Battery 45 A Fuse (ACF) F6001—JDLink™ Unswitched A6000—Modular Telematics Power 7.5 A Fuse Gateway (MTG) F6003—JDLink™ Switched Controller Power 7.5 A Fuse B22— Ambient Air Temperature G1—Battery Sensor G2—Battery B40— Hydraulic Oil Temperature G3—Alternator Sensor K1—Load Dump Relay E22— Battery Disconnect K4—Starter Cut Relay Indicator Light K13— Key Cut Relay F17— Power On 5 A Fuse K19— Battery Relay (marked POWER ON) K34— Starter Relay F18— Idle Stop 5 A Fuse (marked M1—Starter Motor IDLE STOP) R15— Engine Speed Dial F38— Fuel Transfer Pump and S1— Key Switch Controllers 20 A Fuse S91— Battery Disconnect Switch (marked ECU P4)
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), flex power controller (FPC) (A15), and modular telematics gateway (MTG) controller (A6000). The DSZ forwards much of the information across the CAN data line to the monitor where the information 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.)
• 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. Temperature sensor cannot be repaired or replaced without replacing the entire ECU.
• Programming—The ECU can be programmed by
Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The Snapshot information is categorized into two types: Snapshot Capture and Snapshot Recording. For more information, see Snapshot Instructions. (CTM120119.)
• MAP • Engine Speed • Percent Load at Current Speed • Coolant Temperature • Vehicle Speed • Engine Hours (first and last occurrence)
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 top dead center (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 cutout 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)—Unswitched battery power is available from:
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TM13345X19 (23APR18)
X34— Cab Harness-to-Main Controller 30-Pin Connector D X36— Cab Harness-to-Main Controller 26-Pin Connector F X175— Machine Harness-toEngine Interface Harness Connector 1 X5018—Machine Harness-toEngine Interface Harness Connector 2 X6014—Modular Telematics Gateway (MTG) Control Unit Connector
The ECU allows for programming and diagnostic tests using Service ADVISOR™ as follows:
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.) Also, see Regeneration Failure — Possible Causes. (CTM120119.)
The following data is captured automatically for storing each code in the snapshot data buffer:
V1— Battery Relay Diode V3— Load Dump Relay Diode V7— Start Relay Diode V10— Starter Protection Diode V44— Starter Relay Diode X3— Cab Harness-to-Machine Harness 100-Pin Connector X20— Monitor Controller 28-Pin Connector A X22— Monitor Controller 16-Pin Connector D X29— Cab Harness-to-Switch Panel Connector 3 X33— Cab Harness-to-Main Controller 17-Pin Connector C
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Sub-System Diagnostics
• Fuse F8—Pins 12 and 50 of engine control unit (ECU) connector 3 (X5503).
• Fuse F36—Pins 23 and 24 of engine control unit (ECU) connector 3 (X5503).
• Fuse F37—Pins 13 and 14 of engine control unit (ECU) connector 3 (X5503).
Ground is provided at pin 22 via engine control unit (ECU) connector 2 (X5502) and pins 16, 17, 27, 43, and 44 via engine control unit (ECU) connector 3 (X5503). 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 7 of engine control unit (ECU) connector 3 (X5503) 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) to starter relay (K34), energizing the relay. With the starter relay 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 05 of engine control unit (ECU) connector 3 (X5503) is grounded, providing ground to starter cut relay, energizing the relay. With starter cut relay energized, the start signal is removed from the starter relay, de-energizing the starter relay, thus disengaging the starter motor. When the engine is running the ECU provides excitation from pin 34 of engine control unit (ECU) connector 2 (X5502) to pin D+ of the alternator (G3) for the charging circuit. For more information, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.)
torque message is sent. Before applying a new torque command, the ECU verifies the watchdog indicator has changed from the previous message. If the ECU detects that the torque command message is not being updated at the expected rate or if two consecutive messages have the same watchdog indicator value, the ECU will default to the lowest torque curve and set the appropriate diagnostic trouble code (DTC). The FPC is used to monitor the system voltage. The FPC uses engine speed and system voltage data, received via CAN from the ECU, to determine the state of the alternator and battery. If the voltage is below a predefined threshold with the engine running, a DTC is created and a message is sent via CAN to the monitor controller (DSZ) (A4) to activate the alternator light on the monitor. The FPC interfaces with the modular telematics gateway (MTG) controller (A6000) and the monitor controller (DSZ) (A4) to communicate the availability of software updates for the machine controllers via Service ADVISOR™ Remote (SAR). The Service ADVISOR™ Remote (SAR) switch (S18) is used to accept or decline these updates. The FPC monitors the status of parked exhaust filter cleaning cycles. The FPC will generate a DTC to warn the operator of aborted cleaning cycles. The FPC stores the machine model information in nonvolatile memory. On each power cycle, the FPC compares the model received from the main controller (MCZ) (A3) to its own stored model data. If the two do not agree, the machine model can’t be verified and the flex power function will default to the low torque curve. Flex Power Controller (FPC) (Power and Ground)—Unswitched battery power is available at pins L1 and L2 of flex power controller (FPC) (A15) through fuel transfer pump and controllers 20 A fuse (marked ECU P4) (F38) and through flex power controller (FPC) in-line 10 A Fuse (F5004). Ground is provided at pin M2 and pin M3 of FPC.
Flex Power Controller (FPC) (A15)—The FPC provides several functions: flex power control, system voltage monitoring, Service ADVISOR™ Remote (SAR), and exhaust filter cleaning malfunction notice. FPC is used to allow the vehicle system to adjust the maximum available torque between two predefined torque curves. The flex power function allows the engine torque level to be defined via CAN by the FPC. However, the engine control unit (ECU) and FPC both contain a common data table defining the minimum and maximum torque at each speed within the operating range of the engine. The ECU updates the FPC with the current engine speed every 20 milliseconds. Once the FPC receives the engine speed, it then computes the new torque command for that speed as a percentage between the minimum and maximum torque values in the data table. Every 20 milliseconds, the FPC sends an updated torque command to the ECU which also includes a watchdog indicator, which is simply a counter that increments each time the
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 flows through power on 5 A fuse (F17) to pin M1 of FPC, causing the FPC to power up. NOTE: For power up of the other electronic controllers, see the theory of operation of specific component:
• See Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
• See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company Continued on next page
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Sub-System Diagnostics
TX1235640 —UN—13MAR17
RED
RED RED/BLK
RED RED/BLK
RED/BLK
WHT RED
WHT RED
WHT RED
RED
10
4
WHT/GRN
N CAN
BLU
17
14
35
14
38
R5601 CAN 0 TERMINATION RESISTOR X5018 MACHINE HARNESS-TOENGINE INTERFACE HARNESS CONNECTOR 2
K
J
E
BLK (CAN 0 SHLD)
J H A B
WHT VLT/GRN
1
P
3
2
B5102 EXHAUST MANIFOLD PRESSURE SENSOR YEL
BLU GRN
CAN 0
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
D C
WHT VLT/GRN
BRN
30
05
GRN
ORG
36
WHT
PUR
12
WHT
17
GRY
41
BLU
26
GRN
ORG
BRN
BLU
52
X5015
17
X5018
1
4 2
Y5400 EXHAUST GAS RECIRCULATION (EGR) VALVE
1
P
3
2
B5101 ENGINE OIL PRESSURE SENSOR
6
C
VLT/GRN
LT BLU
BRN BRN
3
ORG
DK GRN
6 4
2
PUR
GRY
PUR
T
X5015
1 YEL
BLK R12 BLK (CAN 0 SHLD)
RED
YEL
GRN
BLK
B
ORG/BLK
18
6
LT BLU
LO
A
5
10
08
X5015
DK GRN
BLU
HI
M12 YEL (CAN 0 HIGH)
2
27
1
X5018 S16 EXHAUST FILTER PARKED CLEANING SWITCH
C2
GRN/WHT BLK/YEL YEL/BLK
S
07
11
ORG/GRN
GRN
BRN
44
BLK
27
X5015
M13 GRN (CAN 0 LOW)
3
13
9
X5018
RED/BLU
SIGNAL BLK
16
25
43
X5018 X W U V 5
24
8
2 RED/BLK
RED
ORG
48
RED
GRY
16
BLK
E
RED
BRN
15
RED
WHT
49
BLK
F2
1
24
D2
N CAN
RED
S18 SERVICE ADVISOR REMOTE (SAR) SWITCH
7
RED/BLK
F3
T
1
X5018 MACHINE HARNESS-TO- D ENGINE INTERFACE HARNESS CONNECTOR 2
27 E3
1
RED
YEL (CAN 0 HIGH) GRN (CAN 0 LOW) BLK (CAN 0 SHLD)
-
RED
A
1
B5209 FUEL TEMPERATURE SENSOR
39
17 21
01
A1
C1
M1
1
T
2
B5009 ENGINE COOLANT LOSS LEVEL SENSOR
F37 20A FUSE
23
02
+
F5004 10A FUSE
Q
B5208 ENGINE COOLANT TEMPERATURE SENSOR
53
B1
L2
X5018
50
= X5503
BLU
RED
BLK
L1
B5600 WATERIN-FUEL (WIF) SENSOR
GRY
37
= X5502
A15 FLEX POWER CONTROLLER (FPC)
M3
YEL
= X5501
PUR PUR
RED/BLK
RED/BLK
M2
2
BLK
36
B5107 INLET FUEL PRESSURE SENSOR
3
P
BLK
05
C
GRN
YEL
A1 24 ENGINE CONTROL UNIT (ECU)
22
1
B
GRY
BRN
27
07
3
A
GRY
GRN
34 50
P
B5104 INTAKE MANIFOLD PRESSURE SENSOR
YEL
ORG
12
1
BLU
RED RED
B
3
2
120
1
X5018
P
YEL
T
B5103 EXHAUST GAS RECIRCULATION (EGR) DELTA PRESSURE SENSOR
2
B5207 EXHAUST GAS RECIRCULATION (EGR) TEMPERATURE SENSOR
GRN
2
1
GRY 2
GRY
X5016
2
RETURN
10
X5016 12
DK GRN +5V
LT BLU
DK GRN
F36 20A FUSE
RED
GRY
BLU
RED
RED/BLK
F8 20A FUSE
GRY
B5303 FAN SPEED SENSOR
WHT RED GRY
3
Y5402 EXHAUST THROTTLE ACTUATOR
ORG
WHT VLT/GRN
TX1235640 Engine Control Unit (ECU) Circuit Schematic (S.N. —056599) (2 of 3) Continued on next page
TM13345X19 (23APR18)
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Sub-System Diagnostics
TM13345X19 (23APR18)
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Sub-System Diagnostics
A1—Engine Control Unit (ECU) B5208—Engine Coolant R5601—CAN 0 Termination X5501—Engine Control Unit A15— Flex Power Controller Temperature Sensor Resistor (ECU) Connector 1 (FPC) B5209—Fuel Temperature Sensor S16— Exhaust Filter Parked X5502—Engine Control Unit B5009—Engine Coolant Loss B5303—Fan Speed Sensor Cleaning Switch (ECU) Connector 2 Level Sensor B5600—Water-in-Fuel (WIF) S18— Service ADVISOR™ X5503—Engine Control Unit B5101—Engine Oil Pressure Sensor Remote (SAR) Switch (ECU) Connector 3 Sensor F8— Engine Control Unit (ECU) X1— Service ADVISOR™ Y5400—Exhaust Gas B5102—Exhaust Manifold 20 A Fuse (marked ECU P1) Diagnostic Connector Recirculation (EGR) Valve Pressure Sensor F36— Engine Control Unit (ECU) X5015—Engine Interface Y5402—Exhaust Throttle B5103—Exhaust Gas 20 A Fuse (marked ECU P2) Harness-to-Engine Actuator Recirculation (EGR) Delta F37— Engine Control Unit (ECU) Harness Connector 1 Pressure Sensor 20 A Fuse (marked ECU P3) X5016—Engine Interface B5104—Intake Manifold Pressure F5004—Flex Power Controller Harness-to-Engine Sensor (FPC) In-Line 10 A Fuse Harness Connector 2 B5107—Inlet Fuel Pressure X5018—Machine Harness-toSensor Engine Interface Harness B5207—Exhaust Gas Connector 2 Recirculation (EGR) Temperature Sensor
Service ADVISOR™ Remote (SAR) Switch (S18)—The Service ADVISOR™ Remote (SAR) switch (S18) allows the operator to accept or decline available updates. The flex power controller (FPC) (A15) will create DTCs under certain trigger conditions, which will send a message via CAN to the monitor controller (DSZ) (A4) to prompt the vehicle to display operator instructions on the monitor. 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 through power on 5 A fuse (F17) to pins 1, 7, and 10 of Service ADVISOR™ Remote (SAR) switch (S18). When the SAR switch is pressed to the ACCEPT position, current is sent through pin 3 of the SAR switch to pin C1 of FPC. Pin E3 of FPC, is then grounded, completing the circuit to pin 5 of the SAR switch, activating the ACCEPT (green) light emitting diode (LED). When the SAR switch is pressed to the DECLINE position, current is sent through pin 2 of the SAR switch to pin F2 of FPC. Pin F3 of FPC, is then grounded, completing the circuit to pin 4 of the SAR switch, activating the DECLINE (red) light emitting diode (LED). Cold Weather Starting Aid—Power is available to pin 3 of glow plug relay (K16) from glow plug 50 A fuse (F63). Ground is provided at pin 1 of glow plug relay and to glow plugs (R1—R4). 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 7 of engine control unit (ECU) connector 3 (X5503) through power on 5 A fuse (F17), causing the ECU to power up. The ECU now determines if the glow plugs need to be activated. If the ECU determines the glow plugs are necessary, power is
sent out pin 32 via engine control unit (ECU) connector 1 (X5501) to pin 2 of glow plug relay, energizing the relay. Power is sent to glow plugs and through glow plug resistor (R19) to engine control unit (ECU) connector 1 (X5501) pin 54. For more information on cold start aid, see Cold Weather Starting Aid. (Group 9010-05.) Hydraulic Variable Speed Fan—The variable speed fan cools the machine's systems by a hydraulic pump and motor controlled by a variable speed fan solenoid, providing machine efficiency and reducing fan noise levels by only operating the fan at the minimum speed necessary to cool the machine systems. The engine control unit (ECU) uses the following inputs to determine the proper fan speed:
• B22—Ambient air temperature sensor if air conditioner is ON via CAN.
• B40—Hydraulic oil temperature sensor via controller area network (CAN).
• B5205—Charge air cooler outlet temperature sensor at
pin 29 of engine control unit (ECU) connector 2 (X5502).
• B5208—Engine coolant temperature sensor at pin 16 of engine control unit (ECU) connector 1 (X5501).
• B5209—Fuel temperature sensor at pin 48 of engine control unit (ECU) connector 1 (X5501).
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. The maximum fan speed is limited to engine speed. Temperature thresholds and variable speed fan solenoid duty cycles (fan speeds) are preprogrammed into the ECU and cannot be changed. The variable speed fan solenoid (Y5014) is driven from engine control unit (ECU) pin 32 of engine control unit (ECU) connector 2 (X5502).
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Sub-System Diagnostics Engine Control Unit (ECU) Sensor Input
Temperature
Maximum Fan Speed as % of Engine Speed
Maximum Engine Speed Fan Speed (P-mode engine speed)
Coolant Temperature
103°C (217°F)
80%
1900
Hydraulic Oil Temperature
91°C (196°F)
Ambient Air Temperature (when A/C is ON)
37°C (99°F)*
Fuel Temperature
70°C (158°F)*
Intake Air Temperature
52°C at 25°C ambient (126°F at 77°F ambient)**
To protect the fan pump while operating in cold conditions, the ECU limits the fan speed according to the input from the hydraulic oil temperature sensor (B40). The ECU will increase the fan speed as hydraulic oil warms.
*When the air conditioner is ON and the ambient air temperature is over 15°C (60°F) the engine fan will increase to 1250 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 (80°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).
Hydraulic Temperature °C (°F)
-40°C (-40°F)
-9°C (16°F)
-7°C (19°F)
-3°C (26°F)
4°C (39°F)
6°C (43°F)
11°C (52°F)
12°C (54°F)
Fan Speed Limit (rpm)
350
350
400
600
1000
1250
1750
(not limited by hydraulic temperature)
Hydraulic Variable Speed Fan Reversing Function (if equipped)—The hydraulic variable speed fan with reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit (ECU) automatically controls the speed of the fan by monitoring the following:
• Engine Coolant Temperature • Hydraulic Oil Temperature • Fuel Temperature • Charge Air Cooler Outlet Temperature • Ambient Air Temperature • Air Conditioning State (On-Off)
communicates with the DSZ and ACF to set the A/C compressor value to OFF. The A/C compressor will be temporarily turned off until approximately 1 minute after the completion of a fan reversing cycle; at that time, the ECU will send communication to set the A/C compressor value to ON. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.) NOTE: If a malfunction exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.
The engine coolant temperature sensor (B5208), fuel temperature sensor, and charge air cooler outlet temperature sensor (B5205) are hard wired to the engine control unit (ECU). The hydraulic oil temperature 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 is hard wired to the air conditioner controller (ACF) and continuously transmits information via CAN to communicate with the monitor controller (DSZ), which then forwards the information via CAN to the ECU. During a reversing cycle, the ECU
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 32 of engine control unit (ECU) connector 2 (X5502) to variable speed fan solenoid (Y5014). Static ground is provided to variable speed fan solenoid at all times on pin 21 of engine control unit (ECU) connector 1 (X5501). 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.)
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Sub-System Diagnostics
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 the reversing fan switch (S15). Unswitched power is provided from optional connector and reversing fan 20 A fuse (F6) to pin 3 of reversing fan switch (S15). The reversing fan function can be operated when the ECU determines that the following conditions are met:
• Engine speed is at least 1180 rpm. • Hydraulic oil temperature is greater than 12°C (54°F). • The high temperature lamp is off. See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) • Fan solenoid codes are not present in the monitor. • A reverse sequence is not in progress. NOTE: The reversing fan is inhibited for 7 seconds following a fan reversal cycle and only an ECU reset can interrupt a fan reverse cycle. The first automatic reverse cycle will begin 1 hour after key ON or an ECU reset. When the automatic reversing fan timer in the ECU reaches the preset interval or if manual mode is selected, the ECU begins the reversing sequence as follows: 1. The ECU increases the current to variable speed fan solenoid (Y5014) to slow the fan to minimum fan speed (approximately 350 rpm). 2. When fan speed is at minimum, the ECU sends current out pin 26 of engine control unit (ECU) connector 2 (X5502) to the reversing fan solenoid (Y5015), energizing the solenoid. The fan solenoid reverses the fan direction. 3. With the fan now operating in the reverse direction, the ECU decreases the current applied to the variable speed fan solenoid (Y5014) until maximum fan speed (approximately 1500 rpm) is reached. 4. The ECU operates the fan at maximum speed in reverse direction for approximately 15 seconds, then increases 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 (Y5015), causing the fan to change back to forward direction. 6. With the fan operating in the forward direction, the ECU decreases the variable speed fan solenoid current until the normal operating fan speed is obtained. When an automatic reversing sequence is complete the ECU will start the automatic reversing fan timer according to the preset interval of 60 minutes. The reversing sequence cannot be activated again for approximately 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.
(MCZ) and sensors located on the engine. The ECU is supplied with unswitched power on engine control unit (ECU) connector 3 (X5503) pins 12 and 50 through engine control unit (ECU) 20 A fuse (marked ECU P1) (F8), pins 23 and 24 through engine control unit (ECU) 20 A fuse (marked ECU P2), and pins 13 and 14 through engine control unit (ECU) 20 A fuse (marked ECU P3). Ground is provided on engine control unit (ECU) connector 2 (X5502) pin 22 and engine control unit (ECU) connector 3 (X5503) pins 16, 17, 27, 43, and 44. The ECU is turned on by a power on 5 A fuse (F17) through pin 07 of engine control unit (ECU) connector 3 (X5503). The ECU communicates with the MCZ through a CAN (controller area network). CAN connects to ECU through pins 01, 02, and 21 of engine control unit (ECU) connector 3 (X5503). If there is a malfunction with the ECU or one of the sensor circuits it is connected to, the ECU 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) (A3) to the engine control unit (ECU) (A1). A variable voltage of 0—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. Power is supplied to pin 4 of cab harness-to-switch panel connector 3 (X29) to MCZ connector (X36) pin F25. Signal is sent from pin 5 of cab harness-to-switch panel connector 3 (X29) to MCZ connector (X34) pin D16. Ground is supplied on pin 6 of cab harness-to-switch panel connector 3 (X29) to pin F16 of MCZ connector X36. For information on auto-idle and power modes ECO, PWR, and H/P, see Engine Speed Control System Operation. (Group 9010-05.) 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 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. For more information on auto warm-up control, see Engine Speed Control System Operation. (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.)
Engine Control Unit— The engine control unit (ECU) (A1) manages the engine with input from main controller Continued on next page TM13345X19 (23APR18)
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Sub-System Diagnostics
Exhaust Filter Parked Cleaning Switch (S16)—The exhaust filter parked cleaning switch (S16) allows the operator to perform a parked exhaust filter cleaning. With key switch (S1) 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 through power on 5 A fuse (F17) to pin 1 of exhaust filter parked cleaning switch (S16). When the ECU has determined a parked exhaust filter cleaning is required, ground is provided to pin 5 of exhaust filter parked cleaning switch from pin 35 of engine control unit (ECU) connector 3 (X5503), completing the circuit and activating the light emitting diode (LED). When the exhaust filter parked cleaning switch is held for 3 seconds, pin 38 of engine control unit (ECU) connector 3 (X5503) is connected to ground, initiating the parked exhaust filter cleaning if all requirements are met. NOTE: For component location, see Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location. (Group 9015-10.)
Battery Disconnect Indicator Light (E22)—The battery disconnect indicator light (E22) illuminates when the key switch is in the ON position and stays illuminated until it is safe to turn the battery disconnect switch (S91) to the OFF position. When the key switch is in the ON position the engine control unit (ECU) sends power from pin 30 of engine control unit (ECU) connector 3 (X5503) to the battery disconnect indicator light. When the key switch is turned to the OFF position, the ECU determines when the diesel exhaust fluid (DEF) system has purged the DEF fluid in the DEF lines. NOTE: For component location, see Engine Interface Harness (W5) Component Location. (Group 9015-10.) For more information on the DEF system, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) For more information on the battery disconnect switch, see Battery Disconnect Switch. (Operator’s Manual.)
For more information on exhaust filter parked cleaning, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) Continued on next page
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Sub-System Diagnostics
TX1202902 —UN—22OCT15
PUR
PUR
15
PUR
BRN
7
Y2 ELECTRONIC INJECTOR (CYLINDER 2)
BRN
Y3 ELECTRONIC INJECTOR (CYLINDER 3)
YEL
Y4 ELECTRONIC INJECTOR (CYLINDER 4)
6
2
1
45
2
1
Y5024 FUEL RAIL PRESSURE RELIEF VALVE (PRV)
T 2
37
09
= X5503
19
18
9
6
8
YEL
RED WHT
24
DK GRN
LT BLU
Y5002 SUCTION CONTROL VALVE (SCR)
51
X5016
W LT BLU
F
SHD
X
PUR
GRY
WHT
LT BLU
C
18
29
09
RED
42
B5206 MANIFOLD AIR TEMPERATURE (MAT) SENSOR ORG
1
T
B5205 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
2
B5113 FUEL RAIL PRESSURE SENSOR
P 1
P
3
2
B5105 CRANK CASE PRESSURE SENSOR
1
2
3
1
2
GRN
40
TAN
06
YEL
23
TAN
34
LT GRN
03
H
5
RED
8
PUR
Y1 ELECTRONIC INJECTOR (CYLINDER 1)
GRY
BLU
3
= X5501
ORG
YEL
02
1
X5000 4
54
BRN
RED BRN
DK GRN
G
32
X5604 ENGINE HARNESS-TOGLOW PLUG HARNESS CONNECTOR
GRN
GRN
ORG
B
21
F6 20A FUSE
= X5502
26 E
2
ORG
BRN
14
X5016 X5068 D
R4
F63 50A FUSE
GRN
33
22
BLU
04
1
ORG
26
ORG
43
R3
32
YEL
44
A1 ENGINE CONTROL UNIT (ECU)
WHT
28
28
RED
45
SHD
46
BLK
30
ORG
38
BLU
29
3
BRN
Y5014 VARIABLE SPEED FAN SOLENOID ORG
35
R2
R19 GLOW PLUG RESISTOR DK GRN
2
2
Y5501 FUEL TRANSFER PUMP
PUR
R5603 ENGINE CAN TERMINATION RESISTOR
Y5015 REVERSING FAN SOLENOID
ORG
2
ORG
2
1
ORG
ORG
YEL
DK GRN
GRY
PUR
ORG
DK GRN
SHD
1
B5500 INTAKE AIR SENSOR
4
4
K16 GLOW PLUG RELAY R1
1
M
ORG YEL
3
N2
1
GRN (ENG CAN LOW) YEL (ENG CAN HIGH)
GRY
1
GRN YEL
GRY
N1
3
2
120
2
B5301 CRANKSHAFT POSITION SENSOR
RED
1
B5302 CAMSHAFT POSITION SENSOR
WHT
WHT RED RED P01 RED
WHT RED
DK GRN
WHT RED GRY
X83 CAB HARNESSTO-REVERSING FAN SWITCH HARNESS
M O A
S15 REVERSING FAN SWITCH
3
ORG
BRN
TX1202902 Engine Control Unit (ECU) Circuit Schematic (S.N. —056599) (3 of 3) Continued on next page
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Sub-System Diagnostics
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Sub-System Diagnostics
A1—Engine Control Unit (ECU) F63— Glow Plug 50 A Fuse B5105—Crankcase Pressure K16— Glow Plug Relay Sensor R1—Glow Plug 1 B5113—Fuel Rail Pressure R2—Glow Plug 2 Sensor R3—Glow Plug 3 B5205—Charge Air Cooler Outlet R4—Glow Plug 4 Temperature Sensor R19— Glow Plug Resistor B5206—Manifold Air Temperature R5603—Engine CAN Termination (MAT) Sensor Resistor B5301—Crankshaft Position S15— Reversing Fan Switch Sensor X83— Cab Harness-to-Reversing B5302—Camshaft Position Fan Switch Harness Sensor Connector B5500—Intake Air Sensor X5000—Engine Harness-to-Fuel F6— Optional Connector and Injector Harness Reversing Fan 20 A Fuse Connector (marked OPT. 2 ALT) X5068—Engine Interface Harness-to-Engine Harness Connector 3
Fuel Rail Pressure Sensor (B5113)—The fuel rail pressure sensor (B5113) 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 high-pressure fuel pump pressure control valve (PCV) 1 (Y5022) and high-pressure fuel pump pressure control valve (PCV) 2 (Y5023). 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 37 for supply voltage, pin 09 for ground, and pin 51 for signal on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 17 for supply voltage, pin 26 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501).
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Exhaust Manifold Pressure Sensor (B5102)—The exhaust manifold pressure sensor (B5102) provides feedback to the control systems for the exhaust throttle actuator (Y5402) and exhaust gas recirculation (EGR) valve (Y5400) in order to maximize engine performance while meeting the applicable emissions regulations. The ECU uses the exhaust manifold pressure for the volumetric efficiency calculation. The exhaust manifold pressure sensor uses pin 27 for supply voltage, pin 11 for signal, and pin 25 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
Exhaust Gas Recirculation (EGR) Delta Pressure Sensor (B5103)—The exhaust gas recirculation (EGR) delta pressure sensor (B5103) measures the pressure drop across the EGR venturi tube. The ECU calculates the amount of the recirculated exhaust gas using this measurement and the venturi tube physical dimensions. The ECU controls the EGR valve (Y5400) and turbocharger actuator (Y5500) to recirculate the ideal amount of exhaust gas for the operating condition. The EGR delta pressure sensor uses pin 36 for supply voltage, pin 05 for signal, and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Continued on next page
TM13345X19 (23APR18)
Y2— Electronic Injector 2 (cylinder 2) Y3— Electronic Injector 3 (cylinder 3) Y4— Electronic Injector 4 (cylinder 4) Y5002—Suction Control Valve Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid Y5024—Fuel Rail Pressure Relief Valve (PRV) Y5501—Fuel Transfer Pump
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
X5015—Engine Interface Harness-to-Engine Harness Connector 1 X5016—Engine Interface Harness-to-Engine Harness Connector 2 X5501—Engine Control Unit (ECU) Connector 1 X5502—Engine Control Unit (ECU) Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X5604—Engine Harness-to-Glow Plug Harness Connector Y1— Electronic Injector 1 (cylinder 1)
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Sub-System Diagnostics ECU adjusts the signal going to the EGR valve (Y5400) to compensate the mixture. The ECU also uses this sensor for engine protection purposes.
Intake Manifold Pressure Sensor (B5104)—Intake manifold pressure sensor (B5104) is used to help calculate the amount of air flow into the engine. The intake manifold pressure sensor also supplies the ECU with a direct measurement of turbo boost. The intake manifold pressure sensor uses pin 36 for supply voltage, pin 37 for signal, and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
The charge air cooler outlet temperature sensor uses pin 29 for signal and pin 15 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) Crankcase Pressure Sensor (B5105)—The crankcase pressure sensor (B5105) is used to measure the amount of pressure in the crankcase of the engine. The ECU uses the crankcase pressure sensor value to indicate when the crankcase ventilation filter needs to be replaced or if there is a problem with the crankcase pressure relief valve that is located in the rocker arm cover.
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
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 ECU then compares the temperatures of the recirculated exhaust gas, charge air cooler outlet air, and mixed air in the intake manifold to determine if proper cooling and mixing has occurred. If the temperature is not correct, the ECU adjusts the signal going to the EGR valve (Y5400) to compensate the mixture. The MAT sensor helps the ECU calculate the correct fueling for the engine. The ECU also uses this sensor for engine protection purposes.
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
The MAT sensor uses pin 09 for signal and pin 15 for ground on engine control unit (ECU) connector 2 (X5502).
Inlet Fuel Pressure Sensor (B5107)—The inlet fuel pressure sensor (B5107) sends a pressure equivalent signal to the 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.
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
The crankcase pressure sensor uses pin 15 for supply voltage, pin 18 for signal, and pin 45 for ground on engine control unit (ECU) connector 2 (X5502).
The inlet fuel pressure sensor uses pin 17 for supply voltage, pin 39 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Charge Air Cooler Outlet Temperature Sensor (B5205)—The charge air cooler outlet temperature sensor (B5205) is used to measure the temperature of the charge air cooler outlet air entering the intake manifold. The ECU then compares the temperatures of the recirculated exhaust gas, charge air cooler outlet air, and the mixed air in the intake manifold to determine if proper cooling and mixing has occurred. If the temperature is not correct, the
For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Exhaust Gas Recirculation (EGR) Temperature Sensor (B5207)—The exhaust gas recirculation (EGR) temperature sensor (B5207) is used to measure the temperature of the exhaust gas entering the EGR valve (Y5400). The ECU then compares the temperatures of the EGR exhaust gas, charge air cooler outlet air, and the intake manifold air to determine if proper cooling and mixing has occurred. If the temperature is not correct, the ECU adjusts the signal going to the EGR valve to compensate the mixture. The ECU also uses this sensor for engine protection purposes. The EGR temperature sensor uses pin 27 for signal and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
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Sub-System Diagnostics
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 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, indicating a thermostat is stuck open. The engine coolant temperature sensor uses pin 16 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
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 the information 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, which may require prolonged engine cranking to start the engine. The crankshaft position sensor uses pin 38 for signal and pin 30 for ground on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the signal and ground wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how speed sensors operate, see Measuring Speed. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Fuel Temperature Sensor (B5209)—The fuel temperature sensor (B5209) input is used by the ECU to calculate fuel density and adjust fuel delivery.
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.
The fuel temperature sensor uses pin 48 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
Camshaft position sensor consists of a permanent magnet, coil, and yoke. The sensor 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 electromagnetic interference (EMI). If there is a problem with the camshaft position sensor, the ECU will use the crankshaft position sensor to determine engine timing, which may require prolonged engine cranking to start the engine.
For information on how speed sensors operate, see Measuring Speed. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 ECU determine when cylinder number one or six is at top dead center (TDC) of its compression stroke.
The camshaft position sensor uses pin 28 for signal and pin 29 for ground on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the signal and ground wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how speed sensors operate, see Measuring Speed. (CTM120119.)
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Sub-System Diagnostics
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Fan Speed Sensor (B5303)—The fan speed sensor (B5303) sends the engine control unit (ECU) with the fan speed in revolutions per minute (rpm). The ECU uses the fan speed sensor for more precise control of the fan speed. The fan speed sensor uses pin 36 for supply voltage on engine control unit (ECU) connector 2 (X5502). The fan speed sensor uses pin 53 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). Intake Air Sensor (B5500)—The intake air sensor (B5500) measures temperature, pressure and humidity of the turbocharger compressor inlet air. The location of the measurements is in the intake prior to the fixed geometry turbocharger. The sensor communicates with the ECU over the engine CAN bus. These measurements provide input for fueling calculations made by the ECU. Humidity affects the exhaust gas temperature and the effectiveness of exhaust filter cleaning. The ECU compares turbocharger compressor inlet pressure to barometric air pressure to calculate the intake air pressure drop. The intake air sensor uses pin 28 for supply voltage and pin 14 for ground on engine control unit (ECU) connector 2 (X5502). The intake air sensor uses pins 45 and 46 for CAN communication on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the CAN wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
Engine Coolant Loss Level Sensor (B5009)—The engine coolant loss level sensor (B5009) 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 17 for signal and pin 14 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Interface Harness (W5) Component Location. (Group 9015-10.) 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. (CTM120119.) For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.)
For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.)
For additional information on high-pressure fuel system, see High-Pressure Fuel System Operation. (CTM120119.)
For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Water-in-Fuel (WIF) Sensor (B5600)—The water-in-fuel (WIF) 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 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 15 signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
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 engine control unit (ECU) connector 2 (X5502) pin E2, 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.
Suction Control Valve (Y5002)— The suction control valve (Y5002) is located on the high pressure fuel pump. The engine control unit (ECU) sends an electronic signal to the suction control valve through the solenoid to regulate the delivery of fuel to the high pressure common rail (HPCR). When the suction control valve is energized, fuel is allowed into the pumping chamber of the high pressure fuel pump. The pressurized fuel is then sent to the HPCR. The ECU varies the time of the signal to ensure the proper amount of fuel is available, see High-Pressure Fuel System Operation. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM114619.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Continued on next page
TM13345X19 (23APR18)
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Sub-System Diagnostics
Fuel Rail Pressure Relief Valve (PRV) (Y5024)—The fuel rail pressure relief valve (Y5024) is located on the end of the high-pressure common rail (HPCR). The ECU sends a signal to the pressure relief valve solenoid to regulate the pressure in the HPCR. When the pressure relief valve is energized, fuel pressure in the HPCR is reduced by allowing the fuel to flow to the return manifold. The pressure relief valve works in conjunction with the high-pressure control valves on the high-pressure pump to control fuel pressure in the HPCR. The pressure relief valve is also energized at key OFF to relieve the fuel pressure in the HPCR. The fuel rail pressure relief valve uses pin 06 for supply voltage and pin 34 for ground on engine control unit (ECU) connector 1 (X5501). Pin 23 of ECU connector 1 provides a shield for the CAN wires. For more information on the high-pressure fuel system, see High-Pressure Fuel System Operation. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
fuel delivery by 50% and generate a diagnostic trouble code (DTC). For information on engine derate, see Engine Derate and Shutdown Protection. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For additional information on the EGR valve, see EGR Valve Operation. (CTM120119.) Exhaust Throttle Actuator (Y5402)—The exhaust throttle actuator (Y5402) is located upstream of the intake manifold and is normally open. An electric motor opens and closes a butterfly valve. To raise the exhaust gas temperature before and during exhaust filter cleaning, the ECU commands the intake air throttle valve to close. The actual manifold air pressure may be negative if a vacuum develops in the intake manifold while the butterfly valve is closed. The ECU receives position feedback from a sensor located inside the intake air throttle assembly. The intake air throttle uses pin 17 for supply voltage, pin 36 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501).
For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Exhaust Gas Recirculation (EGR) Valve (Y5400)—The exhaust gas recirculation (EGR) Valve (Y5400) reduces the amount of nitrogen oxides (NOx) emissions by diluting the intake air with exhaust gases by as much 10—12%. NOx emissions are formed when fuel is burned at high temperatures such as in the combustion process. The EGR valve functions only under high loads and when the engine coolant temperature sensor (B5208) is at normal operating temperature; otherwise, the valve remains closed. The ECU controls the EGR valve by calculating engine speed, load requirements, and inputs from various temperature and pressure sensors. The exhaust gas recirculation valve uses pin 27 for supply voltage, 52 for signal, and pin 25 for ground on engine control unit (ECU) connector 1 (X5501). The exhaust gas recirculation valve uses pins 07 and 08 for desired valve position on engine control unit (ECU) connector 1 (X5501).
The intake air throttle uses pins 10 and 12 for controlled valve position on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For more information on the exhaust throttle actuator, see Exhaust Throttle Actuator. (CTM120119.) Fuel Transfer Pump (Y5501)—The fuel transfer pump (Y5501) draws fuel from the fuel tank through the fuel filter head and primary fuel filter. The fuel flows through the secondary fuel filter to the high-pressure fuel pump. For more information, see Electric Low-Pressure Fuel Pump Operation. (CTM120119.) The fuel transfer pump is supplied with power through engine control unit (ECU) pin 22 on engine control unit (ECU) connector 1 (X5501); ground is supplied through engine control unit (ECU) pin 14 on engine control unit (ECU) connector 1 (X5501).
If the ECU detects an incorrect position or a learned value error (EGR valve not controllable), the ECU will derate the Continued on next page
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=671
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-46
160GLC Excavator 042318 PN=672
Sub-System Diagnostics
Engine Control Unit (ECU) Circuit Theory of Operation (S.N. 056600— ) TX1239519 —UN—02JUN17
WHT
BLK
D3
D4
RED/BLK
RED/BLK
RED
LT BLU
RED
WHT RED
BLU
D5
BLK
WHT
V44 STARTER RELAY DIODE
E22 BATTERY DISCONNECT INDICATOR LIGHT
M1 STARTER MOTOR
M12 YEL
M13 GRN
LT BLU
BLK/YEL
RED/YEL
WHT
H2
L1
4
6
R15 ENGINE SPEED DIAL
+
BLU (CAN 1 LOW)
B40 HYDRAULIC OIL TEMPERATURE SENSOR
F6003 7.5A FUSE
RED
5
B
N CAN
WHT BLK
X29 S
2
CAN 1
4
BLK/YEL
CAN 0
K34 STARTER RELAY
A23
LT GRN/BLK
5
2
A24 WHT
T
BLU/WHT
V7 START RELAY DIODE
3
H1
1
RED
-
N CAN
RED WHT WHT VLT/GRN
WHT
CAN 0
CAN 0
WHT VLT/GRN
WHT VLT/GRN
WHT
Engine Control Unit (ECU) Circuit Schematic (S.N. 056600— ) (1 of 3) Continued on next page
TM13345X19 (23APR18)
D2
C1
GRN (CAN 0 HIGH)
RED 1
BLU (CAN 0 LOW)
BLK
RED WHT
D = X34 F = X36
F16
A = X20 D = X22
GRN (CAN 0 HIGH)
BLK
S91 BATTERY DISCONNECT SWITCH BLK
TX1239519
X175
VLT/GRN
RED
BLK
F60 65A FUSE
F25
RED
VLT/GRN
G2 BATTERY
BLK
RED
WHT/RED
WHT
+ V1 BATTERY RELAY DIODE
F45 30A FUSE
RED
A
4
VLT/GRN
-
K19 BATTERY RELAY
5
D16
M2 A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER = X6014
K4 STARTER CUT RELAY
3
40
C = X33
A3 MAIN CONTROLLER (MCZ)
A4 MONITOR CONTROLLER (DSZ)
BLK
WHT
E
2
G1 BATTERY B
G
WHT
RED
+
WHT S
1
F6001 7.5A FUSE
15 20
F17 5A FUSE
G3 ALTERNATOR
D8
G01 BLK
RED
BRN/BLU B17
X5018
WHT
A7 AIR CONDITIONER CONTROLLER (ACF)
X3
BRN/RED
WHT/RED
VLT/GRN
WHT/RED
F61 45A FUSE
4
V10 STARTER PROTECTION DIODE
WHT/BLK
ST
5
1
YEL/GRN
BLU
WHT/RED
M
2
D+
B22 AMBIENT AIR TEMPERATURE SENSOR
WHT
G2
4
WHT
YEL/GRN
G1
5
K1 LOAD DUMP RELAY
ORG
2
K13 KEY CUT RELAY
3
10
2
T B1+
BLU/RED
3
BAT
1
F38 20A FUSE
ORG
1
RED RED/BLK RED WHT RED LT BLU
BLK/YEL
WHT
ACC
RED
YEL/BLK
RED RED
YEL/BLK
BLU
S1 KEY SWITCH
BLU
HEAT OFF ACC ON START
V3 LOAD DUMP RELAY DIODE
F18 5A FUSE
RED
WHT
RED YEL/BLK RED WHT RED LT BLU
RED
RED YEL/BLK
GRN
RED YEL/BLK
M ST
GRN (CAN 1 HIGH)
ACC
CAN 1
G2
BLU
G1
BLU (CAN 0 LOW)
B
POSITION HEAT OFF ACC ON START
9015-15-47
160GLC Excavator 042318 PN=673
JL58967,0000742 -19-01JUN17-15/28
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-48
160GLC Excavator 042318 PN=674
Sub-System Diagnostics
A3—Main Controller (MCZ) F45— Starter In-Line 30 A Fuse A4—Monitor Controller (DSZ) F60— Alternator 65 A Fuse A7—Air Conditioner Controller F61— Battery 45 A Fuse (ACF) F6001—JDLink™ Unswitched A6000—Modular Telematics Power 7.5 A Fuse Gateway (MTG) F6003—JDLink™ Switched Controller Power 7.5 A Fuse B22— Ambient Air Temperature G1—Battery Sensor G2—Battery B40— Hydraulic Oil Temperature G3—Alternator Sensor K1—Load Dump Relay E22— Battery Disconnect K4—Starter Cut Relay Indicator Light K13— Key Cut Relay F17— Power On 5 A Fuse K19— Battery Relay (marked POWER ON) K34— Starter Relay F18— Idle Stop 5 A Fuse (marked M1—Starter Motor IDLE STOP) R15— Engine Speed Dial F38— Fuel Transfer Pump and S1— Key Switch Controllers 20 A Fuse S91— Battery Disconnect Switch (marked ECU P4)
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), flex power controller (FPC) (A15), and modular telematics gateway (MTG) controller (A6000). The DSZ forwards much of the information across the CAN data line to the monitor where the information 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.)
• 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. Temperature sensor cannot be repaired or replaced without replacing the entire ECU.
• Programming—The ECU can be programmed by
Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The Snapshot information is categorized into two types: Snapshot Capture and Snapshot Recording. For more information, see Snapshot Instructions. (CTM120119.)
• MAP • Engine Speed • Percent Load at Current Speed • Coolant Temperature • Vehicle Speed • Engine Hours (first and last occurrence)
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 top dead center (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 cutout 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)—Unswitched battery power is available from:
Continued on next page
TM13345X19 (23APR18)
X34— Cab Harness-to-Main Controller 30-Pin Connector D X36— Cab Harness-to-Main Controller 26-Pin Connector F X175— Machine Harness-toEngine Interface Harness Connector 1 X5018—Machine Harness-toEngine Interface Harness Connector 2 X6014—Modular Telematics Gateway (MTG) Control Unit Connector
The ECU allows for programming and diagnostic tests using Service ADVISOR™ as follows:
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.) Also, see Regeneration Failure — Possible Causes. (CTM120119.)
The following data is captured automatically for storing each code in the snapshot data buffer:
V1— Battery Relay Diode V3— Load Dump Relay Diode V7— Start Relay Diode V10— Starter Protection Diode V44— Starter Relay Diode X3— Cab Harness-to-Machine Harness 100-Pin Connector X20— Monitor Controller 28-Pin Connector A X22— Monitor Controller 16-Pin Connector D X29— Cab Harness-to-Switch Panel Connector 3 X33— Cab Harness-to-Main Controller 17-Pin Connector C
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Sub-System Diagnostics
• Fuse F8—Pins 12 and 50 of engine control unit (ECU) connector 3 (X5503).
• Fuse F36—Pins 23 and 24 of engine control unit (ECU) connector 3 (X5503).
• Fuse F37—Pins 13 and 14 of engine control unit (ECU) connector 3 (X5503).
Ground is provided at pin 22 via engine control unit (ECU) connector 2 (X5502) and pins 16, 17, 27, 43, and 44 via engine control unit (ECU) connector 3 (X5503). 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 7 of engine control unit (ECU) connector 3 (X5503) 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) to starter relay (K34), energizing the relay. With the starter relay 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 05 of engine control unit (ECU) connector 3 (X5503) is grounded, providing ground to starter cut relay, energizing the relay. With starter cut relay energized, the start signal is removed from the starter relay, de-energizing the starter relay, thus disengaging the starter motor. When the engine is running the ECU provides excitation from pin 34 of engine control unit (ECU) connector 2 (X5502) to pin D+ of the alternator (G3) for the charging circuit. For more information, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.)
torque message is sent. Before applying a new torque command, the ECU verifies the watchdog indicator has changed from the previous message. If the ECU detects that the torque command message is not being updated at the expected rate or if two consecutive messages have the same watchdog indicator value, the ECU will default to the lowest torque curve and set the appropriate diagnostic trouble code (DTC). The FPC is used to monitor the system voltage. The FPC uses engine speed and system voltage data, received via CAN from the ECU, to determine the state of the alternator and battery. If the voltage is below a predefined threshold with the engine running, a DTC is created and a message is sent via CAN to the monitor controller (DSZ) (A4) to activate the alternator light on the monitor. The FPC interfaces with the modular telematics gateway (MTG) controller (A6000) and the monitor controller (DSZ) (A4) to communicate the availability of software updates for the machine controllers via Service ADVISOR™ Remote (SAR). The Service ADVISOR™ Remote (SAR) switch (S18) is used to accept or decline these updates. The FPC monitors the status of parked exhaust filter cleaning cycles. The FPC will generate a DTC to warn the operator of aborted cleaning cycles. The FPC stores the machine model information in nonvolatile memory. On each power cycle, the FPC compares the model received from the main controller (MCZ) (A3) to its own stored model data. If the two do not agree, the machine model can’t be verified and the flex power function will default to the low torque curve. Flex Power Controller (FPC) (Power and Ground)—Unswitched battery power is available at pins L1 and L2 of flex power controller (FPC) (A15) through fuel transfer pump and controllers 20 A fuse (marked ECU P4) (F38) and through flex power controller (FPC) in-line 10 A Fuse (F5004). Ground is provided at pin M2 and pin M3 of FPC.
Flex Power Controller (FPC) (A15)—The FPC provides several functions: flex power control, system voltage monitoring, Service ADVISOR™ Remote (SAR), and exhaust filter cleaning malfunction notice. FPC is used to allow the vehicle system to adjust the maximum available torque between two predefined torque curves. The flex power function allows the engine torque level to be defined via CAN by the FPC. However, the engine control unit (ECU) and FPC both contain a common data table defining the minimum and maximum torque at each speed within the operating range of the engine. The ECU updates the FPC with the current engine speed every 20 milliseconds. Once the FPC receives the engine speed, it then computes the new torque command for that speed as a percentage between the minimum and maximum torque values in the data table. Every 20 milliseconds, the FPC sends an updated torque command to the ECU which also includes a watchdog indicator, which is simply a counter that increments each time the
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 flows through power on 5 A fuse (F17) to pin M1 of FPC, causing the FPC to power up. NOTE: For power up of the other electronic controllers, see the theory of operation of specific component:
• See Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
• See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=676
Sub-System Diagnostics
TX1235641 —UN—13MAR17
RED
RED RED/BLK
RED RED/BLK
RED/BLK
WHT RED
WHT RED
WHT RED
RED
3 2
10
4
WHT/GRN
N CAN
GRY
14
35
VLT
17 14
38
30
05
WHT
BRN
36
WHT
ORG
12
WHT
17
GRY
41
BLU
26
VLT
GRN
BLU
YEL
52
ORG
08
18
17
X5015
ORG/BLK
10
6
27
X5015
5
BLU
VLT
27
GRN
BLK
11
1
T
07
BRN
44
BLK
BLK
BLK
27
S
X5018
GRY
SIGNAL
BLK
16
25
ORG/GRN
GRN
BRN
13
9
X5018 S16 EXHAUST FILTER PARKED CLEANING SWITCH RED
ORG
RED
BLU
24
8
2 RED/BLK
23 43
BLK
E
RED
BRN
48
RED
WHT
16
B5009 ENGINE COOLANT LOSS LEVEL SENSOR
F37 20A FUSE 1
RED
RETURN
GRN
15
X5015
X5015
C
X5018
R5601 CAN 0 TERMINATION RESISTOR X5018 MACHINE HARNESS-TOENGINE INTERFACE HARNESS CONNECTOR 2
K
J
J
WHT VLT/GRN
1
H A B
P
3
2
B5102 EXHAUST MANIFOLD PRESSURE SENSOR
D C
WHT VLT/GRN
BRN
3
1
4 2
Y5400 EXHAUST GAS RECIRCULATION (EGR) VALVE
1
P
3
2
B5101 ENGINE OIL PRESSURE SENSOR
6
VLT/GRN
2
YEL BLU GRN
CAN 0
4
E
BLK (CAN 0 SHLD)
6
ORG
BLK
1
DK GRN
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
B
BRN
LO
A
YEL
HI
LT BLU
C2
LT BLU
BLU
RED
49
D2
GRN/WHT BLK/YEL YEL/BLK
1
GRY
YEL (CAN 0 HIGH) GRN (CAN 0 LOW) BLK (CAN 0 SHLD)
X5018 X W U V 5
T
24
DK GRN
RED
S18 SERVICE ADVISOR REMOTE (SAR) SWITCH
7
RED/BLK
F2
1
B5209 FUEL TEMPERATURE SENSOR
39
17 21
01
-
RED
E3
M1
1
2
B5208 ENGINE COOLANT TEMPERATURE SENSOR
T
F36 20A FUSE
X5018 MACHINE HARNESS-TO- D ENGINE INTERFACE HARNESS CONNECTOR 2
02
A1
F3
Q
2
53
B1
C1
1
RED
50
+
F5004 10A FUSE
37
= X5503
L2
2
B5600 WATERIN-FUEL (WIF) SENSOR
GRY
= X5502
A
X5018
= X5501
3
P
2
B5107 INLET FUEL PRESSURE SENSOR
BLU
BLK
L1
YEL
GRY
36
C
M012 YEL (CAN 0 HIGH)
RED
05
A15 FLEX POWER CONTROLLER (FPC)
M3 BLK
24
B
M013 GRN (CAN 0 LOW)
M2
RED/BLK
RED/BLK
22
1
120
07
3
A
GRY
A1 ENGINE CONTROL UNIT (ECU)
YEL
27
50
B5104 INTAKE MANIFOLD PRESSURE SENSOR
2
YEL
GRN
ORG
34
1
N CAN
BLU
RED RED
X5018
3
YEL
1
P
BRN
T
B
2
B5207 EXHAUST GAS RECIRCULATION (EGR) TEMPERATURE SENSOR
VLT VLT
2
B5103 EXHAUST GAS RECIRCULATION (EGR) DELTA PRESSURE P SENSOR
+5V
X5016
R002 BLK (CAN 0 SHLD)
10
GRN
X5016
DK GRN
BLU
LT BLU
DK GRN
12
12
BLU 1
BLU
RED
RED/BLK
F8 20A FUSE
RED/BLU
B5303 FAN SPEED SENSOR
WHT RED GRY
3
Y5402 EXHAUST THROTTLE ACTUATOR
ORG
WHT VLT/GRN
TX1235641 Engine Control Unit (ECU) Circuit Schematic (S.N. 056600— ) (2 of 3) Continued on next page
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=677
JL58967,0000742 -19-01JUN17-18/28
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-52
160GLC Excavator 042318 PN=678
Sub-System Diagnostics
A1—Engine Control Unit (ECU) B5208—Engine Coolant R5601—CAN 0 Termination X5501—Engine Control Unit A15— Flex Power Controller Temperature Sensor Resistor (ECU) Connector 1 (FPC) B5209—Fuel Temperature Sensor S16— Exhaust Filter Parked X5502—Engine Control Unit B5009—Engine Coolant Loss B5303—Fan Speed Sensor Cleaning Switch (ECU) Connector 2 Level Sensor B5600—Water-in-Fuel (WIF) S18— Service ADVISOR™ X5503—Engine Control Unit B5101—Engine Oil Pressure Sensor Remote (SAR) Switch (ECU) Connector 3 Sensor F8— Engine Control Unit (ECU) X1— Service ADVISOR™ Y5400—Exhaust Gas B5102—Exhaust Manifold 20 A Fuse (marked ECU P1) Diagnostic Connector Recirculation (EGR) Valve Pressure Sensor F36— Engine Control Unit (ECU) X5015—Engine Interface Y5402—Exhaust Throttle B5103—Exhaust Gas 20 A Fuse (marked ECU P2) Harness-to-Engine Actuator Recirculation (EGR) Delta F37— Engine Control Unit (ECU) Harness Connector 1 Pressure Sensor 20 A Fuse (marked ECU P3) X5016—Engine Interface B5104—Intake Manifold Pressure F5004—Flex Power Controller Harness-to-Engine Sensor (FPC) In-Line 10 A Fuse Harness Connector 2 B5107—Inlet Fuel Pressure X5018—Machine Harness-toSensor Engine Interface Harness B5207—Exhaust Gas Connector 2 Recirculation (EGR) Temperature Sensor
Service ADVISOR™ Remote (SAR) Switch (S18)—The Service ADVISOR™ Remote (SAR) switch (S18) allows the operator to accept or decline available updates. The flex power controller (FPC) (A15) will create DTCs under certain trigger conditions, which will send a message via CAN to the monitor controller (DSZ) (A4) to prompt the vehicle to display operator instructions on the monitor. 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 through power on 5 A fuse (F17) to pins 1, 7, and 10 of Service ADVISOR™ Remote (SAR) switch (S18). When the SAR switch is pressed to the ACCEPT position, current is sent through pin 3 of the SAR switch to pin C1 of FPC. Pin E3 of FPC, is then grounded, completing the circuit to pin 5 of the SAR switch, activating the ACCEPT (green) light emitting diode (LED). When the SAR switch is pressed to the DECLINE position, current is sent through pin 2 of the SAR switch to pin F2 of FPC. Pin F3 of FPC, is then grounded, completing the circuit to pin 4 of the SAR switch, activating the DECLINE (red) light emitting diode (LED). Cold Weather Starting Aid—Power is available to pin 3 of glow plug relay (K16) from glow plug 50 A fuse (F63). Ground is provided at pin 1 of glow plug relay and to glow plugs (R1—R4). 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 7 of engine control unit (ECU) connector 3 (X5503) through power on 5 A fuse (F17), causing the ECU to power up. The ECU now determines if the glow plugs need to be activated. If the ECU determines the glow plugs are necessary, power is
sent out pin 32 via engine control unit (ECU) connector 1 (X5501) to pin 2 of glow plug relay, energizing the relay. Power is sent to glow plugs and through glow plug resistor (R19) to engine control unit (ECU) connector 1 (X5501) pin 54. For more information on cold start aid, see Cold Weather Starting Aid. (Group 9010-05.) Hydraulic Variable Speed Fan—The variable speed fan cools the machine's systems by a hydraulic pump and motor controlled by a variable speed fan solenoid, providing machine efficiency and reducing fan noise levels by only operating the fan at the minimum speed necessary to cool the machine systems. The engine control unit (ECU) uses the following inputs to determine the proper fan speed:
• B22—Ambient air temperature sensor if air conditioner is ON via CAN.
• B40—Hydraulic oil temperature sensor via controller area network (CAN).
• B5205—Charge air cooler outlet temperature sensor at
pin 29 of engine control unit (ECU) connector 2 (X5502).
• B5208—Engine coolant temperature sensor at pin 16 of engine control unit (ECU) connector 1 (X5501).
• B5209—Fuel temperature sensor at pin 48 of engine control unit (ECU) connector 1 (X5501).
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. The maximum fan speed is limited to engine speed. Temperature thresholds and variable speed fan solenoid duty cycles (fan speeds) are preprogrammed into the ECU and cannot be changed. The variable speed fan solenoid (Y5014) is driven from engine control unit (ECU) pin 32 of engine control unit (ECU) connector 2 (X5502).
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Sub-System Diagnostics Engine Control Unit (ECU) Sensor Input
Temperature
Maximum Fan Speed as % of Engine Speed
Maximum Engine Speed Fan Speed (P-mode engine speed)
Coolant Temperature
103°C (217°F)
80%
1900
Hydraulic Oil Temperature
91°C (196°F)
Ambient Air Temperature (when A/C is ON)
37°C (99°F)*
Fuel Temperature
70°C (158°F)*
Intake Air Temperature
52°C at 25°C ambient (126°F at 77°F ambient)**
To protect the fan pump while operating in cold conditions, the ECU limits the fan speed according to the input from the hydraulic oil temperature sensor (B40). The ECU will increase the fan speed as hydraulic oil warms.
*When the air conditioner is ON and the ambient air temperature is over 15°C (60°F) the engine fan will increase to 1250 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 (80°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).
Hydraulic Temperature °C (°F)
-40°C (-40°F)
-9°C (16°F)
-7°C (19°F)
-3°C (26°F)
4°C (39°F)
6°C (43°F)
11°C (52°F)
12°C (54°F)
Fan Speed Limit (rpm)
350
350
400
600
1000
1250
1750
(not limited by hydraulic temperature)
Hydraulic Variable Speed Fan Reversing Function (if equipped)—The hydraulic variable speed fan with reversing function controls the cooling capacity of the cooling package by varying the speed of the fan. The engine control unit (ECU) automatically controls the speed of the fan by monitoring the following:
• Engine Coolant Temperature • Hydraulic Oil Temperature • Fuel Temperature • Charge Air Cooler Outlet Temperature • Ambient Air Temperature • Air Conditioning State (On-Off)
communicates with the DSZ and ACF to set the A/C compressor value to OFF. The A/C compressor will be temporarily turned off until approximately 1 minute after the completion of a fan reversing cycle; at that time, the ECU will send communication to set the A/C compressor value to ON. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.) NOTE: If a malfunction exists for any of the previously mentioned temperature sensors, the fan speed will go to full speed.
The engine coolant temperature sensor (B5208), fuel temperature sensor, and charge air cooler outlet temperature sensor (B5205) are hard wired to the engine control unit (ECU). The hydraulic oil temperature 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 is hard wired to the air conditioner controller (ACF) and continuously transmits information via CAN to communicate with the monitor controller (DSZ), which then forwards the information via CAN to the ECU. During a reversing cycle, the ECU
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 32 of engine control unit (ECU) connector 2 (X5502) to variable speed fan solenoid (Y5014). Static ground is provided to variable speed fan solenoid at all times on pin 21 of engine control unit (ECU) connector 1 (X5501). 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.)
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Sub-System Diagnostics
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 the reversing fan switch (S15). Unswitched power is provided from optional connector and reversing fan 20 A fuse (F6) to pin 3 of reversing fan switch (S15). The reversing fan function can be operated when the ECU determines that the following conditions are met:
• Engine speed is at least 1180 rpm. • Hydraulic oil temperature is greater than 12°C (54°F). • The high temperature lamp is off. See Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) • Fan solenoid codes are not present in the monitor. • A reverse sequence is not in progress. NOTE: The reversing fan is inhibited for 7 seconds following a fan reversal cycle and only an ECU reset can interrupt a fan reverse cycle. The first automatic reverse cycle will begin 1 hour after key ON or an ECU reset. When the automatic reversing fan timer in the ECU reaches the preset interval or if manual mode is selected, the ECU begins the reversing sequence as follows: 1. The ECU increases the current to variable speed fan solenoid (Y5014) to slow the fan to minimum fan speed (approximately 350 rpm). 2. When fan speed is at minimum, the ECU sends current out pin 26 of engine control unit (ECU) connector 2 (X5502) to the reversing fan solenoid (Y5015), energizing the solenoid. The fan solenoid reverses the fan direction. 3. With the fan now operating in the reverse direction, the ECU decreases the current applied to the variable speed fan solenoid (Y5014) until maximum fan speed (approximately 1500 rpm) is reached. 4. The ECU operates the fan at maximum speed in reverse direction for approximately 15 seconds, then increases 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 (Y5015), causing the fan to change back to forward direction. 6. With the fan operating in the forward direction, the ECU decreases the variable speed fan solenoid current until the normal operating fan speed is obtained. When an automatic reversing sequence is complete the ECU will start the automatic reversing fan timer according to the preset interval of 60 minutes. The reversing sequence cannot be activated again for approximately 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.
(MCZ) and sensors located on the engine. The ECU is supplied with unswitched power on engine control unit (ECU) connector 3 (X5503) pins 12 and 50 through engine control unit (ECU) 20 A fuse (marked ECU P1) (F8), pins 23 and 24 through engine control unit (ECU) 20 A fuse (marked ECU P2), and pins 13 and 14 through engine control unit (ECU) 20 A fuse (marked ECU P3). Ground is provided on engine control unit (ECU) connector 2 (X5502) pin 22 and engine control unit (ECU) connector 3 (X5503) pins 16, 17, 27, 43, and 44. The ECU is turned on by a power on 5 A fuse (F17) through pin 07 of engine control unit (ECU) connector 3 (X5503). The ECU communicates with the MCZ through a CAN (controller area network). CAN connects to ECU through pins 01, 02, and 21 of engine control unit (ECU) connector 3 (X5503). If there is a malfunction with the ECU or one of the sensor circuits it is connected to, the ECU 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) (A3) to the engine control unit (ECU) (A1). A variable voltage of 0—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. Power is supplied to pin 4 of cab harness-to-switch panel connector 3 (X29) to MCZ connector (X36) pin F25. Signal is sent from pin 5 of cab harness-to-switch panel connector 3 (X29) to MCZ connector (X34) pin D16. Ground is supplied on pin 6 of cab harness-to-switch panel connector 3 (X29) to pin F16 of MCZ connector X36. For information on auto-idle and power modes ECO, PWR, and H/P, see Engine Speed Control System Operation. (Group 9010-05.) 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 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. For more information on auto warm-up control, see Engine Speed Control System Operation. (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.)
Engine Control Unit— The engine control unit (ECU) (A1) manages the engine with input from main controller Continued on next page TM13345X19 (23APR18)
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Sub-System Diagnostics
Exhaust Filter Parked Cleaning Switch (S16)—The exhaust filter parked cleaning switch (S16) allows the operator to perform a parked exhaust filter cleaning. With key switch (S1) 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 through power on 5 A fuse (F17) to pin 1 of exhaust filter parked cleaning switch (S16). When the ECU has determined a parked exhaust filter cleaning is required, ground is provided to pin 5 of exhaust filter parked cleaning switch from pin 35 of engine control unit (ECU) connector 3 (X5503), completing the circuit and activating the light emitting diode (LED). When the exhaust filter parked cleaning switch is held for 3 seconds, pin 38 of engine control unit (ECU) connector 3 (X5503) is connected to ground, initiating the parked exhaust filter cleaning if all requirements are met. NOTE: For component location, see Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location. (Group 9015-10.)
Battery Disconnect Indicator Light (E22)—The battery disconnect indicator light (E22) illuminates when the key switch is in the ON position and stays illuminated until it is safe to turn the battery disconnect switch (S91) to the OFF position. When the key switch is in the ON position the engine control unit (ECU) sends power from pin 30 of engine control unit (ECU) connector 3 (X5503) to the battery disconnect indicator light. When the key switch is turned to the OFF position, the ECU determines when the diesel exhaust fluid (DEF) system has purged the DEF fluid in the DEF lines. NOTE: For component location, see Engine Interface Harness (W5) Component Location. (Group 9015-10.) For more information on the DEF system, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) For more information on the battery disconnect switch, see Battery Disconnect Switch. (Operator’s Manual.)
For more information on exhaust filter parked cleaning, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) Continued on next page
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Sub-System Diagnostics
TX1231064 —UN—22DEC16
Y5014 VARIABLE SPEED FAN SOLENOID
PUR
42
15
PUR
BRN
Y2 ELECTRONIC INJECTOR (CYLINDER 2)
BRN
7
2
1
45
2
1
Y5024 FUEL RAIL PRESSURE RELIEF VALVE (PRV)
T 2
37
09
WHT
RED = X5503
19
18
9
6
8
YEL
RED
BLK
BRN
WHT
VLT
24
DK GRN
LT BLU
Y5002 SUCTION CONTROL VALVE (SCR)
51
X5016
W LT BLU
F
SHD
X
PUR
GRY
WHT
LT BLU
C
18
29
09
RED
40
B5206 MANIFOLD AIR TEMPERATURE (MAT) SENSOR ORG
1
T
B5205 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR
2
B5113 FUEL RAIL PRESSURE SENSOR
P 1
P
3
2
B5105 CRANK CASE PRESSURE SENSOR
1
2
3
1
2
GRN
06
TAN
23
YEL
34
6
Y3 ELECTRONIC INJECTOR (CYLINDER 3)
= X5501
TAN
03
YEL
Y4 ELECTRONIC INJECTOR (CYLINDER 4)
54
LT GRN
02
H
5
RED
GRY
Y1 ELECTRONIC INJECTOR (CYLINDER 1)
8
PUR
3
32
ORG
YEL
14
= X5502
1
X5000 4
21
F6 20A FUSE
X5604 ENGINE HARNESS-TOGLOW PLUG HARNESS CONNECTOR
BRN
RED BRN
DK GRN
G
2
GRN
GRN
ORG
B
1
BRN
BRN
22
26
26 E
F63 50A FUSE
BLK
X5016 X5068 D
R4
R19 GLOW PLUG RESISTOR
ORG
33
R3
GRN
04
R2
X5604
BLU
43
BLU
4
32
ORG
44
A1 ENGINE CONTROL UNIT (ECU)
YEL
28
WHT
45
28
PUR
2
K16 GLOW PLUG RELAY R1
23
BLK 46
3
LT BLU
2
Y5501 FUEL TRANSFER PUMP
X5016 ORG
2
Y5015 REVERSING FAN SOLENOID
BLK
R5603 ENGINE CAN TERMINATION RESISTOR
BLK
ORG
YEL
DK GRN
2
RED
30
1
SHD
38
2
M
BLK
29
35
B5500 INTAKE AIR SENSOR
4
1
ORG
9 GRN
GRY
8 YEL
PUR
2 YEL
ORG
X5015 3 GRN
SHD
DK GRN
1
GRN (ENG CAN LOW) YEL (ENG CAN HIGH)
ORG YEL
3
N2
1
BLU
1
GRN YEL
GRY
N1
1
3
120
2
B5301 CRANKSHAFT POSITION SENSOR
GRY
B5302 CAMSHAFT POSITION SENSOR
WHT RED RED P01 RED
WHT RED DK GRN
WHT RED GRY
X83 CAB HARNESSTO-REVERSING FAN SWITCH HARNESS
M O A
S15 REVERSING FAN SWITCH
3
ORG
BRN
TX1231064 Engine Control Unit (ECU) Circuit Schematic (S.N. 056600— ) (3 of 3) Continued on next page
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Sub-System Diagnostics
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=684
Sub-System Diagnostics
A1—Engine Control Unit (ECU) F63— Glow Plug 50 A Fuse B5105—Crankcase Pressure K16— Glow Plug Relay Sensor R1—Glow Plug 1 B5113—Fuel Rail Pressure R2—Glow Plug 2 Sensor R3—Glow Plug 3 B5205—Charge Air Cooler Outlet R4—Glow Plug 4 Temperature Sensor R19— Glow Plug Resistor B5206—Manifold Air Temperature R5603—Engine CAN Termination (MAT) Sensor Resistor B5301—Crankshaft Position S15— Reversing Fan Switch Sensor X83— Cab Harness-to-Reversing B5302—Camshaft Position Fan Switch Harness Sensor Connector B5500—Intake Air Sensor X5000—Engine Harness-to-Fuel F6— Optional Connector and Injector Harness Reversing Fan 20 A Fuse Connector (marked OPT. 2 ALT) X5068—Engine Interface Harness-to-Engine Harness Connector 3
Fuel Rail Pressure Sensor (B5113)—The fuel rail pressure sensor (B5113) 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 high-pressure fuel pump pressure control valve (PCV) 1 (Y5022) and high-pressure fuel pump pressure control valve (PCV) 2 (Y5023). 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 37 for supply voltage, pin 09 for ground, and pin 51 for signal on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 17 for supply voltage, pin 26 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501).
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Exhaust Manifold Pressure Sensor (B5102)—The exhaust manifold pressure sensor (B5102) provides feedback to the control systems for the exhaust throttle actuator (Y5402) and exhaust gas recirculation (EGR) valve (Y5400) in order to maximize engine performance while meeting the applicable emissions regulations. The ECU uses the exhaust manifold pressure for the volumetric efficiency calculation. The exhaust manifold pressure sensor uses pin 27 for supply voltage, pin 11 for signal, and pin 25 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
Exhaust Gas Recirculation (EGR) Delta Pressure Sensor (B5103)—The exhaust gas recirculation (EGR) delta pressure sensor (B5103) measures the pressure drop across the EGR venturi tube. The ECU calculates the amount of the recirculated exhaust gas using this measurement and the venturi tube physical dimensions. The ECU controls the EGR valve (Y5400) and turbocharger actuator (Y5500) to recirculate the ideal amount of exhaust gas for the operating condition. The EGR delta pressure sensor uses pin 36 for supply voltage, pin 05 for signal, and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
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TM13345X19 (23APR18)
Y2— Electronic Injector 2 (cylinder 2) Y3— Electronic Injector 3 (cylinder 3) Y4— Electronic Injector 4 (cylinder 4) Y5002—Suction Control Valve Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid Y5024—Fuel Rail Pressure Relief Valve (PRV) Y5501—Fuel Transfer Pump
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
X5015—Engine Interface Harness-to-Engine Harness Connector 1 X5016—Engine Interface Harness-to-Engine Harness Connector 2 X5501—Engine Control Unit (ECU) Connector 1 X5502—Engine Control Unit (ECU) Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X5604—Engine Harness-to-Glow Plug Harness Connector Y1— Electronic Injector 1 (cylinder 1)
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Sub-System Diagnostics ECU adjusts the signal going to the EGR valve (Y5400) to compensate the mixture. The ECU also uses this sensor for engine protection purposes.
Intake Manifold Pressure Sensor (B5104)—Intake manifold pressure sensor (B5104) is used to help calculate the amount of air flow into the engine. The intake manifold pressure sensor also supplies the ECU with a direct measurement of turbo boost. The intake manifold pressure sensor uses pin 36 for supply voltage, pin 37 for signal, and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
The charge air cooler outlet temperature sensor uses pin 29 for signal and pin 15 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) Crankcase Pressure Sensor (B5105)—The crankcase pressure sensor (B5105) is used to measure the amount of pressure in the crankcase of the engine. The ECU uses the crankcase pressure sensor value to indicate when the crankcase ventilation filter needs to be replaced or if there is a problem with the crankcase pressure relief valve that is located in the rocker arm cover.
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
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 ECU then compares the temperatures of the recirculated exhaust gas, charge air cooler outlet air, and mixed air in the intake manifold to determine if proper cooling and mixing has occurred. If the temperature is not correct, the ECU adjusts the signal going to the EGR valve (Y5400) to compensate the mixture. The MAT sensor helps the ECU calculate the correct fueling for the engine. The ECU also uses this sensor for engine protection purposes.
For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.)
The MAT sensor uses pin 09 for signal and pin 15 for ground on engine control unit (ECU) connector 2 (X5502).
Inlet Fuel Pressure Sensor (B5107)—The inlet fuel pressure sensor (B5107) sends a pressure equivalent signal to the 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.
NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
The crankcase pressure sensor uses pin 15 for supply voltage, pin 18 for signal, and pin 45 for ground on engine control unit (ECU) connector 2 (X5502).
The inlet fuel pressure sensor uses pin 17 for supply voltage, pin 39 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Charge Air Cooler Outlet Temperature Sensor (B5205)—The charge air cooler outlet temperature sensor (B5205) is used to measure the temperature of the charge air cooler outlet air entering the intake manifold. The ECU then compares the temperatures of the recirculated exhaust gas, charge air cooler outlet air, and the mixed air in the intake manifold to determine if proper cooling and mixing has occurred. If the temperature is not correct, the
For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Exhaust Gas Recirculation (EGR) Temperature Sensor (B5207)—The exhaust gas recirculation (EGR) temperature sensor (B5207) is used to measure the temperature of the exhaust gas entering the EGR valve (Y5400). The ECU then compares the temperatures of the EGR exhaust gas, charge air cooler outlet air, and the intake manifold air to determine if proper cooling and mixing has occurred. If the temperature is not correct, the ECU adjusts the signal going to the EGR valve to compensate the mixture. The ECU also uses this sensor for engine protection purposes. The EGR temperature sensor uses pin 27 for signal and pin 24 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
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Sub-System Diagnostics
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 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, indicating a thermostat is stuck open. The engine coolant temperature sensor uses pin 16 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.)
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 the information 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, which may require prolonged engine cranking to start the engine. The crankshaft position sensor uses pin 38 for signal and pin 30 for ground on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the signal and ground wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how speed sensors operate, see Measuring Speed. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Fuel Temperature Sensor (B5209)—The fuel temperature sensor (B5209) input is used by the ECU to calculate fuel density and adjust fuel delivery.
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.
The fuel temperature sensor uses pin 48 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
Camshaft position sensor consists of a permanent magnet, coil, and yoke. The sensor 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 electromagnetic interference (EMI). If there is a problem with the camshaft position sensor, the ECU will use the crankshaft position sensor to determine engine timing, which may require prolonged engine cranking to start the engine.
For information on how speed sensors operate, see Measuring Speed. (CTM120119.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) 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 ECU determine when cylinder number one or six is at top dead center (TDC) of its compression stroke.
The camshaft position sensor uses pin 28 for signal and pin 29 for ground on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the signal and ground wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on how speed sensors operate, see Measuring Speed. (CTM120119.)
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Sub-System Diagnostics
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Fan Speed Sensor (B5303)—The fan speed sensor (B5303) sends the engine control unit (ECU) with the fan speed in revolutions per minute (rpm). The ECU uses the fan speed sensor for more precise control of the fan speed. The fan speed sensor uses pin 36 for supply voltage on engine control unit (ECU) connector 2 (X5502). The fan speed sensor uses pin 53 for signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). Intake Air Sensor (B5500)—The intake air sensor (B5500) measures temperature, pressure and humidity of the turbocharger compressor inlet air. The location of the measurements is in the intake prior to the fixed geometry turbocharger. The sensor communicates with the ECU over the engine CAN bus. These measurements provide input for fueling calculations made by the ECU. Humidity affects the exhaust gas temperature and the effectiveness of exhaust filter cleaning. The ECU compares turbocharger compressor inlet pressure to barometric air pressure to calculate the intake air pressure drop. The intake air sensor uses pin 28 for supply voltage and pin 14 for ground on engine control unit (ECU) connector 2 (X5502). The intake air sensor uses pins 45 and 46 for CAN communication on engine control unit (ECU) connector 1 (X5501). Pin 35 of ECU connector 1 provides a shield for the CAN wires. NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.)
Engine Coolant Loss Level Sensor (B5009)—The engine coolant loss level sensor (B5009) 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 17 for signal and pin 14 for ground on engine control unit (ECU) connector 2 (X5502). NOTE: For component location, see Engine Interface Harness (W5) Component Location. (Group 9015-10.) 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. (CTM120119.) For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.)
For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.)
For additional information on high-pressure fuel system, see High-Pressure Fuel System Operation. (CTM120119.)
For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Water-in-Fuel (WIF) Sensor (B5600)—The water-in-fuel (WIF) 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 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 15 signal and pin 50 for ground on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
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 engine control unit (ECU) connector 2 (X5502) pin E2, 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.
Suction Control Valve (Y5002)— The suction control valve (Y5002) is located on the high pressure fuel pump. The engine control unit (ECU) sends an electronic signal to the suction control valve through the solenoid to regulate the delivery of fuel to the high pressure common rail (HPCR). When the suction control valve is energized, fuel is allowed into the pumping chamber of the high pressure fuel pump. The pressurized fuel is then sent to the HPCR. The ECU varies the time of the signal to ensure the proper amount of fuel is available, see High-Pressure Fuel System Operation. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM114619.)
For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Continued on next page
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Sub-System Diagnostics
Fuel Rail Pressure Relief Valve (PRV) (Y5024)—The fuel rail pressure relief valve (Y5024) is located on the end of the high-pressure common rail (HPCR). The ECU sends a signal to the pressure relief valve solenoid to regulate the pressure in the HPCR. When the pressure relief valve is energized, fuel pressure in the HPCR is reduced by allowing the fuel to flow to the return manifold. The pressure relief valve works in conjunction with the high-pressure control valves on the high-pressure pump to control fuel pressure in the HPCR. The pressure relief valve is also energized at key OFF to relieve the fuel pressure in the HPCR. The fuel rail pressure relief valve uses pin 06 for supply voltage and pin 34 for ground on engine control unit (ECU) connector 1 (X5501). Pin 23 of ECU connector 1 provides a shield for the CAN wires. For more information on the high-pressure fuel system, see High-Pressure Fuel System Operation. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Exhaust Gas Recirculation (EGR) Valve (Y5400)—The exhaust gas recirculation (EGR) Valve (Y5400) reduces the amount of nitrogen oxides (NOx) emissions by diluting the intake air with exhaust gases by as much 10—12%. NOx emissions are formed when fuel is burned at high temperatures such as in the combustion process. The EGR valve functions only under high loads and when the engine coolant temperature sensor (B5208) is at normal operating temperature; otherwise, the valve remains closed. The ECU controls the EGR valve by calculating engine speed, load requirements, and inputs from various temperature and pressure sensors. The exhaust gas recirculation valve uses pin 27 for supply voltage, 52 for signal, and pin 25 for ground on engine control unit (ECU) connector 1 (X5501). The exhaust gas recirculation valve uses pins 07 and 08 for desired valve position on engine control unit (ECU) connector 1 (X5501).
fuel delivery by 50% and generate a diagnostic trouble code (DTC). For information on engine derate, see Engine Derate and Shutdown Protection. (CTM120119.) NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For additional information on the EGR valve, see EGR Valve Operation. (CTM120119.) Exhaust Throttle Actuator (Y5402)—The exhaust throttle actuator (Y5402) is located upstream of the intake manifold and is normally open. An electric motor opens and closes a butterfly valve. To raise the exhaust gas temperature before and during exhaust filter cleaning, the ECU commands the intake air throttle valve to close. The actual manifold air pressure may be negative if a vacuum develops in the intake manifold while the butterfly valve is closed. The ECU receives position feedback from a sensor located inside the intake air throttle assembly. The intake air throttle uses pin 17 for supply voltage, pin 36 for signal, and pin 41 for ground on engine control unit (ECU) connector 1 (X5501). The intake air throttle uses pins 10 and 12 for controlled valve position on engine control unit (ECU) connector 1 (X5501). NOTE: For component location, see Engine Harness (W4) Component Location. (Group 9015-10.) For more information on the exhaust throttle actuator, see Exhaust Throttle Actuator. (CTM120119.) Fuel Transfer Pump (Y5501)—The fuel transfer pump (Y5501) draws fuel from the fuel tank through the fuel filter head and primary fuel filter. The fuel flows through the secondary fuel filter to the high-pressure fuel pump. For more information, see Electric Low-Pressure Fuel Pump Operation. (CTM120119.) The fuel transfer pump is supplied with power through engine control unit (ECU) pin 22 on engine control unit (ECU) connector 1 (X5501); ground is supplied through engine control unit (ECU) pin 14 on engine control unit (ECU) connector 1 (X5501).
If the ECU detects an incorrect position or a learned value error (EGR valve not controllable), the ECU will derate the JL58967,0000742 -19-01JUN17-28/28
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Sub-System Diagnostics
Exhaust Aftertreatment Circuit Theory of Operation Exhaust Aftertreatment Circuit Theory of Operation (S.N. —056599) X5015 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 1
Y5402 EXHAUST THROTTLE ACTUATOR
YEL/BLK
1
F17 5A FUSE
1
5631 BRN
4
5631 BRN
17
2
5633 ORG
11
5633 ORG
41
3
5509 WHT
28
5509 WHT
36
4
5018 GRY
29
5018 GRY
10
6
5016 LT BLU
18
5016 BLU
12
RED/BLK
S16 EXHAUST FILTER PARKED CLEANING SWITCH
BLK
8
9
1
5
A1 ENGINE CONTROL UNIT (ECU)
X5018 MACHINE HARNESSTO-ENGINE INTERFACE HARNESS CONNECTOR 2 ORG/GRN
S
5947 PUR
38
ORG/BLK
T
5796 BLU
35
X5070 EXHAUST AFTERTREATMENT HARNESS-TO-DIESEL PARTICULATE FILTER (DPF) HARNESS CONNECTOR 5785 GRN 5625 GRN 5634 YEL
5 2 1 3
5785 GRN 5625 GRN 5634 YEL
B5213 DIESEL PARTICULATE FILTER (DPF) OUTLET PRESSURE SENSOR
3 2 1
B5109 EXHAUST FILTER DELTA PRESSURE SENSOR
B5214 DIESEL PARTICULATE FILTER (DPF) INLET PRESSURE SENSOR
TX1230052
5634 YEL 5625 GRN 5783 ORG 5786 BLU
4
= X5503
5 2
5785 GRN 5625 GRN 5634 YEL 5783 ORG 5786 BLU
B5201 DIESEL OXIDATION CATALYST (DOC) INLET TEMPERATURE SENSOR
= X5502
1 3 4
47
5785 GRN 5625 GRN 5634 YEL 5783 ORG 5786 BLU
24 6 28 38
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
B5202 DIESEL OXIDATION CATALYST (DOC) OUTLET TEMPERATURE SENSOR
1 2 3 4
B5204 EXHAUST FILTER TEMPERATURE MODULE
TX1230052 —UN—20DEC16
5625 GRN 5634 YEL
= X5501
B5216 SELECTIVE CATALYTIC REDUCTION (SCR) INLET TEMPERATURE SENSOR
Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) Circuit Schematic (S.N. —056599) Continued on next page
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Sub-System Diagnostics B5213—Diesel Particulate Filter 1— Switched Power (DPF) Outlet Pressure A1—Engine Control Unit (ECU) Sensor B5109—Exhaust Filter Delta B5214—Diesel Particulate Filter Pressure Sensor (DPF) Inlet Pressure B5201—Diesel Oxidation Catalyst Sensor (DOC) Inlet Temperature B5216—Selective Catalytic Sensor Reduction (SCR) Inlet B5202—Diesel Oxidation Catalyst Temperature Sensor (DOC) Outlet Temperature F17— Power On 5 A Fuse Sensor (marked POWER ON) B5204—Exhaust Filter S16— Exhaust Filter Parked Temperature Module Cleaning Switch
X5015—Engine Interface X5501—Engine Control Unit Harness-to-Engine (ECU) Connector 2 Harness Connector 1 X5502—Engine Control Unit X5018—Machine Harness-to(ECU) Connector 2 Engine Interface Harness X5503—Engine Control Unit Connector 2 (ECU) Connector 3 X5039—Engine Interface Y5402—Exhaust Throttle Harness-to-Exhaust Actuator Aftertreatment Harness Connector X5070—Exhaust Aftertreatment Harness-to-Diesel Particulate Filter (DPF) Harness Connector
System Overview—The exhaust aftertreatment system involves the following major components:
VERY HIGH. The process takes less than 45 minutes to complete.
• Engine control unit (ECU) (A1) • Monitor controller (DSZ) (A4)
• For more information on the parked cleaning process, see Exhaust Filter. (Operator's Manual.)
The ECU controls engine and exhaust aftertreatment systems. The ECU communicates directly with the DSZ over the controller area network (CAN). The DSZ retains all of the monitor software and communicates directly with the monitor to display various screens and readings for exhaust aftertreatment. For more information on the CAN, ECU, and DSZ:
• See Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Operation. (Group 9015-15.)
• See Monitor Controller (DSZ) Circuit Theory of
Service Cleaning: This process requires activation by the service technician when exhaust filter restriction reaches the SERVICE level. This process is similar to parked cleaning, but requires at least 3 hours to complete. For information on the service cleaning process, see Exhaust Filter No. (Group 9015-16.) Also, see Service Regeneration Instructions. (CTM120119.)
Exhaust Filter Delta Pressure Sensor (B5109)—The exhaust filter delta pressure sensor (B5109) measures the differential pressure between the inlet and outlet of the diesel particulate filter (DPF). Differential pressure across the DPF is an indication of accumulated soot quantity. DPF regeneration is required when there is a high differential pressure. The ECU uses this measurement to determine when regeneration is complete. The exhaust filter delta pressure sensor uses two pressure sensors that are connected by hard lines:
Operation. (Group 9015-15.)
There are four cleaning processes used to clean the exhaust filter:
• Passive cleaning • Auto cleaning • Parked cleaning • Service cleaning Passive and Auto Cleaning: These processes require no interaction from the operator.
• B5213—Diesel particulate filter (DPF) outlet pressure
When enabled, auto cleaning will activate when exhaust filter restriction is MODERATE or HIGH.
sensor
• B5214—Diesel particulate filter (DPF) inlet pressure
• For more information on passive cleaning, see Exhaust
Filter Operation—Passive Regeneration. (CTM120119.)
see Exhaust Filter Operation—Active Regeneration. (CTM120119.) • For more information on the passive and auto cleaning processes, see Exhaust Filter. (Operator's Manual.) • To enable or disable the auto cleaning processes, see Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) • To change default settings for auto cleaning, see Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) Parked Cleaning: This process requires activation by the operator when exhaust filter restriction is HIGH or
Filter Parked Cleaning Switch. (Operator’s Manual.)
System Sensors and Components—The exhaust aftertreatment system uses the following sensors and components:
• See Engine Control Unit (ECU) Circuit Theory of
• For more information on auto cleaning process,
• To activate the parked cleaning process, see Exhaust
sensor
The exhaust filter delta pressure sensor (B5109) receives supply voltage on pin 1 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 2 from pin from pin 24 of engine control unit ECU connector 2, and signal on pin 3 from pin 47 of ECU connector 2.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
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Sub-System Diagnostics
Exhaust Filter Temperature Module (B5204)—The exhaust filter temperature module (B5204) measures temperatures in the exhaust filter and communicates with the ECU over the local interconnect network (LIN) to determine inputs for in-cylinder fuel dosing. The exhaust filter temperature module contains three temperature sensors that are mounted in the exhaust filter:
• Diesel oxidation catalyst (DOC) inlet temperature
valve that is located immediately after the turbocharger, located upstream of the intake manifold. An electric motor opens and closes a butterfly valve. To raise the exhaust gas temperature before and during exhaust filter cleaning, the ECU commands the intake air throttle valve to close. For more information on the intake air throttle, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
sensor (B5201) is used to determine when temperature is high enough for in-cylinder fuel dosing to occur. • Diesel oxidation catalyst (DOC) outlet temperature sensor (B5202) is used to provide regeneration and fuel dosing feedback to the ECU. • Selective catalytic reduction (SCR) inlet temperature sensor (B5216) is used by the ECU to determine when temperature is high enough for DEF injection to occur.
Abort Conditions for Auto Cleaning—Exhaust aftertreatment abort conditions are monitored by the ECU. Auto cleaning is aborted when the ECU detects any of the following:
The exhaust filter temperature module (B5204) receives supply voltage on pin 1 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 2 from pin 24 of ECU connector 2, and signal on pin 4 from pin 38 of ECU connector 2. The exhaust filter temperature module uses pin 3 is for communication over the LIN bus to pin 28 of ECU connector 2.
Abort Conditions for Parked or Service Filter Cleaning—Exhaust aftertreatment abort conditions are monitored by the ECU. If the auto-shutdown feature is enabled, the machine will shut down if an abort is detected.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Exhaust Filter Parked Cleaning Switch (S16)—The exhaust filter parked cleaning switch (S16) allows the operator to perform a parked exhaust filter cleaning. For more information on the exhaust filter parked cleaning switch, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Exhaust Throttle Actuator (Y5402)—The exhaust throttle actuator (Y5402) is a normally open butterfly style
• DOC inlet or DOC outlet temperature is too low. • DOC outlet or DPF outlet temperature is too high. • Exhaust filter parked cleaning switch is pressed. • Component malfunction.
The ECU will abort the exhaust filter cleaning process and send an abort message to the DSZ if the following occurs:
• DOC inlet or DOC outlet temperature is too low. • DOC outlet or DPF outlet temperature is too high. • Removal of safe-state conditions.
- Throttle movement. - Pilot shutoff lever movement. • CAN communication lost from DSZ to ECU. • ECU unable to maintain exhaust temperatures. • Parked or service cleaning takes too long to either prepare the exhaust temperatures or clean the exhaust filter. • Exhaust temperatures too high. • Varying engine loads. • Component malfunction.
For more information on the exhaust aftertreatment system, see Aftertreatment System Operation. (CTM120119.)
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Sub-System Diagnostics
TX1231089 —UN—20DEC16
40 53 51 20
2
5
= X5501 = X5502
Y5019 COOLANT CONTROL VALVE
X5037 ENGINE INTERFACE HARNESS-TO-DIESEL EXHAUST FLUID (DEF) HARNESS CONNECTOR 1
19 46 7 43 35 44 16 50 35 13 1
5329 WHT
23
5329 WHT
5136 BLU 5218 GRY 5309 WHT 5141 BRN 5146 BLU
24 25 8 7 9
5136 BLU 5218 GRY 5309 WHT 5141 BRN 5146 BLU
3
4
B5211 DIESEL EXHAUST FLUID (DEF) TANK TEMPERATURE SENSOR
5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 PUR 5309 WHT 5141 BRN 5146 BLU
Q
B5601 DIESEL EXHAUST FLUID (DEF) TANK LEVEL SENSOR
A5507 DIESEL EXHAUST FLUID (DEF) TANK HEADER ASSEMBLY
5604 YEL (AT CAN HIGH) 5605 GRN (AT CAN LOW) 5636 BLU 5602 RED 5030 BLK
9 8 7 6 10
5604 YEL 5605 GRN 5636 BLU 5602 RED 5030 BLK
5331 BRN 5333 ORG
11 12
5331 BRN 5333 ORG
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
TX1231089
5604 YEL (AT CAN HIGH) 5605 GRN (AT CAN LOW) 5636 BLU 5602 RED 5030 BLK 1
2
Y5020 DIESEL EXHAUST FLUID (DEF) DOSING INJECTOR
1 4 5 6
B5218 AFTERTREATMENT OUTLET NOx SENSOR
9 8 7 6 10
5604 YEL (AT CAN HIGH) 5605 GRN (AT CAN LOW) 5636 BLU 5602 RED 5030 BLK
X5070 EXHAUST AFTERTREATMENT HARNESS-TO-DIESEL PARTICULATE FILTER (DPF) HARNESS CONNECTOR B5503 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
B5501 DIESEL EXHAUST FLUID (DEF) DOSING UNIT
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5604 YEL 5605 GRN
5030 BLK
1 3 4 5 6
B5217 AFTERTREATMENT INLET NOx SENSOR
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) Circuit Schematic (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
5 6 8 9 10 11 12 3 2 4
1
5030 BLK
49 48
T
2
5146 BLU
25
A1 ENGINE CONTROL UNIT (ECU)
2
E5603 DIESEL EXHAUST FLUID (DEF) DOSING UNIT RETURN LINE HEATER
5141 BRN
31 21
2
5313 ORG 5315 GRN 5318 GRY 5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 PUR 5324 YEL 5321 BRN
1
5309 WHT
52 54
2 4 6 12 13 14 15 16 17 18 21 19
E5602 DIESEL EXHAUST FLUID (DEF) DOSING UNIT SUPPLY LINE HEATER
5218 GRY
42 41
5313 ORG 5315 GRN 5318 GRY 5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 PUR 5324 YEL 5321 BRN
1
5602 RED 5636 BLU 5636 BLU 5605 GRN 5604 YEL
39
E5601 DIESEL EXHAUST FLUID (DEF) DOSING UNIT PRESSURE LINE HEATER
1
5136 BLU
X5037 ENGINE INTERFACE HARNESS-TO-DIESEL EXHAUST FLUID (DEF) HARNESS CONNECTOR 1
5329 WHT
5317 PUR 5314 YEL 5311 BRN
5030 BLK
10
5 3 1
5317 PUR 5314 YEL 5311 BRN
5602 RED 5636 BLU 5605 GRN 5604 YEL
12 11
C SHLD
B5502 SELECTIVE CATALYTIC REDUCTION (SCR) INLET NOx SENSOR
B
A
LO
HI
- 120
+
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
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Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-68
160GLC Excavator 042318 PN=694
Sub-System Diagnostics
A1—Engine Control Unit (ECU) A5507—Diesel Exhaust Fluid (DEF) Tank Header Assembly B5211—Diesel Exhaust Fluid (DEF) Tank Temperature Sensor B5217—Aftertreatment Inlet NOx Sensor B5218—Aftertreatment Outlet NOx Sensor B5501—Diesel Exhaust Fluid (DEF) Dosing Unit B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor
B5503—Selective Catalytic R5605—Aftertreatment CAN Reduction (SCR) Outlet Termination Resistor NOx Sensor X5037—Engine Interface B5601—Diesel Exhaust Fluid Harness-to-Diesel (DEF) Tank Level Sensor Exhaust Fluid (DEF) E5601—Diesel Exhaust Fluid Harness Connector 1 (DEF) Dosing Unit X5039—Engine Interface Pressure Line Heater Harness-to-Exhaust E5602—Diesel Exhaust Fluid Aftertreatment Harness (DEF) Dosing Unit Supply Connector Line Heater X5070—Exhaust Aftertreatment E5603—Diesel Exhaust Fluid Harness-to-Diesel (DEF) Dosing Unit Return Particulate Filter (DPF) Line Heater Harness Connector
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) System—The selective catalytic reduction (SCR) and diesel exhaust fluid (DEF) system on 4045HT76 engines are required to reduce NOx emissions generated by the engine. The aftertreatment SCR and DEF system uses the following major components: Diesel Exhaust Fluid (DEF) Tank Header Assembly (A5507)—The diesel exhaust fluid (DEF) tank header assembly (A5507) routes DEF into and out of the DEF tank. The header is equipped with a DEF tank level sensor (B5601), DEF tank temperature sensor (B5211), DEF tank header A (A5507A) 6-pin connector, and coolant control valve (Y5019). The DEF tank level sensor (B5601) uses pin 3 for signal on pin 49 of engine control unit (ECU) connector 2 (X5502). The DEF tank temperature sensor (B5211) uses pin 5 for signal on pin 19 of ECU connector 2. Both sensors are grounded on pin 4 from pin 48 of ECU connector 2. DEF tank header A is also equipped with coolant tubes from the engine cooling system. When the temperature of the DEF is below a predetermined threshold, the ECU grounds the coolant control valve (Y5019) on pin 2 from pin 51 of ECU connector 2 and sends a signal to pin 1 from pin 20 of ECU connector 2, energizing the solenoid and causing the coolant control valve (Y5019) to open. Coolant then flows through the DEF tank header until the DEF temperature rises above the predetermined threshold and the ECU de-energizes the solenoid.
• For more information on DEF tank header, see DEF Tank Header Operation. (CTM120119.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) • To purge the DEF tank header cooling system, see DEF Header Coolant Purge Test. (CTM120119.) Diesel Exhaust Fluid (DEF) Dosing Unit (B5501)—The diesel exhaust fluid (DEF) dosing unit (B5501) is an electrically controlled system for the delivery of DEF. The DEF dosing unit uses internal components to control
priming, pressure, shutdown sequence, and heating of the DEF within the DEF dosing unit. The DEF dosing unit interfaces with DEF tank header assembly (A5507). When the ECU activates the DEF dosing unit, the internal DEF pump draws DEF through the supply line from DEF tank header assembly (A5507) to the DEF dosing injector (Y5020). The priming pump receives power on pin 9 from pin 21 of engine control unit (ECU) connector 2 (X5502), ground on pin 8 from pin 31 of ECU connector 2, and signal on pin 10 from pin 25 of ECU connector 2. The DEF dosing unit pressure sensor receives power on pin 2 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 4 from pin 43 of ECU connector 2, and signal on pin 3 from pin 46 of ECU connector 2. During a key-off event, the ECU opens the valve on the diesel exhaust fluid (DEF) dosing injector (Y5020). The ECU also grounds the DEF dosing unit reversing valve on pin 11 from pin 40 of engine control unit (ECU) connector 2 and sends power to pin 12 from pin 53 of ECU connector 2, energizing the reversing valve solenoid. The DEF is then drawn from the injector pressure line and routed back to the DEF tank through the return line. The remaining DEF in the supply line is pumped to the DEF tank. During cold weather, the ECU monitors the DEF temperature. At a predetermined temperature, the ECU turns on the DEF dosing unit internal heater. The ECU sends power to pin 6 from pin 54 of engine control unit (ECU) connector 2 and grounds pin 5 to pin 52 of ECU connector 2. The heater ensures DEF is able to flow through the DEF dosing unit to allow priming and normal operations (the DEF dosing unit will not prime until the unit is defrosted).
• For operation of module, see DEF Dosing Unit Operation. (CTM120119.)
• For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
• To purge the fuel dosing system, see DEF Pump Diagnostic Test. (CTM120119.)
• To purge the DEF tank header cooling system, see DEF Header Coolant Purge Test. (CTM120119.)
Continued on next page
TM13345X19 (23APR18)
X5501—Engine Control Unit (ECU) Connector 1 X5502—Engine Control Unit (ECU) Connector 2 Y5019—Coolant Control Valve Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector
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Sub-System Diagnostics
Selective Catalytic Reduction (SCR) Inlet NOx Sensor (B5502)—The ECU communicates with the selective catalytic reduction (SCR) inlet NOx sensor (B5502) through the aftertreatment controller area network (CAN). Engine NOx output is measured using the aftertreatment inlet NOx sensor (B5217) prior to the SCR and this measurement is used by the ECU to determine a low SCR NOx conversion efficiency. If a high NOx emission condition exists, the ECU commands the DEF dosing unit (B5501) and DEF dosing injector (Y5020) to inject DEF into the exhaust stream to reduce NOx output. The SCR inlet NOx sensor incorporates a heater element powered by switched battery power and controlled by the ECU. The selective catalytic reduction (SCR) inlet NOx sensor receives switched battery power on pin 1 from pin 50 of engine control unit (ECU) connector 2 and ground on pins 3 and 4 from pin 16 of ECU connector 2. The ECU communicates with the SCR inlet NOx sensor on pins 5 and 6 from pins 35 and 44 of ECU connector 2.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on the aftertreatment CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Selective Catalytic Reduction (SCR) Outlet NOx Sensor (B5503)—The ECU communicates with the aftertreatment selective catalytic reduction (SCR) outlet NOx sensor through the aftertreatment controller area network (CAN) bus. Engine-catalyzed NOx output is measured using aftertreatment outlet NOx sensor (B5218) in the SCR outlet, and this measurement is used by the ECU to determine a low SCR NOx conversion efficiency. If a high NOx emission condition exists, the ECU commands the DEF dosing unit (B5501) and DEF dosing injector (Y5020) to inject DEF into the exhaust stream to reduce NOx output. The SCR inlet NOx sensor incorporates a heater element powered by switched battery power and controlled by the ECU. The selective catalytic reduction (SCR) outlet NOx sensor receives switched battery power on pin 1 from pin 50 of engine control unit (ECU) connector 2 and ground on pin 4 from pin 16 of ECU connector 2. The ECU communicates with the SCR inlet NOx sensor on pins 5 and 6 from pins 35 and 44 of ECU connector 2.
• For component location, see Exhaust Aftertreatment
Harness (W53) Component Location. (Group 9015-10.)
• For information on engine protection and derate
programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Diesel Exhaust Fluid (DEF) Dosing Unit Line Heaters (E5601, E5602, and E5603)—The diesel exhaust fluid (DEF) system utilizes electric DEF dosing unit line heaters for DEF lines. At cold temperatures, the ECU enables the electrical heaters in the DEF system to warm the DEF lines between DEF tank header A (A5507A) and the DEF dosing injector (Y5020). The heaters remain on until the ECU determines that the DEF is no longer frozen.
• Diesel exhaust fluid (DEF) dosing unit pressure line
heater (E5601) receives power on pin 1 from pin 10 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 39 of ECU connector 2. • Diesel exhaust fluid (DEF) dosing unit supply line heater (E5602) receives power on pin 1 from pin 11 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 42 of ECU connector 2. • Diesel exhaust fluid (DEF) dosing unit return line heater (E5603) receives power on pin 1 from pin 12 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 41 of ECU connector 2.
• For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Diesel Exhaust Fluid (DEF) Dosing Injector (Y5020)—The diesel exhaust fluid (DEF) dosing injector (Y5020) is an electrically controlled, normally closed, coolant-cooled injector. The DEF dosing injector receives power on pin 1 from pin 13 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 1 of ECU connector 2, energizing the solenoid. The solenoid opens a valve, causing the injector to inject pressurized DEF supplied by the DEF dosing unit into the aftertreatment system.
• For component location, see Exhaust Aftertreatment
Harness (W53) Component Location. (Group 9015-10.)
• For operation of DEF dosing unit, see DEF Dosing Unit Operation. (CTM120119.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For DEF dosing injector cleaning, see DEF Dosing Injector — Cleaning. (CTM120119.)
• For information on the aftertreatment CAN, see
Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
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Sub-System Diagnostics Exhaust Aftertreatment Circuit Theory of Operation (S.N. 056600— ) X5015 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 1
Y5402 EXHAUST THROTTLE ACTUATOR
YEL/BLK
1
F17 5A FUSE
1
5631 BRN
4
5631 BRN
17
2
5633 ORG
11
5633 ORG
41
3
5509 WHT
28
5509 WHT
36
4
5018 GRY
29
5018 GRY
10
6
5016 LT BLU
18
5016 BLU
12
RED/BLK
S16 EXHAUST FILTER PARKED CLEANING SWITCH
BLK
8
9
1
5
A1 ENGINE CONTROL UNIT (ECU)
X5018 MACHINE HARNESSTO-ENGINE INTERFACE HARNESS CONNECTOR 2 ORG/GRN
S
5947 VLT
38
ORG/BLK
T
5796 BLU
35
X5070 EXHAUST AFTERTREATMENT HARNESS-TO-DIESEL PARTICULATE FILTER (DPF) HARNESS CONNECTOR 5785 GRN 5625 GRN 5634 YEL
5 2 1 3
5785 GRN 5625 GRN 5634 YEL
B5213 DIESEL PARTICULATE FILTER (DPF) OUTLET PRESSURE SENSOR
3 2 1
B5109 EXHAUST FILTER DELTA PRESSURE SENSOR
B5214 DIESEL PARTICULATE FILTER (DPF) INLET PRESSURE SENSOR
TX1230197
5634 YEL 5625 GRN 5783 ORG 5786 BLU
4
= X5503
5 2
5785 GRN 5625 GRN 5634 YEL 5783 ORG 5786 BLU
B5201 DIESEL OXIDATION CATALYST (DOC) INLET TEMPERATURE SENSOR
= X5502
1 3 4
47
5785 GRN 5625 GRN 5634 YEL 5783 ORG 5786 BLU
24 6 28 38
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
B5202 DIESEL OXIDATION CATALYST (DOC) OUTLET TEMPERATURE SENSOR
1 2 3 4
B5204 EXHAUST FILTER TEMPERATURE MODULE
TX1230197 —UN—20DEC16
5625 GRN 5634 YEL
= X5501
B5216 SELECTIVE CATALYTIC REDUCTION (SCR) INLET TEMPERATURE SENSOR
Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) Circuit Schematic (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=697
Sub-System Diagnostics B5213—Diesel Particulate Filter 1— Switched Power (DPF) Outlet Pressure A1—Engine Control Unit (ECU) Sensor B5109—Exhaust Filter Delta B5214—Diesel Particulate Filter Pressure Sensor (DPF) Inlet Pressure B5201—Diesel Oxidation Catalyst Sensor (DOC) Inlet Temperature B5216—Selective Catalytic Sensor Reduction (SCR) Inlet B5202—Diesel Oxidation Catalyst Temperature Sensor (DOC) Outlet Temperature F17— Power On 5 A Fuse Sensor (marked POWER ON) B5204—Exhaust Filter S16— Exhaust Filter Parked Temperature Module Cleaning Switch
X5015—Engine Interface X5501—Engine Control Unit Harness-to-Engine (ECU) Connector 1 Harness Connector 1 X5502—Engine Control Unit X5018—Machine Harness-to(ECU) Connector 2 Engine Interface Harness X5503—Engine Control Unit Connector 2 (ECU) Connector 3 X5039—Engine Interface Y5402—Exhaust Throttle Harness-to-Exhaust Actuator Aftertreatment Harness Connector X5070—Exhaust Aftertreatment Harness-to-Diesel Particulate Filter (DPF) Harness Connector
System Overview—The exhaust aftertreatment system involves the following major components:
VERY HIGH. The process takes less than 45 minutes to complete.
• Engine control unit (ECU) (A1) • Monitor controller (DSZ) (A4)
• For more information on the parked cleaning process, see Exhaust Filter. (Operator's Manual.)
The ECU controls engine and exhaust aftertreatment systems. The ECU communicates directly with the DSZ over the controller area network (CAN). The DSZ retains all of the monitor software and communicates directly with the monitor to display various screens and readings for exhaust aftertreatment. For more information on the CAN, ECU, and DSZ:
• See Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Operation. (Group 9015-15.)
• See Monitor Controller (DSZ) Circuit Theory of
Service Cleaning: This process requires activation by the service technician when exhaust filter restriction reaches the SERVICE level. This process is similar to parked cleaning, but requires at least 3 hours to complete. For information on the service cleaning process, see Exhaust Filter No.(Group 9015-16.) Also, see Service Regeneration Instructions. (CTM120119.)
Exhaust Filter Delta Pressure Sensor (B5109)—The exhaust filter delta pressure sensor (B5109) measures the differential pressure between the inlet and outlet of the diesel particulate filter (DPF). Differential pressure across the DPF is an indication of accumulated soot quantity. DPF regeneration is required when there is a high differential pressure. The ECU uses this measurement to determine when regeneration is complete. The exhaust filter delta pressure sensor uses two pressure sensors that are connected by hard lines:
Operation. (Group 9015-15.)
There are four cleaning processes used to clean the exhaust filter:
• Passive cleaning • Auto cleaning • Parked cleaning • Service cleaning Passive and Auto Cleaning: These processes require no interaction from the operator.
• B5213—Diesel particulate filter (DPF) outlet pressure
When enabled, auto cleaning will activate when exhaust filter restriction is MODERATE or HIGH.
sensor
• B5214—Diesel particulate filter (DPF) inlet pressure
• For more information on passive cleaning, see Exhaust
Filter Operation—Passive Regeneration. (CTM120119.)
see Exhaust Filter Operation—Active Regeneration. (CTM120119.) • For more information on the passive and auto cleaning processes, see Exhaust Filter. (Operator's Manual.) • To enable or disable the auto cleaning processes, see Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) • To change default settings for auto cleaning, see Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) Parked Cleaning: This process requires activation by the operator when exhaust filter restriction is HIGH or
Filter Parked Cleaning Switch. (Operator’s Manual.)
System Sensors and Components—The exhaust aftertreatment system uses the following sensors and components:
• See Engine Control Unit (ECU) Circuit Theory of
• For more information on auto cleaning process,
• To activate the parked cleaning process, see Exhaust
sensor
The exhaust filter delta pressure sensor (B5109) receives supply voltage on pin 1 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 2 from pin from pin 24 of engine control unit ECU connector 2, and signal on pin 3 from pin 47 of ECU connector 2.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on how pressure sensors operate, see Measuring Pressure. (CTM120119.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Continued on next page
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Sub-System Diagnostics
Exhaust Filter Temperature Module (B5204)—The exhaust filter temperature module (B5204) measures temperatures in the exhaust filter and communicates with the ECU over the local interconnect network (LIN) to determine inputs for in-cylinder fuel dosing. The exhaust filter temperature module contains three temperature sensors that are mounted in the exhaust filter:
• Diesel oxidation catalyst (DOC) inlet temperature
valve that is located immediately after the turbocharger, located upstream of the intake manifold. An electric motor opens and closes a butterfly valve. To raise the exhaust gas temperature before and during exhaust filter cleaning, the ECU commands the intake air throttle valve to close. For more information on the intake air throttle, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
sensor (B5201) is used to determine when temperature is high enough for in-cylinder fuel dosing to occur. • Diesel oxidation catalyst (DOC) outlet temperature sensor (B5202) is used to provide regeneration and fuel dosing feedback to the ECU. • Selective catalytic reduction (SCR) inlet temperature sensor (B5216) is used by the ECU to determine when temperature is high enough for DEF injection to occur.
Abort Conditions for Auto Cleaning—Exhaust aftertreatment abort conditions are monitored by the ECU. Auto cleaning is aborted when the ECU detects any of the following:
The exhaust filter temperature module (B5204) receives supply voltage on pin 1 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 2 from pin 24 of ECU connector 2, and signal on pin 4 from pin 38 of ECU connector 2. The exhaust filter temperature module uses pin 3 is for communication over the LIN bus to pin 28 of ECU connector 2.
Abort Conditions for Parked or Service Filter Cleaning—Exhaust aftertreatment abort conditions are monitored by the ECU. If the auto-shutdown feature is enabled, the machine will shut down if an abort is detected.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on how temperature sensors operate, see Measuring Temperature. (CTM120119.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Exhaust Filter Parked Cleaning Switch (S16)—The exhaust filter parked cleaning switch (S16) allows the operator to perform a parked exhaust filter cleaning. For more information on the exhaust filter parked cleaning switch, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Exhaust Throttle Actuator (Y5402)—The exhaust throttle actuator (Y5402) is a normally open butterfly style
• DOC inlet or DOC outlet temperature is too low. • DOC outlet or DPF outlet temperature is too high. • Exhaust filter parked cleaning switch is pressed. • Component malfunction.
The ECU will abort the exhaust filter cleaning process and send an abort message to the DSZ if the following occurs:
• DOC inlet or DOC outlet temperature is too low. • DOC outlet or DPF outlet temperature is too high. • Removal of safe-state conditions.
- Throttle movement. - Pilot shutoff lever movement. • CAN communication lost from DSZ to ECU. • ECU unable to maintain exhaust temperatures. • Parked or service cleaning takes too long to either prepare the exhaust temperatures or clean the exhaust filter. • Exhaust temperatures too high. • Varying engine loads. • Component malfunction.
For more information on the exhaust aftertreatment system, see Aftertreatment System Operation. (CTM120119.)
Continued on next page
TM13345X19 (23APR18)
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Sub-System Diagnostics
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=700
Sub-System Diagnostics
TX1231103 —UN—29JUN17
X5037 ENGINE INTERFACE HARNESS-TO-DIESEL EXHAUST FLUID (DEF) HARNESS CONNECTOR 1
52 54 31 21 25 40 53 51
A1 ENGINE CONTROL UNIT (ECU)
20
5313 ORG 5315 GRN 5318 GRY 5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 VLT 5324 YEL 5321 BRN
2 4 6 12 13 14 15 16 17 18 22 21
5313 ORG 5315 GRN 5318 GRY 5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 VLT 5324 YEL 5321 BRN
1
2
4
Y5019 COOLANT CONTROL VALVE
B5211
1
2
E5602 DIESEL EXHAUST FLUID (DEF) DOSING UNIT SUPPLY LINE HEATER
B5506
T 4
50
5604 YEL 5605 GRN 5636 BLU 5602 RED
9 8 7 6
5604 YEL 5605 GRN 5636 BLU 5602 RED
5331 BRN 5333 ORG
11 12
5331 BRN 5333 ORG
44 35 46 7
16
13 01
27 26 29 31 28 30 8 7 9
5625 GRN 5602 RED 5605 GRN 5605 GRN 5604 YEL 5604 YEL 5309 WHT 5141 BRN 5146 BLU
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
TX1231103
1
2
E5603 DIESEL EXHAUST FLUID (DEF) DOSING UNIT RETURN LINE HEATER
5604 YEL (AT CAN HIGH) 5605 GRN (AT CAN LOW) 5636 BLU 5602 RED 1
2
Y5020 DIESEL EXHAUST FLUID (DEF) DOSING INJECTOR
1 4 5 6
B5218 AFTERTREATMENT OUTLET NOx SENSOR
9 8 7 6
5604 YEL (AT CAN HIGH) 5605 GRN (AT CAN LOW) 5636 BLU 5602 RED
X5070 EXHAUST AFTERTREATMENT HARNESS-TO-DIESEL PARTICULATE FILTER (DPF) HARNESS CONNECTOR B5503 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
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5604 YEL 5605 GRN
1 3 4 5 6
B5217 AFTERTREATMENT INLET NOx SENSOR
5 6 8 9 10 11 12 3 2 4
B5501 DIESEL EXHAUST FLUID (DEF) DOSING UNIT
3
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) Circuit Schematic (S.N. 056600— ) Continued on next page
TM13345X19 (23APR18)
5303 ORG 5301 BRN 5305 GRN 5304 YEL 5306 BLU 5308 GRY 5307 VLT 5309 WHT 5141 BRN 5146 BLU
A5507B DIESEL EXHAUST FLUID (DEF) TANK HEADER B
Q
5602 RED 5636 BLU 5605 GRN 5604 YEL
43
5625 GRN 5602 RED 5605 GRN 5605 GRN 5604 YEL 5604 YEL 5309 WHT 5141 BRN 5146 BLU
2
B5601
= X5502 24
1
5605 GRN 5604 YEL
1
E5601 DIESEL EXHAUST FLUID (DEF) DOSING UNIT PRESSURE LINE HEATER
5146 BLU
42 41
5317 VLT 5314 YEL 5311 BRN
5141 BRN
39
5 3 1
5309 WHT
10
5317 VLT 5314 YEL 5311 BRN
5602 RED 5636 BLU 5636 BLU 5605 GRN 5604 YEL
12 11
C SHLD
B5502 SELECTIVE CATALYTIC REDUCTION (SCR) INLET NOx SENSOR
B
A
LO
HI
- 120
+
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
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Sub-System Diagnostics
TM13345X19 (23APR18)
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160GLC Excavator 042318 PN=702
Sub-System Diagnostics
A1—Engine Control Unit (ECU) A5507B—Diesel Exhaust Fluid (DEF) Tank Header B B5211—Diesel Exhaust Fluid (DEF) Tank Temperature Sensor B5217—Aftertreatment Inlet NOx Sensor B5218—Aftertreatment Outlet NOx Sensor B5501—Diesel Exhaust Fluid (DEF) Dosing Unit B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor
E5603—Diesel Exhaust Fluid B5503—Selective Catalytic X5502—Engine Control Unit (DEF) Dosing Unit Return Reduction (SCR) Outlet (ECU) Connector 2 Line Heater NOx Sensor Y5019—Coolant Control Valve R5605—Aftertreatment CAN B5506—Diesel Exhaust Fluid Y5020—Diesel Exhaust Fluid Termination Resistor (DEF) Tank Concentration (DEF) Dosing Injector X5037—Engine Interface Sensor Harness-to-Diesel B5601—Diesel Exhaust Fluid Exhaust Fluid (DEF) (DEF) Tank Level Sensor Harness Connector 1 E5601—Diesel Exhaust Fluid X5039—Engine Interface (DEF) Dosing Unit Harness-to-Exhaust Pressure Line Heater Aftertreatment Harness E5602—Diesel Exhaust Fluid Connector (DEF) Dosing Unit Supply X5070—Exhaust Aftertreatment Line Heater Harness-to-Diesel Particulate Filter (DPF) Harness Connector
Selective Catalytic Reduction (SCR) and Diesel Exhaust Fluid (DEF) System—The selective catalytic reduction (SCR) and diesel exhaust fluid (DEF) system on 4045HT76 engines are required to reduce NOx emissions generated by the engine. The aftertreatment SCR and DEF system uses the following major components: Diesel Exhaust Fluid (DEF) Tank Header B (A5507B)—The diesel exhaust fluid (DEF) tank header B (A5507B) routes DEF into and out of the DEF tank. The header is equipped with a DEF tank level sensor (B5601), DEF tank temperature sensor (B5211), DEF tank concentration sensor (B5506), and DEF tank header B (A5507B) 4-pin connector. The ECU communicates with the diesel exhaust fluid (DEF) tank header B (A5507B) through the aftertreatment controller area network (CAN). The DEF tank header B receives switched battery power on pin 1 from pin 50 of engine control unit (ECU) connector 2 (X5502) and ground on pin 4 from pin 24 of ECU connector 2. The ECU communicates with the DEF tank header B on pins 2 and 3 from pins 35 and 44 of ECU connector 2. The DEF tank header B is also equipped with coolant tubes from the engine cooling system. When the temperature of the DEF is below a predetermined threshold, the ECU grounds the coolant control valve (Y5019) on pin 4 from pin 51 of ECU connector 2 and sends a signal to pin 1 from pin 20 of ECU connector 2, energizing the solenoid and causing the coolant control valve (Y5019) to open. Coolant then flows through the DEF tank header until the DEF temperature rises above the predetermined threshold and the ECU de-energizes the solenoid.
• For more information on DEF tank header B, see DEF Tank Header Operation. (CTM120119.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.) • To purge the DEF tank header cooling system, see DEF Header Coolant Purge Test. (CTM120119.) Diesel Exhaust Fluid (DEF) Dosing Unit (B5501)—The diesel exhaust fluid (DEF) dosing unit (B5501) is an
electrically controlled system for the delivery of DEF. The DEF dosing unit uses internal components to control priming, pressure, shutdown sequence, and heating of the DEF within the DEF dosing unit. The DEF dosing unit interfaces with DEF tank header B (A5507B). When the ECU activates the DEF dosing unit, the internal DEF pump draws DEF through the supply line from DEF tank header B (A5507B) to the diesel exhaust fluid (DEF) dosing injector (Y5020). The priming pump receives power on pin 9 from pin 21 of engine control unit (ECU) connector 2 (X5502), ground on pin 8 from pin 31 of ECU connector 2, and signal on pin 10 from pin 25 of ECU connector 2. The DEF dosing unit pressure sensor receives power on pin 2 from pin 6 of engine control unit (ECU) connector 2 (X5502), ground on pin 4 from pin 43 of ECU connector 2, and signal on pin 3 from pin 46 of ECU connector 2. During a key-off event, the ECU opens the valve on the diesel exhaust fluid (DEF) dosing injector (Y5020). The ECU also grounds the DEF dosing unit reversing valve on pin 11 from pin 40 of engine control unit (ECU) connector 2 and sends power to pin 12 from pin 53 of ECU connector 2, energizing the reversing valve solenoid. The DEF is then drawn from the injector pressure line and routed back to the DEF tank through the return line. The remaining DEF in the supply line is pumped to the DEF tank. During cold weather, the ECU monitors the DEF temperature. At a predetermined temperature, the ECU turns on the DEF dosing unit internal heater. The ECU sends power to pin 6 from pin 54 of engine control unit (ECU) connector 2 and grounds pin 5 to pin 52 of ECU connector 2. The heater ensures DEF is able to flow through the DEF dosing unit to allow priming and normal operations (the DEF dosing unit will not prime until the unit is defrosted).
• For operation of module, see DEF Dosing Unit Operation. (CTM120119.)
• For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
• To purge the fuel dosing system, see DEF Pump Diagnostic Test. (CTM120119.)
• To purge the DEF tank header cooling system, see DEF Header Coolant Purge Test. (CTM120119.)
Continued on next page
TM13345X19 (23APR18)
9015-15-77
JL58967,0000744 -19-09JAN17-11/12
160GLC Excavator 042318 PN=703
Sub-System Diagnostics
Selective Catalytic Reduction (SCR) Inlet NOx Sensor (B5502)—The ECU communicates with the selective catalytic reduction (SCR) inlet NOx sensor (B5502) through the aftertreatment controller area network (CAN). Engine NOx output is measured using the aftertreatment inlet NOx sensor (B5217) prior to the SCR and this measurement is used by the ECU to determine a low SCR NOx conversion efficiency. If a high NOx emission condition exists, the ECU commands the DEF dosing unit (B5501) and DEF dosing injector (Y5020) to inject DEF into the exhaust stream to reduce NOx output. The SCR inlet NOx sensor incorporates a heater element powered by switched battery power and controlled by the ECU. The selective catalytic reduction (SCR) inlet NOx sensor receives switched battery power on pin 1 from pin 50 of engine control unit (ECU) connector 2 and ground on pins 3 and 4 from pin 16 of ECU connector 2. The ECU communicates with the SCR inlet NOx sensor on pins 5 and 6 from pins 35 and 44 of ECU connector 2.
• For component location, see Diesel Particulate Filter
(DPF) Harness (W62) Component Location. (Group 9015-10.) • For information on the aftertreatment CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Selective Catalytic Reduction (SCR) Outlet NOx Sensor (B5503)—The ECU communicates with the aftertreatment selective catalytic reduction (SCR) outlet NOx sensor through the aftertreatment controller area network (CAN) bus. Engine-catalyzed NOx output is measured using aftertreatment outlet NOx sensor (B5218) in the SCR outlet, and this measurement is used by the ECU to determine a low SCR NOx conversion efficiency. If a high NOx emission condition exists, the ECU commands the DEF dosing unit (B5501) and DEF dosing injector (Y5020) to inject DEF into the exhaust stream to reduce NOx output. The SCR inlet NOx sensor incorporates a heater element powered by switched battery power and controlled by the ECU. The selective catalytic reduction (SCR) outlet NOx sensor receives switched battery power on pin 1 from pin 50 of engine control unit (ECU) connector 2 and ground on pin 4 from pin 16 of ECU connector 2. The ECU communicates with the SCR inlet NOx sensor on pins 5 and 6 from pins 35 and 44 of ECU connector 2.
• For component location, see Exhaust Aftertreatment
Harness (W53) Component Location. (Group 9015-10.)
• For information on engine protection and derate
programs, see Engine Derate and Shutdown Protection. (CTM120119.)
Diesel Exhaust Fluid (DEF) Dosing Unit Line Heaters (E5601, E5602, and E5603)—The diesel exhaust fluid (DEF) system utilizes electric DEF dosing unit line heaters for DEF lines. At cold temperatures, the ECU enables the electrical heaters in the DEF system to warm the DEF lines between DEF tank header B (A5507B) and the DEF dosing injector (Y5020). The heaters remain on until the ECU determines that the DEF is no longer frozen.
• Diesel exhaust fluid (DEF) dosing unit pressure line
heater (E5601) receives power on pin 1 from pin 10 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 39 of ECU connector 2. • Diesel exhaust fluid (DEF) dosing unit supply line heater (E5602) receives power on pin 1 from pin 11 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 42 of ECU connector 2. • Diesel exhaust fluid (DEF) dosing unit return line heater (E5603) receives power on pin 1 from pin 12 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 41 of ECU connector 2.
• For component location, see Diesel Exhaust Fluid (DEF) Harness (W54) Component Location. (Group 9015-10.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For information on engine protection and derate programs, see Engine Derate and Shutdown Protection. (CTM120119.) Diesel Exhaust Fluid (DEF) Dosing Injector (Y5020)—The diesel exhaust fluid (DEF) dosing injector (Y5020) is an electrically controlled, normally closed, coolant-cooled injector. The DEF dosing injector receives power on pin 1 from pin 13 of engine control unit (ECU) connector 2 and ground on pin 2 from pin 1 of ECU connector 2, energizing the solenoid. The solenoid opens a valve, causing the injector to inject pressurized DEF supplied by the DEF dosing unit into the aftertreatment system.
• For component location, see Exhaust Aftertreatment
Harness (W53) Component Location. (Group 9015-10.)
• For operation of DEF dosing unit, see DEF Dosing Unit Operation. (CTM120119.)
• For more information on the DEF system component
location, see Diesel Exhaust Fluid (DEF) System Component Location. (Group 9010-05.) • For DEF dosing injector cleaning, see DEF Dosing Injector — Cleaning. (CTM120119.)
• For information on the aftertreatment CAN, see
Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) JL58967,0000744 -19-09JAN17-12/12
TM13345X19 (23APR18)
9015-15-78
160GLC Excavator 042318 PN=704
Sub-System Diagnostics
Main Controller (MCZ) Circuit Theory of Operation TX1249906 —UN—30JAN18
B
POSITION HEAT OFF ACC ON START
G1
G2
ACC
M ST
RED
RED GRN
V12 STARTER CUT DIODE
5
K13 KEY CUT RELAY
3
2
5
4
YEL/BLK
BLU YEL/GRN
F10 5A FUSE
WHT
1
F17 5A FUSE
B1+
D+
RED
5
4
5
WHT/GRN
WHT
G2
YEL/GRN
M
4
BLU
E
V10 STARTER PROTECTION DIODE
V5 STARTER CUT RELAY DIODE
WHT VLT/GRN
BLU
2
3
5
4
VLT/WHT 2
V9 PILOT SHUTOFF DIODE
YEL/GRN
1
K2 PILOT SHUTOFF SOLENOID RELAY
3
1
X47 ST
G3 ALTERNATOR
RED/BLK
2
G1
K11 IDLE STOP RELAY
BLU
3
RED
1
RED
WHT
ORG
1
WHT
BAT
YEL/GRN
ACC
RED
4
K12 ACCESSORY CUT RELAY
RED
2
3
F4 20A FUSE WHT
1
YEL/BLK
S1 KEY SWITCH
F18 5A FUSE
BLU
RED
WHT/BLK
HEAT OFF ACC ON START
3
BLU
RED
WHT
BLU
WHT
YEL/BLK
BLU
WHT YEL/BLK
RED
V11 ACCESSORY CUT DIODE
YEL/GRN
RED C5
F61 45A FUSE
F13
+ G1 BATTERY -
RED
F1 F2 F3 E5 E6
A3 MAIN CONTROLLER (MCZ) E1 E2 F4 F5
F6
A1
D2
D3
D4
A = X31
C = X33
E = X35
B = X32
D = X34
F = X36
E4
D5 BLU
G2 BATTERY -
GRN
BLU CAN 0 GRN
BLK
K
GRN
GRN
J
YEL
CAN 0
CAN 0
BLK
A25
A = X20 D = X22
X1 C
D
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
= X6014
A1
D2
G1
C2
G2
2
1
GRN
A26
YEL
A23
BLU
A4 MONITOR CONTROLLER (DSZ)
A24
GRN
D6
BLU
S91 BATTERY DISCONNECT SWITCH
GRN
WHT
BLU
CAN 0
X5018 GRN
F60 65A FUSE
BLU CAN 0
YEL
K19 BATTERY RELAY
GRN
A
CAN 1
+
YEL/WHT
E
B
WHT
S
B1
A15 FLEX POWER CONTROLLER (FPC)
A1 ENGINE CONTROL UNIT (ECU) = X5503
TX1249906 Main Controller (MCZ) Circuit Schematic (1 of 2) Continued on next page
TM13345X19 (23APR18)
9015-15-79
160GLC Excavator 042318 PN=705
TX03742,0000118 -19-13FEB18-1/11
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-80
160GLC Excavator 042318 PN=706
Sub-System Diagnostics F61— Battery 45 A Fuse A1—Engine Control Unit (ECU) X11— Machine Controller 20-Pin G1—Battery A3—Main Controller (MCZ) Connector B G2—Battery A4—Monitor Controller (DSZ) X20— Monitor Controller 28-Pin G3—Alternator A15— Flex Power Controller Connector A K2—Pilot Shutoff Solenoid Relay X22— Monitor Controller 16-Pin (FPC) K11— Idle Stop Relay A6000—Modular Telematics Connector D K12— Accessory Cut Relay Gateway (MTG) X31— Cab Harness-to-Main K13— Key Cut Relay Controller Controller 31-Pin F4— Solenoid 20 A Fuse (marked K19— Battery Relay Connector A S1— Key Switch SOLENOID) X32— Cab Harness-to-Main S91— Battery Disconnect Switch F10— Data Converter and Controller 24-Pin V5— Starter Cut Relay Diode Main Controller Battery Connector B V9— Pilot Shutoff Diode Power 5 A Fuse (marked X33— Cab Harness-to-Main V10— Starter Protection Diode CONTROLLER) Controller 17-Pin V11— Accessory Cut Diode F17— Power On 5 A Fuse Connector C V12— Starter Cut Diode (marked POWER ON) X34— Cab Harness-to-Main F18— Idle Stop 5 A Fuse (marked X1— Service ADVISOR™ Controller 30-Pin Diagnostic Connector IDLE STOP) Connector D F60— Alternator 65 A Fuse X35— Cab Harness-to-Main Controller 24-Pin Connector E
X36— Cab Harness-to-Main Controller 26-Pin Connector F X47— Cab Harness-to-Key Switch Harness Connector X5018—Machine Harness-toEngine Interface Harness Connector 2 X5503—Engine Control Unit (ECU) Connector 3 X6014—Modular Telematics Gateway (MTG) Control Unit Connector
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-15-81
TX03742,0000118 -19-13FEB18-2/11
160GLC Excavator 042318 PN=707
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-82
160GLC Excavator 042318 PN=708
Sub-System Diagnostics
TX1250969 —UN—29JAN18
YEL
VLT/WHT
GRN/BLK
BLK
GRN
2
WHT
2
BLK/WHT
2
ORG/RED
GRN 7
1
BRN/YEL
GRY 3
1
BRN/BLU
BLU 5
1
BLU/RED
1
2
0 1
S7 POWER DIG SWITCH
BLU/BLK
PNK 6
2
Y26 PUMP 1 FLOW RATE LIMIT SOLENOID (MARKED SA)
1
Y24 POWER DIG/ TRAVEL SPEED SOLENOID (MARKED SG)
GRN/WHT
2
Y20 PUMP 2 FLOW RATE LIMIT SOLENOID (MARKED SB)
1
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
BRN/WHT A3
A2
A7
A6
A31
A13
A15
A14
A11
A10
A12
A13
F11
F25
F16
F26 F17
D6
D7
D14
D15
D9
C14
C8
C15
C13
D17
D18
C1
YEL/BLK
WHT/VLT
WHT/BLU
LT BLU
F = X36
GRN/YEL
E = X35
D = X34
WHT/GRN
D16
C = X33
B = X32
BRN/BLU
F8
BLK/YEL
F7
A = X31
YEL/RED
F = X36
BLU/YEL
D = X34
BLU/RED
B = X32
A3 MAIN CONTROLLER (MCZ)
BLK/RED
E = X35
GRN/YEL
C = X33
RED/YEL
F9
A = X31
BLK/YEL
A3 MAIN CONTROLLER (MCZ)
RED/YEL
X40
BRN
2
Y21 TORQUE CONTROL SOLENOID (MARKED ST)
GRY
1
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
0 A1
YEL/GRN
S11 TRAVEL MODE SWITCH
BLU/WHT
S8 AUTO-IDLE SWITCH
L H
+
R15 ENGINE SPEED DIAL
BLK
BLK
P
P 2
3
B30 BOOM UP PRESSURE SENSOR (MARKED PI1)
3
B31 ARM IN PRESSURE SENSOR (MARKED PI2)
3
B32 FRONT ATTACHMENT PRESSURE SENSOR (MARKED FRT)
3
B33 SWING PRESSURE SENSOR (MARKED S3)
3
X46 13
17
2
T
X46
2
18
1
1
1
LT GRN/BLK
RED/WHT
BLK/YEL
RED/YEL
YEL
BLK
RED
ORG
RED
BLK
GRY
BLK
RED
VLT
BLK/YEL
1 2
14
BLK/YEL
16
RED/YEL
RED/YEL
20
RED
1
P 2
BLK/YEL
BLK/YEL
RED/YEL
1
P 2
BLK/YEL
RED/YEL
1
P 2
BLK/YEL
RED/YEL
1
X40
BLK
1
BLK/YEL
RED/YEL
BLK/YEL 6
BLK/YEL
RED/YEL 4
RED/YEL
WHT 5
LT GRN/BLK
BLK/BLU 12
LT BLU
ORG 8
ORG
S12 POWER MODE BUTTON
9
WHT
X29
BLK/GRN
1
1
B40 HYDRAULIC OIL TEMPERATURE SENSOR
1
3
B34 TRAVEL PRESSURE SENSOR (MARKED TR)
P 2 3 B35 PUMP 1 DELIVERY PRESSURE SENSOR (MARKED PP1)
P 2 3 B36 PUMP 1 CONTROL PRESSURE SENSOR (MARKED PC1)
P 2 3 B37 PUMP 2 DELIVERY PRESSURE SENSOR (MARKED PP2)
P 2 3 B38 PUMP 2 CONTROL PRESSURE SENSOR (MARKED PC2)
P
P 2
3
B60 ATTACHMENT PRESSURE SENSOR
2
3
B61 ARM OUT PRESSURE SENSOR
TX1250969 Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. —057099) Continued on next page
TM13345X19 (23APR18)
9015-15-83
160GLC Excavator 042318 PN=709
TX03742,0000118 -19-13FEB18-3/11
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-84
160GLC Excavator 042318 PN=710
Sub-System Diagnostics
A3—Main Controller (MCZ) B38— Pump 2 Control Pressure B30— Boom Up Pressure Sensor Sensor (marked PC2) (marked PI1) B40— Hydraulic Oil Temperature B31— Arm In Pressure Sensor Sensor (marked PI2) B60— Attachment Pressure B32— Front Attachment Pressure Sensor Sensor (marked FRT) B61— Arm Out Pressure Sensor B33— Swing Pressure Sensor R15— Engine Speed Dial (marked S3) S7— Power Dig Switch B34— Travel Pressure Sensor S8— Auto-Idle Switch (marked TR) S11— Travel Mode Switch B35— Pump 1 Delivery Pressure S12— Power Mode Button Sensor (marked PP1) X29— Cab Harness-to-Switch B36— Pump 1 Control Pressure Panel Connector 3 Sensor (marked PC1) X31— Cab Harness-to-Main B37— Pump 2 Delivery Pressure Controller 31-Pin Sensor (marked PP2) 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 X46— Attachment Connector
Continued on next page
TM13345X19 (23APR18)
9015-15-85
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) Y26— Pump 1 Flow Rate Limit Solenoid (marked SA)
TX03742,0000118 -19-13FEB18-4/11
160GLC Excavator 042318 PN=711
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-86
160GLC Excavator 042318 PN=712
Sub-System Diagnostics
TX1249812 —UN—29JAN18
0 A1
GRY
BLU
LT GRN
YEL
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
Y24 POWER DIG/ TRAVEL SPEED SOLENOID (MARKED SG)
GRN/BLK BLK
0 1
0 1
2
2
2
BLK
1
S13 TRAVEL ALARM CANCEL SWITCH
1
BLU/RED
BRN/BLU
BRN/YEL
ORG/RED
BLK/WHT
WHT
GRN
YEL
VLT/WHT
GRN/BLK
WHT/RED
A7
A6
A26
A27
A15
A14
A11
A10
A12
A13
F11
C10
+
BLK
P
P 2
3
P 2
P 2
3
3
P 2
3
2
3
P 3
B31 ARM IN PRESSURE SENSOR (MARKED PI2)
B32 FRONT ATTACHMENT PRESSURE SENSOR (MARKED FRT)
B33 SWING PRESSURE SENSOR (MARKED S3)
B34 TRAVEL PRESSURE SENSOR (MARKED TR)
B56 BUCKET CURL PRESSURE SENSOR (MARKED BKC)
18
3
YEL
1
1
3
P
P
B57 BUCKET DUMP PRESSURE SENSOR
3
B35 PUMP 1 DELIVERY PRESSURE SENSOR (MARKED PP1)
P 2
3
B36 PUMP 1 CONTROL PRESSURE SENSOR (MARKED PC1)
P 2
3
B37 PUMP 2 DELIVERY PRESSURE SENSOR (MARKED PP2)
2
3
B38 PUMP 2 CONTROL PRESSURE SENSOR (MARKED PC2)
3
B60 ATTACHMENT PRESSURE SENSOR
1
BLK/YEL 1
P 2
C1
T
RED/WHT
1
BLK
RED
ORG
RED
BLK
GRY
BLK
RED
VLT
1
D18
LT BLU
YEL/BLK
D17
P 2
F = X36
WHT/BLU
GRN/YEL 14
D = X34
BLK/YEL
WHT/GRN 17
B = X32
RED/YEL
BRN/BLU 13
E = X35
WHT/VLT
C13
C = X33
BLK/YEL
C15
RED/YEL
RED/YEL
C8
1
2
B30 BOOM UP PRESSURE SENSOR (MARKED PI1)
16
C14
A = X31
X46
1
P 2
BLK/YEL
YEL/GRN
1
20
RED
1
X40
BLK
1
A16
X3 BLU/GRN
1
BLK/YEL
E13
BRN/WHT
1
RED/YEL
YEL/RED
GRY/RED BLK/YEL
RED/YEL
BLU/YEL BLK/YEL
BLK/YEL
BLK/YEL
RED/YEL
BLK/YEL
BLK/YEL
R15 ENGINE SPEED DIAL
1
D25
X3
6 LT GRN/BLK
4
D8
BLK/YEL
D9
RED/YEL
D15
RED/YEL
D14
RED/YEL
D7
GRN/YEL
D6
BLK/YEL
F26 F17
RED/YEL
F16
YEL/GRN
5
L H
F25
RED/YEL
WHT
BLK/BLU LT BLU
12
D16
BLU/RED
F = X36
BLK/RED
D = X34
GRN/YEL
B = X32
A3 MAIN CONTROLLER (MCZ)
RED/YEL
E = X35
BLK/YEL
C = X33
RED/YEL
A = X31
H4 TRAVEL ALARM
X86
BLU/BLK
X3
GRN/WHT
F17
1
BRN/WHT
F16
1
RED/YEL
X40
A D B C
A2
BLK
7
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
S7 POWER DIG SWITCH
A3
F8
S11 TRAVEL MODE SWITCH
X40
3
BRN/YEL
PNK
5
2
BRN/BLU
BRN
1
ORG
S8 AUTO-IDLE SWITCH
2
6
8
ORG
S12 POWER MODE BUTTON
9
WHT
X29
2
2
F7
BLK/GRN
F9
1
BLU/WHT
A3 MAIN CONTROLLER (MCZ)
1
Y26 PUMP 1 FLOW RATE LIMIT SOLENOID (MARKED SA)
1
BLK
Y20 PUMP 2 FLOW RATE LIMIT SOLENOID (MARKED SB)
Y21 TORQUE CONTROL SOLENOID (MARKED ST)
2
2
B40 HYDRAULIC OIL TEMPERATURE SENSOR
3
B61 ARM OUT PRESSURE SENSOR
TX1249812 Main Controller (MCZ) Circuit Schematic (2 of 2) (S.N. 057100— ) Continued on next page
TM13345X19 (23APR18)
9015-15-87
160GLC Excavator 042318 PN=713
TX03742,0000118 -19-13FEB18-5/11
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-88
160GLC Excavator 042318 PN=714
Sub-System Diagnostics
A3—Main Controller (MCZ) B40— Hydraulic Oil Temperature B30— Boom Up Pressure Sensor Sensor (marked PI1) B56— Bucket Curl Pressure B31— Arm In Pressure Sensor Sensor (marked BKC) (marked PI2) B57— Bucket Dump Pressure B32— Front Attachment Pressure Sensor Sensor (marked FRT) B60— Attachment Pressure B33— Swing Pressure Sensor Sensor (marked S3) B61— Arm Out Pressure Sensor B34— Travel Pressure Sensor H4—Travel Alarm (marked TR) R15— Engine Speed Dial B35— Pump 1 Delivery Pressure S7— Power Dig Switch Sensor (marked PP1) S8— Auto-Idle Switch B36— Pump 1 Control Pressure S11— Travel Mode Switch Sensor (marked PC1) S12— Power Mode Button B37— Pump 2 Delivery Pressure S13— Travel Alarm Cancel Sensor (marked PP2) Switch B38— Pump 2 Control Pressure X3— Cab Harness-to-Machine Sensor (marked PC2) Harness 100-Pin Connector X29— Cab Harness-to-Switch Panel Connector 3
Y20— Pump 2 Flow Rate Limit X31— Cab Harness-to-Main Solenoid (marked SB) Controller 31-Pin Y21— Torque Control Solenoid Connector A (marked ST) X32— Cab Harness-to-Main Y22— Dig Regenerative Solenoid Controller 24-Pin (marked SF) Connector B Y23— Arm Regenerative X33— Cab Harness-to-Main Solenoid (marked SC) Controller 17-Pin Y24— Power Dig/Travel Speed Connector C Solenoid (marked SG) X34— Cab Harness-to-Main Y26— Pump 1 Flow Rate Limit Controller 30-Pin Solenoid (marked SA) 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 X46— Attachment Connector X86— Machine Harness-to-Travel Alarm Harness Connector
Main Controller Power Up (power and ground)—Unswitched battery power is available at pins E5 and E6 of the main controller (MCZ) (A3) through data converter and main controller battery power 5 A fuse (F10). Ground is provided to pins E1, E2, F4, F5, and F6 of the MCZ.
more power to boom up and arm in functions when hydraulic pump delivery pressure is high. The MCZ sends an engine speed request to the ECU via the CAN. The ECU 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.)
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). 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.
Engine Speed Dial (R15)—The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial. The MCZ sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN).
Travel Mode (HP)—When the travel mode switch (S11) is set to fast (rabbit) speed, the switch grounds the MCZ at pin F8. The MCZ then activates the power dig/travel speed solenoid (marked SG) (Y24) depending on the status of the travel pressure sensor (marked TR) (B34), the front attachment pressure sensor (marked FRT) (B32), the pump control pressure sensors (B36 and B38), and the pump delivery pressure sensors (B35 and B37). The power dig/travel speed solenoid is a proportional solenoid controlled by pins A12 and A13 of the MCZ.
• For more information on CAN communication, see
The power dig/travel speed solenoid is activated when:
When battery relay (K19) is energized, current flows through solenoid 20 A fuse (F4) to pins F1, F2, and F3 of the MCZ.
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.)
• Travel mode switch is in fast (rabbit) position • Engine speed dial (R15) is in fast idle position • Travel pressure sensor is sensing pressure (travel
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).
• Both pump 1 and pump 2 control pressure sensor must
When the ECO power mode is selected, the MCZ sends a signal to torque control solenoid (marked ST) (Y21) to reduce swash plate angle on pumps 1 and 2 by 10 percent, which in turn, decreases the pump flow rate. ECO power mode reduces engine speed to reduce fuel consumption versus PWR mode. H/P mode delivers
function actuated)
• Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated)
• Both pump 1 and pump 2 delivery pressure sensor must indicate low pressure
indicate high pressure
Activation of the power dig/travel speed solenoid sends pilot pressure to the travel speed change valve in the travel motors. Pressure at the travel speed change valves changes the displacement of the travel motors allowing for fast travel speed. 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 travel speed will slow as hydraulic oil is routed to other functions. Continued on next page
TM13345X19 (23APR18)
9015-15-89
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160GLC Excavator 042318 PN=715
Sub-System Diagnostics 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).
When the travel mode switch is in the slow (turtle) speed position, the power dig/travel speed solenoid valve is de-energized. For more information, see Travel Motor Speed Circuit Operation. (Group 9025-05.) Power Dig—The power dig/travel speed solenoid (marked SG) (Y24) increases digging force by temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin F11 of the MCZ. The MCZ then energizes the power dig/travel speed solenoid for a maximum of 8 seconds. The power dig/travel speed solenoid is a proportional solenoid and controlled by a pulse width modulated signal from pins A12 and A13 of the MCZ. When the power dig/travel speed solenoid is activated, pilot oil from the power dig/travel speed solenoid valve 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 operating pressure. For more information, see Main Relief Valve 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 MCZ to pin F7 of the MCZ. The MCZ communicates the selected mode through the CAN to the monitor controller (DSZ) (A4), 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 (marked FRT) (B32) or the travel pressure sensor (marked TR) (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.) Cold Fluid Component Protection (CFCP)—CFCP protects components from damage by allowing engine coolant and hydraulic oil time to warm up in low temperatures if engine speed dial is set to high during start-up. After start-up, the CFCP icon on the monitor will illuminate until hydraulic oil temperature and engine coolant temperature conditions have been met. For more information, see Engine Speed Control System Operation. (Group 9010-05.) Hydraulic Oil Warm-Up Circuit—When hydraulic oil temperature is below 0°C (32°F), the 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
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 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 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 MCZ sends the equivalent to target engine speed to the ECU via the CAN. The ECU then increases the engine speed to the idle speed-up speed. Pilot Shutoff Idle Speed-Up Circuit—When engine speed dial (R15) is in the slow idle position and the pilot shutoff lever is in the unlocked (DOWN) position, the MCZ activates the pilot shutoff idle speed up circuit. The MCZ sends the equivalent to target engine speed to the ECU via the CAN, which increases the engine speed by 100 rpm from the slow idle speed in order to prevent engine stall during a function. 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 ECU via the 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 (marked ST) (Y21) can be activated during a travel function. At slow engine speeds, the torque control solenoid is activated and both pumps are moved to maximum displacement. Maximum displacement of the pumps 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 is a proportional solenoid and is controlled by a pulse width modulated signal from pins A2 and A3 of the MCZ. Auto-Shutdown Control—For more information on auto-shutdown control, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM13345X19 (23APR18)
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TX03742,0000118 -19-13FEB18-7/11
160GLC Excavator 042318 PN=716
Sub-System Diagnostics
Work Modes—The DSZ contains several work modes that are communicated by the CAN to 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 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 DSZ via the CAN.
MCZ adjusts the signal to the torque control solenoid 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 signal from pins A2 and A3 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.)
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.)
Dig Regenerative Solenoid (marked SF) (Y22)—The dig regenerative solenoid valve (marked 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 additional oil flow 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 A14 and A15 of the MCZ.
Travel Alarm Circuit— For more information, see Travel Alarm Circuit Theory of Operation. (Group 9015-16.)
The MCZ activates the dig regenerative solenoid when the following conditions have been met:
Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20)—The pump 2 flow rate limit solenoid (marked SB) (Y20) valve limits the pump 2 displacement according to each lever stroke of boom, arm, bucket, and travel in order to reduce fuel consumption. The pump 2 flow rate limit solenoid (marked 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). When the control lever is operated, the MCZ receives signals from the hydraulic pressure sensors and activates maximum pump 2 flow rate limit solenoid according to the sensor input. 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 (marked ST) (Y21)—The torque control solenoid (marked ST) (Y21) helps control pump displacement in response to changes in engine load. As engine load increases, the torque control solenoid 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 and therefore increasing the efficiency of the machine. The 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 CAN. As engine speed varies above or below target speed, the
• Pump 1 delivery pressure sensor (marked PP1) (B35)
and pump 2 delivery pressure sensor (marked PP2) (B37) sensing high pressure • Arm in pressure sensor (marked PI2) (B31) sensing high pressure (arm in function fully actuated) • Boom up pressure sensor (marked PI1) (B30) sensing low pressure When the dig regenerative solenoid is activated, pilot oil from the dig regenerative solenoid valve shifts the dig regenerative valve in the control valve. For more information, see Dig Regenerative Valve Circuit Operation. (Group 9025-05.) Arm Regenerative Solenoid (marked SC) (Y23)—The arm regenerative solenoid (marked SC) (Y23) combines return oil from the arm cylinder rod end with supply oil to the arm cylinder head end. This additional oil flow 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 A10 and A11 of the MCZ. The MCZ activates the arm regenerative solenoid when the following conditions have been met:
• Either pump 1 delivery pressure sensor (marked PP1)
(B35) or pump 2 delivery pressure sensor (marked PP2) (B37) sensing low pressure • Arm in pressure sensor (marked PI2) (B31) sensing high pressure (arm in function fully actuated) • Swing pressure sensor (marked S3) (B33) or boom up pressure sensor (marked PI1) (B30) sensing pressure (swing or boom up function actuated)
Continued on next page
TM13345X19 (23APR18)
9015-15-91
TX03742,0000118 -19-13FEB18-8/11
160GLC Excavator 042318 PN=717
Sub-System Diagnostics
When the arm regenerative solenoid is activated, pilot oil from the arm regenerative solenoid valve shifts the arm regenerative valve in the control valve. The arm regenerative valve blocks return oil from the arm cylinder rod end from returning to the hydraulic oil tank and combines the return oil with supply oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid valve also shifts the arm 2 flow rate 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 and see Arm 2 Flow Rate Control Valve Circuit Operation. (Group 9025-05.) Power Dig/Travel Speed Solenoid (marked SG) (Y24)—The power dig/travel speed solenoid (marked SG) (Y24) increases digging force by temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin F11 of the main controller (MCZ). The MCZ then energizes the power dig/travel speed solenoid (marked SG) (Y24) for a maximum of 8 seconds. The power dig/travel speed solenoid (marked 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 (marked SG) (Y24) is activated, pilot oil from the power dig/travel speed
solenoid (marked 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.) Pump 1 Flow Rate Limit Solenoid (marked SA) (Y26)—The pump 1 flow rate limit solenoid (marked SA) (Y26) limits the pump 1 displacement according to each lever stroke of boom, arm, bucket, and travel in order to reduce fuel consumption. The pump 1 flow rate limit solenoid is a proportional solenoid controlled by a pulse width modulated signal from pins A26 and A27 of the MCZ. When the control lever is operated, the MCZ receives signals from the hydraulic pressure sensors and activates maximum pump 1 flow rate limit solenoid according to the sensor input. Fine adjustments to the pump 1 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 affect MPDr flow adjustments if activated.
Continued on next page
TM13345X19 (23APR18)
9015-15-92
TX03742,0000118 -19-13FEB18-9/11
160GLC Excavator 042318 PN=718
Sub-System Diagnostics
Auxiliary Function Lever (AFL) Theory of Operation TX1195224 —UN—23JUN15
F5 5A FUSE
W37 1
6
WHT/YEL
X536 RIGHT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR (MARKED R_GRIP)
V22 PILOT SHUTOFF SOLENOID DIODE
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
W36
GRY
WHT/BLU
BLU/WHT
YEL/BLU
ORG/BLK
2
7
3
10
WHT/BLU
BLU/WHT
YEL/BLU
ORG/BLK
RED/YEL
6
GRY
BLK/GRN
BLU/YEL
RED/BLU
8
BLK/BLU
9
4
5
BLU/YEL
BLK/GRN
12
BLK/BLU
RED/BLU
11
RED/YEL
BLK/YEL
GRN/BLU 1
BLK/YEL
12 11 14 6 13 1 2 3 4 5
RED/YEL
K31 RIGHT SOLENOID RELAY A (MARKED RSW1)
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
1
P 2
B68 SECONDARY HYDRAULIC OIL TEMPERATURE SENSOR
1
T 2
3
BLK/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
Y61 AUXILIARY FUNCTION LEVER (AFL) SOLENOID A (MARKED 1A) 1
2 1
2
4
BLK/YEL
5
LT GRN/YEL
2
3
GRN/BLU
BLK/YEL RED/YEL GRN/BLU
1
X577 AUXILIARY FUNCTION LEVER (AFL) HARNESSTO-AUXILIARY FUNCTION LEVER (AFL) SOLENOID HARNESS CONNECTOR
B85 AUXILIARY FUNCTION LEVER (AFL) SOLENOID PRESSURE SENSOR (MARKED PS1)
GRY
WHT/YEL
Y66 SECONDARY PILOT SHUTOFF SOLENOID VALVE (MARKED PiC)
BLK/BLU
1
2
BLK
GRN
RED/BLU
5
BLK/BLU
4
BLK
BLU
RED 2
GRN/BLK
1
BLK/YEL
WHT
BLK 3
RED/YEL
LT GRN/YEL
5
GRN/BLU
BRN
S7 POWER DIG SWITCH
8
BLK/GRN
WHT
9
WHT/YEL
S31 RIGHT PILOT CONTROL LEVER SWITCH
S29 AUXILIARY FUNCTION LEVER (AFL) PROPORTIONAL CONTROL SWITCH
WHT/YEL
WHT
WHT/YEL
BRN
S45 AUXILIARY FUNCTION ENABLE SWITCH (MARKED AFL_SW)
RED/YEL
RIGHT PILOT CONTROL LEVER
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR 1
Y62 AUXILIARY FUNCTION LEVER (AFL) SOLENOID B (MARKED 1B)
C2 F16 F17 F22 C12 F25 F26 C6 B2 C7 A22 A23 A25 A24
GRN/BLK
F11
A3 MAIN CONTROLLER (MCZ)
A = X31 B = X32 C = X33 F = X36
TX1195224 Auxiliary Function Lever (AFL) Theory of Operation Continued on next page
TM13345X19 (23APR18)
9015-15-93
160GLC Excavator 042318 PN=719
TX03742,0000118 -19-13FEB18-10/11
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-94
160GLC Excavator 042318 PN=720
Sub-System Diagnostics
A3—Main Controller (MCZ) S31— Right Pilot Control Lever B68— Secondary Hydraulic Oil Switch Temperature Sensor S45— Auxiliary Function Enable B85— Auxiliary Function Lever Switch (marked AFL_SW) (AFL) Solenoid Pressure V22— Pilot Shutoff Solenoid Sensor (marked PS1) Diode F5— Optional and Attachment W36—Cab Harness Ground 2 Connector 5 A Fuse (marked W37—Cab Harness Ground 3 OPT. 1 ALT) X31— Cab Harness-to-Main K31— Right Solenoid Relay A Controller 31-Pin (marked RSW1) Connector A S7— Power Dig Switch X32— Cab Harness-to-Main S29— Auxiliary Function Lever Controller 24-Pin (AFL) Proportional Control Connector B Switch
Auxiliary Function Lever (AFL)— The main controller (MCZ) provides control for AFL control. For more information on MCZ, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.) Auxiliary hydraulic functions are controlled by the MCZ with inputs from the following components:
• B68—Secondary hydraulic oil temperature sensor • B85—Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1)
• S29—Auxiliary function lever (AFL) proportional control switch
• S45—Auxiliary function enable switch (marked AFL_SW)
After the MCZ processes received input signals, output signals are sent to the solenoids to control hydraulic speed and volume with the following components:
• Y61—Auxiliary function lever (AFL) solenoid A (marked 1A)
• Y62—Auxiliary function lever (AFL) solenoid B (marked 1B)
• Y66—Secondary pilot shutoff solenoid valve (marked PiC)
NOTE: AFL will work only when pilot control shutoff lever is in the (DOWN) unlocked position. If a
Y61— Auxiliary Function Lever X33— Cab Harness-to-Main (AFL) Solenoid A (marked Controller 17-Pin 1A) Connector C Y62— Auxiliary Function Lever X36— Cab Harness-to-Main (AFL) Solenoid B (marked Controller 26-Pin 1B) Connector F X536— Right Auxiliary Function Y66— Secondary Pilot Shutoff Solenoid Valve (marked Lever (AFL) Connector PiC) (marked R_GRIP) X574— Auxiliary Function Lever (AFL) Connector 1 X577— Auxiliary Function Lever (AFL) Harness-toAuxiliary Function Lever (AFL) Solenoid Harness Connector
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 (marked PiC) (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). TX03742,0000118 -19-13FEB18-11/11
Machine Controller (BCZ) Circuit Theory of Operation
For more information on lighting circuit theory of operation, see Lighting Circuit Theory of Operation. (Group 9015-15.)
The machine controller (BCZ) controls lighting, windshield wiper, and windshield washer circuits. For more information on windshield wiper and washer circuit theory of operation, see Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.) JS20420,0000D95 -19-29MAY14-1/1
TM13345X19 (23APR18)
9015-15-95
160GLC Excavator 042318 PN=721
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-96
160GLC Excavator 042318 PN=722
Sub-System Diagnostics
Windshield Wiper and Washer Circuit Theory of Operation G1
B
POSITION HEAT OFF ACC ON START
G2
M
ACC
ST
WHT
WHT
WHT
RED/BLK
RED/BLK
RED/BLK WHT
TX1187836 —UN—17MAR15
BLK/RED BLK/YEL
2
GRN/BLU
B13
BLK/WHT
3
BLK/WHT
A4
X30
GRN
5
5
WHT
S91 BATTERY DISCONNECT SWITCH
WHT
BLK
A
G2 BATTERY
WHT
E
K19 BATTERY RELAY
3
X39
1
2
3
5
4
B9
GRY/RED
B1
A5
BLK/BLU
B11
A8
S28 WINDOW SWITCH
GRY/RED
BLK/BLU
BLK
A4 MONITOR CONTROLLER (DSZ) A = X20 C = X23
K9 WINDSHIELD WASHER RELAY
X3
B19
F60 65A FUSE
L
M
LB
B11
M6 WINDSHIELD WASHER MOTOR
M5 WINDSHIELD WIPER MOTOR A10 MONITOR C3
RED/YEL
S
C3 C = X18
A25 A26 WHT WHT
F62 WIPER MOTOR ASSEMBLY CIRCUIT BREAKER
B
M
L E
BLK/BLU
TX1187836 Windshield Wiper and Washer Circuit Theory of Operation Continued on next page
TM13345X19 (23APR18)
4
VLT
GRN (CAN 1 HIGH) BLU (CAN 1 LOW)
V3 LOAD DUMP RELAY DIODE
BLK WHT
B
BLK
E6 SWITCH PANEL BACK LIGHT 2
YEL/RED
RED
RED S
RED/GRN
F12 5A FUSE
G1 BATTERY
4
2
WHT
ST
5
1
BLU
2
YEL/BLK
1
2
K6 WINDSHIELD WIPER RELAY
BLK
RED/BLK
3
BLK/RED
B4
F2 WINDSHIELD WIPER AND WASHER 10A FUSE
BLK/RED
1
WHT
YEL/RED
BLK
1
RED
RED
BLK
YEL/BLK
B3
RED
3
BLU
YEL/GRN
BLU
M
4
4
BLK
GRY/RED
G2
V12 STARTER CUT DIODE
GRN/BLK
BLK/BLU
RED
K13 KEY CUT RELAY
B6
S9 WINDSHIELD WIPER AND WASHER SWITCH
RED
G1
F61 45A FUSE
A = X10 B = X11 BLU
BAT
S1 KEY SWITCH
YEL/BLK
RED
ACC
F10 CONTROLLER 5A FUSE
BLK
F17 POWER ON 5A FUSE
HEAT OFF ACC ON START
A11 MACHINE CONTROLLER (BCZ)
2 1 0
X27
BLK/PNK
RED/BLK
RED
9015-15-97
160GLC Excavator 042318 PN=723
JS20420,0000D96 -19-23JAN18-1/2
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-98
160GLC Excavator 042318 PN=724
Sub-System Diagnostics
A4—Monitor Controller (DSZ) A10— Monitor A11— Machine Controller (BCZ) E6— Switch Panel Back Light 2 F2— Windshield Wiper and Washer 10 A Fuse (marked WIPER) 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 F62— Wiper Motor Assembly Circuit Breaker G1—Battery G2—Battery K6—Windshield Wiper Relay K9—Windshield Washer Relay K13— Key Cut Relay K19— Battery Relay M5—Windshield Wiper Motor M6—Windshield Washer Motor
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. Switched power is also supplied to windshield wiper relay (K6) and windshield washer relay (K9). The BCZ is grounded at pin A8 of machine controller 8-pin connector A. The windshield wiper and washer circuit has four modes of operation:
• Windshield wiper ON (continuous) • Windshield wiper INT (intermittent) • Windshield wiper OFF (park) • Windshield wash Operation of the windshield wiper and washer circuit is controlled by signals from the BCZ and the state of the windshield wiper motor (M5) internal position status switch. Windshield Wiper Continuous Operation—When windshield wiper and washer switch (S9) is placed in the ON position, the BCZ grounds pin B9 at predetermined intervals. When pin B9 is grounded, the windshield wiper relay (K6) is energized. NOTE: Window switch (S28) must be connected for windshield wiper to operate. Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 A 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 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
S1— Key Switch S9— Windshield Wiper and Washer Switch S28— Window Switch S91— Battery Disconnect Switch V3— Load Dump Relay Diode V12— Starter Cut 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
position, BCZ intermittently grounds pin B9. The monitor controller (DSZ) (A4) controls windshield wiper delay time. NOTE: Window switch (S28) must be connected for windshield wiper to operate. Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 A 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 A 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. JS20420,0000D96 -19-23JAN18-2/2
TM13345X19 (23APR18)
9015-15-99
160GLC Excavator 042318 PN=725
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-100
160GLC Excavator 042318 PN=726
Sub-System Diagnostics
Lighting Circuit Theory of Operation TX1250170 —UN—16JAN18
9
RED BLK
1 2
BLK/GRN RED/GRN
3 4
RED BLK
1 2
RED BLK
2 1
X581
TX1250170
Lighting Circuit Theory of Operation (S.N. —056599) Continued on next page
TM13345X19 (23APR18)
9015-15-101
160GLC Excavator 042318 PN=727
BLU/YEL B18
X18
A2 A6
A11 MACHINE CONTROLLER (BCZ)
GRN/WHT
B17
+
13
BLK
14
0 1 2
S10 WORK LIGHT SWITCH
C = X23 A25
A26
GRN (CAN 1 HIGH)
B7
A = X20
A = X10 B = X11
BLU (CAN 1 LOW)
WHT/VLT
A4 MONITOR CONTROLLER (DSZ)
B1 B11
BLU (CAN 1 LOW)
-
E11 CAB X29 ROOF LIGHT 1
WHT/VLT
+
E13 CAB ROOF LIGHT 3
C3
RED/YEL
BLU A4
S14 DOOR SWITCH
BLK
YEL/RED
B10 A7 B19
BLK YEL
RED/YEL
ORG/BLU
RED/BLU
RED/BLU
X580
+
E14 - CAB ROOF LIGHT 4
BRN/BLK
S36 REAR CAB LIGHT SWITCH
RED/BLU
BLK
X582
2
8
GRN
GRN
GRN
+
E12 - CAB ROOF LIGHT 2
GRN/WHT
4
K21 CAB ROOF LIGHT 1 RELAY
WHT/YEL
GRN (CAN 1 HIGH)
GRN 5
10
A8
PNK
RED
2
E2 BOOM LIGHT BLK
K23 REAR CAB LIGHT RELAY
3
ORG/BLU
E9 KEY SWITCH LIGHT
A10 MONITOR
V13 WORK LIGHT 1 DIODE
2
BLK
1
1
E1 WORK LIGHT
YEL
1
3
BLK/RED
C3
V14 WORK LIGHT 2 DIODE
RED
4
X632
X3
X3
4
K22 CAB ROOF LIGHT 2 RELAY
C8
C7
BLK/WHT
X633
RED/GRN
WHT
5
1
4
9
BLK
3
E3 CAB DOME LIGHT
RED/YEL YEL
RED/GRN
2
3
2
0 1
WHT
RED/GRN
RED/GRN 1
S91 BATTERY DISCONNECT SWITCH
4
BLK/WHT
BLK
F60 65A FUSE
GRN
WHT RED BLK BLK/RED 5
5
BLU/RED
BLK BLK
-
WHT
BLK
WHT
2
X26
3
RED/GRN
B
1
BLK
A
K19 BATTERY RELAY
S90 ENGINE COMPARTMENT LIGHT SWITCH
G01 BLK
E
B
G2 BATTERY
5
RED/BLU
ORG/BLU
1
1
RED
S
+
YEL/RED
0 1
-
YEL/RED
A
E18 REAR + CAB LIGHT
-
G22 BRN
2
RED
RED
F46 7.5A FUSE
2
DOOR OFF ON
2
K8 BOOM LIGHT RELAY
RED/BLU
BLK/YEL
WHT
F61 45A FUSE
G1 BATTERY
3
S2 CAB DOME LIGHT SWITCH
RED/YEL
+
E15 ENGINE COMPARTMENT LIGHT
1
2
1
BLK
YEL/BLK
RED B22 RED
3
4
K7 WORK LIGHT RELAY
BLU/RED
WHT
YEL/BLK
X55
1
YEL
4
2
RED/BLU
5
3
5
BLK
2
X56
2
RED/GRN
ST
K13 KEY CUT RELAY
1
X57
RED
3
4
3
2
BLK/RED
1
5
K1 LOAD DUMP RELAY
BLK
BLU 2
WHT
WHT
WHT
RED
RED
3
1
RED/GRN BLK BLK/RED
WHT/BLK M
1
RED
RED
G2
D+
RED/GRN BLK BLK/RED
4
X27
YEL/RED RED/BLU
BLK
RED BLK
5
F10 5A FUSE
F12 5A FUSE
F9 10A FUSE
RED/GRN BLK
2
K12 ACCESSORY CUT RELAY
YEL/BLK
G1
3
F1 20A FUSE
F17 5A FUSE
F22 10A FUSE
G3 ALTERNATOR B1+
1
RED
RED/BLK
WHT
BAT
F32 10A FUSE
RED
ACC
F23 10A FUSE
BLK
S1 KEY SWITCH
V3 LOAD DUMP RELAY DIODE
RED BLK BLK/RED
V11 ACCESSORY CUT DIODE
WHT
V12 STARTER CUT DIODE
RED HEAT OFF ACC ON START
RED GRN WHT YEL/BLK YEL/BLK
RED
M ST
YEL/BLK
ACC
RED
G2
GRN
G1
GRN
B
POSITION HEAT OFF ACC ON START
CAN 1
JL58967,0000734 -19-23JAN18-1/5
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-102
160GLC Excavator 042318 PN=728
Sub-System Diagnostics
A4—Monitor Controller (DSZ) F22— Front Cab Light 1 10 A S10— Work Light Switch X27— Cab Harness-to-Switch A10— Monitor Fuse (marked CAB LAMP S14— Door Switch Panel Connector 1 A11— Machine Controller (BCZ) FRONT) S36— Rear Cab Light Switch X29— Cab Harness-to-Switch E1— Work Light F23— Rear Cab Light 10 A Fuse S90— Engine Compartment Light Panel Connector 3 E2— Boom Light (marked CAB LAMP REAR) Switch X55— Front Cab Light 1 E3— Cab Dome Light F32— Front Cab Light 2 10 A S91— Battery Disconnect Switch Connector (marked CAB E9— Key Switch Light Fuse (marked CAB LAMP V3— Load Dump Relay Diode LAMP FRONT) E11— Cab Roof Light 1 FRONT +2) V11— Accessory Cut Diode X56— Front Cab Light 2 E12— Cab Roof Light 2 F46— Engine Light In-Line 7.5 A V12— Starter Cut Diode Connector (marked CAB E13— Cab Roof Light 3 Fuse V13— Work Light 1 Diode LAMP FRONT +2) E14— Cab Roof Light 4 F60— Alternator 65 A Fuse V14— Work Light 2 Diode X57— Rear Cab Light Connector E15— Engine Compartment Light F61— Battery 45 A Fuse X3— Cab Harness-to-Machine (marked CAB LAMP REAR) E18— Rear Cab Light G1—Battery Harness 100-Pin Connector X580— Cab Roof Light Harness F1— Work and Boom Lights 20 A G2—Battery X10— Machine Controller 8-Pin Connector Fuse (marked LAMP) G3—Alternator Connector A X581— Cab Roof Light Jumper F9— Radio Backup 10 A Fuse K1—Load Dump Relay X11— Machine Controller 20-Pin Harness Connector 1 (marked BACK UP) K7—Work Light Relay Connector B X582— Cab Roof Light Jumper F10— Data Converter and K8—Boom Light Relay X18— Monitor 12-Pin Connector Harness Connector 2 Main Controller Battery K12— Accessory Cut Relay C X632— Rear Cab Light Harness Power 5 A Fuse (marked K13— Key Cut Relay X20— Monitor Controller 28-Pin Connector CONTROLLER) K19— Battery Relay Connector A X633— Rear Cab Light Switch F12— Radio and Dome 5 A Fuse K21— Cab Roof Light 1 Relay X23— Monitor Controller 12-Pin Harness Connector (marked RADIO) K22— Cab Roof Light 2 Relay Connector C (marked CAB LAMP F17— Power On 5 A Fuse K23— Rear Cab Light Relay X26— Optional Connector REAR) (marked POWER ON) S1— Key Switch S2— Cab Dome Light Switch Continued on next page
TM13345X19 (23APR18)
9015-15-103
JL58967,0000734 -19-23JAN18-2/5
160GLC Excavator 042318 PN=729
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-104
160GLC Excavator 042318 PN=730
Sub-System Diagnostics
TX1250171 —UN—16JAN18
9
RED BLK
1 2
BLK/GRN RED/GRN
3 4
RED BLK
1 2
RED BLK
2 1
X581 Lighting Circuit Theory of Operation (S.N. 056600— ) Continued on next page
9015-15-105
160GLC Excavator 042318 PN=731
BLU/YEL B18
X18
A2 A6
A11 MACHINE CONTROLLER (BCZ)
GRN/WHT
B17
+
E11 CAB X29 ROOF LIGHT 1
13
BLK
14
A = X20
A = X10 B = X11
0 1 2
S10 WORK LIGHT SWITCH
C = X23 A25
A26
GRN (CAN 1 HIGH)
B7
BLU (CAN 1 LOW)
WHT/VLT
A4 MONITOR CONTROLLER (DSZ)
B1 B11
BLU (CAN 1 LOW)
-
C3
RED/YEL
BLU A4
S14 DOOR SWITCH
BLK
YEL/RED
ORG/BLU
B10 A7 B19
BLK YEL
RED/YEL +
E13 CAB ROOF LIGHT 3
WHT/VLT
X580
+
E14 - CAB ROOF LIGHT 4
BRN/BLK
S36 REAR CAB LIGHT SWITCH
TX1250171
TM13345X19 (23APR18)
RED/BLU
RED/BLU
BLK
X582
2
8
GRN
GRN
GRN
+
E12 - CAB ROOF LIGHT 2
GRN/WHT
4
K21 CAB ROOF LIGHT 1 RELAY
WHT/YEL
A8
PNK
5
E2 BOOM LIGHT
BLK
RED
2
3
10
E9 KEY SWITCH LIGHT
A10 MONITOR
V13 WORK LIGHT 1 DIODE
2
RED
K23 REAR CAB LIGHT RELAY
E1 WORK LIGHT
YEL
1
3
ORG/BLU
GRN (CAN 1 HIGH)
GRN
1
X3
X3
4
K22 CAB ROOF LIGHT 2 RELAY
C8
C7
BLK/WHT
X632
4
RED/BLU
5
5
BLK/RED
C3
V14 WORK LIGHT 2 DIODE
BLK
1
X26
3
9
BLK
3
E3 CAB DOME LIGHT
RED/BLU
ORG/BLU
1
RED/YEL YEL
RED/GRN
1
4
BLK/WHT
X633
RED/GRN
WHT
4
2
0 1
WHT
5
5
RED/GRN
2
3
YEL/RED
2
E15 ENGINE COMPARTMENT LIGHT
1
S91 BATTERY DISCONNECT SWITCH
WHT
1
RED/GRN
RED/GRN
-
WHT
A15 FLEX POWER CONTROLLER (FPC)
YEL/RED
J4
GRN
WHT 2
BLK
BLK
1
BLK
-
G2 BATTERY
2
K8 BOOM LIGHT RELAY
1
RED
BLK/YEL
+
BLK
K19 BATTERY RELAY F60 65A FUSE
D1
E18 REAR + CAB LIGHT
X27
DOOR OFF ON
2
RED/BLU
-
L055 BRN
A
BLK
WHT
E
B
0 1
G001 BLK
S
RED
RED
F46 7.5A FUSE
G1 BATTERY
P023 RED
F61 45A FUSE
2
3
S2 CAB DOME LIGHT SWITCH
RED/YEL
+ S90 ENGINE COMPARTMENT B LIGHT SWITCH
3
1
BLU/RED
RED
A
X55
1
4
K7 WORK LIGHT RELAY
BLK
YEL/BLK
B022 RED
2
F12 5A FUSE
F9 10A FUSE
BLU/RED
WHT
YEL/BLK
3
YEL
4
X56
2
RED/BLU
5
1
X57
5
BLK
K13 KEY CUT RELAY
3
ST 2
4
RED/GRN
1
5
RED
2
3
2
BLK/RED
BLU
K1 LOAD DUMP RELAY
BLK
3
RED BLK BLK/RED
1
1
RED/GRN BLK BLK/RED
M
RED
RED
WHT/BLK
F10 5A FUSE
YEL/RED RED/BLU
D+
RED
RED
G2
F22 10A FUSE
RED/GRN BLK BLK/RED
4
F17 5A FUSE
BLK
RED BLK
5
K12 ACCESSORY CUT RELAY
F1 20A FUSE
RED/GRN BLK
2
3
YEL/BLK
1
G1
WHT
WHT
WHT B1+
RED
RED/BLK
WHT
BAT
F32 10A FUSE
G3 ALTERNATOR
BLK
ACC
F23 10A FUSE
RED
S1 KEY SWITCH
V3 LOAD DUMP RELAY DIODE
RED BLK BLK/RED
V11 ACCESSORY CUT DIODE
WHT
V12 STARTER CUT DIODE
RED HEAT OFF ACC ON START
RED GRN WHT YEL/BLK YEL/BLK
RED
M ST
YEL/BLK
ACC
RED
G2
GRN
G1
GRN
B
POSITION HEAT OFF ACC ON START
CAN 1
JL58967,0000734 -19-23JAN18-3/5
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-106
160GLC Excavator 042318 PN=732
Sub-System Diagnostics
A4—Monitor Controller (DSZ) F22— Front Cab Light 1 10 A S10— Work Light Switch X29— Cab Harness-to-Switch A10— Monitor Fuse (marked CAB LAMP S14— Door Switch Panel Connector 3 A11— Machine Controller (BCZ) FRONT) S36— Rear Cab Light Switch X55— Front Cab Light 1 A15— Flex Power Controller F23— Rear Cab Light 10 A Fuse S90— Engine Compartment Light Connector (marked CAB (FPC) (marked CAB LAMP REAR) Switch LAMP FRONT) E1— Work Light F32— Front Cab Light 2 10 A S91— Battery Disconnect Switch X56— Front Cab Light 2 E2— Boom Light Fuse (marked CAB LAMP V3— Load Dump Relay Diode Connector (marked CAB E3— Cab Dome Light FRONT +2) V11— Accessory Cut Diode LAMP FRONT +2) E9— Key Switch Light F46— Engine Light In-Line 7.5 A V12— Starter Cut Diode X57— Rear Cab Light Connector E11— Cab Roof Light 1 Fuse V13— Work Light 1 Diode (marked CAB LAMP REAR) E12— Cab Roof Light 2 F60— Alternator 65 A Fuse V14— Work Light 2 Diode X580— Cab Roof Light Harness E13— Cab Roof Light 3 F61— Battery 45 A Fuse X3— Cab Harness-to-Machine Connector E14— Cab Roof Light 4 G1—Battery Harness 100-Pin Connector X581— Cab Roof Light Jumper E15— Engine Compartment Light G2—Battery X10— Machine Controller 8-Pin Harness Connector 1 E18— Rear Cab Light G3—Alternator Connector A X582— Cab Roof Light Jumper F1— Work and Boom Lights 20 A K1—Load Dump Relay X11— Machine Controller 20-Pin Harness Connector 2 Fuse (marked LAMP) K7—Work Light Relay Connector B X632— Rear Cab Light Harness F9— Radio Backup 10 A Fuse K8—Boom Light Relay X18— Monitor 12-Pin Connector Connector (marked BACK UP) K12— Accessory Cut Relay C X633— Rear Cab Light Switch F10— Data Converter and K13— Key Cut Relay X20— Monitor Controller 28-Pin Harness Connector Main Controller Battery K19— Battery Relay Connector A (marked CAB LAMP Power 5 A Fuse (marked K21— Cab Roof Light 1 Relay X23— Monitor Controller 12-Pin REAR) CONTROLLER) K22— Cab Roof Light 2 Relay Connector C F12— Radio and Dome 5 A Fuse K23— Rear Cab Light Relay X26— Optional Connector (marked RADIO) S1— Key Switch X27— Cab Harness-to-Switch F17— Power On 5 A Fuse S2— Cab Dome Light Switch Panel Connector 1 (marked POWER ON)
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 B (X11). When work light relay is energized, the work light will illuminate. 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.)
relay, power is passed through load dump relay diode (V3) to energize the battery relay (K19) through pin S. The battery relay allows current to travel to the alternator B terminal through the alternator 65 A fuse (F60). At the B terminal of the alternator, current is then passed through the work and boom lights 20 A fuse (F1). Current then passes to boom light relay (K8) pins 1 and 3 and to work light relay (K7) pin 3. 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 work light relay, boom light relay, cab roof light 1 relay, and cab roof light 2 relay and illuminates the work light, boom light, and cab roof lights 1—4. When key switch is turned to the OFF position, ground through pin A6 to work light relay is disconnected and work light turns off. With work light switch in position 2 and no ground detected from the key cut relay (K13), BCZ provides ground to pins A2 and A7, illuminating the boom light and key switch light for 30 seconds. After 30 seconds, the MCZ provides ground for the key cut relay through pin 5 cab harness-to-main controller 17-pin connector C. When current passes through key cut relay, power is removed from battery relay and current is removed from lights. 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). NOTE: When work light switch is in position 2, the monitor screen will change to nighttime mode screen. Daytime mode screen can be returned by pressing 0 on the keypad. 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
Engine Compartment Light Operation (S.N. —056599)—Turning the engine compartment light switch (S90) to position 1 activates the engine compartment light (E15).
Continued on next page
TM13345X19 (23APR18)
9015-15-107
JL58967,0000734 -19-23JAN18-4/5
160GLC Excavator 042318 PN=733
Sub-System Diagnostics
The engine compartment light power is supplied from terminal B of battery relay (K19) through engine light in-line 7.5 A fuse (F46). While engine compartment light switch is in position 1, ground is supplied to engine compartment light, illuminating the engine compartment light. Engine Compartment Light Operation (S.N. 056600— )—Turning the engine compartment light switch (S90) to position 1 activates the engine compartment light (E15). The engine compartment light switch power is supplied from terminal B of battery relay (K19) through engine light in-line 7.5 A fuse (F46). When engine compartment light switch is toggled on, current is provided at pin D1 of flex power controller (FPC) (A15). With current detected at pin D1 of FPC, current is sent from pin J4 of FPC to engine compartment light, illuminating the engine compartment light. Rear Cab Light Operation—Switched battery power is supplied to pins 1 and 3 of rear cab light relay (K23). While rear cab light switch (S36) is in the ON position, ground is provided to pin 2 of the rear cab light relay, energizing the relay. With relay energized, current is provided to rear cab light (E18), illuminating the light.
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 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 DOOR 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 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.
Cab Dome Light Continuous Operation—The cab dome light (E3) receives unswitched power through radio JL58967,0000734 -19-23JAN18-5/5
TM13345X19 (23APR18)
9015-15-108
160GLC Excavator 042318 PN=734
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-109
160GLC Excavator 042318 PN=735
Sub-System Diagnostics
Travel Alarm Circuit Theory of Operation WHT
WHT
TO BATTERY RELAY (KI9) (PIN A)
BLK
WHT/RED
WHT/YEL
F11 TRAVEL ALARM 5A FUSE
1
2
2
1
4
3
B34 TRAVEL PRESSURE SENSOR
F25
BLK/YEL
C10
YEL/RED
0 1
D9
F16
F26
A3 MAIN CONTROLLER (MCZ) TX1163184
F17
TX1163184 —UN—13JUN14
BLK
S13 TRAVEL ALARM CANCEL SWITCH
RED/YEL
H4 TRAVEL ALARM
WHT/RED
GRN/BLK
3
Travel Alarm Circuit Schematic
Continued on next page
TM13345X19 (23APR18)
9015-15-110
JS20420,0000D98 -19-13JUN14-1/2
160GLC Excavator 042318 PN=736
Sub-System Diagnostics A3—Main Controller (MCZ) B34— Travel Pressure Sensor (marked TR)
F11— Travel Alarm 5 A Fuse (marked TRAVEL ALARM)
The travel alarm circuit consists of a travel pressure sensor (marked TR) (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
H4—Travel Alarm S13— Travel Alarm Cancel Switch
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 10 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. JS20420,0000D98 -19-13JUN14-2/2
TM13345X19 (23APR18)
9015-15-111
160GLC Excavator 042318 PN=737
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-112
160GLC Excavator 042318 PN=738
Sub-System Diagnostics
Pilot Shutoff Circuit Theory of Operation TX1254801 —UN—10APR18
+
1
G1 BATTERY
2
K4 STARTER CUT RELAY
3
5
4
RED
VLT/GRN
BLK
F60 65A FUSE
WHT/BLK
VLT/GRN
YEL/GRN
S91 BATTERY DISCONNECT SWITCH
A1 ENGINE CONTROL UNIT (ECU)
BLK
X175 1
V7 START RELAY DIODE
05
= X5503
BLK
A
E
K19 BATTERY RELAY
BLK
B
RED
WHT
WHT
S
V1 BATTERY RELAY DIODE
E13 WHT
G2 BATTERY
VLT/GRN
2
4
E03 WHT
S
V44 STARTER RELAY DIODE
BLK
RED/BLK
YEL/BLK WHT VLT
S4 PILOT SHUTOFF SWITCH 2
2
B1+
WHT
G3 ALTERNATOR E
S3 PILOT SHUTOFF SWITCH 1
RED
B
1 ORG
1
ORG
3
YEL
BLU
M1 STARTER MOTOR
A3 MAIN CONTROLLER (MCZ)
C = X33 F = X36
C5
3
2
X65
G02 BLK
BLK
BLK
3
E03 WHT
G02 BLK
V9 PILOT SHUTOFF DIODE
V20 PILOT SHUTOFF SWITCH DIODE
X65
F13 2
RED
RED
WHT
WHT
WHT
WHT YEL/GRN
TX1254801
Pilot Shutoff Circuit Theory of Operation Schematic
9015-15-113
X65 WHT
YEL/GRN
Continued on next page
TM13345X19 (23APR18)
V5 STARTER CUT RELAY DIODE 1
F45 30A FUSE K34 STARTER RELAY
3
F7 5A FUSE
4
WHT/RED
P22 RED
1
+
WHT
VLT
VLT/GRN WHT/RED
5
WHT
RED
F61 45A FUSE
VLT/RED
2
VLT
VLT/GRN
X47
4
3
BLU
WHT/RED
5
1
RED
WHT/RED
2
K2 PILOT SHUTOFF SOLENOID RELAY
3
WHT
3
WHT/RED
VLT/GRN
1
BLK
BLU YEL/GRN
ST
K5 SECURITY RELAY
V10 STARTER PROTECTION DIODE
E03 WHT
4
BLU
RED
BLK
E03 WHT
RED
YEL/GRN
VLT/GRN
WHT
V3 LOAD DUMP RELAY DIODE
B10 A16
A17 RED
YEL/GRN
G2 M
4
WHT/RED
5
WHT/GRN
5
YEL/GRN
G1
2
X75
D = X22
BLK
4
1
V4 SECURITY DIODE
WHT/RED
5
K13 KEY CUT RELAY
RED
2
3
A = X20 B = X21
BLU
BAT
K11 IDLE STOP RELAY
1
D16
A4 MONITOR CONTROLLER (DSZ)
PNK/BLK
WHT
1
3
WHT/RED
WHT/BLU
1
F4 20A FUSE RED
YEL/GRN
ACC
WHT
RED
BLU
3
2
1
F17 5A FUSE
VLT/WHT
WHT/BLK
YEL/BLK
X75
ORG
4
P22 RED
5
YEL/BLK
2
Y10 PILOT SHUTOFF SOLENOID
BLK
2
K12 ACC CUT RELAY
V11 ACCESSORY CUT DIODE
YEL/BLK
3
BLU
S1 KEY SWITCH
HEAT OFF ACC ON START
1
YEL/BLK GRN/WHT
YEL/GRN
BLU
F18 5A FUSE
YEL/BLK GRN/WHT RED
V12 STARTER CUT DIODE
VLT/GRN
BLU
RED
BLU
PNK/WHT
GRN
RED
WHT
RED
M ST
VLT/RED
ACC
GRN/WHT
G2
P22 RED
G1
G02 BLK
B
POSITION HEAT OFF ACC ON START
160GLC Excavator 042318 PN=739
JS20420,0000D99 -19-06APR18-1/2
Sub-System Diagnostics
TM13345X19 (23APR18)
9015-15-114
160GLC Excavator 042318 PN=740
Sub-System Diagnostics
A1—Engine Control Unit (ECU) K2—Pilot Shutoff Solenoid Relay V7— Start Relay Diode A3—Main Controller (MCZ) K4—Starter Cut Relay V9— Pilot Shutoff Diode A4—Monitor Controller (DSZ) K5—Security Relay V10— Starter Protection Diode F4— Solenoid 20 A Fuse (marked K11— Idle Stop Relay V11— Accessory Cut Diode SOLENOID) K12— Accessory Cut Relay V12— Starter Cut Diode F7— Start Position Signal 5 A K13— Key Cut Relay V20— Pilot Shutoff Switch Diode Fuse (marked START) K19— Battery Relay V44— Starter Relay Diode F17— Power On 5 A Fuse K34— Starter Relay X20— Monitor Controller 28-Pin (marked POWER ON) M1—Starter Motor Connector A F18— Idle Stop 5 A Fuse (marked S1— Key Switch X21— Monitor Controller 36-Pin IDLE STOP) S3— Pilot Shutoff Switch 1 Connector B F45— Starter In-Line 30 A Fuse S4— Pilot Shutoff Switch 2 X22— Monitor Controller 16-Pin F60— Alternator 65 A Fuse S91— Battery Disconnect Switch Connector D F61— Battery 45 A Fuse V1— Battery Relay Diode X33— Cab Harness-to-Main G1—Battery V3— Load Dump Relay Diode Controller 17-Pin G2—Battery V4— Security Diode Connector C G3—Alternator V5— Starter Cut Relay Diode X36— Cab Harness-to-Main Controller 26-Pin Connector F
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), and security diode (V4). With key switch (S1) in the ON position, current flows from key switch pin M to key cut relay (K13). Utilizing the normally closed contacts of key cut relay, power is passed through pin 3 of key cut relay through power on 5 A fuse (F17) to monitor controller (A4) pin A16 and to battery relay (K19) pin S. With current at battery relay pin S the relay energizes closing the normally open contact sending current through alternator 65 A fuse (F60) and 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 through pilot shutoff switch diode (V20), indicating that both pilot shutoff switches are in the same position, allowing 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
X47— Cab Harness-to-Key Switch Harness Connector X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector X75— Cab Harness-to-Pilot Shutoff Valve Harness Connector X175— Machine Harness-toEngine Interface Harness Connector 1 X5503—Engine Control Unit (ECU) Connector 3 Y10— Pilot Shutoff 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) and 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 F13 of the 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 D16 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), keeping the machine from being operated when the security system is active. JS20420,0000D99 -19-06APR18-2/2
TM13345X19 (23APR18)
9015-15-115
160GLC Excavator 042318 PN=741
Sub-System Diagnostics
Attachment Control Circuit Theory of Operation RED/YEL
TO F60 ALTERNATOR 65A FUSE
1
3
F5 5A FUSE
RED/WHT
3
V43 2-SPEED ACTIVATION SOLENOID VALVE DIODE
BLK/YEL
LT GRN/BLK
WHT/YEL
B61 ARM OUT PRESSURE SENSOR
2
RED/YEL
X46
1
2
A
1
2
X46
2
BLU/BLK
Y44 FLOW RATE ADJUSTMENT SOLENOID VALVE
1
3
Y43 2-SPEED ACTIVATION SOLENOID VALVE
K
BLK/YEL
X46
11
BLU
B60 ATTACHMENT PRESSURE SENSOR
2
BLK/YEL
BLU/RED
3
BLU
2
RED/YEL
B32 FRONT ATTACHMENT PRESSURE SENSOR
WHT
1
RED/YEL
RED/YEL
10
WHT/BLU
RED
YEL/GRN
D17
F16
D18
B12
B11
TX1187593
1
2
14
X46 Y41 SECONDARY RELIEF SOLENOID VALVE V42 ACCUMULATOR A SOLENOID K VALVE DIODE
BLU
BLU
1
Y42 ACCUMULATOR SOLENOID VALVE
2
BLU
TX1187593 —UN—17MAR15
2
YEL/BLK
BLU/WHT 1
8
X46 Y40 SELECTOR VALVE SOLENOID VALVE V41 SECONDARY A RELIEF K SOLENOID VALVE DIODE
YEL/BLK
GRY/BLK
9
X46
V40 SELECTOR A VALVE SOLENOID K VALVE DIODE
C17 ORG/WHT
C16 BLU/WHT
C4
C3
A = X31 C = X33 D = X34 F = X36
BLU
BLK/YEL
F25
A3 MAIN CONTROLLER (MCZ)
PNK/GRN
WHT/VLT
D14
RED/YEL
BLU/RED
X46
Attachment Control Circuit Schematic
Continued on next page
TM13345X19 (23APR18)
9015-15-116
JJ03229,0000ED2 -19-24APR15-1/9
160GLC Excavator 042318 PN=742
Sub-System Diagnostics A3—Main Controller (MCZ) V40— Selector Valve Solenoid B32— Front Attachment Pressure Valve Diode Sensor V41— Secondary Relief Solenoid B60— Attachment Pressure Valve Diode Sensor V42— Accumulator Solenoid B61— Arm Out Pressure Sensor Valve Diode F5— Optional and Attachment V43— 2-Speed Activation Connector 5 A Fuse (marked Solenoid Valve Diode OPT. 1 ALT) X31— Cab Harness-to-Main F60— Alternator 65 A Fuse Controller 31-Pin Connector A
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 X46— Attachment Connector Y40— Selector Valve Solenoid Valve
The main controller (MCZ) (A3) and monitor allow for the selection of up to six 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 setting 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 through 6) can be customized using MPDr, Service ADVISOR™, and the monitor. To customize options in the monitor, see Service Menu. (Group 9015-16.)
• Return oil flow selection • 2-speed selection • Accumulator selection
MPDr and Service ADVISOR™ can adjust:
• Attachment name • Attachment number • Pump flow • Engine speed • Secondary relief selection
Y41— Secondary Relief Solenoid Valve Y42— Accumulator Solenoid Valve Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve
The monitor can slightly adjust pump 2 flow rate or boom up, arm in, swing and travel priority over attachment flow depending on the options selected. To view the attachment specifications on the monitor, select an attachment from the work mode menu. The monitor will display:
• Attachment name (Thumb, Breaker, Crusher, Pulverizer, Grapple, Other)
• Attachment number (1, 2, 3, 4, or 5) • Pump flow • Engine speed • Secondary relief selection (ON or OFF) • Return oil flow selection (O/T or C/V) • 2-Speed selection (ON or OFF) • Accumulator selection (ON or OFF)
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-15-117
JJ03229,0000ED2 -19-24APR15-2/9
160GLC Excavator 042318 PN=743
Sub-System Diagnostics
Attachment Name—The available attachment names are as follows:
• Thumb 1 • Breaker 1—Hydraulic Breaker 1 (BR) • Breaker 2—Hydraulic Breaker 2 (BR) • Crusher 1—Primary Crusher 1 (CR) • Pulverizer 1—Secondary Crusher 1 (PU) • Grapple 1 • [Removal from monitor screen—(Non)] Crusher 1—Primary Crusher 1 (CR) is considered a heavier crusher than Pulverizer 1—Secondary Crusher 1 (PU). When Crusher 1—Primary Crusher is selected, more priority is given to boom, arm, swing, and travel functions over the attachment function in a combined arm out, boom up, swing, or travel function and attachment function. 5— ATT 4 (attachment 4) 6— Attachment Name 7— Attachment Number
TX1163067A —UN—12JUN14
1— Bucket Mode 2— ATT 1 (attachment 1) 3— ATT 2 (attachment 2) 4— ATT 3 (attachment 3)
Work Mode Screen Continued on next page
TM13345X19 (23APR18)
9015-15-118
JJ03229,0000ED2 -19-24APR15-3/9
160GLC Excavator 042318 PN=744
Sub-System Diagnostics
Attachment Number—Each attachment can be assigned a number from 1 through 5. 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).
TX1088891A —UN—01MAR11
8— ATT 1 Type (attachment 1)
Attachment Type Continued on next page
TM13345X19 (23APR18)
9015-15-119
JJ03229,0000ED2 -19-24APR15-4/9
160GLC Excavator 042318 PN=745
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.)
TX1088894A —UN—01MAR11
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
Attachment Adjustment—Pump Flow Rate 9— ATT 1 Pump 1 Maximum Flow Rate
using a flowmeter to accurately set pump flow. See Pump Flow Test. (Group 9025-25.) See Service Menu. (Group 9015-16.)
Continued on next page
TM13345X19 (23APR18)
9015-15-120
JJ03229,0000ED2 -19-24APR15-5/9
160GLC Excavator 042318 PN=746
Sub-System Diagnostics
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.
TX1088895A —UN—01MAR11
10— ATT 1 Engine Speed
ATT 1 Engine Speed Continued on next page
TM13345X19 (23APR18)
9015-15-121
JJ03229,0000ED2 -19-24APR15-6/9
160GLC Excavator 042318 PN=747
Sub-System Diagnostics
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 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).
Accumulator—The accumulator controls the accumulator solenoid valve (Y42). The accumulator solenoid valve is powered by the optional and attachment 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.
TX1088898A —UN—01MAR11
NOTE: Accumulator control will not work properly unless appropriate kits are installed on machine.
ATT 1 Selector Valve 12— ATT 1 Selector Valve Setting
The accumulator solenoid valve diode (V42) suppresses voltage spikes created when the solenoid valve is activated or deactivated. Continued on next page
TM13345X19 (23APR18)
9015-15-122
JJ03229,0000ED2 -19-24APR15-7/9
160GLC Excavator 042318 PN=748
Sub-System Diagnostics
NOTE: The 2-speed control will not work properly unless appropriate kits are installed on machine.
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, adjusting 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, allowing 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.)
TX1088899A —UN—01MAR11
2-Speed Selector and Auxiliary Flow Combiner Valve—The 2-speed selector icon on the monitor controls the 2-speed activation solenoid valve (Y43) and the flow rate adjustment solenoid valve (Y44). The 2-speed activation solenoid valve is powered by optional and attachment 5 A fuse (F5) and grounded by the main controller (MCZ) pin C3. The flow rate adjustment solenoid valve is powered by MCZ pin B11 and grounded by pin B12. 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, allowing for combined oil flow from pump 1 and pump 2 to operate the attachment.
ATT 1 Auxiliary Flow Combiner Valve 13— ATT 1 Auxiliary Flow Combiner Valve Setting
The 2-speed activation solenoid valve diode (V43) suppresses voltage spikes created when the solenoid valve is energized and de-energized.
Continued on next page
TM13345X19 (23APR18)
9015-15-123
JJ03229,0000ED2 -19-24APR15-8/9
160GLC Excavator 042318 PN=749
Sub-System Diagnostics
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 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.
TX1088896A —UN—01MAR11
11— ATT 1 Relief Valve Setting
ATT 1 Relief Valve JJ03229,0000ED2 -19-24APR15-9/9
TM13345X19 (23APR18)
9015-15-124
160GLC Excavator 042318 PN=750
Group 16
Monitor Operation Service Menu How to Display Service Menu 1. 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.
1. 2. 3. 4. 5. 6. 7. 8.
TX1086439A —UN—03JAN11
4. Rotate monitor dial and highlight service menu. Press monitor dial to access to the following systems: Troubleshooting Monitoring Controller Version Issued Warning Record Operation Machine Setting Monitor Setting Exhaust Filter No. Right Console Panel
5. Use the BACK button (3) to return to the service menu. 1— Key Pad 2— Key Switch 3— BACK Button
4— HOME Button 5— Monitor Dial
DF89619,00B5875 -19-21MAY14-1/1
• Main • Monitor • Information • Air Conditioner
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.
Press monitor dial to view the trouble codes for systems.
3. Rotate monitor dial to highlight the following systems:
4. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.)
• Engine
RH60123,00000D0 -19-15MAR11-1/1
TM13345X19 (23APR18)
9015-16-1
160GLC Excavator 042318 PN=751
Monitor Operation
Monitoring NOTE: Due to different controller versions, items listed in the monitoring section may not appear on or be in the same order as the monitor on the machine.
3. Rotate monitor dial to highlight a system in the monitoring selections:
• Engine • Main • Wiper/Light • Air Conditioner • Start • Clear (Hold)
1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight MONITORING. Press monitor dial to enter the monitoring menu.
4. Press the monitor dial to select the monitoring item to be viewed in the Start monitoring system.
List of Engine Monitoring Items Item
Unit
Data
Engine Torque
%
Input signal from engine control unit (ECU).
Actual Engine Speed
min-1
Input signal from crank speed sensor and cam angle sensor.
Fuel Pressure
kPa
Input signal from inlet fuel pressure sensor.
Engine Oil Pressure
kPa
Input signal from oil pressure sensor.
Coolant Temperature
°C
Input signal from coolant temperature sensor.
Fuel Temperature
°C
Input signal from fuel temperature sensor.
Boost Pressure
kPa
Input signal from intake manifold pressure sensor.
Boost Temperature
°C
Input signal from boost temperature sensor.
Battery Voltage
V
Input signal from engine control unit (ECU).
Engine Fan Speed
min-1
Input signal from fan speed sensor.
Urea Level
%
Input signal from diesel exhaust fluid (DEF) tank header assembly.
Urea Temperature
°C
Input signal from diesel exhaust fluid (DEF) tank header assembly.
Atmospheric Pressure
kPa
Input signal from intake air sensor.
Intake Air Temperature
°C
Input signal from intake air sensor.
Item
Unit
List of Main Controller Monitoring Items Data
-1
Demand Engine Speed
min
Actual Engine Speed
min-1
Input signal from engine control unit (ECU).
Engine Speed Deviation
min-1
Difference between actual engine speed and requested engine speed.
EC Dial
V
Input signal from engine control dial.
Hydraulic Oil Temperature
°C
Input signal from hydraulic oil temperature sensor.
Electric Lever Signal 1
V
Input signal from electric lever 1 (right).
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.
Tgt Pump 1 Displacement
cm3
Calculation signal from engine speed and input signal from pump 1 delivery pressure sensor.
Tgt Pump 2 Displacement
cm3
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.
Pump 1 Delivery Pressure
MPa
Input signal from pump 1 delivery pressure sensor.
Input signal from engine control dial.
Continued on next page
TM13345X19 (23APR18)
9015-16-2
JL58967,00001E9 -19-25JAN18-1/4
160GLC Excavator 042318 PN=752
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
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 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 (bucket roll in).
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).
Electric Lever Pilot Pressure 1
MPa
Control signal to solenoid valve for electric lever 1 (right).
Bucket Roll-Out Pilot Pressure
MPa
Input signal from pressure sensor (bucket roll-out).
ATT 1 Pilot Pressure
MPa
Input from pressure sensor (auxiliary 1).
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 arm regenerative solenoid.
Pressure Boost P/S Output
MPa
Control signal to power dig/travel speed solenoid.
Digging Regen P/S O/P
MPa
Control signal to dig regenerative solenoid.
OPT Cont 1 P/S (E/L) O/P
MPa
Control signal to solenoid valve 1 for electric lever.
OPT Cont 2 P/S (E/L) O/P
MPa
Control signal to solenoid valve 2 for electric lever.
Pump 1 Flw Limit P/S Output
MPa
Analog Output 14
MPa
Control signal to maximum pump 1 flow rate limit control solenoid. -
Analog Output 15
MPa
-
Analog Output 16
MPa
-
Auxil Flw Cont P/S Output
MPa
Control signal to auxiliary flow rate control solenoid valve.
ATT Relief 1 P/S Output
MPa
Control signal to auxiliary overload relief solenoid valve.
ATT Relief 2 P/S Output
MPa
Control signal to auxiliary overload relief solenoid valve.
Breaker Relief P/S Output
MPa
Control signal to breaker relief solenoid valve.
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 O/P FB
mA
Feedback from arm regenerative solenoid output.
Pressure Boost P/S Output FB
mA
Feedback from power dig/travel speed solenoid output.
Digging Regen P/S O/P FB
mA
Feedback from dig regenerative solenoid output.
OPT Cont 1 P/S (E/L) O/P FB
mA
Feedback from solenoid valve 1 for electric lever output.
OPT Cont 2 P/S (E/L) O/P FB
mA
Feedback from solenoid valve 2 for electric lever output. Continued on next page
TM13345X19 (23APR18)
9015-16-3
JL58967,00001E9 -19-25JAN18-2/4
160GLC Excavator 042318 PN=753
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
Pump 1 Flw Limit P/S O/P FB
mA
Analog Output FB 14
mA
Feedback from maximum pump 1 flow rate limit control solenoid valve output. -
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.
ATT Relief 1 P/S O/P FB
mA
Feedback from auxiliary overload relief solenoid valve output.
ATT Relief 2 P/S O/P FB
mA
Feedback from auxiliary overload relief solenoid valve output.
Breaker Relief P/S Output FB
mA
Digital Input 7
OFF/ON
Feedback from breaker relief solenoid valve output. -
Pilot Control Shut-Off Lever Switch
OFF/ON
Breaker Control Switch
OFF/ON
Pilot shutoff switch ON/OFF status. -
Power Boost Switch
OFF/ON
Power digging switch ON/OFF status.
Engine Oil Level Switch
OFF/ON
Engine oil level switch ON/OFF status.
Power Mode Switch
OFF/ON
Power mode switch operating status.
Travel Mode Switch
LO/HI
Travel mode switch selection status.
Auto-Idle Switch
OFF/ON
Digital Input 15
OFF/ON
Auto-idle switch ON/OFF status. -
Digital Input 14
OFF/ON
-
Digital Input 13
OFF/ON
-
Digital Input 12
OFF/ON
-
Digital Input 8
OFF/ON
-
Digital Input 23
OFF/ON
-
Digital Input 22
OFF/ON
-
Digital Input 21
OFF/ON
-
Digital Input 20
OFF/ON
-
Digital Input 19
OFF/ON
-
Digital Input 18
OFF/ON
-
Digital Input 17
OFF/ON
-
Line Filter Restriction Switch
OFF/ON
Digital Input 29
OFF/ON
Clogged line filter status. -
Digital Input 28
OFF/ON
-
Digital Input 27
OFF/ON
-
Digital Input 26
OFF/ON
-
Digital Input 25
OFF/ON
-
Digital Input 24
OFF/ON
-
Warning Buzzer
OFF/ON
-
Swing Alarm
OFF/ON
Swing alarm ON/OFF status.
Travel Alarm
OFF/ON
Travel alarm ON/OFF status.
Auto Shut-Down Relay
OFF/ON
Auto-shutdown relay ON/OFF status.
Selector Valve
OFF/ON
Selector valve ON/OFF status.
Auxiliary Flow Combiner Valve
OFF/ON
ON/OFF Valve Output 11
OFF/ON
Two-speed combined flow control valve ON/OFF status. -
ON/OFF Valve Output 10
OFF/ON
-
ON/OFF Valve Output 9
OFF/ON
-
Continued on next page
TM13345X19 (23APR18)
9015-16-4
JL58967,00001E9 -19-25JAN18-3/4
160GLC Excavator 042318 PN=754
Monitor Operation List of Wiper/Light Controller Monitoring Items Item
Unit
Data
Wiper 1 Input
V
Input signal from wiper switch.
Wiper 2 Input
V
Input signal from wiper switch.
Washer 1 Switch
OFF/ON
Washer 1 switch ON/OFF status.
Washer 2 Switch
OFF/ON
Washer 2 switch ON/OFF status.
Work Light 1 Switch
OFF/ON
Work light switch 1 ON/OFF status.
Work Light 2 Switch
OFF/ON
Work light switch 2 ON/OFF status.
Cab Light Switch
OFF/ON
Cab light switch ON/OFF status.
Wiper 1 Output
OFF/ON
Wiper relay ON/OFF status.
Wiper 2 Output
OFF/ON
Wiper relay ON/OFF status.
Washer 1 Output
OFF/ON
Washer relay ON/OFF status.
Washer 2 Output
OFF/ON
Washer relay ON/OFF status.
Work Light 1 Output
OFF/ON
Work light relay 1 ON/OFF status.
Work Light 2 Output
OFF/ON
Work light relay 2 ON/OFF status.
Cab Light 1 Output
OFF/ON
Cab light ON/OFF status.
Cab Light 2 Output
OFF/ON
Cab light ON/OFF status.
List of Air Conditioner Unit Monitoring Items Item
Unit
Data
Compressor Operation
OFF/ON
Compressor operating status.
Outdoor Air Temperature
°C
Input signal from ambient temperature sensor.
Indoor Air Temperature
°C
Input signal from air conditioner unit.
Amount of Insolation
W/m2
Input signal from solar radiation sensor.
5. Rotate monitor dial to highlight Start. Press the monitor dial to view the monitoring items that were selected.
7. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.)
6. Rotate monitor dial to highlight Clear (Hold). Press the monitor dial to delete the monitoring items that were selected. JL58967,00001E9 -19-25JAN18-4/4
Controller Version
3. The version of each controller will appear.
1. Access service menu. See Service Menu. (Group 9015-16.)
4. Use the BACK button to return to the 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. RH60123,00000D2 -19-15MAR11-1/1
Issued Warning Record 1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight issued warning record. Press monitor dial to enter the issued warning record menu.
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.)
3. The logo and trouble of 10 alarms that were issued recently will be displayed. See Main Menu—Alarm List. (Operator's Manual.) RH60123,00000D3 -19-15MAR11-1/1
TM13345X19 (23APR18)
9015-16-5
160GLC Excavator 042318 PN=755
Monitor Operation
Operation
3. The hour meters will be displayed.
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 Meter
hr.
Breaker Operation
hr.
Attachment Operation
hr.
Travel Operation
hr.
Actual Operation
hr.
4. Use the Back button to return to the Service Menu. See Service Menu. (Group 9015-16.) DF89619,00B5877 -19-10AUG16-1/1
TM13345X19 (23APR18)
9015-16-6
160GLC Excavator 042318 PN=756
Monitor Operation
Machine Setting NOTE: Due to different controller versions, items listed in the monitoring section may not appear on or be in the same order as the monitor on the machine. 1. Access service menu. See Service Menu. (Group 9015-16.)
2. Rotate monitor dial to highlight MACHINE SETTING. Press monitor dial to enter machine setting menu. 3. Rotate monitor dial to highlight a setting in the machine setting selections. Press monitor dial to change machine setting.
List of Machine Setting Items (Constant Change) Item
Unit
Data
Li Speed
min-1
Adjustment of slow idle speed.
Al Speed
-1
min
Adjustment of auto-idle engine speed.
Power Mode Memory Selection
0, 1
Setting of power mode with key switch on: 0: OFF (When power mode is H/P mode with the key switch OFF, PWR mode is selected when turning the key switch on. When power mode is ECO or PWR mode with the key switch OFF, ECO or PWR mode is kept when turning the key switch on.) 1: On (The power mode when turning the key switch OFF is kept.)
Heater Control Selection
0, 1
ON/OFF status of heater control: 0: OFF 1: ON
Work Mode Memory Selection
0, 1
ON/OFF status of attachment mode: 0: OFF 1: ON
Power Mode Selection
0—4
Setting of power mode selection: 0: ECO, PWR mode: Selected 1: ECO mode: Fixed 2: PWR mode: Fixed 3: ECO, PWR, H/P mode: Selected 4: H/P mode: Fixed
Auto Shut-Down Control
0—2
Setting of auto-shutdown control with the key switch ON: 0: OFF when starting 1: ON when starting 2: Previous setting is held
Auto Shut-Down Set Time Holding
0, 1
The time until starting shutdown control is held: 0: Settable 1: Unsettable
Air Conditioner Control Mode
0—10
Selection of air conditioner specification: 0: Unused (without an air conditioner) 1: STD Cab (middle) (with an air conditioner) 2: STD Cab (middle) (without an air conditioner) 3: STD Cab (large) (with an air conditioner) 4: STD Cab (large) (without an air conditioner) 5: US Cab (7 t class) (with an air conditioner) 6: US Cab (7 t class) (without an air conditioner) 7: US Cab (10 t class) (with an air conditioner) 8: US Cab (10 t class) (without an air conditioner) 9: US Cab (20 t class) (with an air conditioner) 10: US Cab (20 t class) (without an air conditioner)
ATT Speed Deceleration Waiting Time
ms
The time when the increased engine speed is held at attachment operation speed increased control.
Breaker Relief Hard Setting
0, 1
Selection of secondary pilot relief valve or breaker relief solenoid valve specification: 0: Fixed 1: Variable
Continued on next page
TM13345X19 (23APR18)
9015-16-7
DF89619,00B5878 -19-25JAN18-1/4
160GLC Excavator 042318 PN=757
Monitor Operation List of Machine Setting Items (Constant Change) Item
Unit
Data
ATT Relief Hard Setting
0, 1
Selection of auxiliary overload relief valve or auxiliary overload relief solenoid valve specification: 0: Fixed 1: Variable
Variable Relief Valve Check
0—4
Setting of auxiliary overload relief solenoid valve: 0: Usual use 1: Check of breaker relief hunting 2: Air bleeding from breaker relief 3: Check of auxiliary overload relief hunting 4: Air bleeding from auxiliary overload relief
List of Setting Item (Attachment Constant Change) Item
Unit
Data
ATT 1 Type
0—10
Types of attachments: 0: Unset 1: Breaker 2: Pulverizer 3: Crusher 4: Vibrating hammer 5: Others 6: Grapple 7: Clamshell 8: Thumb 9: Tilting rotator 10: Tilting bucket
ATT 1 No.
1—5
Selection of attachments setting: 1: 1 2: 2 3: 3 4: 4 5: 5
ATT 1 Pump 1 Maximum Flow Rate
L/min
Adjustment of maximum pump 1 flow rate when using attachment.
ATT 1 Pump 2 Maximum Flow Rate
L/min
Adjustment of maximum pump 2 flow rate when using attachment.
ATT 1 Engine Speed
min-1
Adjustment of engine speed when using attachment.
ATT 1 Relief Valve
0—2
Selection of breaker relief solenoid valve and auxiliary overload relief solenoid valve: 0: Both are disabled 1: ATT relief is enabled 2: Breaker relief is enabled
ATT 1 Selector Valve
0, 1
Selection of return circuit connection of selector valve: 0: C/V 1: O/T
ATT 1 Auxiliary Flow Combiner Valve
0, 1
Setting of auxiliary flow combiner valve selection: 0: OFF 1: ON
ATT 1 Breaker Relief Pressure
MPa
Adjustment of breaker relief solenoid valve.
ATT 1 ATT Relief Pressure
MPa
Adjustment of auxiliary overload relief solenoid valve.
List of Adjustment (Attachment Constant Change) ATT 1 Item
Unit
Initial Value
0—10
Minimum Adjustment -
Adjustable Range
ATT 1 Type
0—10
1
ATT 1 No.
1—5
-
1—5
1
ATT 1 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 1 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
Continued on next page
TM13345X19 (23APR18)
9015-16-8
DF89619,00B5878 -19-25JAN18-2/4
160GLC Excavator 042318 PN=758
Monitor Operation List of Adjustment (Attachment Constant Change) ATT 1 Item
Unit
Minimum Adjustment
Adjustable Range
ATT 1 Engine Speed
min-1
-500—100
0
ATT 1 Relief Valve
0—2
10 -
Initial Value
0—2
0
ATT 1 Selector Valve
0, 1
-
0, 1
1
ATT 1 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
0
ATT 1 Breaker Relief Pressure
MPa
0.5
2—36
21
ATT 1 ATT Relief Pressure
MPa
0.5
10—36
36
List of Adjustment (Attachment Constant Change) ATT 2 Item
Unit
Initial Value
0—10
Minimum Adjustment -
Adjustable Range
ATT 2 Type
0—10
1
ATT 2 No.
1—5
-
1—5
2
ATT 2 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 2 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 2 Engine Speed
min-1
0
0—2
10 -
-500—100
ATT 2 Relief Valve
0—2
0
ATT 2 Selector Valve
0, 1
-
0, 1
1
ATT 2 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
0
ATT 2 Breaker Relief Pressure
MPa
0.5
2—36
36
ATT 2 ATT Relief Pressure
MPa
0.5
10—36
36
List of Adjustment (Attachment Constant Change) ATT 3 Item
Unit
Initial Value
0—10
Minimum Adjustment -
Adjustable Range
ATT 3 Type
0—10
2
ATT 3 No.
1—5
-
1—5
1
ATT 3 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 3 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 3 Engine Speed
min-1
0
0—2
10 -
-500—100
ATT 3 Relief Valve
0—2
1
ATT 3 Selector Valve
0, 1
-
0, 1
0
ATT 3 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
1
ATT 3 Breaker Relief Pressure
MPa
0.5
2—36
36
ATT 3 ATT Relief Pressure
MPa
0.5
10—36
27.5
List of Adjustment (Attachment Constant Change) ATT 4 Item
Unit
Initial Value
0—10
Minimum Adjustment -
Adjustable Range
ATT 4 Type
0—10
3
ATT 4 No.
1—5
-
1—5
1
ATT 4 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 4 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 4 Engine Speed
min-1
-500—100
0
ATT 4 Relief Valve
0—2
10 -
0—2
1
Continued on next page
TM13345X19 (23APR18)
9015-16-9
DF89619,00B5878 -19-25JAN18-3/4
160GLC Excavator 042318 PN=759
Monitor Operation List of Adjustment (Attachment Constant Change) ATT 4 Item
Unit
Initial Value
0, 1
Minimum Adjustment -
Adjustable Range
ATT 4 Selector Valve
0, 1
0
ATT 4 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
1
ATT 4 Breaker Relief Pressure
MPa
0.5
2—36
36
ATT 4 ATT Relief Pressure
MPa
0.5
10—36
27.5
List of Adjustment (Attachment Constant Change) ATT 5 Item
Unit
ATT 5 Type
0—10
Minimum Adjustment -
Adjustable Range
Initial Value
0—10
ATT 5 No.
1—5
-
6
1—5
1
ATT 5 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 5 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 5 Engine Speed
min-1
0
0—2
10 -
-500—100
ATT 5 Relief Valve
0—2
1
ATT 5 Selector Valve
0, 1
-
0, 1
0
ATT 5 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
0
ATT 5 Breaker Relief Pressure
MPa
0.5
2 to 36
21
ATT 5 ATT Relief Pressure
MPa
0.5
10—36
27.5
List of Adjustment (Attachment Constant Change) ATT 6—11 Item
Unit
ATT 6—11 Type
0—10
Minimum Adjustment -
Adjustable Range
Initial Value
0—10
0
ATT 6—11 No.
1—5
-
1—5
0
ATT 6—11 Pump 1 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 6—11 Pump 2 Maximum Flow Rate
L/min
0.5
112—224
224
ATT 6—11 Engine Speed
min-1
0
0—2
10 -
-500—100
ATT 6—11 Relief Valve
0—2
1
ATT 6—11 Selector Valve
0, 1
-
0, 1
0
ATT 6—11 Auxiliary Flow Combiner Valve
0, 1
-
0, 1
0
ATT 6—11 Breaker Relief Pressure
MPa
0.5
2—36
36
ATT 6—11 ATT Relief Pressure
MPa
0.5
10—36
27.5 DF89619,00B5878 -19-25JAN18-4/4
TM13345X19 (23APR18)
9015-16-10
160GLC Excavator 042318 PN=760
Monitor Operation
Monitor Setting
3. Rotate monitor dial to highlight a setting in the monitor setting selections. Press monitor dial to change 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.
List of Monitor Setting Items Item
Unit
Startup Screen Image
2: John Deere
Details -
Initial Value
Startup Screen Control
0: Auto-control: OFF 1: Auto-control: ON
-
1
Counterweight Removal
0: Void 1: Exist
With or without function
0
Work Mode
0: Void 1: Exist
With or without function
1
Crane Function
0: Void 1: ML Crane 2: Overload Alarm 3: Grapple Load Meter
With or without function
0
Crane Switch Memory
0: Non-storable 1: Store
-
1
0: Void 1: Exist
With or without function
0
Setting Menu
0: Void 1: Exist
With or without function
1
Date and Time
0: Void 1: Exist
With or without function
1
Attachment Adjustment
0: Void 1: Exist
With or without function
1
Attachment Name Input
0: Void 1: Exist
With or without function
1
Breaker Alarm
0: Void 1: Exist
With or without function
1
Auto Shut-down
0: Void 1: Exist
With or without function
1
Auto-Lubrication
0: Void 1: Exist
With or without function
0
Sub Meter Selection
0: Void 1: Exist
With or without function
1
Fuel Consumption Indicator
0: Void 1: Exist
With or without function
1
Breaker Hour Meter
0: Void 1: Exist
With or without function
1
Rear View Camera Monitor
0: Void 1: Exist
With or without function
1
Display Item Selection
0: Void 1: Exist
With or without function
1
Brightness Adjustment
0: Void 1: Exist
With or without function
1
Language
0: Void 1: Exist
With or without function
1
Unit Selection
0: Void 1: Exist
With or without function
1
Main Menu Sequence Change
0: Void 1: Exist
With or without function
1
Information Menu
0: Void 1: Exist
With or without function
1
Operation
0: Void 1: Exist
With or without function
1
Maintenance
0: Void 1: Exist
With or without function
1
Continued on next page
TM13345X19 (23APR18)
9015-16-11
2
JL58967,00001EB -19-25MAR15-1/2
160GLC Excavator 042318 PN=761
Monitor Operation List of Monitor Setting Items Item
Unit
Details -
Initial Value
Operation Permission
0: Inhibited 1: Permission
Engine Oil
0: Un-displayed 1: Permission
Display
1
Engine Oil Filter
0: Un-displayed 1: Permission
Display
1
Hydraulic Oil
0: Un-displayed 1: Permission
Display
1
Pilot Hydraulic Oil Filter
0: Un-displayed 1: Permission
Display
1
Hydraulic Oil Full-Flow Filter
0: Un-displayed 1: Permission
Display
1
Pump Transmission Oil
0: Un-displayed 1: Permission
Display
1
Travel Reduction Gear Oil
0: Un-displayed 1: Permission
Display
1
Swing Reduction Gear Oil
0: Un-displayed 1: Permission
Display
1
Swing Drain Filter
0: Un-displayed 1: Permission
Display
0
Swing Bearing Grease
0: Un-displayed 1: Permission
Display
1
Air Cleaner Element
0: Un-displayed 1: Permission
Display
1
Fuel Filter
0: Un-displayed 1: Permission
Display
1
Air Conditioner Filter
0: Un-displayed 1: Permission
Display
1
Line Filter
0: Un-displayed 1: Permission
Display
0
Water Separator Filter
0: Un-displayed 1: Permission
Display
0
User Setting 1
0: Un-displayed 1: Permission
Display
1
User Setting 2
0: Un-displayed 1: Permission
Display
1
Troubleshooting
0: Void 1: Exist
With or without function
1
Monitoring
0: Void 1: Exist
With or without function
1
1
4. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.) JL58967,00001EB -19-25MAR15-2/2
TM13345X19 (23APR18)
9015-16-12
160GLC Excavator 042318 PN=762
Monitor Operation
Alarm Setting
Breaker Alarm ON, OFF, or Change Time
Enable or Disable Breaker Alarm The breaker alarm becomes active to alert operator of continuous auxiliary hydraulic operation. When the alarm becomes active, pump displacement is set to minimum, causing the auxiliary hydraulic (breaker) to slow or stop functioning to prevent hydraulic oil overheating.
1. Turn breaker alarm ON, OFF, or change time in machine settings. a. Access service menu. See Service Menu. (Group 9015-16.) b. Navigate through menu: Setting Menu >> Breaker Alarm.
The breaker alarm set time can be increased, decreased, or disabled completely if desired. 1. Enable or disable breaker alarm function in monitor settings.
c. Select ON to turn on alarm. NOTE: Alarm must NOT be enabled to change time. d. Deselect ON to turn off alarm.
a. Access service menu. See Service Menu. (Group 9015-16.)
e. Select Time Setting and rotate dial to time settings: 15 s, 30 s, 45 s, or 60 s.
b. Navigate through menu: Service Menu >> Monitor Setting >> Breaker Alarm. c. Select 0 to disable or select 1 to enable. 2. Turn key switch to OFF and wait for battery relay to “click”.
f. Select ON to turn on alarm. 2. Turn key switch to OFF and wait for battery relay to “click”. 3. Turn key switch to ON.
3. Turn key switch to ON. BE78919,0000788 -19-06FEB18-1/1
Exhaust Filter No. 1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight exhaust filter. Press monitor dial to enter the exhaust filter menu.
3. The manufacture number of the exhaust filter will be displayed. 4. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.) DF89619,00B587A -19-21MAY14-1/1
TM13345X19 (23APR18)
9015-16-13
160GLC Excavator 042318 PN=763
Monitor Operation
TM13345X19 (23APR18)
9015-16-14
160GLC Excavator 042318 PN=764
Group 20
References • Information (00) • Air Conditioner (00)
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.
4. Press monitor dial to view the trouble codes present for the highlighted system. For more information on the displayed DTCs see:
• See Main Controller (MCZ) Diagnostic Trouble Codes. (Group 9001-10.)
NOTE: The monitor can display up to 20 diagnostic trouble codes for each controller.
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
• See Monitor Controller (DSZ) Diagnostic Trouble
3. 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:
Codes. (Group 9001-30.)
• See Information Controller (ICZ) Diagnostic Trouble Codes. (Group 9001-40.)
• See Air Conditioner Controller (ACF) Diagnostic Trouble Codes. (Group 9001-50.)
• Engine (00) • Main (00) • Monitor (00)
5. Use the BACK button to return to the troubleshooting screen and select another system. MM16284,0001E05 -19-30MAR15-1/1
Service ADVISOR™ Diagnostic Application The Service ADVISOR™ application is what technicians use to diagnose and troubleshoot equipment. The application allows technicians to quickly and easily find information and solve equipment problems. The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program controllers, when possible. The Connection-Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program controllers. With a connection established, the Readings menu allows a
technician to add or remove a reading, set a readings baseline, and create and check recording triggers. With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code often are in a procedural format with links so the technician can work to correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code details. See Service ADVISOR™ Connection Procedure. (Group 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
Service ADVISOR is a trademark of Deere & Company DJ54098,000006F -19-19JUN14-1/1
TM13345X19 (23APR18)
9015-20-1
160GLC Excavator 042318 PN=765
References
Service ADVISOR™ Connection Procedure 1. Park machine and prepare for service. 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. Remove fuse box cover. TX1161769A —UN—30MAY14
4. Remove cap from diagnostic connector (1). 5. Connect service laptop to machine using appropriate cables (3 and 5). Methods for connection include:
• Electronic Data Link (EDL) Stand-Alone USB Device • EDL Using Bluetooth® • Parallel Data Module (PDM) • PDM with USB Adaptor 6. Make sure power indicator light displays on EDL or PDM, depending on connection method. If power indicator light does not display, check fuse to diagnostic connector. 7. Turn machine key switch to ON position.
Service ADVISOR™ Machine Connection 1— Diagnostic Connector 2— Service Laptop 3— PDM-to-Service Laptop Cable
4— PDM 5— PDM-to-Machine Cable
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.) Bluetooth is a trademark of Bluetooth SIG Service ADVISOR is a trademark of Deere & Company JS20420,0000D9C -19-30MAY14-1/1
TM13345X19 (23APR18)
9015-20-2
160GLC Excavator 042318 PN=766
References
TX1002938A —UN—26JAN06
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
Service ADVISOR™—Diagnostic Trouble Codes 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.)
4. From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).
2. Connect service laptop to machine. See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
5. Click the Connected Diagnostic Trouble Codes folder (2).
3. Open Service ADVISOR™ and display appropriate model information. Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9015-20-3
JS20420,0000DA0 -19-30MAY14-1/3
160GLC Excavator 042318 PN=767
References
TX1002997A —UN—26JAN06
6. Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.
Connection Options Dialog Box Continued on next page
TM13345X19 (23APR18)
9015-20-4
JS20420,0000DA0 -19-30MAY14-2/3
160GLC Excavator 042318 PN=768
TX1003001A —UN—26JAN06
References
Select Readings Adapter Dialog Box 5— Available Adaptors Drop-Down List
6— Selected Models List
7— Change Selected Models Button
7. 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:
11. Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for servicing that diagnostic trouble code.
• Electronic Data Link (EDL) Stand-alone USB Device • Electronic Data Link (EDL) Using Bluetooth® • Parallel Data Module (PDM) • Parallel Data Module (PDM) With USB Adapter
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.
8. Make sure to select the correct machine to connect to, shown in the Selected Models list (6) display list. If not, click the Change Selected Models button (7). 9. Click OK to connect to machine.
12. Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.
10. After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab (4) display. Bluetooth is a trademark of Bluetooth SIG JS20420,0000DA0 -19-30MAY14-3/3
MPDr Application MPDr is an application that helps technicians diagnose and troubleshoot machines. MPDr provides access to machine diagnostic trouble codes, their descriptions and limited troubleshooting procedures. MPDr can also display and record live readings for the different controllers on the machine. Special functions in certain controllers may
also be manipulated with MPDr. The special functions available to manipulate vary by controller and by machine model. MPDr is also used to set up some controllers after a controller has been replaced or after other work has been performed on the machine regarding a controller. For more information, see MPDr Operation Manual. DP09616,000057A -19-15MAY14-1/1
TM13345X19 (23APR18)
9015-20-5
160GLC Excavator 042318 PN=769
References
MPDr Connection Procedure 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9001-01.) 2. Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated. 3. Remove fuse box cover (1).
TX1090365A —UN—05APR11
1— Cover
Fuse Box Cover MM16284,0001791 -19-10MAY12-1/2
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. TX1090366A —UN—05APR11
4. 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. 5. Turn machine key switch to the ON position. 6. Refer to the MPDr Operation Manual to complete connection procedure. 2— MPDr Connector 3— Service Laptop 4— TH3100010 MPDr Cable
5— 4668565 RS232C Cable 6— USB-to-Serial Adapter Cable
MPDr Connection Procedure (USB-to-serial adapter cable shown)
MM16284,0001791 -19-10MAY12-2/2
TM13345X19 (23APR18)
9015-20-6
160GLC Excavator 042318 PN=770
References
Controller Area Network (CAN) Circuit Test Controller Area Network (CAN) Theory of Operation (S.N. —056599) TX1239515 —UN—31MAY17
X52B AIR CONDITIONER 10-PIN CONNECTOR
4
BLU
12
CAN 1
10
BLU
GRN
A6 RADIO
4
9
GRN
GRN
+
GRN
A
YEL
BLU CAN 1
20
W5 ENGINE INTERFACE HARNESS
B1
BLU
B11
CAN 1
INTERFACE CAN
-
A11 MACHINE CONTROLLER (BCZ)
GRN
B
W53 EXHAUST AFTERTREATMENT HARNESS
R11 INTERFACE CAN RESISTOR 2
B = X11
C12
GRN
GRN
D4
BLU
D5
CAN 1
CAN 1
GRN
A3 MAIN CONTROLLER D2 (MCZ)
BLU
D3
BLU
1
A23 -
CAN 0
BLU
A25
120
A26
YEL
A1
GRN
B1
A13
BLK/RED
1
A4 A28 MONITOR CONTROLLER (DSZ)
RED/GRN
2
A15 FLEX POWER CONTROLLER (FPC)
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
X2 MPDr 6-PIN CONNECTOR
YEL
35
GRN
44 -
A = X20 +
-
INTERFACE CAN
-
2
GRN
1
YEL
YEL
H1
CAN 0
BLU
BLU
K
GRN
LT GRN
H2
GRN
E15
GRN
GRN
P
YEL
YEL
G1
BLU
E16
BLU
BLU
R
GRN
LT GRN
G2
INTERFACE CAN
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
8
GRN
GRN
W4 ENGINE HARNESS
B
B5500 INTAKE 4 AIR SENSOR 3
YEL GRN
= X5501 = X5502 = X5503
INTERFACE CAN
YEL
A
= X6014 GRN
B
-
W5 ENGINE INTERFACE HARNESS
YEL
1
YEL
YEL
GRN
2
GRN
GRN
A
ENGINE CAN
CAN 0
J
E9
X3 CAB HARNESS-TO-MACHINE HARNESS 100-PIN CONNECTOR
R10 INTERFACE CAN RESISTOR 1
YEL
120
A
46
CAN 0
BLU
INTERFACE CAN
BLU
GRN
+
+ 120
GRN
GRN
A
R5601 CAN 0 TERMINATION RESISTOR
X5016 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 2
B
-
GRN
GRN CAN 0
B
YEL
120
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR E3
YEL
+
X5018 MACHINE HARNESS-TO-ENGINE INTERFACE HARNESS CONNECTOR 2 GRN
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
9
CAN 0
INTERFACE CAN
INTERFACE CAN
BLU
W2 MACHINE HARNESS CAN 0
J
GRN
-
GRN
GRN
YEL
A1 ENGINE CONTROL UNIT (ECU)
120
H
45
YEL CAN 0
BLU
8
AFTERTREATMENT CAN
120
+
GRN CAN 1
C2
GRN
D
GRN
B5502 SELECTIVE CATALYTIC 5 REDUCTION (SCR) INLET NOx SENSOR 6
-
BLU
GRN
+
A5 DATA CONVERTER
C
YEL
120
A24
120
GRN CAN 0
D2
CAN 0
D = X34
+
BLU
YEL INTERFACE CAN
CAN 0
INTERFACE CAN C6
YEL
B5503 5 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
+
BLU
9
6
ENGINE CAN
GRN
2
CAN 1 C11
YEL
X5070
GRN
C5
GRN
AFTERTREATMENT CAN
X42 CAN 1 CONNECTOR (NOT USED)
YEL
W62 DIESEL PARTICULATE FILTER (DPF) HARNESS
-
GRN
120
A7 AIR CONDITIONER CONTROLLER (ACF)
120
5
W1 CAB HARNESS
+
BLU
40
X52A AIR CONDITIONER 10-PIN CONNECTOR
W51 HEATER AND AIR CONDITIONER RELAY HARNESS
AFTERTREATMENT CAN
W41 HEATER AND AIR CONDITIONER HARNESS
R5603 ENGINE CAN TERMINATION RESISTOR
TX1239515 Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. —056599)
Continued on next page
TM13345X19 (23APR18)
9015-20-7
160GLC Excavator 042318 PN=771
MB00333,0000384 -19-06FEB18-1/12
References
TM13345X19 (23APR18)
9015-20-8
160GLC Excavator 042318 PN=772
References
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) A15— Flex Power Controller (FPC) A6000—Modular Telematics Gateway (MTG) Controller B5500—Intake Air Sensor B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X2— MPDr 6-Pin Connector X5039—Engine Interface R5601—CAN 0 Termination X3— Cab Harness-to-Machine Harness-to-Exhaust Resistor Harness 100-Pin Connector Aftertreatment Harness R5603—Engine CAN Termination X11— Machine Controller 20-Pin Connector Resistor Connector B X5070—Exhaust Aftertreatment R5605—Aftertreatment CAN X20— Monitor Controller 28-Pin Harness-to-Diesel Termination Resistor Connector A Particulate Filter (DPF) W1—Cab Harness X34— Cab Harness-to-Main Harness Connector W2—Machine Harness Controller 30-Pin X5501—Engine Control Unit W4—Engine Harness Connector D (ECU) Connector 1 W5—Engine Interface Harness X42— CAN 1 Connector (not X5502—Engine Control Unit W41—Heater and Air Conditioner used) (ECU) Connector 2 Harness X52A— Air Conditioner 10-Pin X5503—Engine Control Unit W51—Heater and Air Conditioner Connector (ECU) Connector 3 Relay Harness X52B— Air Conditioner 10-Pin X6014—Modular Telematics W53—Exhaust Aftertreatment Connector Gateway (MTG) Control Harness X5016—Engine Interface Unit 48-Pin Connector W62—Diesel Particulate Filter Harness-to-Engine (DPF) Harness Harness Connector 2 X1— Service ADVISOR™ X5018—Machine Harness-toDiagnostic Connector Engine Interface Harness Connector 2 Continued on next page
TM13345X19 (23APR18)
9015-20-9
MB00333,0000384 -19-06FEB18-2/12
160GLC Excavator 042318 PN=773
References
TM13345X19 (23APR18)
9015-20-10
160GLC Excavator 042318 PN=774
References
Controller Area Network (CAN) Circuit Theory of Operation (S.N. 056600— ) TX1239516 —UN—31MAY17
W1 CAB HARNESS
GRN
4
CAN 1 BLU
5
BLU
10
BLU
20
GRN
4
GRN
9
GRN
A
YEL CAN 1 B1
BLU
B11
CAN 1
INTERFACE CAN
-
A11 MACHINE CONTROLLER (BCZ)
GRN
B
R11 INTERFACE CAN RESISTOR 2
W54 DIESEL EXHAUST FLUID (DEF) HARNESS
-
GRN
+ 120
A7 AIR CONDITIONER CONTROLLER (ACF)
120
BLU
A6 RADIO
+
40
12
W5 ENGINE INTERFACE HARNESS
B = X11
28
29
AFTERTREATMENT CAN AFTERTREATMENT CAN
30
YEL
3
GRN
2
W53 EXHAUST AFTERTREATMENT HARNESS
31
YEL
YEL
GRN
8
GRN
GRN
GRN
CAN 0 D = X34
GRN
A24
BLU
A23
BLK/RED
1
A4 A28 MONITOR CONTROLLER (DSZ)
RED/GRN
2
INTERFACE CAN
E3
GRN
GRN
J
YEL
CAN 0 B
GRN
45
H1
E9
BLU
BLU
K
GRN
LT GRN
H2
GRN
E15
GRN
GRN
P
YEL
YEL
G1
BLU
E16
BLU
BLU
R
GRN
LT GRN
G2
YEL
2
GRN
1
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
8
GRN
GRN
W4 ENGINE HARNESS
INTERFACE CAN
YEL
A
= X6014 GRN
W5 ENGINE INTERFACE HARNESS
YEL GRN
B
B5500 INTAKE 4 AIR SENSOR 3
= X5501 = X5502 = X5503
YEL
1
YEL
YEL
GRN
2
GRN
GRN
A
ENGINE CAN
B
-
X3 CAB HARNESS-TO-MACHINE HARNESS 100-PIN CONNECTOR
R10 INTERFACE CAN RESISTOR 1
YEL CAN 0
INTERFACE CAN
46
CAN 0
BLU
INTERFACE CAN
GRN
120
A
44
+
INTERFACE CAN BLU
GRN
A
R5601 CAN 0 TERMINATION RESISTOR
X5016 ENGINE INTERFACE HARNESS-TO-ENGINE HARNESS CONNECTOR 2
B
-
GRN
YEL
120
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
YEL
+
X5018 MACHINE HARNESS-TO-ENGINE INTERFACE HARNESS CONNECTOR 2
9
A1 ENGINE CONTROL UNIT (ECU)
CAN 0
BLU
YEL
CAN 0
J
W2 MACHINE HARNESS
INTERFACE CAN
GRN
GRN
A = X20
CAN 0
H
35
-
BLU
YEL
120
D
R5605 AFTERTREATMENT CAN TERMINATION RESISTOR
AFTERTREATMENT CAN
- +
CAN 0
A13
X2 MPDr 6-PIN CONNECTOR
YEL CAN 0
-
B1
GRN
C
+ 120
GRN
120
A25
-
BLU
120
A26
A1
X5039 ENGINE INTERFACE HARNESS-TO-EXHAUST AFTERTREATMENT HARNESS CONNECTOR
+
- +
GRN CAN 1
YEL
A15 FLEX POWER CONTROLLER (FPC)
-
CAN 0
A5 DATA CONVERTER
120
BLU
C6
C2
120
+
INTERFACE CAN
GRN
GRN
D3
D2
AFTERTREATMENT CAN
C12
BLU
YEL INTERFACE CAN
B5502 SELECTIVE CATALYTIC 5 REDUCTION (SCR) INLET NOx SENSOR 6
+
BLU
GRN
A3 MAIN CONTROLLER D2 (MCZ)
B5503 SELECTIVE CATALYTIC REDUCTION (SCR) OUTLET NOx SENSOR
ENGINE CAN
CAN 1 C11
D5
5
9
AFTERTREATMENT CAN
GRN
C5
BLU
CAN 1
CAN 1
GRN
X5070 YEL
BLU
D4
GRN
1
GRN
YEL
GRN
AFTERTREATMENT CAN
2
6
YEL
X5037 X42 CAN 1 CONNECTOR (NOT USED)
YEL
W62 DIESEL PARTICULATE FILTER (DPF) HARNESS
A5507B DIESEL EXHAUST FLUID (DEF) TANK HEADER B
GRN
X52A AIR CONDITIONER 10-PIN CONNECTOR
YEL
W51 HEATER AND AIR CONDITIONER RELAY HARNESS
GRN
X52B AIR CONDITIONER 10-PIN CONNECTOR
YEL
W41 HEATER AND AIR CONDITIONER HARNESS
R5603 ENGINE CAN TERMINATION RESISTOR
TX1239516 Controller Area Network (CAN) Circuit Theory of Operation Schematic (S.N. 056600— )
Continued on next page
TM13345X19 (23APR18)
9015-20-11
160GLC Excavator 042318 PN=775
MB00333,0000384 -19-06FEB18-3/12
References
TM13345X19 (23APR18)
9015-20-12
160GLC Excavator 042318 PN=776
References
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) A15— Flex Power Controller (FPC) A5507B—Diesel Exhaust Fluid (DEF) Tank Header B A6000—Modular Telematics Gateway (MTG) Controller B5500—Intake Air Sensor B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor B5503—Selective Catalytic Reduction (SCR) Outlet NOx Sensor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X2— MPDr 6-Pin Connector X5039—Engine Interface R5601—CAN 0 Termination X3— Cab Harness-to-Machine Harness-to-Exhaust Resistor Harness 100-Pin Connector Aftertreatment Harness R5603—Engine CAN Termination X11— Machine Controller 20-Pin Connector Resistor Connector B X5070—Exhaust Aftertreatment R5605—Aftertreatment CAN X20— Monitor Controller 28-Pin Harness-to-Diesel Termination Resistor Connector A Particulate Filter (DPF) W1—Cab Harness X34— Cab Harness-to-Main Harness Connector W2—Machine Harness Controller 30-Pin X5501—Engine Control Unit W4—Engine Harness Connector D (ECU) Connector 1 W5—Engine Interface Harness X42— CAN 1 Connector (not X5502—Engine Control Unit W41—Heater and Air Conditioner used) (ECU) Connector 2 Harness X52A— Air Conditioner 10-Pin X5503—Engine Control Unit W51—Heater and Air Conditioner Connector (ECU) Connector 3 Relay Harness X52B— Air Conditioner 10-Pin X6014—Modular Telematics W53—Exhaust Aftertreatment Connector Gateway (MTG) Control Harness X5016—Engine Interface Unit 48-Pin Connector W54—Diesel Exhaust Fluid (DEF) Harness-to-Engine Harness Harness Connector 2 W62—Diesel Particulate Filter X5018—Machine Harness-to(DPF) Harness Engine Interface Harness X1— Service ADVISOR™ Connector 2 Diagnostic Connector X5037—Engine Interface Harness-to-Diesel Exhaust Fluid (DEF) Harness Connector 1 MB00333,0000384 -19-06FEB18-4/12
8 3 7
1
2
6 4
TX1110187 —UN—15MAR12
5
TX1110187 Generic CAN Circuit Schematic 1— Controller 1 2— Controller 2 3— Service ADVISOR™ Connector
4— Termination Resistor 1 5— Termination Resistor 2
6— CAN High Wire (yellow) 7— CAN Low Wire (green)
8— Grounded Shield Wire (black)
For additional information, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
9015-20-13
MB00333,0000384 -19-06FEB18-5/12
160GLC Excavator 042318 PN=777
References Controller Area Network (CAN) Diagnostics MB00333,0000384 -19-06FEB18-6/12
• 1
System Check
Key switch in ON position.
Locate Service ADVISOR™ connector and establish machine connection. See Service YES: Go to next step in this ADVISOR™ Connection Procedure. (Group 9015-15.) check. Does Service ADVISOR™ establish a connection?
NO: Go to Service ADVISOR™ Fuse Test.
Do all controllers show up under connected controllers?
YES: Go to CAN Circuit Resistance Check. NO: Go to next step in this check.
Is Service ADVISOR™ able to connect to any machine controllers?
YES: Go to Controller Fuse Check. NO: Go to CAN Circuit Resistance Check.
Service ADVISOR is a trademark of Deere & Company MB00333,0000384 -19-06FEB18-7/12
• 2
Service ADVISOR™ Fuse Test
Check Service ADVISOR™ diagnostic connector fuse and check for continuity. See Fuse and Relay Specifications. (Group 9015-10.)
YES: Go to next step in this check.
Is continuity indicated?
NO: Replace Service ADVISOR™ diagnostic connector fuse.
Measure machine voltage between pin A and pin B of Service ADVISOR™ diagnostic connector (X1). Is machine voltage present?
YES: Go to CAN Circuit Resistance Check. NO: Repair or replace harness as necessary. Continued on next page
TM13345X19 (23APR18)
9015-20-14
MB00333,0000384 -19-06FEB18-8/12
160GLC Excavator 042318 PN=778
References
• 3
CAN Circuit Resistance Check
Key switch in OFF position.
Using schematics included with this test, locate CAN wires and disconnect appropriate connector. Measure resistance between CAN high and CAN low wires.
YES: Go to CAN Wire Voltage Check.
Is resistance between 55—65 ohms?
NO: Go to next step in this check.
Is resistance between 110—130 ohms?
YES: An open circuit exists in one of the CAN wires. Work from controller back to harnesses, checking CAN high and low wires for open circuit. Go to CAN Resistor Check. NO: A short circuit exists on CAN high or CAN low wire. Disconnect one controller at a time to locate short circuit. Repair or replace harness or controller as necessary. MB00333,0000384 -19-06FEB18-9/12
• 4
CAN Resistor Check
Key switch in OFF position.
Disconnect the following resistors:
• Cab harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.) - Interface CAN resistor 1 (R10).
• Engine interface harness (W5). See Engine Interface Harness (W5) Component Location. (Group 9015-10.) - Interface CAN resistor 2 (R11). - CAN 0 termination resistor (R5601).
• Front engine harness (W7). See Front Engine Harness (W7) Component Location. (Group 9015-10.) - Engine CAN termination resistor (R5603).
• Diesel particulate filter (DPF) harness (W62). See Diesel Particulate Filter (DPF) Harness (W62) Component Location. (Group 9015-10.) - Aftertreatment CAN termination resistor (R5605).
Measure the resistance of each resistor.
YES: Go to CAN Wire Voltage Check.
Is the resistance of each resistor between 110—130 ohms? Continued on next page
TM13345X19 (23APR18)
9015-20-15
NO: Replace resistor. MB00333,0000384 -19-06FEB18-10/12
160GLC Excavator 042318 PN=779
References
• 5
CAN Wire Voltage Check
IMPORTANT: Avoid controller damage. Controllers maybe damaged if key switch is in the ON position when connecting and disconnecting controllers. Turn the key switch to the OFF position when disconnecting and connecting controllers. IMPORTANT: Avoid connector and connector terminal damage. Inserting test leads into harness connectors without using spare mating terminal or JDG10466 Flex Probe Kit can damage harness. Key switch in ON position. Measure voltage between each CAN circuit and machine ground.
YES: Checks complete.
Is voltage between 1.50—3.50 volts?
NO: Disconnect one controller at a time and check voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary. MB00333,0000384 -19-06FEB18-11/12
• 6
Controller Fuse Check Remove fuses for missing controllers. Check fuses for continuity.
Is continuity indicated in all fuses?
YES: Go to CAN Circuit Resistance Check. NO: Replace fuses that did not indicate continuity. MB00333,0000384 -19-06FEB18-12/12
TM13345X19 (23APR18)
9015-20-16
160GLC Excavator 042318 PN=780
References
Electrical Component Specifications 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 monitor or check for diagnostic trouble codes (DTCs). Item
NOTE: For more information on engine electrical components, see engine related component technical manual (CTM).
Measurement
Specification
B18—Fuel Level Sensor
Resistance
6—10 ohms @ 100% Fill (full) 26 ohms @ 75% Fill 33—43 ohms @ 50% Fill 53 ohms @ 25% Fill 82—88 ohms @ Low Fuel Alarm 90—100 ohms @ 0% Fill (empty)
B22—Ambient Air Temperature Sensor
Resistance
9.9 kilo-ohms @ 0°C (32°F) 1.6 kilo-ohms @ 40°C (104°F)
B30—Boom Up Pressure Sensor (marked PI1)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B31—Arm In Pressure Sensor (marked PI2)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B32—Front Attachment Pressure Sensor (marked FRT)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B33—Swing Pressure Sensor (marked S3)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B34—Travel Pressure Sensor (marked TR)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B36—Pump 1 Control Pressure Sensor (marked PC1)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B38—Pump 2 Control Pressure Sensor (marked PC2)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B40—Hydraulic Oil Temperature Sensor
Resistance
13.8—16.3 kilo-ohms @ -20°C (-4°F) 5.7 kilo-ohms @ 0°C (32°F) 2.3—2.6 kilo-ohms @ 20°C (68°F) 1.2 kilo-ohms @ 40°C (104°F) 584 ohms @ 60°C (140°F) 310—326 ohms @ 80°C (176°F)
B55—Air Recirculation Sensor
Resistance
9.9 kilo-ohms @ 0°C (32°F) 1.6 kilo-ohms @ 40°C (104°F)
B56—Bucket Curl Pressure Sensor Resistance (marked BKC)
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B57—Bucket Dump Pressure Sensor
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B60—Attachment Pressure Sensor Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B61—Arm Out Pressure Sensor (marked AMD)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
Resistance
5—15 kilo-ohms (Pins 1—2) 30—50 kilo-ohms (Pins 2—3)
Sensor Specifications
Continued on next page
TM13345X19 (23APR18)
9015-20-17
MM16284,0001E6D -19-10APR18-1/3
160GLC Excavator 042318 PN=781
References Item
Measurement
Specification
Resistance
209—231 kilo-ohms
R10—Interface CAN Resistor 1
Resistance
110—130 ohms
R11—Interface CAN Resistor 2
Resistance
110—130 ohms
R5601—CAN 0 Termination Resistor
Resistance
110—130 ohms
R5603—Engine CAN Termination Resistor
Resistance
110—130 ohms
R5605—Aftertreatment CAN Termination Resistor
Resistance
110—130 ohms
Y10—Pilot Shutoff Solenoid
Resistance
42—58 ohms
Y11—Air Conditioner Compressor Clutch
Resistance
12.6—15.4 ohms
Y40—Selector Valve Solenoid Valve
Resistance
44—54 ohms
Y41—Secondary Relief Solenoid Valve
Resistance
17.5—21.5 ohms
Y43—2-Speed Activation Solenoid Valve
Resistance
17.5—21.5 ohms
Y66—Secondary Pilot Shutoff Solenoid (marked PiC)
Resistance
54.5—64.5 ohms
Y5015—Reversing Fan Solenoid
Resistance
37.5—45.8 ohms
Y5019—Coolant Control Valve Proportional Solenoid Specifications
Resistance
46 ohms
Y20—Pump 2 Flow Rate Limit Solenoid (marked SB)
Resistance
20—24 ohms
Y21—Torque Control Solenoid (marked ST)
Resistance
20—24 ohms
Y22—Dig Regenerative Solenoid (marked SF)
Resistance
20—24 ohms
Y23—Arm Regenerative Solenoid (marked SC)
Resistance
20—24 ohms
Y24—Power Dig/Travel Speed Solenoid (marked SG)
Resistance
20—24 ohms
Y26—Pump 1 Flow Rate Limit Solenoid (marked SA))
Resistance
20—24 ohms
Y44—Flow Rate Adjustment Solenoid Valve (if equipped)
Resistance
17.5—21.5 ohms
Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A)
Resistance
20—24 ohms
B5600—Water-in-Fuel (WIF) Sensor Resistor Specifications
ON/OFF Solenoid Specifications
Continued on next page
TM13345X19 (23APR18)
9015-20-18
MM16284,0001E6D -19-10APR18-2/3
160GLC Excavator 042318 PN=782
References Item
Measurement
Specification
Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B)
Resistance
20—24 ohms
Y5014—Variable Speed Fan Solenoid
Resistance
37.5—45.8 ohms MM16284,0001E6D -19-10APR18-3/3
TM13345X19 (23APR18)
9015-20-19
160GLC Excavator 042318 PN=783
References
Alternator Test 5 3
7
6
8
4 10
9
12 15 G 1 -
11
13 U
TX1045884 —UN—23JUL08
+
16 14 2
TX1045884 Common Alternator Circuit 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)
assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
12 V System 1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater1.
24 V System
2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater1.
1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater2.
3. If voltage from previous steps is below 13.5 VDC1, 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).
2. With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater2.
4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC. 5. Repeat above steps with lights on to load the alternator. 6. If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator
3. If voltage from previous steps is below 27.5 VDC2, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC or greater, check for an open diode, wiring problem, or blown fuse in the alternator excitation circuit (wire to D+ terminal). 4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC. 5. Repeat above steps with lights on to load the alternator.
Continued on next page
TM13345X19 (23APR18)
9015-20-20
DJ54098,000007A -19-04MAY12-1/2
160GLC Excavator 042318 PN=784
References assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
6. If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator 1
Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. 2 Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. DJ54098,000007A -19-04MAY12-2/2
Electrical Component Checks The following checks can be used to test electrical components in all machine circuits. JA66566,0003389 -19-18FEB15-1/13
Component Checks JA66566,0003389 -19-18FEB15-2/13
Relay Check
TX1054856A —UN—22JAN09
Relay 1— Terminal 30 2— Terminal 85 3— Terminal 87A 4— Terminal 87 5— Terminal 86 Key switch to OFF position. Remove relay from machine. Measure continuity between terminals #30 and #87A. Is continuity measured? Connect battery voltage to terminal #86. Ground terminal #85. Does relay click?
YES: Relay is good. Check wiring harness.
With battery voltage still applied to terminal #86, measure continuity between terminals NO: Replace relay. #30 and #87. Is continuity measured? Continued on next page
TM13345X19 (23APR18)
9015-20-21
JA66566,0003389 -19-18FEB15-3/13
160GLC Excavator 042318 PN=785
References Key Switch Check
T8357AK —UN—09NOV94
Key Switch Check 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.) Turn key switch to the ACC position. Measure continuity between key switch terminals 1 to 4. Turn key switch to the ON position. Measure continuity between key switch terminals 1 to 5 and 1 to 4. Turn key switch to the START position. Measure continuity between key switch terminals 1 to 6, 1 to 5, and 1 to 3. LOOK: Is continuity measured between terminals?
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.)
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.
NO: Key switch has malfunctioned. Replace the key switch.
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. Continued on next page
TM13345X19 (23APR18)
9015-20-22
JA66566,0003389 -19-18FEB15-4/13
160GLC Excavator 042318 PN=786
References Battery Relay Check
T8182AK —UN—03MAR94
Battery Relay Check Disconnect machine harness (W2) from battery relay (K19). See Machine Harness (W2) Component Location. (Group 9015-10.) Connect 24 volts to small terminal S and ground small terminal E. LISTEN: Does the relay click? Connect the multimeter to large terminals A and B. LOOK: Is continuity measured?
YES: Battery relay is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
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.
NO: Battery relay malfunctioned. Replace the relay.
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. JA66566,0003389 -19-18FEB15-5/13
Battery Voltage Check
T7487AF —UN—20MAR91
Voltage Check Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and (+) positive battery terminal connected to machine harness.
YES: Batteries are OK.
LOOK: Are 24 to 28 volts measured?
NO: Batteries are undercharged. Charge batteries. See Using Battery Charger. (Operator's Manual.) Continued on next page
TM13345X19 (23APR18)
9015-20-23
JA66566,0003389 -19-18FEB15-6/13
160GLC Excavator 042318 PN=787
References Alternator and Battery Fuse Check
TX1077075 —UN—30APR10
Alternator and Battery Fuse Check 1— Locking Tab 2— Lift Direction Press locking tab on side of fuse and lift from holder. Connect a multimeter to female terminals inside fuse. LOOK: Does the multimeter read continuity?
YES: Fuse is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
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.
NO: Fuse malfunctioned. Replace the fuse. See Fuse and Relay Specifications. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. Continued on next page
TM13345X19 (23APR18)
9015-20-24
JA66566,0003389 -19-18FEB15-7/13
160GLC Excavator 042318 PN=788
References Glow Plug Relay Check
TX1087353A —UN—27JAN11
Glow Plug Relay 1— Terminal 1 2— Terminal 2 3— Terminal 3 4— Terminal 4 Disconnect glow plug harness (W40) from glow plug relay (K16). See Glow Plug Harness (W40) Component Location. (Group 9015-10.) Connect 24 volts to terminal 1 and ground terminal 2. LISTEN: Does relay click?
YES: Relay is OK. Check engine control unit (ECU) 30 A fuse. See Fuse and Relay Specifications. (Group 9015-10.)
Measure continuity at terminals 3 and 4.
YES: Check wiring harness. See Glow Plug Harness (W40) Wiring Diagram. (Group 9015-10.)
LOOK: Is continuity measured?
NO: Relay malfunction. Replace glow plug relay. See Glow Plug Harness (W40) Component Location. (Group 9015-10.) Continued on next page
TM13345X19 (23APR18)
9015-20-25
JA66566,0003389 -19-18FEB15-8/13
160GLC Excavator 042318 PN=789
References Diode Check
T164619B —UN—27JAN03
Diode Check Remove diode from connector. Test diode using diode test function of multimeter. LISTEN: Does the multimeter beep?
YES: If multimeter beeps in both checks, diode malfunctioned. Replace the diode.
Reverse multimeter probes.
NO: If multimeter does not beep in either check, diode malfunctioned. Replace the diode.
LISTEN: Does the multimeter beep?
NO: If multimeter beeps in one check and not the other, diode is OK. Continued on next page
TM13345X19 (23APR18)
9015-20-26
JA66566,0003389 -19-18FEB15-9/13
160GLC Excavator 042318 PN=790
References Travel Alarm Check
A
B
D
C
T158291 —UN—08AUG02
Travel Alarm Harness Check Disconnect travel alarm harness (W26) from travel alarm (H4). See Travel Alarm Harness (W26) Component Location. (Group 9015-10.) Connect multimeter to travel alarm connector pin B and frame ground. Turn key switch to ON position. LOOK: Is battery voltage measured? Connect multimeter to travel alarm connector pin D and frame ground. LOOK: Is continuity measured?
YES: Travel alarm has malfunctioned. Replace the travel alarm.
Connect multimeter to travel alarm connector pin A and frame ground.
NO: If battery voltage is not measured, check travel alarm 5 A fuse. See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Is continuity measured when the travel alarm cancel switch is pressed?
NO: Check travel alarm cancel switch. See Travel Alarm Cancel Switch Harness (W16) Wiring Diagram. (Group 9015-10.)
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.
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.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in.
JA66566,0003389 -19-18FEB15-10/13
Monitor Warning Alarm Check
Disconnect monitor harness (W3) from monitor warning alarm (H3). See Monitor Harness (W3) Component Location. (Group 9015-10.)
YES: Alarm is OK. Check power on 5 A fuse. See Fuse and Relay Specifications. (Group 9015-10.)
Connect 24 volts to terminal 1 and ground terminal 2.
YES: Check wiring harness. See Monitor Harness (W3) Wiring Diagram. (Group 9015-10.)
LISTEN: Does monitor warning alarm sound?
NO: Alarm malfunction. Replace monitor warning alarm. See Monitor Harness (W3) Component Location. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9015-20-27
JA66566,0003389 -19-18FEB15-11/13
160GLC Excavator 042318 PN=791
References CAN Bus Terminator Check
Turn key switch OFF. Disconnect harness from CAN bus terminator.
T140697B —UN—29MAR01
CAN Bus Terminator Measure resistance across terminator pins.
YES: CAN bus terminator is OK.
LOOK: Does the multimeter read 105—135 ohms?
NO: CAN bus terminator malfunctioned. Replace the CAN bus terminator.
Continued on next page
TM13345X19 (23APR18)
9015-20-28
JA66566,0003389 -19-18FEB15-12/13
160GLC Excavator 042318 PN=792
References Alternator Resistor Check Turn key switch OFF. Disconnect harness from alternator resistor (R13).
TX1095684A —UN—08AUG11
Alternator Resistor 1— Terminal 1 2— Terminal 2 Measure resistance across resistor terminals 1 and 2.
YES: Alternator resistor is OK.
LOOK: Does the multimeter read 900—1100 ohms?
NO: Alternator resistor malfunctioned. Replace the alternator resistor. JA66566,0003389 -19-18FEB15-13/13
TM13345X19 (23APR18)
9015-20-29
160GLC Excavator 042318 PN=793
References
Battery Remove and Install 2 3 4
2 3
5 6
4
6 5
7
6 6 3
8
8 9
10 11 9 12
3 TX1087165 —UN—21JAN11
13 1
1
TX1087165
Battery Connections 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
CAUTION: Prevent personal injury from exploding battery. Keep sparks and flames away from batteries. Always remove grounded (-) battery clamp first and replace it last.
1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Remove wing nuts (2) and washers (3). 3. Remove covers (4) and brackets (8). 4. Disconnect cables (10—12). Continued on next page
TM13345X19 (23APR18)
12— Negative Cable 13— Cap Screw
9015-20-30
MM16284,0001799 -19-15MAY14-1/2
160GLC Excavator 042318 PN=794
References
5. Remove batteries (1).
7. Install batteries.
6. Check cables and clamps for wear or corrosion. Verify batteries are fully charged.
8. Connect cables.
IMPORTANT: Prevent electrical system damage. If one battery in a 24-volt system has malfunctioned, replace both batteries.
9. Install brackets and covers. 10. Install washers and wing nuts. MM16284,0001799 -19-15MAY14-2/2
TM13345X19 (23APR18)
9015-20-31
160GLC Excavator 042318 PN=795
References
Rear Cover Remove and Install
1 7 1
7
2 8
8
2
R9
G5
9 2
5
6 12
12 12
13
13 13
3
TX1087220 —UN—24JAN11
4 14
10
10
11
TX1087220
11
Rear Cover Assembly 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)
IMPORTANT: Avoid possible electrical wiring and electrical component damage. Rear covers may catch wiring during removal. Use care when removing rear covers.
11— Washer (2 used) 12— Plug (3 used) 13— Cap Screw (3 used) 14— Lower Rear Cover
G5—12-Volt Power Outlet R9—Lighter
2. Remove plugs (1) and cap screws (2). 3. Remove right cover (3).
4. Remove cap screws (4 and 5). 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9001-01.) Continued on next page
TM13345X19 (23APR18)
9015-20-32
JA66566,0003387 -19-12JUN14-1/2
160GLC Excavator 042318 PN=796
References
5. Install identification tags and disconnect lighter (R9) and 12-volt power outlet (G5). See Cab Harness (W1) Component Location. (Group 9015-10.)
15. Install washers (11) and cap screws (10).
6. Remove left cover (6).
16. Install upper rear cover (9).
7. Remove plugs (7) and cap screws (8).
17. Install cap screws (8) and plugs (7).
8. Remove upper rear cover (9).
18. Connect lighter (R9) and 12-volt power outlet (G5). Install left cover (6).
9. Remove cap screws (10) and washers (11). 10. Remove plugs (12) and cap screws (13). 11. Remove lower rear cover (14).
14. Install cap screws (13) and plugs (12).
19. Install cap screws (4 and 5). 20. Install right cover (3). 21. Install cap screws (2) and plugs (1).
12. Repair or replace as necessary. 13. Install lower rear cover (14). JA66566,0003387 -19-12JUN14-2/2
TM13345X19 (23APR18)
9015-20-33
160GLC Excavator 042318 PN=797
References
Main Controller (MCZ) Remove and Install IMPORTANT: Avoid possible machine damage. When replacing main controller (MCZ) (A3) and monitor controller (DSZ) (A4), only one controller may be replaced at a time. After replacement, machine must be operated for 30 minutes to synchronize controller data.
TX1161245A —UN—23MAY14
1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9001-01.) IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Main Controller (MCZ)
3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 4. Remove cap screws (3) and set aside relay bracket (5). NOTE: Main controller (MCZ) connector locations may vary depending on mounting orientation.
1— Cap Screw (4 used) 2— Screw (4 used) 3— Cap Screw (2 used) 4— Controller Bracket 5— Relay Bracket A3—Main Controller (MCZ)
5. Install identification tags and disconnect electrical connectors (X31—X36). See Cab Harness (W1) Component Location. (Group 9015-10.) 6. Remove cap screws (1) and controller bracket (4). 7. Remove screws (2). Remove main controller (MCZ) from controller bracket. 8. Replace as necessary.
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
9. Install main controller (MCZ) in controller bracket. Install screws (2). 10. Install controller bracket and cap screws (1). 11. Connect electrical connectors (X31—X36). See Cab Harness (W1) Component Location. (Group 9015-10.) 12. Install relay bracket and cap screws (3). 13. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.)
IMPORTANT: Avoid possible machine damage. When replacing main controller (MCZ) and monitor controller (DSZ), only one controller may be replaced at a time. After replacement, machine must be operated for 30 minutes to synchronize controller data. 15. Operate machine for 30 minutes to synchronize controller data.
14. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) JA66566,00033A0 -19-09APR18-1/1
TM13345X19 (23APR18)
9015-20-34
160GLC Excavator 042318 PN=798
References
Monitor Controller (DSZ) Remove and Install IMPORTANT: Avoid possible machine damage. When replacing main controller (MCZ) and monitor controller (DSZ), only one controller may be replaced at a time. After replacement, machine must be operated for 30 minutes to synchronize controller data. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.)
TX1087238A —UN—22JAN11
IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 4. Install identification tags and disconnect electrical connectors (X20—X24) from monitor controller (DSZ) (A4). 5. Remove cap screws (1) and monitor controller (DSZ). 6. Repair or replace as necessary. 7. Install monitor controller (DSZ) and cap screws.
Monitor Controller (DSZ) 1— Cap Screw (4 used) A4—Monitor Controller (DSZ) X20— Monitor Controller 28-Pin Connector A X21— Monitor Controller 36-Pin Connector B
8. Connect electrical connectors (X20—X24) to monitor controller (DSZ). See Cab Harness (W1) Component Location and see Monitor Harness (W3) Component Location. (Group 9015-10.) 9. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 10. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) IMPORTANT: Avoid possible machine damage. When replacing main controller (MCZ) and
X22— Monitor Controller 16-Pin Connector D X23— Monitor Controller 12-Pin Connector C X24— Monitor Controller 2-Pin Connector G
monitor controller (DSZ), only one controller may be replaced at a time. After replacement, machine must be operated for 30 minutes to synchronize controller data. 11. Operate machine for 30 minutes to synchronize controller data. 12. Check controller synchronization by verifying machine hours using the monitor. JA66566,0003388 -19-16DEC15-1/1
Heater Control Disable and Enable
3. Select Machine Body.
1. Connect the service laptop containing the MPDr application to the machine. See MPDr Connection Procedure. (Group 9015-20.) 2. Select Functions.
4. Select Constant Change. 5. Set the Heater Control Selection field to 1 to enable heater control or 0 to disable heater control. MB00333,000036F -19-10APR17-1/1
TM13345X19 (23APR18)
9015-20-35
160GLC Excavator 042318 PN=799
References
TM13345X19 (23APR18)
9015-20-36
160GLC Excavator 042318 PN=800
Contents
Section 9020 Power Train
Page
Group 05—Theory of Operation Track Adjuster and Recoil Spring Operation............................................... 9020-05-1 Travel Gear Case Operation ..................... 9020-05-2 Group 15—Diagnostic Information Noisy or Loose Track Chain ......................9020-15-1 Noisy or Loose Track Chain Diagnostic Procedure..............................................9020-15-1 Tight Track Chain ......................................9020-15-1 Tight Track Chain Diagnostic Procedure..............................................9020-15-1 Frequent Track Chain Sag Adjustment Required................................................9020-15-2 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure..............................................9020-15-2 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers ...................................................9020-15-2 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure..............................................9020-15-2 Bent Track Shoes ......................................9020-15-2 Bent Track Shoes Diagnostic Procedure..............................................9020-15-2 “Popping” of Track .....................................9020-15-3 “Popping” of Track Diagnostic Procedure..............................................9020-15-3 Cracked Track Link....................................9020-15-3 Cracked Track Link Diagnostic Procedure..............................................9020-15-3 Chipped Link Rails.....................................9020-15-4 Chipped Link Rails Diagnostic Procedure..............................................9020-15-4 Individual Undercarriage Component Wear......................................................9020-15-5 Individual Undercarriage Component Wear Diagnostic Procedure ..................9020-15-5 Measure Swing Bearing Wear................... 9020-15-6
TM13345X19 (23APR18)
9020-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9020-2
160GLC Excavator 042318 PN=2
Group 05
Theory of Operation Track Adjuster and Recoil Spring Operation VALVE 2
FRONT IDLER
GREASE RELIEF 3 PASSAGE
YOKE 5
4 CYLINDER
9 GREASE TX1073389
RECOIL 8 SPRING
6
TX1073389 —UN—02FEB11
GREASE FITTING 1
7 PISTON
10 TRACK ADJUSTER AND RECOIL SPRING Track Adjuster and Recoil Spring
1— Grease Fitting 2— Valve 3— Grease Relief Passage
4— Cylinder 5— Yoke 6— Front Idler 7— Piston
8— Recoil Spring 9— Grease 10— Track Adjuster and Recoil Spring
The track adjuster and recoil spring (10) 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. 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). JW00603,0000239 -19-10NOV10-1/1
TM13345X19 (23APR18)
9020-05-1
160GLC Excavator 042318 PN=803
Theory of Operation
Travel Gear Case Operation
5 2
10 6 3
7
8
9
11
4
1 12
13
16
15
14
17 TX1001983 —UN—04JAN06
18
TX1001983 Travel Gear Case Operation 1— Travel Motor Valve Housing 2— Travel Motor Housing 3— Metal Face Seal 4— Bearing Cone and Cup (2 used) 5— Bearing Nut
6— Ring Gear 7— Third Stage Carrier 8— Third Stage Sun Gear 9— Second Stage Carrier 10— Second Stage Sun Gear
The travel gear case is a triple reduction gear system. It converts high speed, low torque from travel motor into low speed, high torque rotation. The gear case is
11— First Stage Carrier 12— First Stage Sun Gear (input shaft) 13— Thrust Pad 14— First Stage Planetary Gear
interchangeable from right side to left side of machine. The travel gear case housing is fastened to the track frame.
Continued on next page
TM13345X19 (23APR18)
15— Second Stage Planetary Gear 16— Third Stage Planetary Gear 17— Drum 18— Sprocket
9020-05-2
MM16284,0001652 -19-24FEB12-1/2
160GLC Excavator 042318 PN=804
Theory of Operation
The travel motor driveshaft is connected to the first stage sun gear (input shaft) (12) by a spline coupler. Travel motion is transferred from the first stage sun gear to the sprocket (18) by the three planetary gear sets that mesh with the ring gear (6). As the first stage sun gear is rotated, it rotates the first stage planetary gears (14), causing the first stage carrier (11) to rotate. The first stage carrier is connected to the second stage sun gear (10). The second stage sun gear meshes with the second stage planetary gears (15). Second stage
planetary gears are connected to the second stage carrier (9). The second stage carrier is connected to the third stage sun gear (8). The third stage sun gear rotate the third stage planetary gears (16). The third stage planetary gears are fastened to the gear case housing and do not rotate. The rotation is transferred to the ring gear. The ring gear, drum (17) and sprocket are fastened together and turn as one unit which rotates the track to move the machine. A replaceable thrust pad (13) is used in the gear case cover to keep the first stage sun gear in position. MM16284,0001652 -19-24FEB12-2/2
TM13345X19 (23APR18)
9020-05-3
160GLC Excavator 042318 PN=805
Theory of Operation
TM13345X19 (23APR18)
9020-05-4
160GLC Excavator 042318 PN=806
Group 15
Diagnostic Information Noisy or Loose Track Chain JA66566,00033D0 -19-01AUG14-1/5
Noisy or Loose Track Chain Diagnostic Procedure JA66566,00033D0 -19-01AUG14-2/5
• 1
Incorrect Track Sag Adjustment
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Loose Track Shoes.
Is track sag within specification?
NO: Adjust track sag. JA66566,00033D0 -19-01AUG14-3/5
• 2
Loose Track Shoes
Remove loose track shoes to clean material from between track shoes and links. Install YES: Go to Grease Leaking track shoes and tighten cap screws in proper sequence. See Track Shoe Remove from Track Adjuster Seals, and Install. (Group 0130.) Grease Fittings, or Relief Valve. Are track shoes properly installed and clean of debris?
NO: Install track shoes properly. JA66566,00033D0 -19-01AUG14-4/5
• 3
Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve
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.)
YES: Replace grease fitting, relief valve or seals as necessary.
Are grease fittings, relief valves, or seals leaking?
NO: Diagnostic checkout complete. JA66566,00033D0 -19-01AUG14-5/5
Tight Track Chain JW00603,0000223 -19-11NOV10-1/4
Tight Track Chain Diagnostic Procedure JW00603,0000223 -19-11NOV10-2/4
• 1
Material Packing in Sprocket
Clean material from sprockets.
YES: Go to Track Sag Less Than Specification.
Is sprocket free of material?
NO: Clean material from sprockets. JW00603,0000223 -19-11NOV10-3/4
• 2
Track Sag Less Than Specification
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Diagnostic checkout complete.
Is track sag within specification?
NO: Adjust track sag. JW00603,0000223 -19-11NOV10-4/4
TM13345X19 (23APR18)
9020-15-1
160GLC Excavator 042318 PN=807
Diagnostic Information
Frequent Track Chain Sag Adjustment Required JA66566,00033CF -19-01AUG14-1/3
Frequent Track Chain Sag Adjustment Required Diagnostic Procedure JA66566,00033CF -19-01AUG14-2/3
• 1
Grease Leaking from Track Adjuster Seals, Grease Fittings, or Relief Valve
YES: Replace grease 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. fitting, relief valve or seals (Group 0130.) as necessary.
Are grease fittings, relief valves, or seals leaking?
NO: Diagnostic checkout complete. JA66566,00033CF -19-01AUG14-3/3
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers JW00603,0000225 -19-11NOV10-1/3
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure JW00603,0000225 -19-11NOV10-2/3
• 1
Loose Plugs, Worn or Damaged O-rings, or Metal Faced Seals
Check for loose, worn or damaged plugs, O-rings, or metal faced seals.
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.)
Are plugs, O-rings or metal faced seals leaking?
NO: Diagnostic checkout complete. JW00603,0000225 -19-11NOV10-3/3
Bent Track Shoes JA66566,0000A44 -19-30OCT15-1/5
Bent Track Shoes Diagnostic Procedure JA66566,0000A44 -19-30OCT15-2/5
• 1
Excessive Grouser Wear
Measure grouser height specification for rebuilding or replacing track shoes. See 160GLC Three Bar Grouser Height. (SP326VOL1 Undercarriage Appraisal Manual.)
YES: Go to Loose Track Shoes.
Is grouser height to specification?
NO: Repair or replace track shoes. See Track Shoe Remove and Install. (Group 0130.) Continued on next page
TM13345X19 (23APR18)
9020-15-2
JA66566,0000A44 -19-30OCT15-3/5
160GLC Excavator 042318 PN=808
Diagnostic Information
• 2
Loose Track Shoes
Remove loose track shoes to clean material from between track shoes and links. Install YES: Go to Excessive High track shoes and tighten cap screws in proper sequence. See Track Shoe Remove Speed Operation On Rough and Install. (Group 0130.) and Rocky Terrain. Are track shoes properly installed?
NO: Install track shoes properly. JA66566,0000A44 -19-30OCT15-4/5
• 3
Excessive High Speed Reduce speed on rough and rocky terrain. Place travel speed switch in slow speed Operation On Rough (turtle) mode. See Switch Panel. (Operator's Manual.) and Rocky Terrain
Is travel speed switch in slow seed (turtle) mode?
YES: Diagnostic checkout complete
NO: Place travel speed switch in slow speed (turtle) mode. JA66566,0000A44 -19-30OCT15-5/5
“Popping” of Track JW00603,0000228 -19-11NOV10-1/5
“Popping” of Track Diagnostic Procedure JW00603,0000228 -19-11NOV10-2/5
• 1
High Travel Loads in Reverse
High travel speeds in reverse can cause the recoil spring to retract allowing sprocket to YES: Go to Material slip in chain. Minimize travel loads in reverse. Packing in Sprocket.
Are travel loads in reverse minimized?
NO: Minimize travel loads in reverse. JW00603,0000228 -19-11NOV10-3/5
• 2
Material Packing in Sprocket
Clean material from sprockets.
YES: Go to Track Sag Less Than Specification.
Is sprocket free of material?
NO: Clean material from sprockets. JW00603,0000228 -19-11NOV10-4/5
• 3
Track Sag Less Than Specification
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Diagnostic checkout complete.
Is track sag within specification?
NO: Adjust track sag. JW00603,0000228 -19-11NOV10-5/5
Cracked Track Link MM16284,0001659 -19-02DEC14-1/6
Cracked Track Link Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9020-15-3
MM16284,0001659 -19-02DEC14-2/6
160GLC Excavator 042318 PN=809
Diagnostic Information
• 1
Material Packing in Sprocket
Clean material from sprockets.
YES: Go to Track Sag Less Than Specification.
Is sprocket free of material?
NO: Clean material from sprockets. MM16284,0001659 -19-02DEC14-3/6
• 2
Track Sag Less Than Specification
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Excessive High Speed Operation On Rough and Rocky Terrain.
Is track sag within specification?
NO: Adjust track sag. MM16284,0001659 -19-02DEC14-4/6
• 3
Excessive High Speed Reduce speed on rough and rocky terrain. Place travel mode switch in slow speed Operation On Rough (turtle) mode. See Switch Panel. (Operator's Manual.) and Rocky Terrain
Is travel mode switch in slow seed (turtle) mode?
YES: Go to Track Shoes too Wide for Ground Conditions.
NO: Place travel mode switch in slow speed (turtle) mode. MM16284,0001659 -19-02DEC14-5/6
• 4
Track Shoes too Wide Use the narrowest possible shoes for required flotation. for Ground Conditions
Are the narrowest possible shoes for required flotation being used?
YES: Diagnostic checkout complete.
NO: Select the narrowest shoes possible for required flotation. MM16284,0001659 -19-02DEC14-6/6
Chipped Link Rails JA66566,0000A45 -19-15FEB16-1/5
Chipped Link Rails Diagnostic Procedure JA66566,0000A45 -19-15FEB16-2/5
• 1
Repeated High Impacts With Roller Tread On Flanges Caused by a Loose or Snaky Track
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Track Shoes too Wide for Ground Conditions.
Is track sag within specification?
NO: Adjust track sag. Continued on next page
TM13345X19 (23APR18)
9020-15-4
JA66566,0000A45 -19-15FEB16-3/5
160GLC Excavator 042318 PN=810
Diagnostic Information
• 2
Track Shoes too Wide Use the narrowest possible shoes for required flotation. for Ground Conditions
Are the narrowest possible shoes for required flotation being used?
YES: Go to Correct Track Chain Pitch.
NO: Select the narrowest shoes possible for required flotation. JA66566,0000A45 -19-15FEB16-4/5
• 3
Correct Track Chain Pitch
Check track chain pitch specifications. See 160GLC Track Chain Pitch. (SP326VOL1 Undercarriage Appraisal Manual.)
YES: Diagnostic checkout complete.
Is track chain pitch within specification?
NO: Repair or replace track chain as necessary. See Track Chain Remove and Install. (Group 0130.) JA66566,0000A45 -19-15FEB16-5/5
Individual Undercarriage Component Wear JW00603,000022B -19-19JUN14-1/3
Individual Undercarriage Component Wear Diagnostic Procedure JW00603,000022B -19-19JUN14-2/3
• 1
Some Wear is Normal
Measure components to determine if they can be rebuilt using weld. See Component Rebuild. (SP326VOL1 Undercarriage Appraisal Manual.)
YES: Diagnostic checkout complete.
Is component wear within specification?
NO: Repair or replace components as necessary. JW00603,000022B -19-19JUN14-3/3
TM13345X19 (23APR18)
9020-15-5
160GLC Excavator 042318 PN=811
Diagnostic Information
Measure Swing Bearing Wear SPECIFICATIONS Swing Bearing Swing Bearing Play
0.2—1.00 mm normal 0.008—0.039 in. normal
Swing Bearing Play
2.80 mm maximum allowable 0.110 in. maximum allowable
SERVICE EQUIPMENT AND TOOLS Dial Indicator
T140090 —UN—17MAY01
CAUTION: Stay clear of moving parts. Position dial indicator so it can be seen while the operator can see spotter. NOTE: Two people are needed to take the measurement; one to operate the machine and one to take the readings. 1. 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.)
T140090 Dial Indicator Location
3. Check that bearing rotation is smooth and without noise. 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. 4. 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. 5. Move boom and arm to the position shown with bucket off the ground. Bucket must be empty. 6. Turn dial indicator to zero. T7886AJ —UN—23NOV92
7. Lower the boom to raise front idlers off the ground approximately 500 mm (20 in.). 8. Record dial indicator reading. Swing Bearing—Specification Swing Bearing—Play..............................................0.2—1.00 mm normal 0.008—0.039 in. normal Play............................................................2.80 mm maximum allowable 0.110 in. maximum allowable
Machine Positions for Check
If play is more than specified, check for wear to balls, spacers, and bearing race. See Swing Bearing Remove and Install. (Group 4350.) JL58967,00001CE -19-18MAR15-1/1
TM13345X19 (23APR18)
9020-15-6
160GLC Excavator 042318 PN=812
Section 9025 Hydraulic System Contents Page Page
Group 05—Theory of Operation Hydraulic System Operation...................... 9025-05-1 Fan Drive Hydraulic System Operation............................................... 9025-05-2 Pilot System Operation.............................. 9025-05-4 Pilot Pump, Pressure Regulating Valve and Filter Operation ..................... 9025-05-5 Pilot Shutoff Solenoid Valve Operation............................................... 9025-05-6 Pilot Control Valve Operation .................... 9025-05-9 Travel Pilot Control Valve Operation............................................. 9025-05-12 Single Pedal Travel Operation—If Equipped ............................................. 9025-05-14 Pilot Operation of Control Valve Operation............................................. 9025-05-17 Pilot Signal Manifold Operation ............... 9025-05-20 Pump 1, Pump 2, and Drive Gear Case Operation ................................... 9025-05-30 Pump 1 and Pump 2 Regulator Operation............................................. 9025-05-33 Engine Speed Sensing Control Circuit Operation.................................. 9025-05-38 Control Valve Operation .......................... 9025-05-40 Control Valve Check Valves Identification and Operation................. 9025-05-58 Main Relief Valve Circuit Operation............................................. 9025-05-61 Circuit Relief and Anticavitation Valve Operation ................................... 9025-05-65 Travel Flow Combiner Valve Operation............................................. 9025-05-66 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation............................................. 9025-05-69 Boom Lower Meter-In Cut Valve Operation............................................. 9025-05-73 Boom Regenerative Valve Circuit Operation............................................. 9025-05-75 Dig Regenerative Valve Circuit Operation............................................. 9025-05-77 Arm Regenerative Valve Circuit Operation............................................. 9025-05-83 Bucket Regenerative Valve Circuit Operation............................................. 9025-05-89 Boom and Arm Reduced Leakage Valves Operation ................................. 9025-05-92 Arm 1 Flow Rate Control Valve Circuit Operation.................................. 9025-05-95 Arm 2 Flow Rate Control Valve Circuit Operation.................................. 9025-05-99
Bucket Flow Rate Control Valve Circuit Operation................................ 9025-05-103 Boom Flow Rate Control Valve Circuit Operation................................ 9025-05-107 Auxiliary Flow Rate Control Valve Circuit Operation................................ 9025-05-112 Swing Reduction Gear Case Operation........................................... 9025-05-115 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation ................................. 9025-05-116 Swing Motor Damper Valve ................... 9025-05-119 Swing Motor Park Brake Release Circuit Operation................................ 9025-05-127 Center Joint Operation .......................... 9025-05-128 Travel Motor and Park Brake Valve Operation........................................... 9025-05-130 Travel Motor Speed Circuit Operation........................................... 9025-05-139 Cylinder Operation................................. 9025-05-143 Return Filter Operation .......................... 9025-05-144 Auxiliary System Operation ................... 9025-05-145 Auxiliary Pilot Control Valve Operation........................................... 9025-05-145 Flow Rate Select Solenoid Valve Operation........................................... 9025-05-156 Flow Rate Pressure Reducing Valve Operation ................................. 9025-05-157 Secondary Auxiliary Relief Valve Solenoid Valve Operation .................. 9025-05-157 Secondary Auxiliary Relief Control Valve Operation ................................. 9025-05-158 Secondary Auxiliary Relief Valve Operation........................................... 9025-05-158 Selector Valve Solenoid Valve Operation........................................... 9025-05-159 Selector Valve Operation....................... 9025-05-159 Auxiliary Shuttle Valve Operation .......... 9025-05-160 Auxiliary High Flow Line Kit Operation........................................... 9025-05-161 Two Way Solenoid Kit Operation........... 9025-05-165 Two Pump Combined Flow Kit Operation........................................... 9025-05-169 Secondary Auxiliary Relief Kit Operation........................................... 9025-05-174 Low Flow Kit Operation ......................... 9025-05-177 Group 15—Diagnostic Information All Hydraulic Functions Slow .....................9025-15-1 All Hydraulic Functions Slow Diagnostic Procedure..............................................9025-15-1 Continued on next page
TM13345X19 (23APR18)
9025-1
160GLC Excavator 042318 PN=1
Contents
Page
Page
Hydraulic Oil Overheats.............................9025-15-2 Hydraulic Oil Overheats Diagnostic Procedure..............................................9025-15-2 No Hydraulic Functions .............................9025-15-4 No Hydraulic Functions Diagnostic Procedure..............................................9025-15-4 No Hydraulic Functions—Electrical Checks ..................................................9025-15-5 No Hydraulic Functions—Electrical Checks Diagnostic Procedure .......................................................9025-15-5 Function Does Not Stop When Control Lever Released .....................................9025-15-7 Function Does Not Stop When Control Lever Released Diagnostic Procedure..............................................9025-15-7 Load Drifts Down When Control Lever is in Neutral Position .............................9025-15-8 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure..............................................9025-15-8 Load Falls When Control Valve is Actuated To Raise Load ......................9025-15-10 Load Falls When Control Valve is Actuated To Raise Load Diagnostic Procedure............................................9025-15-10 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal.................................................9025-15-10 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure............................................9025-15-10 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal ................................9025-15-12 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure............................................9025-15-12 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal ................................9025-15-13 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure............................................9025-15-13 Swing Speed Slow During Arm In Function ..............................................9025-15-14 Swing Speed Slow During Arm In Function Diagnostic Procedure............................................9025-15-14 Boom Cannot Raise Track Off Ground ................................................9025-15-14 Boom Cannot Raise Track Off Ground Diagnostic Procedure..........................9025-15-14 Swing Function Does Not Operate in Both Directions....................................9025-15-16
Swing Function Does Not Operate in Both Directions Diagnostic Procedure............................................9025-15-16 Swing Speed Slow in Both Directions ............................................9025-15-18 Swing Speed Slow in Both Directions Diagnostic Procedure..........................9025-15-18 Swing Speed Slow or Does Not Operate in One Direction ....................9025-15-19 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure............................................9025-15-19 Upperstructure Drift With Swing Valve in Neutral.............................................9025-15-20 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure............................................9025-15-20 Machine Freewheels Down an Incline..................................................9025-15-22 Machine Freewheels Down an Incline Diagnostic Procedure..........................9025-15-22 Track Will Not Move in Either Direction ..............................................9025-15-22 Track Will Not Move in Either Direction Diagnostic Procedure..........................9025-15-23 Machine Mistracks...................................9025-15-24 Machine Mistracks Diagnostic Procedure............................................9025-15-24 Machine Mistracks Left During Combined Travel and Dig Functions.............................................9025-15-26 Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure..........................9025-15-26 Machine Will Not Shift Into Fast (rabbit) Speed..................................................9025-15-26 Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure ..............9025-15-27 Pump 1, Pump 2, and Pilot Pump Line Identification................................. 9025-15-29 Control Valve Line Identification .............. 9025-15-30 Swing Motor Line Identification................ 9025-15-33 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern............... 9025-15-35 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern................. 9025-15-39 Pilot Signal Manifold-to-Control Valve Line Connection ......................... 9025-15-42 Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped ............................................. 9025-15-46 Travel System Component Location ............................................... 9025-15-46 Travel Hydraulic System Line Connections......................................... 9025-15-47 Auxiliary Attachment Schematic .............. 9025-15-55 Continued on next page
TM13345X19 (23APR18)
9025-2
160GLC Excavator 042318 PN=2
Contents
Page
Page
Auxiliary System Line Connections......................................... 9025-15-81 Hydraulic System Schematic................... 9025-15-89 Hydraulic System Component Location ............................................. 9025-15-108 Hydraulic System Line Connections....................................... 9025-15-109 Fan Drive Hydraulic System Component Location ......................... 9025-15-113 Fan Drive Hydraulic System Schematic.......................................... 9025-15-116
Fan Speed Test ....................................... 9025-25-55
Group 25—Tests JT05800 Digital Thermometer Installation................ 902525-1 JT02156A Digital Pressure and Temperature Analyzer.....................................................9025-25-1 General Hydraulic Oil Cleanup Procedure .............................................. 9025-25-2 Hydraulic Component Failure Cleanup Procedure................................ 9025-25-4 Hydraulic Oil Tank Pressure Release Procedure................................ 9025-25-5 Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-6 Pilot Pressure Regulating Valve Test and Adjustment .............................. 9025-25-8 Control Valve Spool Actuating Pilot Pressure Test....................................... 9025-25-10 Dig Regenerative Solenoid Valve Test and Adjustment ............................ 9025-25-12 Arm Regenerative Solenoid Valve Test and Adjustment ............................ 9025-25-14 Power Dig/Travel Speed Solenoid Valve Test and Adjustment .................. 9025-25-16 Torque Control Solenoid Valve Test and Adjustment.................................... 9025-25-18 Pump Control Pilot Pressure Signal Test ...................................................... 9025-25-20 Main Relief and Power Dig Valve Test and Adjustment ............................ 9025-25-22 Circuit Relief Valve Test and Adjustment........................................... 9025-25-25 Swing Motor Crossover Relief Valve Test and Adjustment .................. 9025-25-28 Travel Motor Crossover Relief Valve Test and Adjustment .................. 9025-25-30 Pump Regulator Test and Adjustment—Minimum Flow................ 9025-25-33 Pump Regulator Test and Adjustment—Maximum Flow............... 9025-25-35 Pump Flow Test ....................................... 9025-25-37 Comprehensive Pump Flow Test............. 9025-25-40 Control Pressure Pump Flow Test............ 9025-25-43 Swing Motor Leakage Test ...................... 9025-25-46 Travel Motor Leakage Test ...................... 9025-25-47 Cylinder Drift Test—Boom, Arm, and Bucket........................................... 9025-25-49 Upperstructure Drift Test.......................... 9025-25-51 Fan Drive Pump Flow Test ...................... 9025-25-53 TM13345X19 (23APR18)
9025-3
160GLC Excavator 042318 PN=3
Contents
TM13345X19 (23APR18)
9025-4
160GLC Excavator 042318 PN=4
Group 05
Theory of Operation Hydraulic System Operation See Hydraulic System Schematic as a reference for hydraulic system operation. (Group 9025-15.) Main hydraulic system is an open-center hydraulic system. Main pump housing contains a pilot pump (28), pump 1 (15), and pump 2 (16). Pump 1 is on the right side as you are looking at the pump compartment (toward front of machine), pump 2 is on the left side (toward rear of machine) and the pilot pump is mounted adjacent to pump 2 (toward the rear of machine). The engine drives the pumps through a coupler and a gear case. Hydraulic oil flows from hydraulic oil tank (31) through suction screen (35) to pump 1 and pump 2. Pump 1 delivers high pressure oil to right control valve (4-spool) (73), and pump 2 delivers high pressure oil to left control
valve (5-spool) (74). High pressure oil is routed to motor(s) (52, 61, and 63) and cylinder(s) (125, 126, and 127) by valve spool(s) of their respective valve section (75—110). Hydraulic oil tank is pressurized to ensure oil flows from hydraulic oil tank, through suction line, and into pumps. Return oil from motor(s) and cylinder(s) is routed into return passages in control valve by valve spools. From return passages, return oil flows out of control valve, through hydraulic oil cooler (36), and then to hydraulic oil tank. Oil cooler bypass valve (124) opens to route return oil around oil cooler and directly to hydraulic oil tank when resistance to flow through oil cooler becomes high because oil is cold (high viscosity), there is surge of return oil, or oil cooler becomes plugged. Back pressure in the return passage provides makeup oil to swing motor. JA66566,000263D -19-03AUG12-1/1
TM13345X19 (23APR18)
9025-05-1
160GLC Excavator 042318 PN=817
Theory of Operation
Fan Drive Hydraulic System Operation
134
133 Y5014
B
A
132
36
34
31
600 604
TX1156892
TX1156892 —UN—21MAY14
32
Fan Drive Hydraulic System Schematic 31— Hydraulic Oil Tank 32— Return Filter 34— Filter Bypass 36— From Hydraulic Oil Cooler
132— Fan Drive Pump 133— Fan Drive Motor 134— Fan Speed Control Valve
600— High-Pressure Oil 604— Return Oil Y5014—Proportional Fan Speed Solenoid Valve Continued on next page
TM13345X19 (23APR18)
9025-05-2
DF89619,00B57C3 -19-19MAY14-1/3
160GLC Excavator 042318 PN=818
Theory of Operation
133
Y5015
Y5014
135
132
34 32 600 31
604
TX1156893
TX1156893 —UN—21MAY14
36
Fan Drive Hydraulic System Schematic—Reversing (if equipped) 31— Hydraulic Oil Tank 32— Return Filter 34— Filter Bypass 36— From Hydraulic Oil Cooler
132— Fan Drive Pump 600— High-Pressure Oil 133— Fan Drive Motor 604— Return Oil 135— Fan Speed and Reversing Y5014—Proportional Fan Speed Control Valve—If Equipped Solenoid Valve
See Fan Drive Hydraulic System Schematic. (Group 9025-15.)
• Fan drive pump (132) • Fan speed control valve (134) or fan speed and reversing control valve—if equipped (135)
See Fan Drive Hydraulic System Component Location. (Group 9025-15.)
• Fan drive motor (133)
A hydraulic-powered cooling fan is used to provide air flow for the machine's cooling package. The fan drive system consists of:
Standard Hydraulic Fan Function
Continued on next page
TM13345X19 (23APR18)
Y5015—Reversing Fan Solenoid Valve
9025-05-3
DF89619,00B57C3 -19-19MAY14-2/3
160GLC Excavator 042318 PN=819
Theory of Operation
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 proportional fan speed solenoid valve (Y5014) regulates oil flow and pressure buildup in the fan drive system. Engine control unit (ECU) reads fan speed from fan speed sensor (B53), located on fan drive motor. See Fan Harness (W57) Component Location. (Group 9015-10.) The more oil flow to fan drive motor, the greater the fan speed. How much oil flow is routed to fan drive motor, depends on current applied to proportional fan speed solenoid valve from ECU. The ECU uses five parameters to control the current sent to the integrated proportional fan speed solenoid valve. The engine coolant temperature sensor (B4), hydraulic oil temperature sensor (B40), intercooler 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 proportional fan speed solenoid valve. 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 proportional fan speed solenoid valve. The decrease in current applied, causes the solenoid valve to shift and restrict oil flow through the proportional 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 proportional fan speed solenoid valve. 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 fault or unplugged proportional fan speed solenoid, the ECU supplies no current to the proportional fan speed solenoid valve. With the solenoid de-energized, the proportional fan speed solenoid valve is fully shifted to allow maximum oil flow to the fan drive motor. The fan drive motor and cooling fan operate at maximum speed. Reverse Fan Function—If Equipped The optional reversing function, reverses cooling fan to help clean 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. In order to reverse the fan manually, the engine must be running above 1180 rpm and the hydraulic oil temperature must be above 12°C (54°F). 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 proportional fan speed solenoid valve 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 (Y5015) shifts to reverse oil flow. The ECU then removes current to the proportional fan speed solenoid valve, 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 proportional fan speed solenoid valve while the reversing fan solenoid resets to normal operation. DF89619,00B57C3 -19-19MAY14-3/3
Pilot System Operation See Hydraulic System Schematic as a reference for the hydraulic system operation. (Group 9025-15.) Pilot system is used to operate control circuits for pump 1 and pump 2 regulators (17 and 18), to shift the right and left control valve (73 and 74) spools, to release the swing park brake (56), and as a supply source for functions of the solenoid valve manifold (37).
The pilot pump (28) supplies oil to the pilot system. From the pilot pump, oil flows to the pilot pressure regulating valve (30), which houses the pilot oil filter and pilot oil bypass valve (29). After leaving the filter, oil is supplied to the pilot shutoff valve, the pump regulators, and the solenoid manifold. When no functions are activated, the oil returns to hydraulic oil tank (31).
MM16284,0000FCC -19-17DEC11-1/1
TM13345X19 (23APR18)
9025-05-4
160GLC Excavator 042318 PN=820
Theory of Operation
TX1033508 —UN—31JAN08
Pilot Pump, Pressure Regulating Valve and Filter Operation
Pilot Pump, Pressure Regulating Valve, and Filter 6— Port TA to Hydraulic Return 11— Test Port (port PF) 2— Driven Gear 15— Spring Manifold 3— From Hydraulic Pump Suction 12— From Pilot Pump Outlet (port 16— Shim (as required) 7— Plug (port PC) Line PA) 28— Pilot Pump 8— Plug (port PG) 4— Drive Gear 13— Pilot Filter Element 30— Pilot Pressure Regulating 10— Regulated Pilot Oil (port PD) 14— Pilot Pressure Regulating 5— Port PC to Pump 1 and 2 Valve to Solenoid Valve Manifold Servo Pistons and Regulators Valve Spool
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.
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 PC 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). See Hydraulic System Schematic for pilot filter, bypass valve, and pilot pressure regulating valve in Pilot Control Valves and Pilot Signal Manifold Schematic (Group 9025-15.)
The pilot pressure regulating valve is a relief valve that is used to regulate pilot oil pressure to a constant pressure MM16284,0000FCD -19-14DEC11-1/1
TM13345X19 (23APR18)
9025-05-5
160GLC Excavator 042318 PN=821
Theory of Operation
TX1104882 —UN—07FEB12
Pilot Shutoff Solenoid Valve Operation
Pilot Shutoff Solenoid Valve Port Locations A1—To Travel Pilot Control Valve A4—To Pilot Signal Manifold Port T1— From Travel Pilot Control T4— Return to Hydraulic Oil Tank A2—To Right Pilot Control Valve PI Valve A3—To Left Pilot Control Valve HT—Port HT (plugged) T2— From Right Pilot Control P—Pilot Oil from Pilot Pump Valve T3— From Left Pilot Control Valve
The pilot shutoff solenoid valve is a solenoid actuated spool type valve. The solenoid is electrically operated by the pilot control shutoff lever.
See Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
9025-05-6
ML82895,00006C0 -19-29FEB12-1/3
160GLC Excavator 042318 PN=822
Theory of Operation
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 the pilot pump (P) is blocked by the spool. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI 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.
P
Y10
P—Pilot Oil from Pilot Pump T1— From Travel Pilot Control Valve T2— From Right Pilot Control Valve T3— From Left Pilot Control Valve T4— Return to Hydraulic Oil Tank Y10— Pilot Shutoff Solenoid Valve
HT
A4
T3
T1
T2
A1
A2
A3
604 609
TX1088624
TX1088624 —UN—24FEB11
604— Return Oil 609— Pilot Oil A1—To Travel Pilot Control Valve A2—To Right Pilot Control Valve A3—To Left Pilot Control Valve A4—To Pilot Signal Manifold Port PI HT—Port HT (plugged)
T4
De-Energized Pilot Shutoff Solenoid Valve Schematic
Y10
A1 A2 A3 A4 P 604 TX1088626
609
HT
TX1088626 —UN—24FEB11
T1 T2 T3 T4
De-Energized Pilot Shutoff Solenoid Valve Section Continued on next page
TM13345X19 (23APR18)
9025-05-7
ML82895,00006C0 -19-29FEB12-2/3
160GLC Excavator 042318 PN=823
Theory of Operation
With the pilot control shutoff lever in the unlocked position, the lever is down. The solenoid for the pilot shutoff solenoid valve 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.
Y10
P—Pilot Oil from Pilot Pump T1— From Travel Pilot Control Valve T2— From Right Pilot Control Valve T3— From Left Pilot Control Valve T4— Return to Hydraulic Oil Tank Y10— Pilot Shutoff Solenoid Valve
HT
A4
T3
T1
T2
A1
A2
A3
604 609
TX1088627
TX1088627 —UN—24FEB11
604— Return Oil 609— Pilot Oil A1—To Travel Pilot Control Valve A2—To Right Pilot Control Valve A3—To Left Pilot Control Valve A4—To Pilot Signal Manifold Port PI HT—Port HT (plugged)
T4
Energized Pilot Shutoff Solenoid Valve Schematic
Y10
A1 A2 A3 A4
P
604
TX1088628
HT
609
TX1088628 —UN—24FEB11
T1 T2 T3 T4
Energized Pilot Shutoff Solenoid Valve Section ML82895,00006C0 -19-29FEB12-3/3
TM13345X19 (23APR18)
9025-05-8
160GLC Excavator 042318 PN=824
Theory of Operation
Pilot Control Valve Operation
1 1
2 6 3 7 4 5 10
11
12
6
12
604
11
609
8 14
9
TX1086423 —UN—07JAN11
7
13
10
TX1086423 Pilot Control Valve Metering and Full Stroke 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
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. See Pilot Signal Manifold Operation for pilot valve operation. (Group 9025-05.) See Pilot Operation of Control Valve Operation for 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.
Continued on next page
TM13345X19 (23APR18)
13— Deadband Area 14— Initial Movement 604— Return Oil 609— Pilot Oil
9025-05-9
MM16284,0000FCF -19-08FEB11-1/2
160GLC Excavator 042318 PN=825
Theory of Operation
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. MM16284,0000FCF -19-08FEB11-2/2
TM13345X19 (23APR18)
9025-05-10
160GLC Excavator 042318 PN=826
Theory of Operation
TM13345X19 (23APR18)
9025-05-11
160GLC Excavator 042318 PN=827
Theory of Operation
Travel Pilot Control Valve Operation
6 5 4
7
3 8 9
2
10
1
11
12 6 8 12
12
11
10
604 609
TX1086424
TX1086424 —UN—07JAN11
13
1
Travel Pilot Control Valve Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-12
JA66566,0002642 -19-03AUG12-1/3
160GLC Excavator 042318 PN=828
Theory of Operation 1— Spool 2— Washer 3— Spring Guide 4— Plunger 5— Adjustment Screw 6— Cam and Pedal
7— Sleeve 12— Port 1, 2, 3, or 4 to Control 8— Balance Spring Valve Pilot Cap 9— Return Spring 13— Travel Pilot Control 10— Port T to Hydraulic Oil Tank Valve—Full Stroke 11— Port P From Pilot Shutoff Solenoid Valve
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. See Pilot Signal Manifold Operation for pilot valve operation. (Group 9025-05.) See Pilot Operation of Control Valve Operation for 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), 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 (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.
604— Return Oil 609— Pilot Oil
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.
JA66566,0002642 -19-03AUG12-2/3
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.
16
15
17 18
18— Bracket 19— Gear 2 20— Gear 1
19
TX1033296 —UN—02JAN08
14— Travel Pedal 15— Spring Pin 16— Damper 17— Support
14
20
Travel Pilot Pedal (shockless function) JA66566,0002642 -19-03AUG12-3/3
TM13345X19 (23APR18)
9025-05-13
160GLC Excavator 042318 PN=829
Theory of Operation
Single Pedal Travel Operation—If Equipped
251 9
38
10
11
12 10 12
1 3
P
T
4
2
P
9 11
T
2
1
A1 T1
LR
LF
RR
RF
SF
SR
252
300 302
303 VLR
VLF
J
I
VRF
K
VRR
L
604 609
TX1251179
TX1251179 —UN—25JAN18
301
Single Pedal Travel Operation (left travel forward shown) 9— Left Travel Forward (pilot) 10— Left Travel Reverse (pilot) 11— Right Travel Forward (pilot) 12— Right Travel Reverse (pilot) 38— Travel Pilot Control Valve 251— Single Pedal Travel Pilot Control Valve
252— Single Pedal Travel Pilot 604— Return Oil L— To Pilot Signal Manifold (port Manifold 609— Pilot Oil L) 300— Shuttle Valve (left, forward) A1—From Pilot Shutoff Valve T1— To Pilot Shutoff Valve (port 301— Shuttle Valve (left, reverse) (port A1) T1) 302— Shuttle Valve (right, I— To Pilot Signal Manifold (port forward) I) 303— Shuttle Valve (right, J— To Pilot Signal Manifold (port reverse) J) K—To Pilot Signal Manifold (port K) Continued on next page
TM13345X19 (23APR18)
9025-05-14
DF89619,00B68F8 -19-06FEB18-1/3
160GLC Excavator 042318 PN=830
Theory of Operation
251 38 9
10
11
12 10 12
1 3
P
T
4
2
P
9 11
T
2
1
A1 T1
LR
LF
RR
RF
SF
SR
252
300 302
303 VLR
VLF
J
VRF
I
K
VRR
L
604 609
TX1251180
TX1251180 —UN—29JAN18
301
Single Pedal Travel Operation (single pedal travel forward shown) 9— Left Travel Forward (pilot) 10— Left Travel Reverse (pilot) 11— Right Travel Forward (pilot) 12— Right Travel Reverse (pilot) 38— Travel Pilot Control Valve 251— Single Pedal Travel Pilot Control Valve
252— Single Pedal Travel Pilot 604— Return Oil L— To Pilot Signal Manifold (port Manifold 609— Pilot Oil L) 300— Shuttle Valve (left, forward) A1—From Pilot Shutoff Valve T1— To Pilot Shutoff Valve (port 301— Shuttle Valve (left, reverse) (port A1) T1) 302— Shuttle Valve (right, I— To Pilot Signal Manifold (port forward) I) 303— Shuttle Valve (right, J— To Pilot Signal Manifold (port reverse) J) K—To Pilot Signal Manifold (port K)
The single pedal travel pilot manifold (252) directs pilot oil (609) from the travel pilot control valve (38) and single pedal travel pilot control valve (251) to the appropriate
port of the pilot signal manifold. For additional information on the pilot signal manifold, see Pilot Signal Manifold Operation. (Group 9025-05.)
Continued on next page
TM13345X19 (23APR18)
9025-05-15
DF89619,00B68F8 -19-06FEB18-2/3
160GLC Excavator 042318 PN=831
Theory of Operation
When a single pedal travel function is actuated, pilot oil is routed from the single pedal travel pilot control valve to the single pedal travel pilot manifold. Pilot oil is directed within
the manifold via shuttle valves (300—303) to appropriate output port. DF89619,00B68F8 -19-06FEB18-3/3
TM13345X19 (23APR18)
9025-05-16
160GLC Excavator 042318 PN=832
Theory of Operation
Pilot Operation of Control Valve Operation TX1173133 —UN—29SEP14
A3
37
Y10
A2
28 B30
Y24
T2 T1 T3 3
HT
T4
PH
DF
PI
P T
J
4
K L
11
2
I
11
12 4
B34
11
104
38
9 10 TR
101
A1
Y22
P
Y23
117 101
97
1
108
D
4
107
98
74
110
2
SA
95
P T
SN SP
3
46
44 77
45
42
1
1
H
8
73
4
84
SE
90
P T
120
85
2
SH SL
76 91
39
1
94
A
SK
1
75
93
1
4
4
SB
B31
4
2
C B
3
118
G
1
11
3
81
E
85
F M
7 6 S3 5 13
B33
40
SM
Pilot Operation of Control Valve Operation Continued on next page
TM13345X19 (23APR18)
9025-05-17
160GLC Excavator 042318 PN=833
N
TX1173133
14
41
609
DF89619,00B571F -19-29SEP14-1/2
Theory of Operation
TM13345X19 (23APR18)
9025-05-18
160GLC Excavator 042318 PN=834
Theory of Operation
1— Boom Up (pilot) 4— Arm In (pilot) 11— Right Travel Forward (pilot) 28— Pilot Pump 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 44— Travel Flow Combiner Valve Pilot Valve (port SL) 45— Swing Park Brake Release Pilot Valve (port SH)
46— Bucket Flow Rate Pilot Valve 93— Bypass Shutoff Valve (port SK) 94— Arm Regenerative Valve 73— Right Control Valve (4-spool) 95— Swing Spool 74— Left Control Valve (5-spool) 97— Arm 1 Spool 75— Right Travel Spool 98— Arm 1 Flow Rate Control 76— Bucket Spool Valve (valve and poppet) 77— Bucket Flow Rate Control 101— Arm Reduced Leakage Valve (valve and poppet) Valve (valve and poppet) 81— Boom 1 Spool 104— Boom 2 Spool 84— Dig Regenerative Valve 107— Auxiliary Spool 85— Boom Reduced Leakage 108— Auxiliary Flow Rate Valve (valve and poppet) Control Valve (valve and 90— Arm 2 Spool poppet) 91— Arm 2 Flow Rate Control 110— Left Travel Spool Valve (valve and poppet) 117— Main Relief and Power Dig Valve 118— Auxiliary Flow Combiner Valve
The pilot control valves and travel pilot control valves are connected to the control valve by 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. Pilot oil also flows through the shuttle valves in the pilot signal manifold and shifts the pilot valves.
120— Travel Flow Combiner Valve 609— Pilot Oil B30— Boom Up Pressure Sensor B31— Arm In Pressure Sensor B33— Swing Pressure Sensor B34— Travel Pressure Sensor Y10— Pilot Shutoff Solenoid Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
The following valves in the control valve are controlled by pilot oil from the pilot control valves, pilot valves in the pilot signal manifold, and solenoid valve manifold (37):
Auxiliary Flow Combiner Valve (118)
See Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation. (Group 9025-05.)
Main Relief and Power Dig Valve (117)
See Main Relief Valve Circuit Operation. (Group 9025-05.)
Travel Flow Combiner Valve (120)
See Travel Flow Combiner Valve Operation. (Group 9025-05.)
Right and Left Travel Valve Spools (75 and 110)
...........................................................................................
Bucket Flow Rate Control Valve (valve and poppet) (77)
See Bucket Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
Bucket Spool (76)
........................................................................................... ...........................................................................................
Auxiliary Spool (107) Auxiliary Flow Rate Control Valve (valve and poppet) (108)
See Auxiliary Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
Boom 1 and Boom 2 Valve Spools (81 and 104)
...........................................................................................
Boom Reduced Leakage Valve (valve and poppet) (85)
See Boom and Arm Reduced Leakage Valves Operation. (Group 9025-05.)
Dig Regenerative Valve (84)
See Dig Regenerative Valve Circuit Operation. (Group 9025-05.)
Arm 2 and Arm 1 Spools (90 and 97)
...........................................................................................
Arm Regenerative Valve (94)
See Arm Regenerative Valve Circuit Operation. (Group 9025-05.)
Arm 2 Flow Rate Control Valve (valve and poppet) (91)
See Arm 2 Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
Arm 1 Flow Rate Control Valve (valve and poppet) (98)
See Arm 1 Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
Arm Reduced Leakage Valve (valve and poppet) (101)
See Boom and Arm Reduced Leakage Valves Operation. (Group 9025-05.)
Bypass Shutoff Valve (93)
See Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation. (Group 9025-05.)
Swing Spool (95)
........................................................................................... DF89619,00B571F -19-29SEP14-2/2
TM13345X19 (23APR18)
9025-05-19
160GLC Excavator 042318 PN=835
Theory of Operation
Pilot Signal Manifold Operation
SM
1
S3
C
13
3
2
5
SK
4
F
SE
SA PI
A
M
E D
B
H
14 7
PH
SB G
N I
K
9
6
10
41B 8
SL
SN
SH
41A TR
12
SP
11
L
J DF
129 42
48
47
45 44 TX1086686
TX1086686 —UN—10JAN11
46
43
Pilot Signal Manifold Pilot Valves and Ports
Continued on next page
TM13345X19 (23APR18)
9025-05-20
MM16284,0000FD2 -19-17DEC11-1/11
160GLC Excavator 042318 PN=836
Theory of Operation 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 48— Pump 1 Flow Rate Pilot Valve (port SA) Pilot Signal Manifold 129— Orifice 42— Boom Down Shockless DF—To Hydraulic Oil Tank Valve 43— Arm 1 (Swing Priority) Flow PH—Plug PI— From Pilot Shutoff Solenoid Rate Pilot Valve (port SE) Valve 44— Travel Flow Combiner Pilot S3— B33 Swing Pressure Sensor Valve (port SL) 45— Swing Park Brake Release SA—To Pump 1 Regulator Remote Control Spool Pilot Valve (port SH) 46— Bucket Flow Rate Pilot Valve SB—To Pump 2 Regulator Remote Control Spool (port SK) SE—To Arm 1 (swing priority) 47— Pump 2 Flow Rate Pilot Flow Rate Control Valve Valve (port SB)
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. See Hydraulic System Schematic. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
SH—To Swing Park Brake SK—To Bucket Flow Rate Control Valve SL—To Travel Flow Combiner Valve SM—To Hydraulic Oil Tank SN—Plug (not used) SP—To Solenoid Valve Manifold (port DP) TR—B34 Travel Pressure Sensor
9025-05-21
MM16284,0000FD2 -19-17DEC11-2/11
160GLC Excavator 042318 PN=837
TX1086701 —UN—07FEB11
Theory of Operation
Boom Down Shockless Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-22
MM16284,0000FD2 -19-17DEC11-3/11
160GLC Excavator 042318 PN=838
Theory of Operation 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 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
Boom Down Shockless Valve The boom down shockless valve (42) regulates the return oil flow from the pilot cap during boom down operation. Regulating the return oil flow controls the movement of boom 1 and boom 2 spools to provide precise control of boom down function. Actuating boom up sends pilot oil to pilot signal manifold port A. Pilot oil flows past the tapered land (140) on the boom down shockless valve spool and into the oil chamber (144). The tapered land acts as a variable orifice between the spool and manifold as the spool is shifted back and forth. Pilot oil flows from the oil chamber, through the orifice (141), into 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. Because 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.
Continued on next page
TM13345X19 (23APR18)
9025-05-23
MM16284,0000FD2 -19-17DEC11-4/11
160GLC Excavator 042318 PN=839
Theory of Operation
SA SB
41B
SA SB
151
47 150
150
151
48
146
146
47 48 149 50 149 50 50
50
148 148
TX1086702 —UN—10JAN11
148
147
147
148
41A TX1086702 Pump 1 or Pump 2 Flow rate Pilot Valve 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 SB—Port SB to Pump 2 Regulator Pilot Control Valves 149— Pilot Oil from Port PI 150— Spring Chamber 151— Passage A SA—Port SA to Pump 1 Regulator
Pump 1 Flow Rate Pilot Valve (SA) and Pump 2 Flow Rate Pilot Valve (SB)
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. See Pump 1 and Pump 2 Regulator Operation. (Group 9025-05.)
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)
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
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.
Continued on next page
TM13345X19 (23APR18)
9025-05-24
MM16284,0000FD2 -19-17DEC11-5/11
160GLC Excavator 042318 PN=840
Theory of Operation
TX1086703 —UN—10JAN11
Bucket Flow Rate Pilot Valve (SK) Bucket flow rate pilot valve is shifted by the pilot oil pressure (152) from arm in to port D and through the shuttle valves. The pilot valve routes pilot oil pressure from boom up (Port A) (155) to the bucket flow rate valve in the control valve. The bucket flow rate valve restricts the flow of supply oil to the bucket spool during arm in and boom up operation to ensure a flow of supply oil to the boom 1 spool. 152— Pilot Oil Pressure 153— To Hydraulic Oil Tank 154— To Bucket Flow Rate Valve
Bucket Flow Rate Pilot Valve
155— Pilot Oil Pressure from Boom Up 156— Spring
MM16284,0000FD2 -19-17DEC11-6/11
TX1086703 —UN—10JAN11
Travel Flow Combiner Pilot Valve (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 (155) 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. See Travel Flow Combiner Valve Operation. (Group 9025-05.)
Travel Flow Combiner Pilot Valve 152— Pilot Oil Pressure 153— To Hydraulic Oil Tank 154— To Travel Flow Combiner Valve
155— Control Pressure Pilot Oil 156— Spring
MM16284,0000FD2 -19-17DEC11-7/11
TX1086703 —UN—10JAN11
Swing Park Brake Release Pilot Valve (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 (155) 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. See Swing Motor Park Brake Release Circuit Operation. (Group 9025-05.)
Swing Park Brake Release Pilot Valve 152— Pilot Oil Pressure 153— To Hydraulic Oil Tank 154— To Travel Flow Combiner Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-25
155— Control Pressure Pilot Oil 156— Spring
MM16284,0000FD2 -19-17DEC11-8/11
160GLC Excavator 042318 PN=841
Theory of Operation
Arm 1 Swing Priority Flow Rate Control Pilot Valve (SE)
TX1086703 —UN—10JAN11
Arm 1 flow rate control pilot valve is shifted by arm in pilot oil pressure (152). The pilot valve then routes swing pressure pilot oil (155) to arm 1 flow rate control valve (154) in the control valve. 152— Arm In Pilot Oil Pressure 153— To Hydraulic Oil Tank 154— To Arm 1 Flow Rate Control Valve
155— Swing Pressure Pilot Oil 156— Spring Arm 1 Flow Rate Control Pilot Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-26
MM16284,0000FD2 -19-17DEC11-9/11
160GLC Excavator 042318 PN=842
Theory of Operation
TX1086704 —UN—04MAR11
3
P
T
4
2
2
1
P
T
4
1
3
2
P
T
4
1
3
I Y10
A3 A2 A1
T2 T1
PH
T3
J
K
50A
L
D
C
B
50D
50C
A
H
G
M
N
50Q 50N
50O
50P
50I 50K 50E
50H
50F
HT
P
E
50H
50B
42
A4
F
50I
50D
41B
50O
50L
50F
T4
50J
50P
50Q
50K 50L
DF 45
50M
50G
PI
9 41A
10 TR
11
12
4
48
50G
SA
SN
43
47
50C
50J
SP
B34
46 3
2
SB
SK
1
SH SL
44
SE
8
7
6
S3 5 13
B33
SM
14 50E
50B
50M
50N
50A
TX1086704 Pilot Signal Manifold Shuttle Valve
MM16284,0000FD2 -19-17DEC11-10/11
Continued on next page
TM13345X19 (23APR18)
9025-05-27
160GLC Excavator 042318 PN=843
Theory of Operation 41A— Control Valve Side of Pilot Signal Manifold 41B— Pilot Control Valve Side of Pilot Signal Manifold 42— Boom Down Shockless Valve 43— Swing Priority Flow Rate Pilot Valve (SE) 44— Travel Flow Combiner Pilot Valve (SL)
45— Swing Park Brake Release Pilot Valve (SH) 46— Bucket Flow Rate Pilot Valve (SK) 47— Pump 2 Flow Rate Pilot Valve (SB) 48— Pump 1 Flow Rate Pilot Valve (SA) 50— Shuttle Valve (17 used) 50A— Left Travel
50K— Boom, Arm, Bucket 50L— Arm, Boom Up, Swing, Auxiliary 50M— Boom, Arm, Bucket, Swing, Auxiliary 50N— Bucket 50O— Swing 50P— Auxiliary 50Q— Swing, Auxiliary
50B— Left Travel, Right Travel 50C— Right Travel 50D— Arm 50E— Boom, Arm, Bucket, Right Travel 50F— Boom, Arm 50G— Booom, Arm, Bucket, Right Travel 50H— Boom 50I— Arm, Boom Up 50J— Boom, Arm, Bucket, Left Travel, Swing
Shuttle Valves (50A—50Q) Pilot oil pressure from the actuated travel pilot control valves and left and right function pilot control valves is routed by the shuttle valves (50) to shift the respective pilot valves (42—48) and actuate the travel pressure sensor port TR and swing pressure sensor port S3 in the pilot signal manifold. Actuated Function To Shift Pilot Valve Function and Pilot Signal Manifold Ports
Pump 1 Flow Rate Pilot Valve
Pump 2 Flow Rate Pilot Valve
Boom Up, A
X
X
Boom Down, B
X
Arm In, D
X
X
Arm Out, C
X
X
Travel Flow Combiner Valve Pilot Valve
Bucket Flow Rate Pilot Valve
Swing Park Brake Release Pilot Valve X
X
X
Bucket Curl, G
X
X
X
X X
Right Swing, F
X
X
Left Swing, E X
X
X
Bucket Dump, H
Right Travel, L, K
Arm 1 (Swing Priority) Flow Rate Pilot Valve
X
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. Six Outputs of Pilot Signal Manifold Output
Input Number 1
Input Number 2
Travel Flow Combiner
Any Dig or Swing Function
Right Travel
Bucket Flow Rate Control
Arm In
Boom Up
Arm 1 (Swing Priority) Flow Rate Control
Arm In
Swing
Release Swing Brake
Any Dig or Swing Function
P1 Flow Rate Control
Right Travel, Boom, Arm or Bucket
P2 Flow Rate Control
Left Travel, Boom, Arm or Swing
MM16284,0000FD2 -19-17DEC11-11/11
TM13345X19 (23APR18)
9025-05-28
160GLC Excavator 042318 PN=844
Theory of Operation
TM13345X19 (23APR18)
9025-05-29
160GLC Excavator 042318 PN=845
Theory of Operation
TX1106997 —UN—31JAN12
Pump 1, Pump 2, and Drive Gear Case Operation
Pumps and Gear Case
Continued on next page
TM13345X19 (23APR18)
9025-05-30
TX03742,000011C -19-06OCT17-1/3
160GLC Excavator 042318 PN=846
Theory of Operation 12— Pump 2 Discharge Port 2— Pump Drive Gear Case 3— Damper Drive (Flex Coupling) 13— Dipstick 14— Fill Plug 4— Drive Shaft 15— Pump 1 5— Air Bleed Plug (2 used) 16— Pump 2 9— Pump 1 Discharge Port 17— Pump 1 Regulator 10— Pump 1 Attenuator Port 18— Pump 2 Regulator 11— Pump 2 Attenuator Port 28— Pilot Pump 29— Suction Line Port
B35— Pump 1 Delivery Pressure Y21— Torque Control Solenoid Sensor (marked ST) B36— Pump 1 Control Pressure Y26— Pump 1 Flow Rate Limit Sensor Solenoid (marked SA) B37— Pump 2 Delivery Pressure Sensor B38— Pump 2 Control Pressure Sensor Y20— Pump 2 Flow Rate Limit Solenoid (marked SB) Continued on next page
TM13345X19 (23APR18)
9025-05-31
TX03742,000011C -19-06OCT17-2/3
160GLC Excavator 042318 PN=847
Theory of Operation
26
24
4
19
TX1104399 —UN—10JAN12
22
72 65
TX1104399
21
Pump Cross Section 4— Drive Shaft 19— Servo Piston 21— Cylinder Block
22— Valve Plate 24— Drive Gear 26— Feedback Link
65— Piston (7 used) 72— Center Shaft
Pump 1 (15), pump 2 (16) and pilot pump (28) are driven by the engine at engine speed through the drive gear (24) in pump drive gear case (2). The pump 2 drive shaft is connected to the engine flywheel through a damper drive (flex coupling). Pump 1 and pump 2 are variable displacement, bent-axis, piston type pumps. Two identical pumps are used to generate high pressure oil flow in the hydraulic system. The pumps can vary from minimum displacement to maximum displacement depending on hydraulic demand of the system. Pump 1 regulator (17) and pump 2 regulator (18) are attached to the top of pump housing. The regulators control the movement of the servo piston (19) by sending or releasing oil from the large end of the piston. The servo piston moves the valve plate (22) and cylinder block (21) changing the pump displacement. The feedback link (26), connected to the valve plate, provides a mechanical
feedback to the remote control sleeve in the regulator. The remote control sleeve blocks the flow of oil and traps the oil at both ends of the servo piston, stopping its movement at the flow rate in proportion to the control lever actuation. See Pump 1 and Pump 2 Regulator Operation. (Group 9025-05.) The pump displacement, or flow rate, is varied by changing the angle of the cylinder block with respect to the drive shaft. Expanding 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. An attenuator hose is connected to pump 1 attenuator port and pump 2 attenuator port (10 and 11) to the machine frame. The attenuator hoses help reduce pump vibrations during operation. TX03742,000011C -19-06OCT17-3/3
TM13345X19 (23APR18)
9025-05-32
160GLC Excavator 042318 PN=848
Theory of Operation
Pump 1 and Pump 2 Regulator Operation
2
3
4
5
6 7
1
8
14
11
10
TX1087317 —UN—26JAN11
13 12 9
TX1087317 Pump Regulator Component Identification 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
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.
Remote control sleeve (4) and load sleeve (12) are moved by feedback link blocking flow of oil to or from large end of servo piston.
Piston (6) controls 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. See Pilot Signal Manifold Operation for pump 1 or pump 2 flow rate pilot valves operation. (Group 9025-05.) Load piston (14) controls load spool (13) movement against inner and outer springs (10 and 11) in response to pilot oil pressure from torque control solenoid valve and supply oil pressure from pump 1 and pump 2. Supply 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. See Engine Speed Sensing Control Circuit Operation. (Group 9025-05.))
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. See the following tests and adjustments for minimum flow adjusting screw (7):
• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)
See the following tests and adjustments for flow adjusting cartridge (track cycle time) (1) and maximum flow adjusting screw (2):
• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)
Continued on next page
TM13345X19 (23APR18)
11— Outer Spring 12— Load Sleeve 13— Load Spool 14— Load Piston
9025-05-33
MM16284,0000FD4 -19-13MAR18-1/5
160GLC Excavator 042318 PN=849
Theory of Operation
6 15
5
4
16
23 22
600 603
19 12 14 13
15
TX1087318 —UN—04MAR11
21 20 609
18 611 613 17
TX1087318
Pump Regulator Control by Flow Rate Pilot Valve—Increasing 16— From Pump 1 or Pump 2 4— Remote Control Sleeve Flow Rate Pilot Valve (SA or 5— Remote Control Spool SB) 6— Piston 17— Servo Piston 12— Load Sleeve 18— Feedback Link 13— Load Spool 19— Pilot Oil Inlet 14— Load Piston 15— To Large End of Servo Piston 20— Pump 1 Pressure Inlet
Pump Regulator Control by Flow Rate Pilot Valve—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 (19) at each pump regulator, 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 oil from large end of servo piston (15). Flow rate valve pilot oil (613) from pump 1 and pump 2 flow rate pilot valves (SA or SB) in pilot signal manifold is sensed by piston (6) in its respective regulator. Supply 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.
21— Pump 2 Pressure Inlet 22— Torque Sensing Port 23— Return to Pump Housing 600— Supply Oil 603— Return or Pressure-Free Oil
609— Pilot Oil 611— Torque Sensing Pilot Oil 613— Flow Rate Valve Pilot Oil
Increasing Flow Rate (Displacement)—Actuating a function increases flow rate valve pilot oil (613) pressure from pump 1 or pump 2 flow rate pilot valve (SA or SB) (16) to piston (6). Oil pressure pushes piston and remote control spool (5) to left against spring. Movement of spool opens path from large end of servo piston (15) to return in pump housing (23). Pilot oil on small end of servo piston pushes piston down, increasing pump angle which increases flow rate (displacement). Servo piston movement is transmitted to remote control sleeve (14) and load sleeve (12) by feedback link (18). Sleeves move left until path to return is closed. Oil at large end of servo piston is now trapped, holding pump at flow rate (displacement) that is proportional to pressure of flow rate valve pilot oil.
Torque sensing pilot oil (611) from torque control solenoid valve is routed through steel lines to torque sensing port (22) in each pump regulator.
Continued on next page
TM13345X19 (23APR18)
9025-05-34
MM16284,0000FD4 -19-13MAR18-2/5
160GLC Excavator 042318 PN=850
Theory of Operation
Maximum Flow Rate (Displacement)—When controller lever or pedal is actuated to full stroke, flow rate valve pilot oil (613) from pump 1 or pump 2 flow rate pilot valve (SA or SB) (16) to piston (6) increases to its maximum pressure. Oil pressure pushes piston and remote control spool to left until spool contacts maximum flow adjusting screw. Movement of spool opens path from large end of servo piston to return in pump housing (23). 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 (18). Sleeves move left until path to return is closed. Oil at large end of servo piston is now trapped, holding pump at maximum flow rate (displacement).
oil (613) pressure sensed at piston (6) also decreases. Spring pushes remote control spool and piston to right. Movement of spool opens path for pilot oil (609) from pilot oil inlet (19) to flow to large end of servo piston (17). Pilot oil pressure applied to large end of servo piston pushes piston up against pilot oil pressure applied to small end decreasing pump flow. Remote control spool continues to move to right in response to decreasing flow rate valve pilot oil pressure until it contacts piston cylinder. As pump flow rate (displacement) decreases, servo piston movement is transmitted to remote control sleeve (4) and load sleeve (12) by feedback link (18). Sleeves move right until path 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 flow rate valve pilot oil.
Decreasing Flow Rate (Displacement)—As controller lever or pedal is returned to neutral, flow rate valve pilot Continued on next page
TM13345X19 (23APR18)
9025-05-35
MM16284,0000FD4 -19-13MAR18-3/5
160GLC Excavator 042318 PN=851
Theory of Operation
5
4
6 16
23
22 600 19 12
603 21 20
14
13 15
TX1087319 —UN—26JAN11
609
18
611 613
17
TX1087319
Pump Regulator Control by Supply Oil Pressure—Decreasing 16— From Pump 1 or Pump 2 4— Remote Control Sleeve Flow Rate Pilot Valve (SA or 5— Remote Control Spool SB) 6— Piston 17— Servo Piston 12— Load Sleeve 18— Feedback Link 13— Load Spool 19— Pilot Oil Inlet 14— Load Piston 15— To Large End of Servo Piston 20— Pump 1 Pressure Inlet
21— Pump 2 Pressure Inlet 22— Torque Sensing Port 23— Return to Pump Housing 600— Supply Oil 603— Return or Pressure-Free Oil
Pump Regulator Control by Supply Oil Pressure—Supply oil (600) pressure (load) for each pump is sensed on shoulders of load piston (14) through pump 1 and pump 2 pressure inlets (20 and 21) in each pump regulator. Area of each shoulder is equal. Therefore, force applied through load spool (13) to inner and outer springs is an average of supply oil pressures. Springs are adjusted against average pressure so flow rate of each pump is approximately equal and uses approximately one-half engine output.
feedback link 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 output. For decreasing supply oil, pressure (load) springs push load spool and pistons to right against supply oil pressure, opening path for oil to flow from large end of servo piston (15) through load sleeve and remote control sleeve to return in pump housing (23). Flow rate increases until feedback link moves load sleeve and remote control sleeve blocking flow of oil.
Increasing supply oil pressure (load) pushes load pistons and spools against springs, opening path for pilot oil (609) to flow from pilot oil inlet (19), through load sleeve (12) to large end of servo pistons (15). Flow rate decreases until
Engine output is not exceeded, even if one pump is loaded relatively high while other pump stays relatively low.
Continued on next page
TM13345X19 (23APR18)
609— Pilot Oil 611— Torque Sensing Pilot Oil 613— Flow Rate Valve Pilot Oil
9025-05-36
MM16284,0000FD4 -19-13MAR18-4/5
160GLC Excavator 042318 PN=852
Theory of Operation
5
4
6 16
23
22 600 603 21 20
14
13 15
TX1087320 —UN—27JAN11
609
19 12
18
611 613
17
TX1087320
Pump Regulator Control by Speed Sensing Pilot Oil—Decreasing 16— From Pump 1 or Pump 2 4— Remote Control Sleeve Flow Rate Pilot Valve (SA or 5— Remote Control Spool SB) 6— Piston 17— Servo Piston 12— Load Sleeve 18— Feedback Link 13— Load Spool 19— Pilot Oil Inlet 14— Load Piston 15— To Large End of Servo Piston 20— Pump 1 Pressure Inlet
21— Pump 2 Pressure Inlet 22— Torque Sensing Port 23— Return to Pump Housing 600— Supply Oil 603— Return or Pressure-Free Oil
Pump Regulator Control by Speed Sensing Pilot Oil—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 sensing pilot oil (611) pressure to torque sensing port (22) and load piston (14).
sensing pilot oil pressure, releasing oil from large end of servo piston to return in pump housing (23) allowing pump displacement to increase. As pump flow rate increases engine output is used more efficiently.
As load on engine increases, speed difference between target and actual engine speed increases. Main controller decreases voltage to torque control solenoid valve, which increases torque sensing pilot oil pressure to load piston. Torque sensing pilot oil along with supply oil pressure shifts load spool so pilot oil (609) flows to large end of servo piston (15), decreasing flow rate (displacement). As flow rate of both pumps decreases, load on engine also decreases allowing actual engine speed to increase. As load on engine decreases, speed difference between target and actual engine speed decreases. Main controller increases voltage to torque control solenoid valve, which decreases torque sensing pilot oil pressure to load piston. Spring shifts load spool in response to decreasing torque
609— Pilot Oil 611— Torque Sensing Pilot Oil 613— Flow Rate Valve Pilot Oil
Also, actuating travel function at slow engine speed causes pump flow rate to increase. Flow rate is increased to prevent mistracking, which may occur at lower flow rate if there are any differences between pump 1 and pump 2 flow rates. Main controller processes voltage signals from engine speed dial, travel pressure sensor, and pump 1 and pump 2 pressure sensors. Main controller sends an increasing voltage to torque control solenoid valve, which decreases torque sensing pilot oil pressure to load piston. Springs shift load spool in response to decreasing torque sensing pilot oil pressure, releasing oil from large end of servo piston allowing pump flow rate (displacement) to increase. At increased flow rate, machine does not mistrack at slow engine speed. Increased flow rate continues even if dig function is actuated while traveling at slow engine speed. See Engine Speed Sensing Control Circuit Operation. (Group 9025-05.) MM16284,0000FD4 -19-13MAR18-5/5
TM13345X19 (23APR18)
9025-05-37
160GLC Excavator 042318 PN=853
Theory of Operation
Engine Speed Sensing Control Circuit Operation
B34 B5301 B37
B35
16
15
R15 B5302
18
A3
17
600 609 Y21
650
TX1156089
TX1156089 —UN—17MAR14
A1
Engine Speed Sensing Control Circuit
Y21
1
2
3
4
5
6
7
604
TX1088709 —UN—28FEB11
609
Torque Control Solenoid 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 15— Pump 1 16— Pump 2
17— Pump 1 Regulator 18— Pump 2 Regulator 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil 650— Electrical Signal A1—Engine Control Unit (ECU)
A3—Main Controller (MCZ) B5302—Camshaft Position B34— Travel Pressure Sensor Sensor B35— Pump 1 Delivery Pressure R15— Engine Speed Dial Sensor Y21— Torque Control Solenoid B37— Pump 2 Delivery Pressure (marked ST) Sensor B5301—Crankshaft Position Sensor
Engine Speed Sensing Control (Torque Control Solenoid)—The function of engine speed sensing control is to regulate pump flow rate in response to engine speed
changes caused by load variations, allowing engine output to be used efficiently.
Continued on next page
TM13345X19 (23APR18)
9025-05-38
DF89619,00B5722 -19-02APR14-1/2
160GLC Excavator 042318 PN=854
Theory of Operation
The engine control unit (ECU) (A1) receives signals from crankshaft position sensor (B5301) and camshaft position sensor (B5302), calculates engine speed, and sends information to the main controller (MCZ) (A3) using CAN communication.
in response to the decreasing pilot oil pressure, releasing oil from the large end of servo piston thus increasing pump displacement. As pump flow rate increases, engine output is used more efficiently. See Pump 1 and Pump 2 Regulator Operation. (Group 9025-05.)
The MCZ calculates the speed difference between target and actual engine speed. Target engine speed is a value set by the position of engine speed dial (R15). Actual engine speed is calculated by the ECU using crankshaft position sensor and camshaft position sensor inputs. The MCZ then actuates the torque control solenoid (Y21) to change the pump displacement to increase or decrease pump flow rate.
Travel Torque-Up Control (Slow Speed Sensing)—The function of travel torque-up control is to increase pump flow rate when travel functions are actuated at slow engine speed.
As a load on the engine increases, the actual engine speed becomes less than the target engine speed. The MCZ decreases the electrical signal to the torque control solenoid valve, which increases the pilot oil (609) pressure to load piston 1 in the pump 1 regulator (17) and pump 2 regulator (18). Pilot oil pressure on load piston 1 and high-pressure oil (600) on load piston 2 shifts load spool (6), allowing pilot oil flow to the large end of servo piston thus decreasing the pump displacement. As pump flow rate is reduced, the load on the engine is reduced. As the load on the engine decreases, actual engine speed becomes greater than target engine speed. The MCZ increases the electrical signal to the torque control solenoid, which decreases pilot oil pressure to the load piston in the regulators. The spring (1) shifts the load spool
Actuating travel functions with engine at slow idle causes the pumps to go to maximum displacement. Pump 1 and 2 flow rates are increased to prevent mistracking. Mistracking can occur at lower flow rates if there are differences between pumps 1 and 2. When the engine speed requested by the engine speed dial is slow, the MCZ processes the electrical signals from the travel pressure sensor (B34), pump 1 delivery pressure sensor (B35), and pump 2 delivery pressure sensor (B37). The MCZ sends an increasing electrical signal to the torque control solenoid, which decreases 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 and allowing pump displacement to increase. 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. DF89619,00B5722 -19-02APR14-2/2
TM13345X19 (23APR18)
9025-05-39
160GLC Excavator 042318 PN=855
Theory of Operation
Control Valve Operation 90 88
106 B31
81
76 85 79
75
95 130 73
85
94
117
93 77
92 91A 87 74
TX1156439 —UN—19MAR14
83
91B 109 89
120
80
B30
102 84
118
TX1156439 Component Identification—Right Side, Bottom 73— Right Control Valve (4-spool) 81— Boom 1 Spool 74— Left Control Valve (5-spool) 83— Boom Flow Rate Control 75— Right Travel Spool Valve (valve and poppet) 76— Bucket Spool 84— Dig Regenerative Valve 77— Bucket Flow Rate Control 85— Boom Reduced Leakage Valve (valve and poppet) Valve (valve and poppet) 79— Bucket Dump Circuit Relief 87— Boom Lower Meter-In Cut and Anticavitation Valve Valve 80— Bucket Curl Circuit Relief 88— Boom Up Circuit Relief and and Anticavitation Valve Anticavitation Valve 89— Boom Down Circuit Relief and Anticavitation Valve
90— Arm 2 Spool 91A— Valve for Arm 2 Flow Rate Control Valve 91B— Poppet for Arm 2 Flow Rate Control Valve 92— Check Valve (lift check)—Arm 2 Neutral Passage 93— Bypass Shutoff Valve 94— Arm Regenerative Valve 95— Swing Spool 102— Arm In Circuit Relief and Anticavitation Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-40
106— Check Valve—Dig Regenerative Circuit 109— Plug 117— Main Relief and Power Dig Valve 118— Auxiliary Flow Combiner Valve 120— Travel Flow Combiner Valve 130— Manual Boom Lower Screw B30— Boom Up Pressure Sensor B31— Arm In Pressure Sensor DF89619,00B5748 -19-08AUG16-1/16
160GLC Excavator 042318 PN=856
Theory of Operation
110
75
107
76
104
81 90
97
117
B31 103 95 94 109 109
109 73 112
101
118
100
108 105
TX1156440 —UN—19MAR14
119
74 84 102
TX1156440
98
96
Component Identification—Left Side 73— Right Control Valve (4-spool) 97— Arm 1 Spool 74— Left Control Valve (5-spool) 98— Arm 1 Flow Rate Control 75— Right Travel Spool Valve (valve and poppet) 76— Bucket Spool 100— Check Valve (lift 81— Boom 1 Spool check)—Dig Regenerative 84— Dig Regenerative Valve Circuit 90— Arm 2 Spool 101— Arm Reduced Leakage 94— Arm Regenerative Valve Valve (valve and poppet) 95— Swing Spool 102— Arm In Circuit Relief and 96— Check Valve (lift Anticavitation Valve check)—Swing Neutral 103— Arm Out Circuit Relief and Passage 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 (3 used) 110— Left Travel Spool 112— Check Valve (lift check)—Left Travel Power Passage
Continued on next page
TM13345X19 (23APR18)
9025-05-41
117— Main Relief and Power Dig Valve 118— Auxiliary Flow Combiner Valve 119— Check Valve—Auxiliary Flow Combiner Valve Circuit B31— Arm In Pressure Sensor
DF89619,00B5748 -19-08AUG16-2/16
160GLC Excavator 042318 PN=857
Theory of Operation
75
110 117 103
79
101 116 130 115
85
122 109
73
74
TX1220108 —UN—28JUL16
77
119
121 111 102
80 TX1220108
120
118 Control Valve Operation—Front
73— Right Control Valve (4-spool) 85— Boom Reduced Leakage 115— Main Relief Valve Isolation 121— Check Valve—Travel Flow Valve (valve and poppet) 74— Left Control Valve (5-spool) Check Valve (5-spool) Combiner Valve Circuit 101— Arm Reduced Leakage 75— Right Travel Spool 116— Main Relief Valve Isolation 122— Check Valve (lift check) Valve (valve and poppet) 77— Bucket Flow Rate Control Check Valve (4-spool) and Orifice—Travel and 102— Arm In Circuit Relief and 117— Main Relief and Power Dig Valve (valve and poppet) Bucket Combiner Circuit Anticavitation Valve 79— Bucket Dump Circuit Relief Valve 130— Manual Boom Lower Screw 103— Arm Out Circuit Relief and 118— Auxiliary Flow Combiner and Anticavitation Valve Anticavitation Valve 80— Bucket Curl Circuit Relief Valve 109— Plug and Anticavitation Valve 119— Check Valve—Auxiliary 110— Left Travel Spool Flow Combiner Valve 111— Check Valve (lift Circuit check)—Left Travel Neutral 120— Travel Flow Combiner Passage Valve Continued on next page
TM13345X19 (23APR18)
9025-05-42
DF89619,00B5748 -19-08AUG16-3/16
160GLC Excavator 042318 PN=858
Theory of Operation
75
81
76
90
116
78
82
TX1156444 —UN—19MAR14
TX1156444
94
Control Valve Cross Section—4-Spool Side 75— Right Travel Spool 76— Bucket Spool 78— Bucket Regenerative Valve
81— Boom 1 Spool 82— Boom Regenerative Valve 90— Arm 2 Spool
94— Arm Regenerative Valve 116— Main Relief Valve Isolation Check Valve (4-spool) Continued on next page
TM13345X19 (23APR18)
9025-05-43
DF89619,00B5748 -19-08AUG16-4/16
160GLC Excavator 042318 PN=859
Theory of Operation
99 117
95
97
84
104
107
TX1220115 —UN—28JUL16
111
110
TX1220115 Control Valve Cross Section--5-Spool Side 84— Dig Regenerative Valve 104— Boom 2 Spool 117— Main Relief and Power Dig 95— Swing Spool 107— Auxiliary Spool Valve 97— Arm 1 Spool 110— Left Travel Spool 99— Check Valve (lift 111— Check Valve (lift check)—Arm 1 Regenerative check)—Left Travel Neutral Circuit Passage
The control valve consists of two monoblock valves referred to as the left control valve (5-spool) (74) and right control valve (4-spool) (73). The 4-spool and 5-spool valves 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. All other functions are supplied by a single spool in one or the other of the valves. All spools are moved by pilot oil. Check valves are used as lift checks and to route supply 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. See Hydraulic System Schematic for more information. (Group 9025-15.) All valves are accessible from the outside of control valve by removing a plug, cover, or the pilot caps. See Control Valve Line Identification. (Group 9025-15.) See Control Valve Check Valves Identification and Operation for check valves. (Group 9025-05.)
Continued on next page
TM13345X19 (23APR18)
9025-05-44
DF89619,00B5748 -19-08AUG16-5/16
160GLC Excavator 042318 PN=860
Theory of Operation
TX1158028 —UN—17APR14
RIGHT TRAVEL MOTOR 61
126 90
125 75
15 PUMP 1
124 76
93 81
RIGHT 73 CONTROL VALVE 36 HYDRAULIC OIL COOLER 128
16 PUMP 2 LEFT 74 CONTROL VALVE
117
110
97
107
95
52 SWING MOTOR
LEFT TRAVEL MOTOR 63 104
127 600 604 610 TX1158028 Neutral and Power Passages Operation Continued on next page
TM13345X19 (23APR18)
9025-05-45
160GLC Excavator 042318 PN=861
DF89619,00B5748 -19-08AUG16-6/16
Theory of Operation
TM13345X19 (23APR18)
9025-05-46
160GLC Excavator 042318 PN=862
Theory of Operation
15— Pump 1 (4-spool) 74— Left Control Valve (5-spool) 16— Pump 2 (5-spool) 75— Right Travel Spool 36— Hydraulic Oil Cooler 76— Bucket Spool 52— Swing Motor 81— Boom 1 Spool 61— Right Travel Motor 90— Arm 2 Spool 63— Left Travel Motor 93— Bypass Shutoff Valve 73— Right Control Valve (4-spool) 95— Swing Spool 97— Arm 1 Spool
104— Boom 2 Spool 107— Auxiliary Spool 110— Left Travel Spool 117— Main Relief and Power Dig Valve 124— Hydraulic Oil Cooler Bypass Valve 125— Boom Cylinder (2 used)
Supply oil from pump 1 (15) flows to the right control valve (73). Supply oil from pump 2 (16) flows to the left control valve (74). When all functions are in neutral, supply oil flows through the neutral and power passages for each valve spool section and then into the return passage. Neutral and power passages in the left and right control valves are used to route supply oil for the combined operation of functions. Combiner oil (610) is connected in
combiner passages between arm 1 and 2 spools (97 and 90), and boom 1 and 2 spools (81 and 104), so supply oil from both pump 1 and pump 2 flows to the cylinders during a single operation. Supply oil from pump 2 can be combined with supply oil from pump 1 by the auxiliary combiner power passage to supply the auxiliary spool (107).
Continued on next page
TM13345X19 (23APR18)
9025-05-47
126— Bucket Cylinder 127— Arm Cylinder 128— Check Valve 600— High-Pressure Oil 604— Return Oil 610— Combiner Oil
DF89619,00B5748 -19-08AUG16-7/16
160GLC Excavator 042318 PN=863
Theory of Operation
117
119
74
TX1156511 —UN—20MAR14
73
120
118
TX1156511 Front Section Cross Section From Rear 73— Right Control Valve (4-spool) 117— Main Relief and Power Dig 119— Check Valve—Auxiliary 74— Left Control Valve (5-spool) Valve Flow Combiner Valve 118— Auxiliary Flow Combiner Circuit Valve 120— Travel Flow Combiner Valve
See Main Relief Valve Circuit Operation for main relief and power dig valve (117). (Group 9025-05.) Auxiliary flow combiner valve (118) is used when optional attachments are installed on the machine. See Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation for more information. (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve—auxiliary flow combiner valve (119). (Group 9025-05.) See Travel Flow Combiner Valve Operation for travel flow combiner valve (120). (Group 9025-05.)
Continued on next page
TM13345X19 (23APR18)
9025-05-48
DF89619,00B5748 -19-08AUG16-8/16
160GLC Excavator 042318 PN=864
Theory of Operation
74
73
TX1156513
TX1156513 —UN—20MAR14
75
110
Left and Right Travel Valve Cross Section From Rear 73— Right Control Valve (4-spool) 74— Left Control Valve (5-spool)
75— Right Travel Spool 110— Left Travel Spool
Continued on next page
TM13345X19 (23APR18)
9025-05-49
DF89619,00B5748 -19-08AUG16-9/16
160GLC Excavator 042318 PN=865
Theory of Operation
76
107
79
109
108 77
TX1156514 —UN—20MAR14
78
73
74 109 80
TX1156514 Auxiliary and Bucket Valve Sections From Rear 73— Right Control Valve (4-spool) 78— Bucket Regenerative Valve 74— Left Control Valve (5-spool) 79— Bucket Dump Circuit Relief and Anticavitation Valve 76— Bucket Spool 80— Bucket Curl Circuit Relief 77— Bucket Flow Rate Control and Anticavitation Valve Valve (valve and poppet)
107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve (valve and poppet) 109— Plug (2 used)
See Bucket Flow Rate Control Valve Circuit Operation for bucket flow rate control valve (valve and poppet) (77). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for bucket dump and curl circuit relief and anticavitation valves (79 and 80). (Group 9025-05.)
See Bucket Regenerative Valve Circuit Operation for bucket regenerative valve (78). (Group 9025-05.)
See Auxiliary Flow Rate Control Valve Circuit Operation for auxiliary flow rate control valve (108). (Group 9025-05.) Continued on next page
TM13345X19 (23APR18)
9025-05-50
DF89619,00B5748 -19-08AUG16-10/16
160GLC Excavator 042318 PN=866
Theory of Operation
81
104
85
130
105
TX1156516 —UN—20MAR14
83
74 73 82 TX1156516
B30
89
Boom 1 and Boom 2 Valve Cross Section From Rear 73— Right Control Valve (4-spool) 83— Boom Flow Rate Control 74— Left Control Valve (5-spool) Valve (valve and poppet) 81— Boom 1 Spool 85— Boom Reduced Leakage 82— Boom Regenerative Valve Valve (valve and poppet)
89— Boom Down Circuit Relief and Anticavitation Valve 104— Boom 2 Spool 105— Check Valve (lift check)—Boom 2 Power Circuit
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 (valve and poppet) (83). (Group 9025-05.) See Boom and Arm Reduced Leakage Valves Operation for boom reduced leakage valve (valve and poppet) (85). (Group 9025-05.)
130— Manual Boom Lower Screw B30— Boom Up Pressure Sensor
See Control Valve Check Valves Identification and Operation for boom down circuit relief and anticavitation valve (89). (Group 9025-05.) See Lower Boom with Engine Stopped for use of manual boom lower screw (130). (Operator's Manual.) See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for boom up pressure sensor (B30). (Group 9015-10.)
See Circuit Relief and Anticavitation Valve Operation for boom down circuit relief and anticavitation valve (89). (Group 9025-05.) Continued on next page
TM13345X19 (23APR18)
9025-05-51
DF89619,00B5748 -19-08AUG16-11/16
160GLC Excavator 042318 PN=867
Theory of Operation
103
86
91B
87
TX1156651 —UN—25MAR14
100 84 74
73
TX1156651 Boom-to-Arm Section Cross Section From Rear 73— Right Control Valve (4-spool) 86— Orifice 100— Check Valve (lift 74— Left Control Valve (5-spool) 87— Boom Lower Meter-In Cut check)—Dig Regenerative 84— Dig Regenerative Valve Valve Circuit 91B— Poppet of Arm 2 Flow Rate 103— Arm Out Circuit Relief and Control Valve Anticavitation Valve
See Dig Regenerative Valve Circuit Operation for dig regenerative valve (84). (Group 9025-05.)
See Boom Lower Meter-In Cut Valve Operation for boom lower meter-in cut valve (87). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for arm out circuit relief and anticavitation valve (103). (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—dig regenerative circuit (100). (Group 9025-05.)
See Arm 2 Flow Rate Control Valve Circuit Operation for poppet of arm 2 flow rate control valve (91B). (Group 9025-05.) Continued on next page
TM13345X19 (23APR18)
9025-05-52
DF89619,00B5748 -19-08AUG16-12/16
160GLC Excavator 042318 PN=868
Theory of Operation
97
90 88
101
98
92
TX1156652 —UN—25MAR14
91A
74 73
TX1156652
102 Arm 1 and Arm 2 Valve Cross Section From Rear
73— Right Control Valve (4-spool) 90— Arm 2 Spool 74— Left Control Valve (5-spool) 91A— Valve of Arm 2 Flow Rate 88— Boom Up Circuit Relief and Control Valve Anticavitation Valve 92— Check Valve (lift check)—Arm 2 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
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 Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and poppet) (101). (Group 9025-05.)
See Arm 2 Flow Rate Control Valve Circuit Operation for valve of arm 2 flow rate control valve (91A). (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—arm 2 neutral passage (92). (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.) Continued on next page
TM13345X19 (23APR18)
9025-05-53
DF89619,00B5748 -19-08AUG16-13/16
160GLC Excavator 042318 PN=869
Theory of Operation
95
94
93
74
74
73
TX1156653 —UN—25MAR14
96
73
TX1156653 Swing Valve and Rear Section Cross Section From Rear 73— Right Control Valve (4-spool) 93— Bypass Shutoff Valve 74— Left Control Valve (5-spool) 94— Arm Regenerative Valve
See Arm Regenerative Valve Circuit Operation for arm regenerative valve (94). (Group 9025-05.) See Control Valve Check Valves Identification and Operation for check valve (lift check)—swing neutral passage (96). (Group 9025-05.)
95— Swing Spool 96— Check Valve (lift check)—Swing Neutral Passage
Bypass shutoff valve (93) is used when optional attachments are installed on the machine. See Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation. (Group 9025-05.) Continued on next page
TM13345X19 (23APR18)
9025-05-54
DF89619,00B5748 -19-08AUG16-14/16
160GLC Excavator 042318 PN=870
Theory of Operation
122
73
121
120
74 TX1220116 —UN—28JUL16
111
TX1220116 Front Components Cross Section 73— Right Control Valve (4-spool) 120— Travel Flow Combiner 74— Left Control Valve (5-spool) Valve 111— Check Valve (lift 121— Check Valve—Travel Flow check)—Left Travel Neutral Combiner Valve Circuit Passage
122— Check Valve (lift check) and Orifice—Travel and Bucket Combiner Circuit
See Control Valve Check Valves Identification and Operation for check valve (lift check)—left travel neutral passage (111). (Group 9025-05.)
circuit (122) and check valve—travel flow combiner valve circuit (121). (Group 9025-05.)
See Travel Flow Combiner Valve Operation for check valve (lift check) and orifice—travel and bucket combiner Continued on next page
TM13345X19 (23APR18)
9025-05-55
DF89619,00B5748 -19-08AUG16-15/16
160GLC Excavator 042318 PN=871
Theory of Operation
73
TX1156655 —UN—28MAR14
112
TX1156655 Check Valve (lift check)—Left Travel Power Passage Cross Section 73— Right Control Valve (4-spool) 112— Check Valve (lift check)—Left Travel Power Passage
See Control Valve Check Valves Identification and Operation for check valve (lift check)—left travel power passage (112). (Group 9025-05.) DF89619,00B5748 -19-08AUG16-16/16
TM13345X19 (23APR18)
9025-05-56
160GLC Excavator 042318 PN=872
Theory of Operation
TM13345X19 (23APR18)
9025-05-57
160GLC Excavator 042318 PN=873
Theory of Operation
Control Valve Check Valves Identification and Operation 117
74
115
118
116
73
120
119
121 122 123
113
110
75
77 111
112
76
107
79 78 108
80
104
87
83 84
106
81
105
88
86
82
101 103
89 102
91
100
85
97 99
92 98 90
95
93
96
36 124
136 16
15
TX1014069
TX1014069 —UN—27NOV06
94
Control Valve Check Valves
Continued on next page
TM13345X19 (23APR18)
9025-05-58
JA66566,0002649 -19-03AUG12-1/3
160GLC Excavator 042318 PN=874
Theory of Operation 101— Arm Reduced Leakage 15— Pump 1 (right, 4-spool) 86— Orifice 116— Main Relief Valve Isolation Valve (valve and poppet) 16— Pump 2 (left, 5-spool) 87— Boom Lower Meter-In Cut Check Valve—4-Spool 102— Arm In Circuit Relief and 117— Main Relief and Power Dig 36— Hydraulic Oil Cooler Valve Anticavitation Valve 73— Right Control Valve (4-spool) 88— Boom Up Circuit Relief and Valve 103— Arm Out Circuit Relief and 118— Auxiliary Function Flow 74— Left Control Valve (5-spool) Anticavitation Valve Anticavitation Valve 75— Right Travel Spool 89— Boom Down Circuit Relief Combiner Valve 104— Boom 2 Spool 76— Bucket Spool and Anticavitation Valve 119— Check Valve—Auxiliary 105— Check Valve (lift 77— Bucket Flow Rate Control 90— Arm 2 Spool Function Flow Combiner check)—Boom 2 Power Valve (valve and poppet) 91— Arm 2 Flow Rate Control Valve Circuit Circuit 78— Bucket Regenerative Valve Valve (valve and poppet) 120— Travel Flow Combiner 106— Check Valve—Dig 79— Bucket Dump Circuit Relief 92— Check Valve (lift Valve Regenerative Circuit and Anticavitation Valve check)—Arm 2 Neutral 121— Check Valve—Travel Flow 107— Auxiliary Spool 80— Bucket Curl Circuit Relief Passage Combiner Valve Circuit 108— Auxiliary Flow Rate and Anticavitation Valve 93— Bypass Shutoff Valve 122— Check Valve (lift Control Valve (valve and 81— Boom 1 Spool 94— Arm Regenerative Valve check)—Bucket poppet) 82— Boom Regenerative Valve 95— Swing Spool 123— Orifice—Bucket Power 110— Left Travel Spool 83— Boom Flow Rate Control 96— Check Valve (lift Circuit 111— Check Valve (lift Valve (valve and poppet) check)—Swing Neutral 124— Hydraulic Oil Cooler check)—Left Travel Neutral 84— Dig Regenerative Valve Passage Bypass Valve Passage 85— Boom Reduced Leakage 97— Arm 1 Spool 136— Restriction Valve 112— Check Valve (lift Valve (valve and check 98— Arm 1 Flow Rate Control check)—Left Travel Power valve) Valve (valve and poppet) Passage 99— Check Valve (lift check)—Arm 1 Regenerative 113— Orifice—Left Travel Power Passage Circuit 115— Main Relief Valve Isolation 100— Check Valve (lift Check Valve—5-Spool check)—Dig Regenerative Circuit
arm 1 spool to the return passage. The flow of return oil from the rod end is blocked by the arm 2 spool. See Arm Regenerative Valve Circuit Operation for more information. (Group 9025-05.)
For location of check valves and orifices in the right and left 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.
Operational Check: Arm in function is slow or lacks power when dig. Inspect check valve for leakage. Also inspect the orifice (notch) in arm 1 spool and the orifice in the arm regenerative valve for restriction.
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.) 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). Check Valve (lift check)—Arm 1 Regenerative Circuit (99): During arm in regenerative operation when the arm regenerative valve (94) is closed, check valve (99) is pushed open when return oil from the rod end of arm cylinder becomes greater than high pressure oil from pump 2 (16). Return oil combines with the high pressure oil flow to the head end of arm cylinder preventing cavitation. When high pressure oil pressure to the head end of arm cylinder is higher, all return oil from rod end flows to the return passage through the orifice (notch) in the arm 1 spool (97) and orifice in the arm regenerative valve. Return oil from the rod end only flows through the
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 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).
Continued on next page
TM13345X19 (23APR18)
9025-05-59
JA66566,0002649 -19-03AUG12-2/3
160GLC Excavator 042318 PN=875
Theory of Operation
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.
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. Check Valve—Dig Regenerative Circuit (106): Not used in this configuration. 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.
Check Valve (lift check) (122) and Orifice (123): The check valve functions as a lift check for the bucket spool (76). JA66566,0002649 -19-03AUG12-3/3
TM13345X19 (23APR18)
9025-05-60
160GLC Excavator 042318 PN=876
Theory of Operation
Main Relief Valve Circuit Operation 1 2
3 5
4
6 7 8
10 600
11
604 12 TX1087551
13
609
14
TX1087551 —UN—03FEB11
9
Main Relief and Power Dig Valve 1— First Adjusting Plug 2— 27 mm Nut 3— Second Adjusting Plug 4— 32 mm Nut 5— Piston
10— Main Poppet 11— Return Passage 12— Power Passage 13— Normal Operation 14— Power Dig Operation
6— Left Control Valve Housing 7— Pilot Poppet Spring 8— Pilot Poppet 9— Main Poppet Spring
600— High-Pressure Oil 604— Return Oil 609— Pilot Oil
to the bottom of its bore, increasing the pressure setting of pilot poppet spring (7). The main hydraulic system now operates at a higher operating pressure for approximately 8 seconds.
Main Relief and Power Dig Valve (117)—The function of the main relief and power dig valve is to limit the main hydraulic system operating pressure. Main relief and power dig valve is pilot operated, poppet type relief valve with a piston (5). When the high-pressure oil (600) in the power passage (12) exceeds the relief valve pressure setting, pilot poppet (8) is pushed off its seat letting oil behind main poppet (10) flow to the return passage (11). A pressure difference is created across main poppet because oil flows out faster than oil can flow through orifice in the poppet. The main poppet is pushed open to relieve pressure oil to return passage.
Main relief valve isolation check valves are used in the left and right control valve to route the higher high-pressure oil to the main relief and power dig valve. The higher pressure closes an isolation check valve against the lower pressure so it cannot flow to the lower pressure side. The higher pressure is then sensed by the main relief and power dig valve. For main relief valve isolation check valves, see Control Valve Check Valves Identification and Operation (Group 9025-05.)
For power dig operation (14), pilot oil (609) from the power dig/travel speed solenoid pushes the piston down Continued on next page
TM13345X19 (23APR18)
9025-05-61
DF89619,00B58AD -19-19JAN16-1/4
160GLC Excavator 042318 PN=877
Theory of Operation
S7
A3 16
TX1107938 —UN—10FEB12
15
609
Y24
650 117
TX1107938 Power Dig Control Circuit 15— Pump 2 609— Pilot Oil 16— Pump 1 650— Electrical Voltage 117— Main Relief and Power Dig A3—Main Controller (MCZ) Valve
S7— Power Dig Switch Y24— Power Dig/Travel Speed Solenoid (marked SG)
Power Dig Control Circuit—The function of the power dig control circuit is to increase the system operating pressure temporarily.
valve down increasing the pressure setting. Main hydraulic system now operates at the higher operating pressure.
When the power dig switch (S7) is pushed and held, the main controller (MCZ) (A3) sends electrical voltage (650) to energize the power dig/travel speed solenoid (Y24) coil. Pilot oil (609) flows from the valve to the piston in main relief and power dig valve (117). The pilot oil pressure pushes the piston in the main relief valve and power dig
The power dig control circuit stays actuated for approximately 8 seconds as long as the switch is held closed. After 8 seconds, the switch must be released and pushed again to actuate the power dig control circuit. A timer circuit in the MCZ controls the length of time control circuit is actuated. Releasing the switch before 8 seconds causes the power dig control circuit to turn off.
Continued on next page
TM13345X19 (23APR18)
9025-05-62
DF89619,00B58AD -19-19JAN16-2/4
160GLC Excavator 042318 PN=878
Theory of Operation
B30 B31
B37
B35 S7
A3 16
TX1107939 —UN—10FEB12
15
609
Y24
650 117
TX1107939 Auto-Power Dig Control Circuit
15— Pump 1 B35— Pump 1 Delivery Pressure S7— Power Dig Switch A3—Main Controller (MCZ) 16— Pump 2 Sensor (marked PP1) B30— Boom Up Pressure Sensor Y24— Power Dig/Travel Speed 117— Main Relief and Power Dig B37— Pump 2 Delivery Pressure (marked P11) Solenoid (marked SG) Valve Sensor (marked PP2) B31— Arm In Pressure Sensor 609— Pilot Oil (marked P12) 650— Electrical Voltage
Auto-Power Dig Control Circuit—The function of the auto-power dig control circuit is to increase the system operating pressure during boom up operation. Control circuit is also activated during combined operations except when the arm in function is used. During boom up operation, the main controller (MCZ) (A3) actuates the power dig/travel speed solenoid (Y24) under the following conditions:
• Pilot control valve is actuated, sending pilot oil to the
pilot cap, shifting boom 1 and 2 spools to some extent. Also pressurizes the boom up pressure sensor (B30), sending an electrical signal to the main controller. • Pump 1 (15) delivery pressure is high. Pump 1 delivery pressure sensor (B35) sends an electrical signal to the MCZ indicating the high pressure.
• Control lever for arm in is in neutral. Electrical signal for arm in pressure sensor (B31) is at zero.
When all conditions are met, the MCZ sends an electrical signal to energize the power dig/travel speed solenoid coil, allowing pilot oil (609) to flow to the piston in main relief and power dig valve (117). The pilot oil pressure shifts the piston in the main relief and power dig valve against spring pressure to increase the pressure setting. The main hydraulic system now operates at the higher operating pressure.
Continued on next page
TM13345X19 (23APR18)
9025-05-63
DF89619,00B58AD -19-19JAN16-3/4
160GLC Excavator 042318 PN=879
Theory of Operation
Y23
Y24
Y22
20
24
23 22
24
19 22
21
604 18
20 TX1107926
21
609 613
19
TX1107926 —UN—30MAR12
17
Power Dig/Travel Speed Solenoid Operation 17— Adjusting Screw 18— Nut 19— From Pilot Shutoff Solenoid Valve 20— To Main Relief and Power Dig Valve
21— To Hydraulic Oil Tank 22— Spool 23— Pressure Equals or Greater Than Magnetic Force 24— Solenoid Coil
Power Dig/Travel Speed Solenoid Operation—The power dig/travel speed solenoid (Y24) is a proportional solenoid valve type. The solenoid valve is activated by an electrical signal from the main controller (MCZ). The electrical signal is DC voltage that is turned on and off to form a pulse-width, modulated signal. Solenoid coil (24) reacts to the average voltage to create a magnetic force to shift the spool (22) left against a spring. When shifted left, reduced pilot oil (613) is sent to the main relief and power dig valve (20). The pressure of reduced pilot oil is in proportion to the electrical signal to the solenoid coil. When de-energized, the spool is pushed to the right by a spring. The main relief and power dig valve is then connected to the hydraulic oil tank (21) through the spool.
604— Return Oil Y24— Power Dig/Travel Speed 609— Pilot Oil Solenoid (marked SG) 613— Reduced Pilot Oil Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC)
When energized, the magnetic force shifts the spool left against the spring. Pilot oil (609) flows past the spool flange and out the port as a reduced pilot oil to the main relief and power dig valve. 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 electrical signal to the solenoid increases. When the reduced pilot oil pressure equals or greater than magnetic force (23), the spool is pushed to the right closing the passage. The reduced pilot oil to the main relief and power dig valve is trapped. The spool is moving constantly to maintain the reduced pilot oil pressure in response to the electrical signal to the solenoid coil. DF89619,00B58AD -19-19JAN16-4/4
TM13345X19 (23APR18)
9025-05-64
160GLC Excavator 042318 PN=880
Theory of Operation
Circuit Relief and Anticavitation Valve Operation
11
12
4
5
6
7
8
600 3
604 2
624
9 10
1 TX1087587
TX1087587 —UN—25FEB11
602
Circuit Relief Valve and Anticavitation Valve 1— To Return 2— Piston 3— From Work Circuit 4— Check Valve 5— Pilot Poppet
6— Check Valve Spring 7— Pilot Poppet Spring 8— Screw 9— Piston Spring 10— Main Poppet
At pressures below the circuit relief setting, the main poppet (10) remains closed. In relief operation (11), the relief valve opens in three steps. In the first step, the pilot poppet (5) is opened. Flow restriction through the hollow piston (2) causes the pressure in the cavity behind the main poppet to decrease. In the second step of relief operation, the piston seats against the pilot poppet. This further reduces oil flow into the cavity and greatly decreases the pressure against the back side of main poppet. The main poppet opens in the third step of relief operation.
11— Relief Operation 12— Anticavitation Operation 600— Supply Oil 602— Operating Pressure Oil
604— Return Oil 624— Low Pressure (cavitation)
During anticavitation operation (12), the check valve (4) retracts to allow oil to flow from the return passage into the work circuit. During normal operation, the operating pressure oil (602) on the inner shoulder holds the check valve against its seat. This pressure decreases as pressure in the work circuit decreases. The return oil (604) on the outer shoulder moves the check valve, main poppet, and piston against the springs to open the valve. MM16284,0000FD9 -19-25FEB11-1/1
TM13345X19 (23APR18)
9025-05-65
160GLC Excavator 042318 PN=881
Theory of Operation
Travel Flow Combiner Valve Operation 63
61 74
120
117
73
121
110 122
75
123
600 604
16 15
TX1091155
609
TX1091155 —UN—19APR11
76
Travel Flow Combiner Valve Operation 15— Pump 1 (right, 4-spool) 74— Left Control Valve (5-spool) 120— Travel Flow Combiner 16— Pump 2 (left, 5-spool) 75— Right Travel Spool Valve 61— Right Travel Motor 76— Bucket Spool 121— Check Valve—Travel Flow 63— Left Travel Motor 110— Left Travel Spool Combiner Valve Circuit 73— Right Control Valve (4-spool) 117— Main Relief and Power Dig 122— Check Valve (lift Valve check)—Bucket Continued on next page
TM13345X19 (23APR18)
9025-05-66
123— Orifice—Bucket Power Passage 600— Supply Oil 604— Return Oil 609— Pilot Oil MM16284,00010A8 -19-15JAN16-1/2
160GLC Excavator 042318 PN=882
Theory of Operation
117
73
74
151 152
153 121
TX1001466 —UN—17DEC05
120
147 TX1001466 Travel Flow Combiner Valve and Check Valve 73— Right Control Valve (4-spool) 120— Travel Flow Combiner 151— To Control Valve Return 74— Left Control Valve (5-spool) Valve Passage 117— Main Relief and Power Dig 121— Check Valve—Travel Flow 152— From Pump 1 (4-spool) Valve Combiner Valve Passage 153— To Left Travel Spool by 147— Pilot Oil From Travel Flow Combiner Passage Combiner Pilot Valve (port SL)
When travel only is actuated, supply oil (600) from pump 2 (16) flows through the neutral passage of swing, arm 1, boom 2, and auxiliary spools, then through the left travel spool (110) and out to the left travel motor (63). Supply 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 supply oil through the neutral passage of bucket (76), boom 1, and arm 2. When dig functions are actuated at the same time as travel, the travel flow combiner valve (120) is shifted by pilot oil (609) from the travel flow combiner pilot valve (port SL) in the pilot signal manifold. See Pilot Signal Manifold Operation for operation of pilot valves. (Group 9025-05.)
Supply oil from pump 1 flows to right travel spool and now through the travel flow combiner valve to the left travel spool and bucket spool. Supply oil flow from pump 1 to both left and right travel motors prevents mistracking. When travel is not actuated, return oil and spring force keeps the travel flow combiner valve closed. Supply oil from pump 2 (16) is used for the swing, arm, and boom functions and when connected, the auxiliary function.
MM16284,00010A8 -19-15JAN16-2/2
TM13345X19 (23APR18)
9025-05-67
160GLC Excavator 042318 PN=883
Theory of Operation
TM13345X19 (23APR18)
9025-05-68
160GLC Excavator 042318 PN=884
Theory of Operation
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation TX1149092 —UN—11DEC13
DH
156 143
73
93 75
90 76
81
14 15
118
119
107
108 16
117 150
108 74
95
110 104
97
600 604
TX1149092
157
609
13 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-69
160GLC Excavator 042318 PN=885
DF89619,00B566C -19-19DEC13-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-70
160GLC Excavator 042318 PN=886
Theory of Operation
13— Auxiliary (pilot) 81— Boom 1 Spool 14— Auxiliary (pilot) 90— Arm 2 Spool 15— Pump 1 (4-spool) 93— Bypass Shutoff Valve 16— Pump 2 (5-spool) 95— Swing Spool 73— Right Control Valve (4-spool) 97— Arm 1 Spool 74— Left Control Valve (5-spool) 104— Boom 2 Spool 75— Right Travel Spool 107— Auxiliary Spool 76— Bucket 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 143— Auxiliary Shuttle Valve 150— Auxiliary Attachment
NOTE: Auxiliary flow combiner valve (118) and bypass shutoff valve (93) will not work properly unless appropriate kits are installed on machine.
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 (150).
156— From Flow Rate Select Solenoid Valve 157— To Flow Rate Select Reducing Valve 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil DH—To Solenoid Valve Manifold Port DH
The combined functions of auxiliary flow combiner valve (118) and bypass shutoff valve (93) combine DF89619,00B566C -19-19DEC13-2/4
Auxiliary Flow Combiner Valve Operation
107
156
15 119 118
In combined operation with travel and dig functions, pilot oil from flow rate select reducing valve (157) 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 neutral position, blocking flow of pump 1 oil to the auxiliary spool. 15— From Pump 1 107— To Auxiliary Spool 118— Auxiliary Flow Combiner Valve 119— Check Valve—Flow Combiner Valve Circuit 156— From Flow Rate Select Solenoid Valve
600
157— To Flow Rate Select Reducing Valve 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil
604 157 Auxiliary Flow Combiner Valve Continued on next page
TM13345X19 (23APR18)
609
TX1148757 —UN—04DEC13
Actuating an auxiliary function, with 2-speed activation solenoid valve (Y43) energized, routes pilot oil (609) from flow rate select solenoid valve (156) 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 back flow of oil through the auxiliary flow combiner valve.
9025-05-71
DF89619,00B566C -19-19DEC13-3/4
160GLC Excavator 042318 PN=887
Theory of Operation Bypass Shutoff Valve Operation
15 93
143
DH
High-pressure oil from pump 1 can then be routed through the auxiliary flow combiner valve, if equipped with two pump combined flow kit. For more information, see Two Pump Combined Flow Kit Operation. (Group 9025-05.) 15— From Pump 1 93— Bypass Shutoff Valve 143— From Auxiliary Shuttle Valve 219— To Hydraulic Oil Tank
600— High-Pressure Oil 604— Return Oil 609— Pilot Oil DH—To Solenoid Valve Manifold Port DH
600 604
219
609
TX1148758 —UN—04DEC13
When an auxiliary 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.
Bypass Shutoff Valve DF89619,00B566C -19-19DEC13-4/4
TM13345X19 (23APR18)
9025-05-72
160GLC Excavator 042318 PN=888
Theory of Operation
Boom Lower Meter-In Cut Valve Operation 83
87
2 83
87
104 81 82
88
89 85
603 604 606 TX1087667
609 16
15
TX1087667 —UN—10FEB11
600
Boom Lower Meter-In Cut Valve Circuit Operation Schematic 2— Boom Down (pilot) 15— Pump 1 16— Pump 2 81— Boom 1 Spool 82— Boom Regenerative Valve 83— Boom Flow Rate Control Valve (switch valve and poppet)
85— Boom Reduced Leakage Valve 87— Boom Lower Meter-In Cut Valve 88— Boom Up Circuit Relief and Anticavitation Valve
The boom lower meter-in cut valve (87), located in the boom lower circuit, controls the boom flow rate control
89— Boom Down Circuit Relief and Anticavitation Valve 104— Boom 2 Spool 600— Supply Oil 603— Regenerative Oil
valve (83) and control pilot oil (609) to the boom 2 spool (104). Continued on next page
TM13345X19 (23APR18)
604— Return Oil 606— Trapped Oil 609— Control Pilot Oil
9025-05-73
MM16284,0000FDA -19-10FEB11-1/3
160GLC Excavator 042318 PN=889
Theory of Operation
During boom down (2) operation the boom lower meter-in cut valve is shifted by regenerative oil (603) from the boom cylinders. See Boom Regenerative Valve Circuit Operation. (Group 9025-05.) The boom lower meter-in cut valve blocks control pilot oil to the boom 2 spool and directs it to the switch valve in the boom flow rate control valve. The poppet of boom flow rate control valve now restricts supply oil (600) flow from pump 1 to the boom 1 spool. See Boom Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
Supply oil is restricted to the boom 1 spool. Regenerative oil from the boom cylinder head end is routed through the boom regenerative valve (82) to the boom cylinder rod end. Supply oil flows unrestricted to the other circuits that pump 1 supplies. When boom cylinder return oil pressure drops, the boom lower meter-in cut valve shifts. The switch valve in the boom flow rate control valve opens and allows supply oil from pump 1 to flow to the boom 1 spool. Boom down control pilot oil can now shift the boom 2 spool.
During operation of boom down and other function, the boom lowers due to own weight. MM16284,0000FDA -19-10FEB11-2/3
During boom down operation, control pilot oil (609) flows to the boom 2 spool through boom lower meter-in cut valve. Regenerative oil from the boom cylinders flows to the spring chamber (5) in boom lower meter-in cut valve through the orifice (4).
3 1
2
4
When pressure in the spring chamber becomes larger than the spring force, the boom lower meter-in cut valve is shifted.
Control pilot oil flows to and shifts the switch valve in the boom flow rate control valve. See Boom Flow Rate Control Valve Circuit Operation. (Group 9025-05.) During combined operation of boom lower and other functions, more supply oil is available to the other functions to ensure priority to them. 1— To Hydraulic Oil Tank 2— From Boom Down (pilot) 3— From Boom Cylinders 4— Orifice 5— Spring Chamber 6— From Boom 2 Spool
7— To Boom Flow Rate Control Valve (switch valve) 87— Boom Lower Meter-In Cut Valve 603— Regenerative Oil 604— Return Oil 609— Control Pilot Oil
5
87 7
603
6 604 609
TX1087668 —UN—10FEB11
Therefore, return oil is directed to the hydraulic oil tank through the passage in the boom lower meter-in cut valve. Boom 2 spool is returned to the neutral position.
Boom Lower Meter-In Cut Valve
MM16284,0000FDA -19-10FEB11-3/3
TM13345X19 (23APR18)
9025-05-74
160GLC Excavator 042318 PN=890
Theory of Operation
Boom Regenerative Valve Circuit Operation 125 83
57 88 86
85
81
82
600 89 85
TX1122120 —UN—14SEP12
604 609 610
TX1122120 Boom Regenerative Valve Circuit Schematic 57— Orifice 81— Boom 1 Spool 82— Boom Regenerative Valve 83— Boom Flow Rate Control Valve (valve and poppet)
85— Boom Reduced Leakage Valve 86— Drilled Passage 88— Boom Up Circuit Relief and Anticavitation Valve
The boom regenerative valve (82) is located inside the boom 1 spool (81). The boom regenerative valve improves boom control and prevents boom cylinder cavitation during boom down operation.
When regenerative oil (610) pressure is more than pump 1 supply oil (600), the boom regenerative valve (82) is open. Regenerative oil is combined with pump 1 supply oil and both are supplied to the boom cylinders rod end. When pump 1 supply oil is more than regenerative oil pressure, the boom regenerative valve is closed. Pump 1 supply oil only flows to the boom cylinders rod end. Regenerative oil passes through an orifice (57) and back to hydraulic oil tank.
Continued on next page
TM13345X19 (23APR18)
604— Return Oil 609— Pilot Oil 610— Regenerative Oil
Leakage Valves Operation. (Group 9025-05.) Oil then flows to the boom 1 spool. At the boom 1 spool, oil flows through a drilled passage (86) to the center of the spool.
The boom regenerative valve operates under the following operating conditions: low pump 1 delivery pressure and pilot oil pressure to the pilot cap for boom down, the weight of boom, arm, and bucket causes the boom to lower faster than the pump can supply oil to the boom cylinder rod end. Pilot oil (609) shifts the boom 1 spool to the boom down position. The pilot oil also shifts the boom reduced leakage valve (85) to allow oil to flow from the head end of the boom cylinders. See Boom and Arm Reduced
89— Boom Down Circuit Relief and Anticavitation Valve 125— Boom Cylinder (2 used) 600— Supply Oil
9025-05-75
JJ03229,000059B -19-26JAN16-1/2
160GLC Excavator 042318 PN=891
Theory of Operation
2
2
85 201
102
85
16
83
83 15 202
604 81
82
89
609 610
TX1122122
TX1122122 —UN—14SEP12
600
Boom Regenerative Valve Circuit Cross Section 2— Boom Down (pilot) 15— Pump 1 Supply Oil 16— Pump 2 Supply Oil 81— Boom 1 Spool 82— Boom Regenerative Valve
83— Boom Flow Rate Control Valve (valve and poppet) 85— Boom Reduced Leakage Valve 89— Boom Down Circuit Relief and Anticavitation Valve
102— Boom 2 Spool 609— Pilot Oil 201— From Boom Cylinder Head 610— Regenerative Oil End 202— To Boom Cylinder Rod End 600— Supply Oil 604— Return Oil JJ03229,000059B -19-26JAN16-2/2
TM13345X19 (23APR18)
9025-05-76
160GLC Excavator 042318 PN=892
Theory of Operation
Dig Regenerative Valve Circuit Operation TX1156174 —UN—21APR14
127 B30
3
107
110
104
117 95 98
100
97 2
B30 4 B31
B31 B37
A3
B35
84
16 2 76
75
15 91 600 604 606
81
609 90
610 3
Y22
650 1
DZ 125
TX1156174 Dig Regenerative Valve Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-77
160GLC Excavator 042318 PN=893
DF89619,00B5727 -19-08DEC15-1/5
Theory of Operation
TM13345X19 (23APR18)
9025-05-78
160GLC Excavator 042318 PN=894
Theory of Operation
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 15— Pump 1 (4-spool) 16— Pump 2 (5-spool) 75— Right Travel Spool 76— Bucket Spool 81— Boom 1 Spool 84— Dig Regenerative Valve 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (valve and poppet)
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 117— Main Relief and Power Dig Valve 125— Boom Cylinder (2 used)
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 return oil from boom cylinder (125) rod ends with the pump supply oil to the arm cylinder. 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) and pump 2 delivery pressure sensor (B37)
• Pressure at arm in pressure sensor (B31) • Pressure at boom up pressure sensor (B30)
B35— Pump 1 Delivery Pressure 127— Arm Cylinder Sensor (marked (PP1) 600— High-Pressure Oil B37— Pump 2 Delivery Pressure 604— Return Oil Sensor (marked (PP2) 606— Trapped Oil DZ—To Solenoid Valve Manifold 609— Pilot Oil Port DZ 610— Regenerative Oil Y22— Dig Regenerative Solenoid 650— Voltage Signal (marked SF) A3—Main Controller (MCZ) B30— Boom Up Pressure Sensor (marked P11) B31— Arm In Pressure Sensor (marked (P12)
See Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.) The solenoid valve then sends pilot oil (609) pressure to shift the dig regenerative valve. With the dig regenerative valve shifted, return oil from boom cylinder rod ends flows through boom 1 spool (81), dig regenerative valve, and check valve (lift check)—dig regenerative circuit (100) and is combined with high-pressure oil (600) from hydraulic pump 2 (16) and routed through the arm 1 spool (97) to the arm cylinder (127) head end, increasing cylinder speed and preventing cavitation.
Continued on next page
TM13345X19 (23APR18)
9025-05-79
DF89619,00B5727 -19-08DEC15-2/5
160GLC Excavator 042318 PN=895
Theory of Operation
201
100
84
200
202 604 609 610 TX1122125
TX1122125 —UN—14SEP12
Y22
Dig Regenerative Valve Schematic 84— Dig Regenerative Valve 200— Return Oil From Boom 100— Check Valve (lift Cylinder Rod End check)—Dig Regenerative 201— To Arm 1 Spool Circuit 202— Spring
604— Return Oil 609— Pilot Oil 610— Regenerative Oil Y22— From Dig Regenerative Solenoid (marked SF) Continued on next page
TM13345X19 (23APR18)
9025-05-80
DF89619,00B5727 -19-08DEC15-3/5
160GLC Excavator 042318 PN=896
Theory of Operation
Y24
Y22
Y23
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1107930
609 30
613 6
TX1107930 —UN—15NOV12
30
Dig Regenerative Solenoid Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-81
DF89619,00B5727 -19-08DEC15-4/5
160GLC Excavator 042318 PN=897
Theory of Operation 1— Solenoid 2— Spool 3— To Valve Function 5— Pressure Equals Magnetic Force 6— Energized
7— De-Energized 30— From Pilot Pressure Regulator Valve 31— To Hydraulic Oil Tank 604— Return Oil
The dig regenerative solenoid (marked SF) (Y22) is a proportional-type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse width modulated signal. The solenoid (1) reacts to the average voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on versus how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (7), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port.
609— Pilot Oil Y24— Power Dig/Travel Speed 613— Reduced Pilot Oil Solenoid (marked SG) Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC)
regulator valve (30) 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.)
When energized (6), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot pressure DF89619,00B5727 -19-08DEC15-5/5
TM13345X19 (23APR18)
9025-05-82
160GLC Excavator 042318 PN=898
Theory of Operation
Arm Regenerative Valve Circuit Operation TX1156171 —UN—21APR14
127 5
B30
52
43 DE
3
107
110
99 117 98 6
97
95
104
B30 4 B31
B31 B33
A3
B37
B35
16
94
81
76
75
15 91 600 602 604 606
90
609
3 Y23
610 DD
TX1156171
Arm Regenerative Valve Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-83
160GLC Excavator 042318 PN=899
1
650 DF89619,00B5728 -19-08DEC15-1/5
Theory of Operation
TM13345X19 (23APR18)
9025-05-84
160GLC Excavator 042318 PN=900
Theory of Operation
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) 43— From Arm 1 Flow Rate Pilot Valve (port SE) 52— Swing Motor 75— Right Travel Spool 76— Bucket Spool 81— Boom 1 Spool 90— Arm 2 Spool
91— Arm 2 Flow Rate Control 117— Main Relief and Power Dig B33— Swing Pressure Sensor Valve (valve and poppet) Valve (marked S3) 94— Arm Regenerative Valve 127— Arm Cylinder B35— Pump 1 Delivery Pressure 95— Swing Spool 600— High-Pressure Oil Sensor (marked PP1) 97— Arm 1 Spool 602— Low-Pressure Oil B37— Pump 2 Delivery Pressure 98— Arm 1 Flow Rate Control 604— Return Oil Sensor (marked PP2) Valve (valve and poppet) 606— Trapped Oil DD—To Solenoid Valve Manifold 99— Check Valve (lift 609— Pilot Oil Port DD check)—Arm 1 Regenerative 610— Regenerative Oil DE—To Solenoid Valve Manifold Circuit 650— Voltage Signal Port DE 104— Boom 2 Spool A3—Main Controller (MCZ) Y23— Arm Regenerative 107— Auxiliary Spool B30— Boom Up Pressure Sensor Solenoid (marked SC) 110— Left Travel Spool (marked P11) B31— Arm In Pressure Sensor (marked P12)
The arm regenerative valve (94) improves arm control and prevents arm cylinder (127) cavitation during arm in operation by combining return oil from arm cylinder rod end with the pump supply oil to the arm cylinder. The main controller (MCZ) (A3) sends a voltage signal (650) to arm regenerative solenoid (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)
The solenoid valve then routes pilot oil (609) to shift the arm regenerative valve and arm 2 flow rate control valve (91) switch valve. The return oil (604) route from arm cylinder (127) rod end to tank is blocked while arm regenerative valve is shifted, causing pressure to rise. Return oil pressure opens check valve (99) and is combined with supply oil from pump 2 (16). Regenerative oil (610) and supply oil flows through arm 1 spool (97) and is routed to arm cylinder head end increasing cylinder speed and preventing cavitation. For more information on arm 2 flow rate control valve, see Arm 2 Flow Rate Control Valve Circuit Operation. (Group 9025-05.)
See Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
9025-05-85
DF89619,00B5728 -19-08DEC15-2/5
160GLC Excavator 042318 PN=901
Theory of Operation
4
94
Y23 99 TX1156763
97
600
609
604
610
TX1156763 —UN—04APR14
91
Arm Regenerative Valve Section 4— Arm In (pilot) 97— Arm 1 Spool 604— Return Oil 91— To Arm 2 Flow Rate Control 99— Check Valve (lift 609— Pilot Oil Valve (valve and poppet) check)—Arm 1 Regenerative 610— Regenerative Oil 94— Arm Regenerative Valve Circuit Y23— From Arm Regenerative 600— High-Pressure Oil Solenoid (marked SC) Continued on next page
TM13345X19 (23APR18)
9025-05-86
DF89619,00B5728 -19-08DEC15-3/5
160GLC Excavator 042318 PN=902
Theory of Operation
Y24
Y22
Y23
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1107930
609 30
613 6
TX1107930 —UN—15NOV12
30
Arm Regenerative Solenoid Valve Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-87
DF89619,00B5728 -19-08DEC15-4/5
160GLC Excavator 042318 PN=903
Theory of Operation 1— Solenoid 2— Spool 3— To Valve Function 5— Pressure Equals Magnetic Force 6— Energized
7— De-Energized 30— From Pilot Pressure Regulator Valve 31— To Hydraulic Oil Tank 604— Return Oil
The arm regenerative solenoid (marked SC) (Y23) is a proportional-type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ) (A3). The voltage signal is a DC voltage that is turned on and off to form a pulse width modulated signal. The solenoid (1) coil reacts to the “average” voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on versus how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (7), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port.
609— Pilot Oil Y24— Power Dig/Travel Speed 613— Reduced Pilot Oil Solenoid (marked SG) Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC)
regulating valve (30) 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.)
When energized (6), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot pressure DF89619,00B5728 -19-08DEC15-5/5
TM13345X19 (23APR18)
9025-05-88
160GLC Excavator 042318 PN=904
Theory of Operation
Bucket Regenerative Valve Circuit Operation 600 77
604
15
609 76
610
57 126 7
79
86
TX1122129 —UN—14SEP12
78 201 202 80
TX1122129 Bucket Regenerative Valve Circuit Schematic 7— From Bucket Curl Pilot Valve 15— High Pressure Oil From Pump 1 57— Orifice 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
86— Orifice 126— Bucket Cylinder 201— Return Oil from Bucket Cylinder Rod End 202— Return Oil to Bucket Cylinder Head End 600— High Pressure Oil
bucket cylinder rod end is higher than the pump 1 delivery pressure, the bucket regenerative valve is opened. Regenerative oil is combined with high pressure oil from hydraulic pump 1 and routed to the bucket cylinder head end. Regenerative oil not used flows through orifice (57) to return oil (604).
The bucket regenerative valve (78) is located inside the bucket spool (76). The bucket regenerative valve combines regenerative oil (610) from the bucket cylinder (126) rod end with pump 1 high pressure oil (600) to prevent cavitation and improve function control. The bucket regenerative valve functions under the following operating conditions: low pump 1 (15) delivery pressure and pilot oil (609) pressure to the pilot cap for bucket curl (7). When bucket curl function is actuated, pilot oil pressure shifts the bucket spool to the bucket regenerative valve position. Regenerative oil passes through an orifice (86) in the bucket spool. If pressure of the oil returning from the
When the oil pressure to the bucket cylinder head end increases above the oil pressure from the bucket cylinder rod end, the bucket regenerative valve closes. Only high pressure oil (600) from pump 1 flows to the bucket cylinder head end. All returning oil from the bucket cylinder rod end then flows through the orifice to return oil.
Continued on next page
TM13345X19 (23APR18)
604— Return Oil 609— Pilot Oil 610— Regenerative Oil
9025-05-89
JJ03229,000059E -19-29OCT12-1/3
160GLC Excavator 042318 PN=905
Theory of Operation
600
7
604 609 610
79
86 76 201
57
15
77
78
80 TX1122130
TX1122130 —UN—14SEP12
202
Bucket Regenerative Valve Section
Continued on next page
TM13345X19 (23APR18)
9025-05-90
JJ03229,000059E -19-29OCT12-2/3
160GLC Excavator 042318 PN=906
Theory of Operation 7— Bucket Curl Pilot Oil 15— High Pressure Oil From Pump 1 57— Orifice 76— Bucket Spool 77— Bucket Flow Rate Control Valve
78— Bucket Regenerative Valve 79— Bucket Dump Circuit Relief and Anticavitation Valve 80— Bucket Curl Circuit Relief and Anticavitation Valve
86— Drilled Passage 201— Return Oil From Bucket Cylinder Rod End 202— Return Oil to Bucket Cylinder Head End 600— High Pressure Oil
604— Return Oil 609— Pilot Oil 610— Regenerative Oil
JJ03229,000059E -19-29OCT12-3/3
TM13345X19 (23APR18)
9025-05-91
160GLC Excavator 042318 PN=907
Theory of Operation
Boom and Arm Reduced Leakage Valves Operation 81 104 1
31 A
31
85 2
125
85 A 125
81
85
85 125 81 1
600 602
606 85 609
85
TX1088019
TX1088019 —UN—14FEB11
604
31
Boom Reduced Leakage Valve Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-92
AS79221,00003D8 -19-18MAR11-1/2
160GLC Excavator 042318 PN=908
Theory of Operation 1— Pilot Pressure from Pilot Control Valve 2— Manual Boom Lower Screw 31— Hydraulic Oil Tank
81— Boom 1 Spool 85— Boom Reduced Leakage Valve 104— Boom 2 Spool 125— Boom Cylinders
NOTE: The operational principles of the boom and arm reduced leakage valves are identical. Therefore, boom reduced leakage valve operation is used as an example. Reduced leakage valves are used in the boom head end circuit and arm rod end circuit. The function of a reduced leakage valve is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve. When the control valve is in neutral, the oil pressure generated by the load on the cylinders is applied to the spring end of boom reduced leakage valve (85) check valve through the boom reduced leakage valve switch valve. The check valve is held closed against the seat in housing trapping the oil from the cylinders at the work port.
600— High Pressure Oil 602— Low Pressure Supply Oil 604— Return Oil or Pressure-Free Oil
606— Trapped Oil 609— Pilot Oil
pressure from the cylinder is blocked by the switch valve. The oil pressure at the top (spring end) of the check valve can now flow through the pilot valve to the air bleed passage in the pilot caps and then to the hydraulic oil tank (31). The oil pressure from the cylinder pushes the check valve off its seat, opening the passage for oil to flow into the control valve return passage. The check valve is pushed off its seat because the OD of the upper land at the head end of check valve is slightly larger than at the lower land. The manual boom lower screw (2) is used to lower the boom if the engine should stop with the boom in the raised position. See Lower Boom with Engine Stopped. (Operator’s Manual.)
When a function is actuated, the pilot pressure (609) from pilot control valve (1) shifts the switch valve. The oil AS79221,00003D8 -19-18MAR11-2/2
TM13345X19 (23APR18)
9025-05-93
160GLC Excavator 042318 PN=909
Theory of Operation
TM13345X19 (23APR18)
9025-05-94
160GLC Excavator 042318 PN=910
Theory of Operation
Arm 1 Flow Rate Control Valve Circuit Operation TX1088029 —UN—07MAR11
52
5
SE
98 95
102
103
97
4
16
15
600 602 604
90
606 609 TX1088029 Arm 1 Flow Rate Control Valve Circuit Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-95
160GLC Excavator 042318 PN=911
MM16284,0000FE0 -19-18JAN16-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-96
160GLC Excavator 042318 PN=912
Theory of Operation 4— Arm In Pilot 5— Swing Left Pilot 15— Pump 1 16— Pump 2 52— Swing Motor 90— Arm 2 Spool 95— Swing Spool
97— Arm 1 Spool 98— Arm 1 Flow Rate Control Valve (switch valve and poppet) 102— Arm In Circuit Relief and Anticavitation Valve
The function of arm 1 flow rate control valve (switch valve and poppet) (98) is to restrict the flow of supply oil (600) from pump 2 (16) to the arm 1 spool (97) to ensure a
103— Arm Out Circuit Relief and 606— Trapped Oil Anticavitation Valve 609— Pilot Oil 600— Supply Oil SE—From Pilot Signal Manifold 602— Restricted Supply Oil (port SE) 604— Return Oil
priority flow of supply oil to the swing spool (95) during combined operation. MM16284,0000FE0 -19-18JAN16-2/4
Normal Operation—Supply oil (600) from pump 2 opens the check valve (200) in the poppet (201) of arm 1 flow rate control valve because the switch valve (203) is open. Supply oil flows through the check valve and switch valve to the arm 1 spool (97). As the load increases, the pressure increases pushing the poppet open and supply oil flows through the poppet to arm 1 spool.
98
200
201
204 97 16
202— To Solenoid Valve Manifold (port DE) 203— Switch Valve 204— From Arm 1 Flow Rate Pilot Valve (port SE) 600— Supply Oil 604— Return Oil
203 97 202
600 604
TX1088030 —UN—07MAR11
16— From Pump 2 97— To Arm 1 Spool 98— Arm 1 Flow Rate Control Valve 200— Check Valve 201— Poppet
Arm 1 Flow Rate Control Valve Normal Operation Continued on next page
TM13345X19 (23APR18)
9025-05-97
MM16284,0000FE0 -19-18JAN16-3/4
160GLC Excavator 042318 PN=913
Theory of Operation
The control pilot oil shifts the switch valve trapping oil (606) in the backside of poppet (201) which forces the poppet towards the close position. The poppet now restricts the flow of supply oil (600) to arm 1 spool. Supply oil now flows through the swing spool to the swing motor against the higher load pressure. 16— Supply Oil From Pump 2 97— To Arm 1 Spool (Restricted) 98— Arm 1 Flow Rate Control Valve 200— Check Valve 201— Poppet 202— To Solenoid Valve Manifold (port DE) 203— Switch Valve
97
201 98
200
204 16 203 97
202
204— From Arm 1 Flow Rate Pilot Valve (port SE) 600— Supply Oil 602— Restricted Supply Oil 604— Return Oil 606— Trapped Oil 609— Control Pilot Oil
600
606
602
609
604
TX1088031 —UN—07MAR11
Combined Operation—During swing and arm in combined operation, the arm 1 flow rate pilot valve (port SE) (204), in the pilot signal manifold, is shifted by control pilot oil (609) from arm in. The pilot valve then routes a portion of control pilot oil (609) from swing to the switch valve (203) of arm 1 flow rate control valve (98). For operation of pilot valves, see Pilot Signal Manifold Operation. (Group 9025-05.)
Arm 1 Flow Rate Control Valve Combined Operation
MM16284,0000FE0 -19-18JAN16-4/4
TM13345X19 (23APR18)
9025-05-98
160GLC Excavator 042318 PN=914
Theory of Operation
Arm 2 Flow Rate Control Valve Circuit Operation TX1088047 —UN—14FEB11
127
3
5
97
1 104
4 16 2
15
2 4 91
81
90
1 600 3 602
125
604 7 606 609
TX1088047 Arm 2 Flow Rate Control Valve Circuit Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-99
160GLC Excavator 042318 PN=915
MM16284,0000FE1 -19-18JAN16-1/3
Theory of Operation
TM13345X19 (23APR18)
9025-05-100
160GLC Excavator 042318 PN=916
Theory of Operation 1— Boom Up Pilot 2— Boom Down Pilot 3— Arm Out Pilot 4— Arm In Pilot 5— Swing Left Pilot 7— Pilot Oil From Arm Regenerative Solenoid Valve
15— Pump 1 16— Pump 2 81— Boom 1 Spool 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (switch valve and poppet)
The function of arm 2 flow rate control valve (switch valve and poppet) (91) is to restrict the flow of supply oil (600) from pump 1 (15) to the arm 2 spool (90) to ensure a
97— Arm 1 Spool 104— Boom 2 Spool 125— Boom Cylinder (2 used) 127— Arm Cylinder 600— Supply Oil 602— Restricted Supply Oil
604— Return Oil 606— Trapped Oil 609— Pilot Oil
priority flow of supply oil to the boom 1 spool (81) during arm in, boom up, and swing combined operation. MM16284,0000FE1 -19-18JAN16-2/3
6
93
204
98 17
92 98
202
Combined Operation—During combined operation of boom up, arm in, and swing, the arm regenerative solenoid is activated. When activated, control pilot oil shifts the switch valve of the arm 2 flow rate control valve.
600 604 Arm 2 Flow Rate Control Valve (normal operation)
With the switch valve shifted, high pressure oil is trapped on the backside of poppet, 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 pump 2 high pressure oil and the arm 1 spool regenerative circuit. See Arm Regenerative Valve Circuit Operation. (Group 9025-05.) 6— Check Valve 17— From Pump 1 92— Switch Valve 93— Poppet 98— To Arm 2 Spool 99— Arm 2 Flow Rate Control Valve 202— To Solenoid Valve Manifold (port DD)
204— From Arm Regenerative Solenoid Valve (port SC) 600— High Pressure Oil 602— Low Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
TX1148439 —UN—12DEC13
Normal Operation—High pressure oil from pump 1 (17) opens the check valve (6) in the poppet of arm 2 flow rate control valve because the switch valve is open. The high pressure oil flows through the check valve and switch valve to the arm 2 spool. As load increases, pressure increases pushing the poppet open and high pressure oil flows through the poppet to arm 2 spool.
99
99
6
93
98
204 17
92
98 202 600
606
602
609
604
TX1148442 —UN—12DEC13
The switch valve (92) and poppet (93) of arm 2 flow rate control valve (99) are located in separate areas on the hydraulic control valve. The switch valve of the arm 2 flow rate control valve is located in the arm 2 valve section of the control valve. The poppet of the arm 2 flow rate control valve is located in a section between the arm 2 valve and the boom 1 spool section. For layout of the hydraulic control valve, see Control Valve Operation. (Group 9025-05.)
Arm 2 Flow Rate Control Valve (combined operation) MM16284,0000FE1 -19-18JAN16-3/3
TM13345X19 (23APR18)
9025-05-101
160GLC Excavator 042318 PN=917
Theory of Operation
TM13345X19 (23APR18)
9025-05-102
160GLC Excavator 042318 PN=918
Theory of Operation
Bucket Flow Rate Control Valve Circuit Operation TX1105897 —UN—01FEB12
127
3 97
1 104
4 16 2
15
2
77
7
4 91
76
81
90
1 600 3 602
125
8
205
604 204
202 606 126
609
TX1105897 Bucket Flow Rate Control Valve Circuit Operation Continued on next page
TM13345X19 (23APR18)
9025-05-103
160GLC Excavator 042318 PN=919
MM16284,0000FE2 -19-19JAN16-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-104
160GLC Excavator 042318 PN=920
Theory of Operation 1— Boom Up Pilot 2— Boom Down Pilot 3— Arm Out Pilot 4— Arm In Pilot 7— Bucket Curl Pilot 8— Bucket Dump Pilot 15— Pump 1 16— Pump 2 76— Bucket Spool 77— Bucket Flow Rate Control Valve (switch valve and poppet)
81— Boom 1 Spool 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (switch valve and poppet) 97— Arm 1 Spool 104— Boom 2 Spool 125— Boom Cylinder (2 used) 126— Bucket Cylinder
127— Arm Cylinder 602— Restricted Supply Oil 202— To Solenoid Manifold Valve 604— Return Oil (port DK) 606— Trapped Oil 204— From Bucket Flow Rate 609— Pilot Oil Pilot Valve (port SK) 205— From Arm Regenerative Solenoid Valve (port SL) 600— Supply Oil
Restriction of supply oil to the bucket spool ensures a priority flow of supply oil to the boom 1 spool (81) during combined operation.
The function of the bucket flow rate control valve (switch valve and poppet) (77) is to restrict the flow of supply oil (600) from pump 1 (15) to the bucket spool (76) during bucket, arm in, and boom up combined operation.
MM16284,0000FE2 -19-19JAN16-2/4
Normal Operation—Supply oil (600) from pump 1 opens the check valve (200) in the poppet (201) of bucket flow rate control valve (77) because the switch valve is open. The supply oil flows through the check valve and switch valve to the bucket spool (76). As the load increases, the pressure increases, pushing the poppet open and supply oil flows through the poppet to bucket spool. 202— To Solenoid Manifold Valve (port DK) 203— Switch Valve 204— From Bucket Flow Rate Pilot Valve (port SK) 600— Supply Oil 604— Return Oil
200
201
204 76 203
15 76
202
600 604
TX1088052 —UN—07MAR11
15— From Pump 1 76— To Bucket Spool 77— Bucket Flow Rate Control Valve 200— Check Valve 201— Poppet
77
Bucket Flow Rate Control Valve (normal operation) Continued on next page
TM13345X19 (23APR18)
9025-05-105
MM16284,0000FE2 -19-19JAN16-3/4
160GLC Excavator 042318 PN=921
Theory of Operation
Boom up pilot oil now flows from port SK to the switch valve. Shifting the switch valve, trapping supply oil (606) on the backside of poppet. The poppet now restricts the flow of supply oil to the bucket spool (76). Supply oil (600) now flows to the arm 2 and boom 1 spools to ensure priority flow of supply oil to the arm in and boom up functions. Also, the arm 2 flow rate control valve circuit is actuated during the combined operation of bucket, arm in and boom up. Priority is given to the boom up function. See Arm 2 Flow Rate Control Valve Circuit Operation. (Group 9025-05.) 15— From Pump 1 76— To Bucket Spool 77— Bucket Flow Rate Control Valve 200— Check Valve 201— Poppet 202— To Solenoid Manifold Valve (port DK) 203— Switch Valve
77 200 201
204
76 15
203
76 202
204— From Bucket Flow Rate Pilot Valve (port SK) 600— Supply Oil 602— Restricted Supply Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
600 602
606
604
609
TX1088053 —UN—07MAR11
Combined Operation—During bucket, arm in, and boom up combined operation, the bucket flow rate pilot valve (port SK) (204), in the pilot signal manifold, is shifted by pilot oil (609) from arm in. For operation of pilot valves, see Pilot Signal Manifold Operation. (Group 9025-05.)
Bucket Flow Rate Control Valve (combined operation)
MM16284,0000FE2 -19-19JAN16-4/4
TM13345X19 (23APR18)
9025-05-106
160GLC Excavator 042318 PN=922
Theory of Operation
Boom Flow Rate Control Valve Circuit Operation TX1157663 —UN—21MAY14
DD
1
125 90 85
87 86
91 83
75
15 PUMP 1
124
82 81
93
76 RIGHT 73 CONTROL VALVE
84 36 HYDRAULIC OIL COOLER B31
2
128 4
16 PUMP 2 LEFT 74 CONTROL VALVE
117
95
107 110
600 104
602
97
127 604 3
B30
606 609 610
TX1157663 Boom Flow Rate Control Valve Circuit Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-107
160GLC Excavator 042318 PN=923
DF89619,00B574B -19-20JAN16-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-108
160GLC Excavator 042318 PN=924
Theory of Operation 82— Boom Regenerative Valve 1— Boom Up (pilot) 83— Boom Flow Rate Control 2— Boom Down (pilot) Valve (valve and poppet) 3— Arm Out (pilot) 84— Dig Regenerative Valve 4— Arm In (pilot) 85— Boom Reduced Leakage 15— Pump 1 Valve (valve and check 16— Pump 2 valve) 36— Hydraulic Oil Cooler 73— Right Control Valve (4-spool) 86— Orifice 74— Left Control Valve (5-spool) 87— Boom Lower Meter-In Cut Valve 75— Right Travel Spool 90— Arm 2 Spool 76— Bucket Spool 91— Arm 2 Flow Rate Control 81— Boom 1 Spool Valve (valve and poppet)
93— Bypass Shutoff Valve 95— Swing Spool 97— Arm 1 Spool 104— Boom 2 Spool 107— Auxiliary Spool 110— Left Travel Spool 117— Main Relief and Power Dig Valve 124— Oil Cooler Bypass Valve 125— Boom Cylinder (2 used) 127— Arm Cylinder 128— Check Valve
The purpose of the boom flow rate control valve (valve and poppet) (83) is to restrict supply oil in the circuit to ensure that there is sufficient supply oil for other functions during boom down and to restrict supply oil through boom 1 spool (81) during boom down so that boom regenerative valve (82) in boom 1 spool works properly.
600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil 610— Regenerative Oil B30— Boom Up Pressure Sensor B31— Arm In Pressure Sensor DD—To Solenoid Valve Manifold Port DD
During boom down and other functions, the boom lowers due to its own weight by the boom regenerative circuit and uses supply oil from the pump for other functions. This ensures that other functions maintain normal operation. See Boom Regenerative Valve Circuit Operation. (Group 9025-05.)
During boom down, the boom flow rate control valve restricts supply oil flow to the boom 1 spool from pump 1 (15). DF89619,00B574B -19-20JAN16-2/4
Normal Operation—When boom down is actuated, supply oil flows to the 4-spool side of the control valve from pump 1 (15). Supply oil opens the check valve (200) in the poppet (201) of the boom flow rate control valve (83) because the switch valve (203) is open due to no pilot oil pressure. Supply oil flows through boom flow rate control valve without any restriction and continues on to the boom 1 spool (81). 202— To Solenoid Valve Manifold Port DD 203— Switch Valve 204— From Boom Lower Meter-In Cut Valve 600— High-Pressure Oil 604— Return Oil
201
204 81 203
15 81
202
600 604 TX1088058
TX1088058 —UN—15FEB11
15— From Pump 1 81— To Boom 1 Spool 83— Boom Flow Rate Control Valve 200— Check Valve 201— Poppet
200 83
Boom Flow Rate Control Valve Normal Operation Continued on next page
TM13345X19 (23APR18)
9025-05-109
DF89619,00B574B -19-20JAN16-3/4
160GLC Excavator 042318 PN=925
Theory of Operation
Combined Operation—When boom down is actuated, return oil (604) 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.)
81
201 200
203 204
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 boom 1 spool. Consequently, more pump 1 high-pressure oil is available to other functions.
202
When supply oil pressure to boom 1 spool is less than return oil pressure during boom down operation, the return oil shifts the boom regenerative valve (82) and combine with supply oil. See Boom Regenerative Valve Circuit Operation. (Group 9025-05.)
83 81 600
604
602
606
609
TX1088059 —UN—14FEB11
Boom down pilot oil (609) from boom lower meter-in cut valve (87) shifts the switch valve (203) in the boom flow rate control valve.
Boom Flow Rate Control Valve Combined Operation 15— From Pump 1 81— To Boom 1 Spool 83— Boom Flow Rate Control Valve 200— Check Valve 201— Poppet 202— To Solenoid Valve Manifold Port DD 203— Switch Valve
204— From Boom Lower Meter-In Cut Valve 600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
DF89619,00B574B -19-20JAN16-4/4
TM13345X19 (23APR18)
9025-05-110
160GLC Excavator 042318 PN=926
Theory of Operation
TM13345X19 (23APR18)
9025-05-111
160GLC Excavator 042318 PN=927
Theory of Operation
Auxiliary Flow Rate Control Valve Circuit Operation 156
74
150
73
110 75
118 107
76
14 108
13 156 DY
104
81
97
90 52 93 6 95
143 16
TX1203094
15
600
604
602
606
609
124
TX1203094 —UN—12OCT15
5
Auxiliary Flow Rate Control Valve Schematic (auxiliary spool shifted and swing left active)
Continued on next page
TM13345X19 (23APR18)
9025-05-112
JJ03229,0000AE1 -19-19OCT15-1/4
160GLC Excavator 042318 PN=928
Theory of Operation 5— Swing Left (pilot) 75— Right Travel Spool 6— Swing Right (pilot) 76— Bucket Spool 13— Auxiliary (pilot) 81— Boom 1 Spool 14— Auxiliary (pilot) 90— Arm 2 Spool 15— Pump 1 93— Bypass Shutoff Valve 16— Pump 2 95— Swing Spool 52— Swing Motor 97— Arm 1 Spool 73— Right Control Valve (4-spool) 104— Boom 2 Spool 74— Left Control Valve (5-spool) 107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve (valve and poppet)
110— Left Travel Spool 118— Auxiliary Function Flow Combiner Valve 124— Oil Cooler Bypass Valve 143— From Auxiliary Shuttle Valve 150— Auxiliary Attachment 156— From Flow Rate Select Solenoid Valve (2 used)
Auxiliary flow rate control valve is used when two pump combined flow kit is installed on the machine.
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 with any of these inputs:
• Pressure on arm out pressure sensor (B61). • Pressure on arm out pressure sensor (B61) and boom
NOTE: Auxiliary flow rate control valve will not work properly unless two pump combined flow kit is installed on machine and appropriate work mode is enabled.
up pressure sensor (B30).
• Pressure on swing pressure sensor (B33). • Pressure on travel pressure sensor (B34).
The function of the auxiliary flow rate control valve (valve and poppet) (108) is to restrict supply oil 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.) For auxiliary flow rate control valve circuit location information, see Control Valve Operation. (Group 9025-05.)
• Two-speed on (combined flow on). • Pressure on attachment pressure sensor (B60).
JJ03229,0000AE1 -19-19OCT15-2/4
Normal Operation—Supply oil from pump 2 (16) opens check valve (300) in the poppet (301) of auxiliary flow rate control valve (108) because the switch valve (302) is open. The supply oil flows through the check valve and switch valve to auxiliary spool (107). As the load increases, the pressure increases pushing poppet open, allowing supply oil to flow through the poppet to auxiliary spool. 301— Poppet 302— Switch Valve 600— High-Pressure Oil 604— Return Oil DY—To Solenoid Manifold Valve (port DY)
301
156
107
302
16
DY
107
600 604
TX1166252 —UN—21JUL14
16— From Pump 2 107— To Auxiliary Spool 108— Auxiliary Flow Rate Control Valve 156— To Flow Rate Select Solenoid Valve 300— Check Valve
300 108
Auxiliary Flow Rate Control Valve (normal operation) Continued on next page
TM13345X19 (23APR18)
9025-05-113
JJ03229,0000AE1 -19-19OCT15-3/4
160GLC Excavator 042318 PN=929
Theory of Operation
Control Operation—Auxiliary flow rate valve is shifted by pilot oil from flow rate select solenoid valve (156) when combined with one of the following operations:
• Arm out • Boom up • Swing • Travel
301
107
156
Pilot oil (609) from flow rate select solenoid valve shifts switch valve (302), creating trapped oil (606) on the backside of poppet (301). The poppet now restricts the flow of supply oil from pump 2 (16) to auxiliary spool (107). Supply oil from pump 2 flows to arm, boom, and swing spools to ensure priority flow of supply oil to these functions.
16 302 DY
600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil DY—To Solenoid Manifold Valve (port DY)
108 107 600
604
602
606
609
TX1166253 —UN—21JUL14
See Flow Rate Select Solenoid Valve Operation and see Two Pump Combined Flow Kit Operation. (Group 9025-05.)
16— From Pump 2 107— To Auxiliary Spool 108— Auxiliary Flow Rate Control Valve 156— From Flow Rate Select Solenoid Valve 300— Check Valve 301— Poppet 302— Switch Valve
300
Auxiliary Flow Rate Control Valve (control operation)
JJ03229,0000AE1 -19-19OCT15-4/4
TM13345X19 (23APR18)
9025-05-114
160GLC Excavator 042318 PN=930
Theory of Operation
Swing Reduction Gear Case Operation
52
9
2
10
3
1
8
4
7
TX1088093 —UN—15FEB11
5
6 TX1088093 Swing Gear Case Cross Section 1— Swing Motor Shaft 2— First Stage Planetary Gear 3— Ring Gear
4— Second Stage Planetary Gear 8— Second Stage Sun Gear 5— Housing 9— First Stage Carrier 6— Shaft 10— First Stage Sun Gear 7— Second Stage Carrier
Swing gear case is two stage planetary type gear case. The ring gear (3) is attached to gear case housing (5). The swing motor shaft (1) rotates the first stage sun gear (10). Power is transferred from the first stage sun gear to the second stage sun gear (8) through the first stage planetary gear (2) and the first stage carrier (9). The second stage
52— Swing Motor
sun gear rotates the shaft (6) through the second stage planetary gear (4) and the second stage carrier (7). The swing bearing internal gear is mounted to the undercarriage. The shaft is engaged in the internal gear and rotates the upperstructure. RH60123,0000CDA -19-02APR13-1/1
TM13345X19 (23APR18)
9025-05-115
160GLC Excavator 042318 PN=931
Theory of Operation
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation
54 11 1 2
10
3 9
4 8
7
TX1088113
TX1088113 —UN—25FEB11
5
6
Swing Motor 1— Spring 2— Brake Piston 3— Brake Plate 4— Friction Disc
5— Piston 6— Shoe 7— Shaft 8— Swash Plate 9— Housing
10— Cylinder Block 11— Valve Plate 54— Swing Crossover Relief Valve
Swing Motor—The swing motor is a fixed-displacement, axial-piston motor consisting of swash plate (8), cylinder block (10), valve plate (11), housing (9), and swing park brake. Swing park brake consists of spring (1), brake piston (2), brake plate (3), and friction disc (4). Piston (5) is inserted into cylinder block which is splined to shaft (7).
Piston is pushed by pressurized oil from pump. Shoe (6) 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.)
Continued on next page
TM13345X19 (23APR18)
9025-05-116
DF89619,00B572B -19-03FEB17-1/3
160GLC Excavator 042318 PN=932
Theory of Operation
12
53
53
22
21
13
20
18 17 54
54
16 15 14
TX1088115
TX1088115 —UN—16FEB11
19
Swing Crossover Relief Valve and Make-Up Check Valve 12— Poppet 13— Port 14— Cavity 15— Passage 16— Passage
17— Piston 18— Cavity 19— Cavity 20— Spring 21— Poppet
22— Orifice 53— Make-Up Check Valve (2 used) 54— Crossover Relief Valve (2 used)
Continued on next page
TM13345X19 (23APR18)
9025-05-117
DF89619,00B572B -19-03FEB17-2/3
160GLC Excavator 042318 PN=933
Theory of Operation
21 22
20
15
16
17
54
TX1088116 —UN—16FEB11
24 14 19
23
18
TX1088116 Crossover Relief Valve (exploded view) 14— Cavity 15— Passage 16— Passage 17— Piston
18— Cavity 19— Cavity 20— Spring 21— Poppet
22— Orifice 23— Low-Pressure Port 24— High-Pressure Port
Swing Motor Crossover Relief Valve—The swing motor crossover relief valves (54) are direct-acting relief valves with a shock-reducing function. Low-Pressure Relief Operation (shockless function): High pressure at port (24) flows into cavity (14) through poppet (21). Pressure oil from cavity (14) flows into cavities (18 and 19) via passages (15 and 16). Cavity (18) is larger than cavity (19) so that the piston moves to the left. A pressure difference is created from one side of the poppet to the other. When pressure difference is increased more than spring force, the poppet is open and pressure oil flows to port (23). When piston reaches full stroke the pressure difference is eliminated, the poppet is closed and the pressure in the swing circuit reaches set pressure. High-Pressure Relief Operation (overload prevention): After the piston is moved full stroke, the spring is compressed and circuit pressure becomes the
54— Crossover Relief Valve
set-pressure. If pressure at port (24) increases more than the spring set-pressure, the poppet is open and pressure oil flows to port (23). When pressure at port (24) is reduced to the specified level, the poppet is closed by the spring force. 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 continues 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 make-up check valve (53) provides oil to the low-pressure side of the swing motor to prevent cavitation. DF89619,00B572B -19-03FEB17-3/3
TM13345X19 (23APR18)
9025-05-118
160GLC Excavator 042318 PN=934
Theory of Operation
Swing Motor Damper Valve 2
2
BCD
E 1
C D 4
E 3
1
Time to Pressure Output Curve for Inlet Side
TX1014237 —UN—20NOV06
A
B
TX1014236 —UN—20NOV06
A
Time to Pressure Output Curve for Return Side
17 16 7
15
14
13
12
11
10
9 16
18
6
600 604 606
TX1088166
TX1088166 —UN—01MAR11
5
8
Swing Damper Valves—When Relieving
Continued on next page
TM13345X19 (23APR18)
9025-05-119
MM16284,0000FE7 -19-19JAN16-1/8
160GLC Excavator 042318 PN=935
Theory of Operation 1— Time 2— Pressure 3— Without Swing Damper Valve 4— With Swing Damper Valve 5— Swing Damper Valve A 6— Swing Damper Valve B 7— Orifice 8— Spring 9— Poppet 10— Chamber M 11— Ball
12— Plunger 13— Spring 14— Chamber N 15— Piston 16— Spring Chamber 17— Swing Motor 18— Control Valve Swing Spool 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil
The function of swing damper valves A and B (5 and 6) is to relieve the pressure spike and aftershock at swing motor (17) when control valve swing spool (18) is returned to neutral. In neutral, the swing spool stops the flow of supply oil to the inlet side of swing motor and blocks the flow of return oil (604) from the return side. As the swing motor continues to rotate due to the inertia force of upperstructure, pressure in the return side increases momentarily. The inlet side of swing motor goes to a lower pressure. When the swing motor stops rotating, an aftershock or pressure increase is created at the inlet side of swing motor. The swing crossover relief valves and swing damper valves relieve the pressure increase and aftershock as shown by the time (1) to pressure (2) output curves. Between A and B (when relieving), the swing crossover relief valves, and swing damper valves operate as follows:
Swing Crossover Relief Valves: 1. High-pressure oil (600) of the pressure spike at return side of swing motor (17) is relieved to inlet side through the swing crossover relief valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation. (Group 9025-05.) Swing Damper Valve A (5): 1. High-pressure oil pushes the ball (11) off seat of poppet (9) and then flows through the plunger (12) to chamber N (14). 2. Pressure in chamber N increases pushing the piston (15) against the plug. 3. When pressure increase becomes greater than the force of springs (8 and 13), plunger, ball, and poppet are pushed to the right compressing the springs. Swing Damper Valve B (6): 1. High-pressure oil flows through inner passage to spring chamber (16). 2. When pressure increase becomes greater than the force of springs, the piston, plunger, ball, and poppet are pushed to the left compressing the springs. The valves remain at this state until the high-pressure oil on return side of swing motor begins to decrease (B to C—pressure begins to decrease).
Continued on next page
TM13345X19 (23APR18)
9025-05-120
MM16284,0000FE7 -19-19JAN16-2/8
160GLC Excavator 042318 PN=936
Theory of Operation
2
2
BCD
E 1
C D E
4
3 1
Time to Pressure Output Curve for Inlet Side
TX1014237 —UN—20NOV06
A
B
TX1014236 —UN—20NOV06
A
Time to Pressure Output Curve for Return Side
17
16
7 8
10 5
15
14 13 12
9
11
600 18
601 606
TX1088167
TX1088167 —UN—18FEB11
6
Swing Damper Valves—Pressure Begins to Decrease
Continued on next page
TM13345X19 (23APR18)
9025-05-121
MM16284,0000FE7 -19-19JAN16-3/8
160GLC Excavator 042318 PN=937
Theory of Operation 1— Time 2— Pressure 3— Without Swing Damper Valve 4— With Swing Damper Valve 5— Swing Damper Valve A 6— Swing Damper Valve B 7— Orifice 8— Spring 9— Poppet 10— Chamber M 11— Ball
12— Plunger 13— Spring 14— Chamber N 15— Piston 16— Spring Chamber 17— Swing Motor 18— Control Valve Swing Spool 600— High-Pressure Oil 601— Medium-Pressure Oil 606— Trapped Oil
When swing motor (17) rotation due to the inertia force of upperstructure is reduced, the pressure spike at return side of swing motor also decreases. Between B and C (pressure begins to decrease) the swing damper valves operate as follows: Swing Damper Valve A (5): 1. When pressure spike at return side of swing motor (17) begins to decrease to medium-pressure oil (601),
pressure in chamber N (14) also begins to decrease. When pressure becomes less than force of spring (13), the plunger (12), is pushed to the left. 2. At the same time, poppet (9) is pushed to the left by its spring (8). Poppet moves more slowly because oil in chamber M (10) must flow through the orifice (7) causing pressure in chamber M to increase. 3. Therefore, the plunger moves away from the poppet, opening a passage for pressure oil to flow from the return side to inlet side of swing motor. 4. As pressure oil flows to the other side, pressure in the return side is controlled and aftershock is reduced. Swing Damper Valve B (6): 1. No operation between B to C—pressure begins to decrease. The valves remain at this state until the pressure spike at return side of swing motor decreases more (C to D—pressure at return side decreases).
Continued on next page
TM13345X19 (23APR18)
9025-05-122
MM16284,0000FE7 -19-19JAN16-4/8
160GLC Excavator 042318 PN=938
Theory of Operation
2
2
BCD
E 1
Time to Pressure Output Curve for Inlet Side
C D E
4
3 1
TX1014237 —UN—20NOV06
A
B
TX1014236 —UN—20NOV06
A
Time to Pressure Output Curve for Return Side
17
7
10
8
9
5
8
10
11
12
13
14 15
6
16
7
600 602
18 TX1088168
TX1088168 —UN—08MAR11
9
Swing Damper Valves—Pressure at Return Side Decreases
Continued on next page
TM13345X19 (23APR18)
9025-05-123
MM16284,0000FE7 -19-19JAN16-5/8
160GLC Excavator 042318 PN=939
Theory of Operation When swing motor (17) rotation due to the inertia of upperstructure is reduced, the pressure spike at return side of swing motor also decreases. Between C and D (pressure at return side decreases) the swing damper valves operate as follows: Swing Damper Valve A (5): 1. Poppet (9) continues to be pushed to the left by its spring (8) but moves slowly because oil in chamber M (10) must flow through the orifice (7) causing pressure in chamber M to increase. Swing Damper Valve B (6): 1. When pressure spike at return side of swing motor decreases to low-pressure oil (602), pressure in chamber N (14) also decreases. When pressure becomes less than force of spring (13), plunger (12) is pushed to the right. 2. At the same time, poppet (9) is pushed to the right by its spring (8). Poppet moves slowly because oil in chamber M (10) must flow through the orifice (7) causing pressure in chamber M to increase.
1— Time 2— Pressure 3— Without Swing Damper Valve 4— With Swing Damper Valve 5— Swing Damper Valve A 6— Swing Damper Valve B 7— Orifice 8— Spring 9— Poppet 10— Chamber M
3. Therefore, the plunger moves away from the poppet, opening a passage for pressure oil to flow from the return side to inlet side of swing motor. Pressure oil now acts on ball (11) and poppet pushing the ball and poppet to the right compressing spring. 4. As the pressure oil flows to the inlet side, aftershock pressure in the return side is relieved promptly to the inlet side. The valves remain at this state until the aftershock pressure is sensed at the inlet side (D to E—during aftershock).
Continued on next page
TM13345X19 (23APR18)
11— Ball 12— Plunger 13— Spring 14— Chamber N 15— Piston 16— Spring Chamber 17— Swing Motor 18— Control Valve Swing Spool 600— High-Pressure Oil 602— Low-Pressure Oil
9025-05-124
MM16284,0000FE7 -19-19JAN16-6/8
160GLC Excavator 042318 PN=940
Theory of Operation
2
2
BCD
E 1
C D 4
E 3
1
Time to Pressure Output Curve for Inlet Side
TX1014237 —UN—20NOV06
A
B
TX1014236 —UN—20NOV06
A
Time to Pressure Output Curve for Return Side
17
16 7
5
15
14
13 12
11
10
8
9
601 18
602
TX1088169
TX1088169 —UN—18FEB11
6
Swing Damper Valves—During Aftershock
Continued on next page
TM13345X19 (23APR18)
9025-05-125
MM16284,0000FE7 -19-19JAN16-7/8
160GLC Excavator 042318 PN=941
Theory of Operation When swing motor (17) stops rotating, the pressure spike at the inlet side of swing motor increases causing an aftershock. Between D and E (during aftershock) the swing damper valves operate as follows: Swing Damper Valve A (5): 1. Medium-pressure oil (601) from inlet side of swing motor, acts on ball (11) and poppet (9) through inner passage. Ball and poppet are pushed to the right compressing spring (8). Swing Damper Valve B (6): 1. Medium-pressure oil from inlet side of swing motor, pushes the ball off seat of poppet and oil flows through inner passage to the return side of swing motor.
1— Time 2— Pressure 3— Without Swing Damper Valve 4— With Swing Damper Valve 5— Swing Damper Valve A 6— Swing Damper Valve B 7— Orifice 8— Spring 9— Poppet 10— Chamber M
11— Ball 12— Plunger 13— Spring 14— Chamber N 15— Piston 16— Spring Chamber 17— Swing Motor 18— Control Valve Swing Spool 601— Medium-Pressure Oil 602— Low-Pressure Oil
The valves repeat these operations until pressure spike is controlled and aftershock is relieved. When pressures at the inlet and return side of swing motor decrease completely, the damper valves stop operating. MM16284,0000FE7 -19-19JAN16-8/8
TM13345X19 (23APR18)
9025-05-126
160GLC Excavator 042318 PN=942
Theory of Operation
Swing Motor Park Brake Release Circuit Operation 52
1 2
3
8 5
4
7
TX1002396 —UN—09JAN06
6
TX1002396 Swing Park Brake Release Circuit Operation 1— Spring 2— Brake Piston 3— Orifice
4— Check Valve 5— Brake Piston Chamber
Releasing Park Brake—When any dig or swing function is operated, the swing park brake release pilot valve is shifted allowing pilot pressure oil through check valve (4) to move brake piston (2). As brake piston moves, plate (7) and friction plate (6) disengage, which releases the swing park brake. Applying Park Brake—When the dig or swing control lever is returned to neutral, the swing park brake release pilot valve stops the flow of pilot oil to the swing motor.
6— Friction Plate 7— Plate 8— Cylinder Block
52— Swing Motor
The spring (1) pushes the brake piston down, forcing the oil through the orifice (3) 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 engages the friction plate (6), which acts on the cylinder block (8), and the plate (7), which acts on the inside of the swing motor housing, securing the upperstructure from moving. MM16284,0000FE8 -19-16FEB11-1/1
TM13345X19 (23APR18)
9025-05-127
160GLC Excavator 042318 PN=943
Theory of Operation
Center Joint Operation 3
4
2
6
3
4
5
5
2
72 1
6
1
1
4
72
6
6
6
5 6
2 1
3
4
2
600
TX1088186 —UN—17FEB11
3 5
604 609 1
TX1088186 Center Joint 1— Drain 2— Left Travel Forward 3— Left Travel Reverse
4— Right Travel Forward 5— Right Travel Reverse 6— Travel Speed Change
The center joint (72) is a 360° rotary manifold. It allows oil to flow to and from the travel motors 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.
72— Center Joint 600— Supply Oil 604— Return Oil
609— Pilot Oil
Oil flows into and through the spindle to passages in the housing, and then out of the housing to the travel motors. Sealing rings stop oil from leaking between the spindle and housing into adjacent passages.
MM16284,0000FE9 -19-14JAN16-1/1
TM13345X19 (23APR18)
9025-05-128
160GLC Excavator 042318 PN=944
Theory of Operation
TM13345X19 (23APR18)
9025-05-129
160GLC Excavator 042318 PN=945
Theory of Operation
Travel Motor and Park Brake Valve Operation
60
61 75B
B
75A
A
37
72
64
64 B
110A
A 63
65
66
67
110B
68 71
70
604 606 TX1085865
TX1085865 —UN—29FEB12
69
62
Travel Motor and Brake Valve Schematic
Continued on next page
TM13345X19 (23APR18)
9025-05-130
MM16284,0000FEA -19-08MAR11-1/9
160GLC Excavator 042318 PN=946
Theory of Operation 37— From Solenoid Valve Manifold—Travel Speed Solenoid Valve (SI) 60— Right Travel Device 61— Right Travel Motor 62— Left Travel Device 63— Left Travel Motor
64— Travel Park Brake 65— Servo Piston 66— Travel Speed Change Valve 67— Shuttle Valve 68— Travel Motor Crossover Relief Valve 69— Check Valve 70— Orifice
71— Counterbalance Valve 72— Center Joint 75A— From Right Travel Spool Bottom Port—Reverse 75B— From Right Travel Spool Top Port—Forward 110A— From Left Travel Spool Top Port—Forward
Continued on next page
TM13345X19 (23APR18)
9025-05-131
110B— From Left Travel Spool Bottom Port—Reverse 604— Return Oil 606— Trapped Oil
MM16284,0000FEA -19-08MAR11-2/9
160GLC Excavator 042318 PN=947
Theory of Operation
9 8
7
TX1088187 —UN—17FEB11
4
6
1
5
64
3
2 65
TX1088187 Travel Motor and Brake Valve Components 1— Spring 2— Swash Plate 3— Ball Guide 4— Piston (9 used)
8— Brake Valve Housing 9— Park Brake Piston 64— Travel Park Brake
5— Cylinder Block 6— Drive Shaft 7— Valve Plate
65— Servo Piston
Travel Motor and Brake Valve—The travel motor is a variable-displacement, swash plate (2), axial-piston type motor that includes the brake valve housing (8) and travel park brake (64). Brake valve housing consist of the following components:
hydraulically released (negative type). The brake is released when travel function is actuated and supply 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.
• Travel Speed Change Valve (66) • Shuttle Valve (67) • Orifice (70) • Counterbalance Valve (71) • Travel Motor Crossover Relief Valve (2 used) (68) • Check Valve (2 used) (69)
When travel function is released, the counterbalance valve returns to center position blocking the supply oil acting on park brake piston (9). The disk spring pushing against the park brake piston forces the oil to flow through the orifice in the piston and into propel motor housing. The delay caused by oil flowing through the orifice is enough to slow engagement to ensure that park brake is only fully applied after the machine has stopped.
Travel Park Brake—The travel park brake is a wet-type multi-disk brake. The brake is spring applied and
Continued on next page
TM13345X19 (23APR18)
9025-05-132
MM16284,0000FEA -19-08MAR11-3/9
160GLC Excavator 042318 PN=948
Theory of Operation
37
67
66
10
65 4
2
70
TX1088188 —UN—17FEB11
604
TX1088188 Travel Motor Slow Speed Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-133
MM16284,0000FEA -19-08MAR11-4/9
160GLC Excavator 042318 PN=949
Theory of Operation 2— Swash Plate 4— Piston (9 used) 10— Spring 37— From Solenoid Valve Manifold—Travel Speed Solenoid Valve (SI)
65— Servo Piston 66— Travel Speed Change Valve 67— Shuttle Valve
Travel Motor Slow Speed—At slow speed (turtle), the oil acting on the travel speed change valve (66) is open to return through the travel speed solenoid valve (37). Travel speed change valve is held up by the spring (10). See Travel Motor Speed Circuit Operation for more information. (Group 9025-05.)
70— Orifice 604— Return Oil
travel speed change valve blocks the flow of supply oil to the servo piston. Supply oil from the pressurized motor work port is routed to the valve by the shuttle valve (67). The swash plate (2) is held at maximum displacement. At maximum displacement the motor turns at slow speed with high torque.
The oil acting on the servo piston (65) is routed to return through the center of travel speed change valve. The Continued on next page
TM13345X19 (23APR18)
9025-05-134
MM16284,0000FEA -19-08MAR11-5/9
160GLC Excavator 042318 PN=950
Theory of Operation
37
67
66
10
4
2
65
600 604 609 TX1088189
TX1088189 —UN—17FEB11
70
Travel Motor Fast Speed Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-135
MM16284,0000FEA -19-08MAR11-6/9
160GLC Excavator 042318 PN=951
Theory of Operation 2— Swash Plate 4— Piston (9 used) 10— Spring 37— From Solenoid Valve Manifold—Travel Speed Solenoid Valve (SI)
65— Servo Piston 66— Travel Speed Change Valve 67— Shuttle Valve
Travel Motor Fast (Rabbit) Speed—At fast speed (rabbit), pilot oil (609) from the travel speed solenoid valve (37) pushes the travel speed change valve (66) down. See Travel Motor Speed Circuit Operation for more information. (Group 9025-05.)
70— Orifice 600— Supply Oil 604— Return Oil 609— Pilot Oil
(70), and to the servo piston (65). The piston then moves the swash plate (2) to its minimum angle. At minimum angle, the travel motors turn at fast speed with reduced torque. Orifice controls the flow of supply oil to the piston to modulate the change in speed.
Supply oil (600) flows from the motor work port, through the shuttle valve (67), travel speed change valve, orifice Continued on next page
TM13345X19 (23APR18)
9025-05-136
MM16284,0000FEA -19-08MAR11-7/9
160GLC Excavator 042318 PN=952
Theory of Operation
75B
75A
71
65
70
17
11
69
69 67
23 110
12
16 13
14 600 601 602 604
60
15
65 66
71
68
67
75B
61
A
64
37
69
TX1088190
75A
TX1088190 —UN—08MAR11
B
Counterbalance Valve Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-137
MM16284,0000FEA -19-08MAR11-8/9
160GLC Excavator 042318 PN=953
Theory of Operation 11— Restriction 12— Poppet 13— Orifice 14— Piston 15— Spring 16— To Fast Speed Servo Piston 17— Spring (2 used) 37— To Travel Speed Solenoid Valve (SI)
60— Right Travel Device 61— Travel Motor 64— Travel Park Brake 65— Piston 66— Travel Speed Change Valve 67— Shuttle Valve 68— Travel Motor Crossover Relief Valve
Counterbalance Valve (71)—When the travel spools in the control valve are in neutral, counterbalance valve is held in the center position by springs (17). Both travel motor work ports (75A and 75B) 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, supply oil (600) 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 (604) from the motor. The increased pressure is sensed at the end of counterbalance valve through orifice (70) and begins to shift the counterbalance valve. As the valve shifts, a path is opened for return oil to flow to the control valve. Supply oil flows to the park brake piston (14) to release the travel park brake (64). Supply 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
69— Check Valve 70— Orifice 71— Counterbalance Valve 75A— Travel Motor Work Port 75B— Travel Motor Work Port 110— To Travel Motor 600— Supply Oil
601— Medium Pressure Oil 602— Low Pressure Oil 604— Return Oil
of motor, the spring begins to shift the counterbalance valve towards the neutral position. A restriction is created restricting the flow of return oil 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 the 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 oil is then created in the return side of motor and low pressure oil (602) on the other. When pressure in the return side becomes higher than the low pressure side of motor, the check valve is pushed open. Return oil from the return side flows to low pressure side preventing cavitation. MM16284,0000FEA -19-08MAR11-9/9
TM13345X19 (23APR18)
9025-05-138
160GLC Excavator 042318 PN=954
Theory of Operation
Travel Motor Speed Circuit Operation B37 B34
B35
B32
1 A3
S11 2 47 B38 48
609
TX1107910 —UN—10FEB12
B36
Y24 63
650
66
61
TX1107910 Travel Motor Speed Circuit Fast Speed Operation 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 B35— Pump 1 Delivery Pressure S11— Travel Mode Switch Sensor (marked PP1) 609— Pilot Oil Y24— Power Dig/Travel Speed B36— Pump 1 Control Pressure 650— Electrical Voltage Solenoid (marked SG) Sensor (marked PC1) A3—Main Controller (MCZ) B32— Front Attachment Pressure B37— Pump 2 Delivery Pressure Sensor (marked PP2) Sensor (marked FRT) B38— Pump 2 Control Pressure B34— Travel Pressure Sensor Sensor (marked PC2) (marked TR)
Travel Motor Slow (turtle) Speed—When the travel mode switch (S11) is in the slow (turtle) speed (2) position, the power dig/travel speed solenoid (Y24) is de-energized. The travel speed change valve (66) 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.)
The power dig/travel speed solenoid (Y24) is energized only when all of the following conditions are met:
Travel Motor Fast (rabbit) Speed—When travel mode switch is in the fast (rabbit) speed (1) position, the power dig/travel speed solenoid (Y24) is energized. Pilot oil (609) is routed to the travel speed change valve (66), and the travel motors are shifted to fast speed. See Travel Motor and Park Brake Valve Operation. (Group 9025-05.)
• Both pump 1 and pump 2 control pressure sensor must
• Travel mode switch is at fast (rabbit) speed position • Travel pressure sensor is on • Front attachment pressure sensor is off • Both pump 1 and pump 2 delivery pressure sensor must indicate low pressure
indicate high pressure
See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for electrical circuit information. (Group 9015-10.)
Continued on next page
TM13345X19 (23APR18)
9025-05-139
DF89619,00B58AE -19-01MAY15-1/4
160GLC Excavator 042318 PN=955
Theory of Operation
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).
Continued on next page
TM13345X19 (23APR18)
9025-05-140
DF89619,00B58AE -19-01MAY15-2/4
160GLC Excavator 042318 PN=956
Theory of Operation
Y24
Y22
Y23
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1107930
609 30
613 6
TX1107930 —UN—15NOV12
30
Power Dig/Travel Speed Solenoid Operation
Continued on next page
TM13345X19 (23APR18)
9025-05-141
DF89619,00B58AE -19-01MAY15-3/4
160GLC Excavator 042318 PN=957
Theory of Operation 1— Solenoid 2— Spool 3— To Valve Function 5— Pressure Equals Magnetic Force 6— Energized
7— De-Energized 30— From Pilot Pressure Regulator Valve 31— To Hydraulic Oil Tank 604— Return Oil
Power Dig/Travel Speed Solenoid (marked SG) (Y24)—is a proportional type solenoid valve. The solenoid valve is actuated by a voltage signal from the main controller (MCZ). The voltage signal is a DC voltage that is turned on and off to form a pulse width modulated signal. The solenoid (1) coil reacts to the “average” voltage to create a magnetic force to shift the spool (2) left against a spring. The reduced pilot oil (613) pressure sent to the valve function (3) depends on how long the voltage signal is on versus on how long it is off. The reduced pilot oil pressure is in proportion to the voltage signal. When de-energized (7), the spool is pushed to the right by a spring. The valve function port is connected to the hydraulic oil tank (31) port.
609— Pilot Oil Y24— Power Dig/Travel Speed 613— Reduced Pilot Oil Solenoid (marked SG) Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC)
regulator valve (30) 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.)
When energized (6), the magnetic force shifts the spool left against the spring. Pilot oil (609) from the pilot pressure DF89619,00B58AE -19-01MAY15-4/4
TM13345X19 (23APR18)
9025-05-142
160GLC Excavator 042318 PN=958
Theory of Operation
Cylinder Operation
2
9
3
1
4
5
6
10
11
10
9
7 8
15
16
14
13
12 TX1211249 —UN—22FEB16
17
TX1211249 Cylinder Operation 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)
Boom, Arm, and Bucket Cylinders The boom, arm, and bucket cylinders are similar in design. 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).
11— Cap Seal 12— Set Screw 13— Nut 14— Cushion 15— Barrel 16— Cylinder Rod
17— Rod Guide
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 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.
JA66566,000265F -19-22FEB16-1/1
TM13345X19 (23APR18)
9025-05-143
160GLC Excavator 042318 PN=959
Theory of Operation
Return Filter Operation 5
2 6
4
1 3 5
3 6
TX1093786 —UN—31MAY16
4
TX1093786 Return Filter Operation 1— Return Filter Bypass Operation 2— Return Filter Normal Operation
3— Bypass Valve 4— Filter Element 5— Return Oil From Oil Cooler
The filter element (4) is located in a chamber inside the hydraulic oil tank. O-rings are used at each end of filter element to prevent leakage. A spring holds filter element on its seat. Return oil from oil cooler (5) and control valve (6) flow through the filter element from outside to center. Filtered oil flows out the bottom of filter into hydraulic oil tank.
6— Return Oil From Control Valve
in return circuit and allows a path for return oil if filter element becomes plugged. During bypass operation, oil flows into chamber faster than it can flow through the filter element, causing pressure to increase. The higher pressure forces bypass valve open allowing oil to flow down center of filter element and into hydraulic oil tank. The bypass valve closes when pressure decreases below pressure setting of bypass valve.
A bypass valve (3) is located at the top of filter. The valve opens to protect filter element against pressure surges JA66566,0002660 -19-03AUG12-1/1
TM13345X19 (23APR18)
9025-05-144
160GLC Excavator 042318 PN=960
Theory of Operation
Auxiliary System Operation
• Low Flow Kit, for more information, see Low Flow Kit
NOTE: For auxiliary attachments to work properly multiple kits may be required.
• Secondary Auxiliary Relief Kit, for more information,
Operation. (Group 9025-05.)
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.
see Secondary Auxiliary Relief 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.
The following kits are available for auxiliary attachments:
• Auxiliary High Flow Line Kit, for more information, see
Auxiliary High Flow Line Kit Operation. (Group 9025-05.)
• Two Pump Combined Flow Kit, for more information,
see Two Pump Combined Flow Kit Operation. (Group 9025-05.) JJ03229,0000AE2 -19-19JUN14-1/1
Auxiliary Pilot Control Valve Operation The auxiliary pilot control valve regulates the pilot oil pressure to actuate the pilot valve in the pilot signal manifold and to shift the auxiliary control valve spool to actuate the auxiliary functions.
See Pilot Signal Manifold Operation for pilot valve operation. (Group 9025-05.) See Pilot Operation of Control Valve Operation for control valve operation. (Group 9025-05.) Continued on next page
TM13345X19 (23APR18)
9025-05-145
DF89619,00B572D -19-16OCT15-1/9
160GLC Excavator 042318 PN=961
Theory of Operation
TM13345X19 (23APR18)
9025-05-146
160GLC Excavator 042318 PN=962
Theory of Operation
TX1156310 —UN—27MAR14
P
A3 A2 A1
T4
T2 T1 T3
37
28 Y23
Y22
HT
PH
Y24 B34
9
I
10
J
TR
104
K 11
74
41 12
K
4
D
117 SA
107 SN
95
97
110 SP
3
C
2 B
118
SB
171 46 SK
47 604
A
1
609 90
81
SH
76
56 75
120
93
SL
44
45
164
42
SE
73
P T
B33
B60
8
H
7
G
6
F
S3
E
5 13
M
2
SM N
TX1156310 Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted) Continued on next page
TM13345X19 (23APR18)
1
14
9025-05-147
160GLC Excavator 042318 PN=963
DF89619,00B572D -19-16OCT15-2/9
Theory of Operation
TM13345X19 (23APR18)
9025-05-148
160GLC Excavator 042318 PN=964
Theory of Operation 28— Pilot Pump 56— To Swing Park Brake 110— Left Travel Spool 37— Solenoid Valve Manifold 73— Right Control Valve (4-spool) 117— Main Relief 41— Pilot Signal Manifold 74— Left Control Valve (5-spool) 118— Auxiliary Function Flow 42— Boom Down Shockless 75— Right Travel Spool Combiner Valve Valve 76— Bucket Spool 120— Travel Flow Combiner 44— Travel Flow Combiner Pilot 81— Boom 1 Spool Valve Valve (port SL) 90— Arm 2 Spool 164— Auxiliary Pilot Control 45— Swing Park Brake Release 93— Bypass Shutoff Valve Valve Pilot Valve (port SH) 95— Swing Spool 171— To Pump 2 Flow Rate 46— Bucket Flow Rate Pilot Valve 97— Arm 1 Spool Solenoid Valve (port SK) 104— Boom 2 Spool 604— Return Oil 47— Pump 2 Flow Rate Pilot 107— Auxiliary Spool 609— Pilot Oil Valve (port SB) B33— Swing Pressure Sensor (marked S3) Continued on next page
TM13345X19 (23APR18)
9025-05-149
B34— Travel Pressure Sensor (marked TR) B60— Attachment Pressure Sensor Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
DF89619,00B572D -19-16OCT15-3/9
160GLC Excavator 042318 PN=965
Theory of Operation
6 5 4
7
3 8 9
2
10
1
11
12 6 8 12
12
11
10
604 609
TX1086424
TX1086424 —UN—07JAN11
13
1
Auxiliary Pilot Control Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-150
DF89619,00B572D -19-16OCT15-4/9
160GLC Excavator 042318 PN=966
Theory of Operation 1— Spool 2— Washer 3— Spring Guide 4— Plunger 5— Adjustment Screw 6— Pedal 7— Sleeve
8— Balance Spring 12— Port 13 or 14 To Control 9— Return Spring Valve Pilot Cap 10— To Pilot Shutoff Solenoid 13— Auxiliary Pilot Control Valve Port T2 Valve—Full Stroke 11— From Pilot Shutoff Solenoid Valve Port A3
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 (9) 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 pushing the spool moves 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 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.
Continued on next page
TM13345X19 (23APR18)
604— Return Oil 609— Pilot Oil
9025-05-151
DF89619,00B572D -19-16OCT15-5/9
160GLC Excavator 042318 PN=967
Theory of Operation
TM13345X19 (23APR18)
9025-05-152
160GLC Excavator 042318 PN=968
Theory of Operation
TX1156311 —UN—27MAR14
P
A3 A2 A1
T4
T2 T1 T3
37
28 Y23
Y22
HT
PH
Y24 B34
9
I
10
J
TR
104
K 11
74
41 12
K
4
D
117 SA
107 SN
95
97
110 SP
3
C
2 B SB
118
171 46 SK
149
47 A
1
81
90
SH
76
56 75
120
93
SL
44
45
42
SE
73
B33
B60
8
H
7
G
6
F
S3
E
5 13
M
604
SM N 14
TX1156311 Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted) Continued on next page
TM13345X19 (23APR18)
9025-05-153
160GLC Excavator 042318 PN=969
148
609
DF89619,00B572D -19-16OCT15-6/9
Theory of Operation
TM13345X19 (23APR18)
9025-05-154
160GLC Excavator 042318 PN=970
Theory of Operation 28— Pilot Pump 56— To Swing Park Brake 117— Main Relief 37— Solenoid Valve Manifold 73— Right Control Valve (4-spool) 118— Auxiliary Function Flow 41— Pilot Signal Manifold 74— Left Control Valve (5-spool) Combiner Valve 42— Boom Down Shockless 75— Right Travel Spool 120— Travel Flow Combiner Valve 76— Bucket Spool Valve 44— Travel Flow Combiner Pilot 81— Boom 1 Spool 148— Auxiliary Pilot Solenoid Valve (port SL) 90— Arm 2 Spool Valve 45— Swing Park Brake Release 93— Bypass Shutoff Valve 149— Auxiliary Pilot Pressure Pilot Valve (port SH) 95— Swing Spool Reducing Valve 46— Bucket Flow Rate Pilot Valve 97— Arm 1 Spool 171— To Pump 2 Flow Rate (port SK) 104— Boom 2 Spool Solenoid Valve 47— Pump 2 Flow Rate Pilot 107— Auxiliary Spool 604— Return Oil Valve (port SB) 110— Left Travel Spool 609— Pilot Oil B33— Swing Pressure Sensor (marked S3)
B34— Travel Pressure Sensor (marked TR) B60— Attachment Pressure Sensor Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
DF89619,00B572D -19-16OCT15-7/9
Auxiliary Solenoid Valve Operation- When auxiliary solenoid valve (148) 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 control valve auxiliary spool and high-pressure oil is sent from control valve to the auxiliary attachment. 221— To Pilot Signal Manifold Port M 604— Return Oil 609— Pilot Oil
221 148 TX1136522 —UN—08AUG13
141— From Pilot Shutoff Valve 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve 220— To Pilot Signal Manifold Port N
220
149
141
604
609
Auxiliary Solenoid Valve Operation DF89619,00B572D -19-16OCT15-8/9
When auxiliary solenoid valve (148) 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 control valve auxiliary spool and high-pressure oil is sent from control valve to the auxiliary attachment. 221— To Pilot Signal Manifold Port M 604— Return Oil 609— Pilot Oil
221 148
149
141
604
609
TX1136519 —UN—08AUG13
141— From Pilot Shutoff Valve 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve 220— To Pilot Signal Manifold Port N
220
Auxiliary Solenoid Valve Operation DF89619,00B572D -19-16OCT15-9/9
TM13345X19 (23APR18)
9025-05-155
160GLC Excavator 042318 PN=971
Theory of Operation
Flow Rate Select Solenoid Valve Operation 41B 93 118
The function of the flow rate select solenoid valve (156) 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:
41A
• Two-speed on (combined flow on) • Pressure on attachment pressure sensor (B60)
108
Y44
Y43
Combined with any of these inputs:
• Pressure on arm out pressure sensor (B61) • Pressure on arm out pressure sensor (B61) and boom up pressure sensor (B30)
37
• Pressure on swing pressure sensor (B33) • Pressure on travel pressure sensor (B34)
TX1135894 —UN—21AUG13
219
For more information on sensors, see System Functional Schematic. (Group 9015-10.) NOTE: Two-Speed control will not work properly unless appropriate kits are installed on machine.
156
When energized, solenoid valve (Y43) sends pilot oil from pilot signal manifold port SM (41A), to pilot signal manifold port SP (41B), to bypass shutoff valve (93), and to auxiliary function flow combiner valve (118). Pilot oil sent to auxiliary function 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 (219).
Flow Rate Select Solenoid Valve Schematic (2-speed solenoid energized)
When energized, the flow rate adjustment solenoid valve (Y44) routes pilot oil from solenoid valve manifold port PE (37) to auxiliary flow rate control valve (108). This adjusts the auxiliary flow rate control valve to provide more or less priority to the swing and travel functions over the attachment function. 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
37— From Solenoid Valve Manifold Port PE 41A— From Pilot Signal Manifold Port SM 41B— To Pilot Signal Manifold Port SP 93— To Bypass Shutoff Valve 108— To Auxiliary Flow Rate Control Valve
118— To Auxiliary Function Flow Combiner Valve 156— Flow Rate Select Solenoid Valve 219— To Hydraulic Oil Tank Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve
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. JA66566,000339E -19-22SEP15-1/1
TM13345X19 (23APR18)
9025-05-156
160GLC Excavator 042318 PN=972
Theory of Operation
Flow Rate Pressure Reducing Valve Operation
74
The function of the flow rate reducing valve (157) 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 (41) when a pump 1 function is activated. The pilot oil is then routed through the flow rate pressure reducing valve (157) to control valve port SN (74). 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 control valve port SN exceeds set pressure of flow rate reducing valve, the valve shifts allowing pilot oil to control valve port SN to flow to hydraulic oil tank (219) 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.)
157
TX1135893 —UN—22MAY13
219
41
Flow Rate Pressure Reducing Valve Schematic 41— From Pilot Signal Manifold Port SN 74— To Control Valve Port SN
157— Flow Rate Reducing Valve 219— To Hydraulic Oil Tank JJ03229,0000AE5 -19-19JUN14-1/1
Secondary Auxiliary Relief Valve Solenoid Valve Operation
158
The secondary auxiliary relief valve solenoid valve is controlled by settings in MP Dr and Service ADVISOR™. See Attachment Control Circuit Theory of Operation. (Group 9015-15.) When the secondary auxiliary relief valve solenoid valve (158) is activated, valve is shifted and pilot oil from solenoid valve manifold port PE (218) is sent to secondary auxiliary relief control valve (160). This shifts the secondary auxiliary relief control valve to route high-pressure oil to the secondary auxiliary relief valve. When the secondary auxiliary relief valve solenoid valve is deactivated, spring tension shifts the valve. Pilot oil to secondary auxiliary relief control valve is sent to hydraulic oil tank (219). This shifts the secondary auxiliary relief control valve to stop routing high-pressure oil to the secondary auxiliary relief valve.
TX1136497 —UN—16MAY13
160
The function of the secondary auxiliary relief valve solenoid valve (158) is to shift secondary auxiliary relief control valve to open or close high-pressure oil flow to secondary auxiliary relief valve.
218
219
Secondary Relief Valve Solenoid Valve 158— Secondary Auxiliary Relief Valve Solenoid Valve 160— To Secondary Auxiliary Relief Control Valve
218— From Solenoid Valve Manifold Port PE 219— To Hydraulic Oil Tank
For more information, see Secondary Auxiliary Relief Kit Operation. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company JJ03229,0000AE6 -19-19JUN14-1/1
TM13345X19 (23APR18)
9025-05-157
160GLC Excavator 042318 PN=973
Theory of Operation
Secondary Auxiliary Relief Control Valve Operation
150
TX1147648 —UN—26NOV13
The function of the secondary auxiliary relief control valve (160) is to open or close flow of high-pressure oil from auxiliary attachment (150) to secondary auxiliary relief valve (159). When secondary auxiliary relief valve solenoid valve energizes, pilot oil is sent from secondary auxiliary relief valve solenoid valve (158) shifting secondary auxiliary relief control valve to open the circuit allowing high-pressure oil flow to secondary auxiliary relief valve. When secondary auxiliary relief valve solenoid valve de-energizes, pilot oil from secondary auxiliary relief valve solenoid valve is routed to hydraulic oil tank and spring tension closes secondary auxiliary relief control valve circuit. For more information, see Secondary Auxiliary Relief Kit Operation. (Group 9025-05.)
158
159
160 Secondary Pilot Relief Control Valve 150— From Auxiliary Attachment 158— From Secondary Auxiliary Relief Valve Solenoid Valve
159— To Secondary Auxiliary Relief Valve 160— Secondary Auxiliary Relief Control Valve
JJ03229,0000AE7 -19-03FEB17-1/1
Secondary Auxiliary Relief Valve Operation
At pressures below the circuit relief setting, spring tension in the secondary auxiliary relief valve closes flow of auxiliary high-pressure oil from auxiliary attachment to hydraulic oil tank. When pressure exceeds the secondary auxiliary relief valve setting, auxiliary high-pressure oil overcomes spring tension and shifts secondary auxiliary relief valve, opening flow of auxiliary high-pressure oil from auxiliary attachment (160) to hydraulic oil tank. For more information, see Secondary Auxiliary Relief Kit Operation. (Group 9025-05.)
TX1136501 —UN—16AUG13
159
The function of the secondary auxiliary relief valve (159) is to limit the auxiliary hydraulic pressure on the work port side of an attachment.
150
Secondary Auxiliary Relief Valve Operation 159— Secondary Auxiliary Relief Valve
150— From Auxiliary Attachment JJ03229,0000AE8 -19-19JUN14-1/1
TM13345X19 (23APR18)
9025-05-158
160GLC Excavator 042318 PN=974
Theory of Operation
Selector Valve Solenoid Valve Operation 155
154
TX1136973 —UN—23MAY13
The function of the selector valve solenoid valve (154) is to shift the selector valve for attachment flow to return to the control valve or directly to hydraulic oil tank (219). 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 is energized, pilot oil from solenoid valve manifold port PE (218) is directed to selector valve (155). When the selector valve is de-energized spring tension shifts the spool and pilot oil to the selector will flow to hydraulic oil tank (219). For more information, see Auxiliary High Flow Line Kit Operation. (Group 9025-05.)
218
219
Selector Valve Solenoid Valve Schematic 218— From Solenoid Valve Manifold Port PE 219— To Hydraulic Oil Tank
154— Selector Valve Solenoid Valve 155— To Selector Valve
Service ADVISOR is a trademark of Deere & Company JJ03229,0000AE9 -19-19JUN14-1/1
Selector Valve Operation
NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.
154
222
A
P
One-Way Flow Operation
T
Pilot oil from selector valve solenoid valve (154) shifts selector valve (155) allowing high-pressure oil from auxiliary cylinder rod end (222) to flow directly to hydraulic oil tank (219).
219
DR
TX1136970 —UN—16AUG13
155
The function of the selector valve (155) is to allow the attachment to operate in one-way flow or two-way flow.
37
B
74
Selector Valve Operation
Two-Way Flow Operation Without pilot oil from selector valve solenoid valve, spring tension shifts selector valve allowing high-pressure oil to and from control valve port A7 (74). 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 control valve auxiliary spool to the hydraulic oil tank.
37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7 154— From Selector Valve Solenoid Valve
155— Selector Valve 219— To Hydraulic Oil Tank 222— From Auxiliary Cylinder Rod End
For more information, see Auxiliary High Flow Line Kit Operation. (Group 9025-05.) JJ03229,0000AEA -19-19JUN14-1/1
TM13345X19 (23APR18)
9025-05-159
160GLC Excavator 042318 PN=975
Theory of Operation
Auxiliary Shuttle Valve Operation
93
74
41
The auxiliary shuttle valve (143) allows pilot oil from flow rate select solenoid valve (156) or from boom lower meter cut-in valve (87) to shift bypass shutoff valve (93). Pilot oil from flow rate select solenoid valve port A1 or boom lower meter-in cut valve, is sent to bypass shutoff valve, without backfeeding between the circuits.
41— To Pilot Signal Manifold (port SP) 74— To Left Control Valve (5-spool) 87— From Boom Lower Meter-In Cut Valve 93— To Bypass Shutoff Valve
109— Plug 143— Auxiliary Shuttle Valve 156— From Flow Rate Select Solenoid Valve (port A1)
87
156 143
TX1140968 —UN—06AUG13
For more information, see Control Valve Operation and see Two Pump Combined Flow Kit Operation. (Group 9025-05.)
Auxiliary Shuttle Valve Schematic
156 109
87
74
93
TX1140967 —UN—06AUG13
143
Auxiliary Shuttle Valve JJ03229,0000AEB -19-19JUN14-1/1
TM13345X19 (23APR18)
9025-05-160
160GLC Excavator 042318 PN=976
Theory of Operation
Auxiliary High Flow Line Kit Operation TX1157670 —UN—11APR14
74
73
150 155 75
110
76 154
13
14 107
Y40
104
81
97
37
90
95 28
124 16
15
600
604
609
TX1157670 Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted) Continued on next page
TM13345X19 (23APR18)
9025-05-161
160GLC Excavator 042318 PN=977
DF89619,00B57BF -19-19JUN14-1/6
Theory of Operation
TM13345X19 (23APR18)
9025-05-162
160GLC Excavator 042318 PN=978
Theory of Operation
13— Auxiliary (pilot) 74— Left Control Valve (5-spool) 14— Auxiliary (pilot) 75— Right Travel Spool 15— Pump 1 76— Bucket Spool 16— Pump 2 81— Boom 1 Spool 28— Pilot Pump 90— Arm 2 Spool 37— Solenoid Valve Manifold 95— Swing Spool 73— Right Control Valve (4-spool) 97— Arm 1 Spool
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.
104— Boom 2 Spool 107— Auxiliary Spool 110— Left Travel Spool 124— Oil Cooler Bypass Valve 150— Auxiliary Attachment 154— Selector Valve Solenoid Valve
155— Selector Valve 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil Y40— Selector Valve Solenoid Valve
The selector valve solenoid valve (Y40) is controlled by settings in the monitor. See Attachment Control Circuit Theory of Operation for more information. (Group 9015-15.) DF89619,00B57BF -19-19JUN14-2/6
154— Selector Valve Solenoid Valve 155— To Selector Valve 218— From Solenoid Valve Manifold Port PE
155
154
219— To Hydraulic Oil Tank 604— Return Oil 609— Pilot Oil
604 218
219
609
TX1138748 —UN—17JUN13
Selector Valve Solenoid Valve De-Energized— For operation of selector valve solenoid valve (154) see Selector Valve Solenoid Valve Operation. (Group 9025-05.)
Selector Valve Solenoid Valve De-Energized DF89619,00B57BF -19-19JUN14-3/6
154— Selector Valve Solenoid Valve 155— To Selector Valve 218— From Solenoid Valve Manifold Port PE
155
154
219— To Hydraulic Oil Tank 604— Return Oil 609— Pilot Oil
604 218
219
609
TX1138751 —UN—05AUG13
Selector Valve Solenoid Valve Energized—For operation of selector valve solenoid valve (154) see Selector Valve Solenoid Valve Operation. (Group 9025-05.)
Selector Valve Solenoid Valve Energized Continued on next page
TM13345X19 (23APR18)
9025-05-163
DF89619,00B57BF -19-19JUN14-4/6
160GLC Excavator 042318 PN=979
Theory of Operation
37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7 154— From Selector Valve Solenoid Valve 155— Selector Valve
219— To Hydraulic Oil Tank 222— From Auxiliary Cylinder Rod End 604— Return Oil 609— Pilot Oil
222
155 A
P
154
T
DR
37
B
604 74 219
609
TX1138757 —UN—20AUG13
Selector Valve One-Way Operation— For operation of the selector valve see Selector Valve Operation. (Group 9025-05.)
Selector Valve One-Way Operation DF89619,00B57BF -19-19JUN14-5/6
37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7 154— From Selector Valve Solenoid Valve 155— Selector Valve
219— To Hydraulic Oil Tank 222— From Auxiliary Cylinder Rod End 604— Return Oil
155
154
222
A
P T
DR
37
B
74 219
604
TX1138756 —UN—20AUG13
Selector Valve Two-Way Operation— For operation of the selector valve see Selector Valve Operation. (Group 9025-05.)
Selector Valve Two-Way Operation DF89619,00B57BF -19-19JUN14-6/6
TM13345X19 (23APR18)
9025-05-164
160GLC Excavator 042318 PN=980
Theory of Operation
Two Way Solenoid Kit Operation TX1156311 —UN—27MAR14
P
A3 A2 A1
T4
T2 T1 T3
37
28 Y23
Y22
HT
PH
Y24 B34
9
I
10
J
TR
104
K 11
74
41 12
K
4
D
117 SA
107 SN
95
97
110 SP
3
C
2 B SB
118
171 46 SK
149
47 A
1
81
90
SH
76
56 75
120
93
SL
44
45
42
SE
73
B33
B60
8
H
7
G
6
F
S3
E
5 13
M
604
SM N 14
TX1156311 Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted) Continued on next page
TM13345X19 (23APR18)
9025-05-165
160GLC Excavator 042318 PN=981
148
609
DF89619,00B572F -19-19JUN14-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-166
160GLC Excavator 042318 PN=982
Theory of Operation 28— Pilot Pump 56— To Swing Park Brake 117— Main Relief 37— Solenoid Valve Manifold 73— Right Control Valve (4-spool) 118— Auxiliary Function Flow 41— Pilot Signal Manifold 74— Left Control Valve (5-spool) Combiner Valve 42— Boom Down Shockless 75— Right Travel Spool 120— Travel Flow Combiner Valve 76— Bucket Spool Valve 44— Travel Flow Combiner Pilot 81— Boom 1 Spool 148— Auxiliary Pilot Solenoid Valve (port SL) 90— Arm 2 Spool Valve 45— Swing Park Brake Release 93— Bypass Shutoff Valve 149— Auxiliary Pilot Pressure Pilot Valve (port SH) 95— Swing Spool Reducing Valve 46— Bucket Flow Rate Pilot Valve 97— Arm 1 Spool 171— To Pump 2 Flow Rate (port SK) 104— Boom 2 Spool Solenoid Valve 47— Pump 2 Flow Rate Pilot 107— Auxiliary Spool 604— Return Oil Valve (port SB) 110— Left Travel Spool 609— Pilot Oil B33— Swing Pressure Sensor (marked S3)
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.
B34— Travel Pressure Sensor (marked TR) B60— Attachment Pressure Sensor Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
Pressure Reducing Valve— The auxiliary pressure reducing valve (149) reduces the pressure to the auxiliary solenoid valve (148) 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.
NOTE: The right pilot control lever switches are standard from the factory, left pilot control lever switches are a field kit installation. DF89619,00B572F -19-19JUN14-2/4
Auxiliary Solenoid Valve— When the auxiliary solenoid valve (148) 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 on port of the control valve to the auxiliary attachment.
220
221
TX1136522 —UN—08AUG13
148
149 141— From Pilot Shutoff Valve 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve 220— To Pilot Signal Manifold Port N
221— To Pilot Signal Manifold Port M 604— Return Oil 609— Pilot Oil
141
604
609
Auxiliary Solenoid Valve Schematic DF89619,00B572F -19-19JUN14-3/4
When the auxiliary solenoid valve (148) 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 on port of the control valve to the auxiliary attachment. 221— To Pilot Signal Manifold Port M 604— Return Oil 609— Pilot Oil
221 148
149
141
604
609
TX1136519 —UN—08AUG13
141— From Pilot Shutoff Valve 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve 220— To Pilot Signal Manifold Port N
220
Auxiliary Solenoid Valve Schematic DF89619,00B572F -19-19JUN14-4/4
TM13345X19 (23APR18)
9025-05-167
160GLC Excavator 042318 PN=983
Theory of Operation
TM13345X19 (23APR18)
9025-05-168
160GLC Excavator 042318 PN=984
Theory of Operation
Two Pump Combined Flow Kit Operation TX1148728 —UN—04DEC13
B61 Y44 157 156
143
Y43
B60
73
28 93 75
90 76
81 171 56 172 14
SM
13 5 S3
6
7
8
SE
SL SH
1
SK
SB
2
15
118
41
3
SP
SN
SA
4
12
D
K
11
TR 10
9
J
I
48
47 45
119
107
108 16
117 108 N
M
E
F
G
H
A
B
C
K
74
95
110 104
600
97
604 609 TX1148728 Two Pump Combined Flow Kit Schematic (Y43 energized and Y44 de-energized) Continued on next page
TM13345X19 (23APR18)
9025-05-169
160GLC Excavator 042318 PN=985
JA66566,000339F -19-06FEB17-1/7
Theory of Operation
TM13345X19 (23APR18)
9025-05-170
160GLC Excavator 042318 PN=986
Theory of Operation 15— Pump 1 75— Right Travel Spool 16— Pump 2 76— Bucket Spool 28— Pilot Pump 81— Boom 1 Spool 41— Pilot Signal Manifold 90— Arm 2 Spool 45— Swing Park Brake Release 93— Bypass Shutoff Valve Pilot Valve 95— Swing Spool 47— Pump 2 Flow Rate Pilot Valve 97— Arm 1 Spool 48— Pump 1 Flow Rate Pilot Valve 104— Boom 2 Spool 56— To Swing Park Brake 107— Auxiliary Spool 73— Right Control Valve (4-spool) 108— Auxiliary Flow Rate 74— Left Control Valve (5-spool) Control Valve (valve and poppet) 110— Left Travel Spool 117— Main Relief and Power Dig Valve
118— Auxiliary Function Flow 600— High-Pressure Oil Combiner Valve 604— Return Oil 119— Check Valve—Auxiliary 609— Pilot Oil Flow Combiner Valve B60— Attachment Pressure Circuit Sensor 143— Auxiliary Shuttle Valve B61— Arm Out Pressure Sensor 156— Flow Rate Select Solenoid Y43— 2-Speed Activation Valve Solenoid Valve 157— Flow Rate Select Reducing Y44— Flow Rate Adjustment Valve Solenoid Valve (if 171— To Pump 2 Flow Rate equipped) Solenoid Valve 172— To Torque Control Solenoid Valve
NOTE: Two pump combined flow kit will not work properly unless appropriate kits are installed on machine.
flow rate control valve (valve and poppet) (108) when multiple function are used with auxiliary attachments.
The function of the two pump combined flow kit is to control auxiliary function flow combiner valve (118) and auxiliary JA66566,000339F -19-06FEB17-2/7
Auxiliary Shuttle Valve— For more information, see Auxiliary Shuttle Valve Operation. (Group 9025-05.) 41— To Pilot Signal Manifold (port SP) 74— To Control Valve (port SM) 87— From Boom Lower Meter-In Cut Valve (port P19) 93— To Bypass Shutoff Valve (port SJ2)
93
74
41
104— To Boom 2 Spool 143— Auxiliary Shuttle Valve 156— From Flow Rate Select Solenoid Valve (port A1)
87
156 143
TX1141531 —UN—06AUG13
104
Auxiliary Shuttle Valve Schematic Continued on next page
TM13345X19 (23APR18)
9025-05-171
JA66566,000339F -19-06FEB17-3/7
160GLC Excavator 042318 PN=987
Theory of Operation
Flow Rate Pressure Reducing Valve Operating Below Set Pressure— For more information, see Flow Rate Pressure Reducing Valve Operation. (Group 9025-05.)
74B
156 143
156— Flow Rate Select Solenoid Valve 157— Flow Rate Select Reducing Valve 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve (if equipped)
74A
Y44
157
Y43
B60 28 41A 41B
604
609
TX1148967 —UN—09DEC13
28— Pilot Pump 41A— From Pilot Signal Manifold Port SM 41B— From Pilot Signal Manifold Port SN 41C— To Pilot Signal Manifold Port SP 74A— To Control Valve Port SY 74B— To Control Valve Port SN 143— To Auxiliary Shuttle Valve
41C
Flow Rate Pressure Reducing Valve Operating Below Set Pressure JA66566,000339F -19-06FEB17-4/7
Flow Rate Pressure Reducing Valve Above Set Pressure— For more information, see Flow Rate Pressure Reducing Valve Operation. (Group 9025-05.)
156 143
156— Flow Rate Select Solenoid Valve 157— Flow Rate Reducing Valve 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve (if equipped)
74A
Y44
157
Y43
B60 28 41A 41B
604
609
TX1148968 —UN—09DEC13
28— Pilot Pump 41A— From Pilot Signal Manifold Port SM 41B— From Pilot Signal Manifold Port SN 41C— To Pilot Signal Manifold Port SP 74A— To Control Valve Port SY 74B— To Control Valve Port SN 143— To Auxiliary Shuttle Valve
41C 74B
Flow Rate Pressure Reducing Valve Operating Above Set Pressure Continued on next page
TM13345X19 (23APR18)
9025-05-172
JA66566,000339F -19-06FEB17-5/7
160GLC Excavator 042318 PN=988
Theory of Operation
Flow Rate Select Solenoid Valve Energized— For more information, see Flow Rate Select Solenoid Valve Operation. (Group 9025-05.)
74B
156 143
156— Flow Rate Select Solenoid Valve 157— Flow Rate Select Reducing Valve 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve (if equipped)
74A
Y44
157
Y43
B60 28 41A 41B
604
609
TX1148967 —UN—09DEC13
28— Pilot Pump 41A— From Pilot Signal Manifold Port SM 41B— From Pilot Signal Manifold Port SN 41C— To Pilot Signal Manifold Port SP 74A— To Control Valve Port SY 74B— To Control Valve Port SN 143— To Auxiliary Shuttle Valve
41C
Flow Rate Select Solenoid Valve Energized JA66566,000339F -19-06FEB17-6/7
Flow Rate Solenoid Valve De-Energized— For more information, see Flow Rate Select Solenoid Valve Operation. (Group 9025-05.)
156 143
156— Flow Rate Select Solenoid Valve 157— Flow Rate Reducing Valve 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve (if equipped)
Y43
157
74A
Y44
B60 28 41A 41B
604
609
TX1148969 —UN—10DEC13
28— Pilot Pump 41A— From Pilot Signal Manifold Port SM 41B— From Pilot Signal Manifold Port SN 41C— To Pilot Signal Manifold Port SP 74A— To Control Valve Port SY 74B— To Control Valve Port SN 143— To Auxiliary Shuttle Valve
41C 74B
Flow Rate Solenoid Valve De-Energized JA66566,000339F -19-06FEB17-7/7
TM13345X19 (23APR18)
9025-05-173
160GLC Excavator 042318 PN=989
Theory of Operation
Secondary Auxiliary Relief Kit Operation 150
110 74
136
107 14
137 108
13 159
160 158
104
Y41
37
95
28
16 600
TX1148731
604
609
TX1148731 —UN—04DEC13
97
Secondary Auxiliary Relief Kit Schematic (auxiliary spool shifted)
Continued on next page
TM13345X19 (23APR18)
9025-05-174
DF89619,00B566A -19-10DEC13-1/4
160GLC Excavator 042318 PN=990
Theory of Operation 13— Auxiliary (pilot) 14— Auxiliary (pilot) 16— Pump 2 28— Pilot Pump 37— Solenoid Valve Manifold 74— Left Control Valve (5-spool) 95— Swing Spool 97— Arm 1 Spool
104— Boom 2 Spool 137— Auxiliary Circuit Relief and 160— Secondary Auxiliary Relief 107— Auxiliary Spool Anticavitation Valve Control Valve 108— Auxiliary Flow Rate 150— Auxiliary Attachment 600— High-Pressure Oil Control Valve (valve and 158— Secondary Auxiliary Relief 604— Return Oil poppet) Valve Solenoid Valve 609— Pilot Oil 110— Left Travel Spool 159— Secondary Auxiliary Relief Y41— Secondary Relief Solenoid 136— Auxiliary Circuit Relief and Valve Valve Anticavitation Valve
Secondary auxiliary relief kit is used when optional attachments are installed on the machine needing work port pressure relief.
attachments. The secondary relief solenoid valve (Y41) is controlled by the main controller and is turned on or off through settings in MPDr or Service ADVISOR™. For more information, see Attachment Control Circuit Theory of Operation. (Group 9015-15.)
NOTE: Secondary auxiliary relief will not work properly unless secondary auxiliary relief kit is installed on machine. The function of the secondary auxiliary relief kit is to give pressure relief to high-pressure oil (600) work side line of Service ADVISOR is a trademark of Deere & Company
DF89619,00B566A -19-10DEC13-2/4
Auxiliary Secondary Relief Solenoid Valve De-Energized— When the secondary relief solenoid valve (Y41) is de-energized, spring tension shifts secondary auxiliary relief valve solenoid valve to allow pilot oil (609) from secondary auxiliary relief control valve (160) to flow to hydraulic oil tank (219). With no pilot oil pressure to secondary auxiliary relief control valve (160), spring tension shifts secondary auxiliary relief control valve, blocking high-pressure oil (600) from auxiliary attachment work port (217) to secondary auxiliary relief valve (159). 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil Y41— Secondary Relief Solenoid Valve
Y41 160 218
219
600
606
604
609
Auxiliary Secondary Relief Solenoid Valve De-Energized
Continued on next page
TM13345X19 (23APR18)
217 TX1148855 —UN—06DEC13
158— Secondary Auxiliary Relief Valve Solenoid Valve 159— Secondary Auxiliary Relief Valve 160— Secondary Auxiliary Relief Control Valve 217— From Auxiliary Attachment Work Port 218— From Solenoid Valve Manifold 219— To Hydraulic Oil Tank
159 158
9025-05-175
DF89619,00B566A -19-10DEC13-3/4
160GLC Excavator 042318 PN=991
Theory of Operation
158— Secondary Auxiliary Relief Valve Solenoid Valve 159— Secondary Auxiliary Relief Valve 160— Secondary Auxiliary Relief Control Valve 217— From Auxiliary Attachment Work Port 218— From Solenoid Valve Manifold
159 158 217 Y41 600 160 218
219— To Hydraulic Oil Tank 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil Y41— Secondary Relief Solenoid Valve
219
604 609
TX1148856 —UN—06DEC13
Auxiliary Secondary Relief Solenoid Valve Energized— When the secondary relief solenoid valve (Y41) is energized, the secondary auxiliary relief valve solenoid valve shifts to allow pilot oil (609) to flow to secondary auxiliary relief control valve (160). Pilot oil shifts secondary auxiliary relief control valve, allowing high-pressure oil (600) from auxiliary attachment work port (217) to secondary auxiliary relief valve (159). When pressure from auxiliary attachment work port (217) exceeds set point, secondary auxiliary relief valve (159) opens to allow high-pressure oil (600) to flow to hydraulic oil tank (219).
Auxiliary Secondary Relief Solenoid Valve Energized
DF89619,00B566A -19-10DEC13-4/4
TM13345X19 (23APR18)
9025-05-176
160GLC Excavator 042318 PN=992
Theory of Operation
Low Flow Kit Operation TX1156399 —UN—27MAR14
LEFT FORWARD
LEFT REVERSE
RIGHT FORWARD
10
9
11
RIGHT REVERSE
ARM OUT
ARM IN
3
4
12
BOOM DOWN
SWING LEFT
SWING RIGHT
6
5
BUCKET DUMP
BOOM UP
1
2
8
BUCKET CURL
7 164
R1 2
144
M P
3
T
P
T
4
2
1
2
P
T
4 1
3
2
P
T
4
1
1 AUX B1
AUX A1
14
13
3
B1
T
141
A3
A2
T2
A1
A4
TA
T1
T3 HT
41
PA
145 PD
PC
PG
PD
DH
PF
P
P
T4
I
J
9
10
K
L
D
12
4
C
B
A
H
G
F
E
M
8
7
6
S3 5 13
N
PH
PE
DE
PE
DP
DK DY
DN DS
DZ PF TR
B34
11
SA
SN
SP
3
2
SB
SK
1
SH SL
SE
SM
14
B33 37
DM
DD SC
SF
56
SG
600
604
606
609
TX1156399 Low Flow Kit Schematic (foot pedal operated) Continued on next page
TM13345X19 (23APR18)
9025-05-177
160GLC Excavator 042318 PN=993
DF89619,00B5731 -19-19JUN14-1/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-178
160GLC Excavator 042318 PN=994
Theory of Operation
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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— Auxiliary A1 (pilot) 14— Auxiliary B1 (pilot)
37— Solenoid Valve Manifold 41— Pilot Signal Manifold 56— To Swing Park Brake 141— Pilot Shutoff Valve 144— Low Flow Control Valve 145— Pilot Low Flow Pump 164— Auxiliary Pilot Control Valve
Continued on next page
TM13345X19 (23APR18)
9025-05-179
B33— Swing Pressure Sensor B34— Travel Pressure Sensor 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
DF89619,00B5731 -19-19JUN14-2/4
160GLC Excavator 042318 PN=995
Theory of Operation
TM13345X19 (23APR18)
9025-05-180
160GLC Excavator 042318 PN=996
Theory of Operation
TX1156400 —UN—26MAR14
LEFT FORWARD
LEFT REVERSE
RIGHT FORWARD
10
9
11
RIGHT REVERSE
ARM OUT
ARM IN
3
4
12
BOOM DOWN
SWING LEFT
SWING RIGHT
6
5
BUCKET DUMP
BOOM UP
1
2
8
BUCKET CURL
AUX B1
AUX A1
14
13
7 148
R1
144
M P
3
T
P
T
4
2
1
2
P
T
4 1
3
2
P
T
4
1
3
149 B1
141
A3
A2
T2
A1
A4
TA
T1
T3 HT
41
PA
145 PD
PC
PG
PD
DH
PF
P
T4
I
J
9
10
K
L
D
12
4
C
B
A
H
G
F
E
M
8
7
6
S3 5 13
N
PH
PE
DE
PE
DP
DK DY
DN DS
DZ PF TR
B34
11
SA
SN
SP
3
2
SB
SK
1
SH SL
SE
SM
14
B33 37
DM
DD SC
SF
56
SG
600
604
606
609
TX1156400 Low Flow Kit Schematic (solenoid operated) Continued on next page
TM13345X19 (23APR18)
9025-05-181
160GLC Excavator 042318 PN=997
DF89619,00B5731 -19-19JUN14-3/4
Theory of Operation
TM13345X19 (23APR18)
9025-05-182
160GLC Excavator 042318 PN=998
Theory of Operation
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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— Auxiliary A1 (pilot) 14— Auxiliary B1 (pilot) 37— Solenoid Valve Manifold
NOTE: The low flow kit will not work properly unless appropriate supporting kits are installed on machine. The function of the low flow kit is to operate auxiliary attachments requiring lower hydraulic flow for operation.
41— Pilot Signal Manifold 56— To Swing Park Brake 141— Pilot Shutoff Valve 144— Low Flow Control Valve 145— Pilot Low Flow Pump 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve
B33— Swing Pressure Sensor B34— Travel Pressure Sensor 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
to the low flow control valve (144). The low flow control valve is operated by pilot control valve, see Auxiliary Pilot Control Valve Operation. (Group 9025-05.) High pressure oil flows through the low flow control valve to operate auxiliary attachments requiring reduced pump flow.
A pilot low flow pump (145) is installed to replace the existing pilot pump, this sends high-pressure oil (600) DF89619,00B5731 -19-19JUN14-4/4
TM13345X19 (23APR18)
9025-05-183
160GLC Excavator 042318 PN=999
Theory of Operation
TM13345X19 (23APR18)
9025-05-184
160GLC Excavator 042318 PN=1000
Group 15
Diagnostic Information All Hydraulic Functions Slow JJ03229,000112C -19-30OCT15-1/10
All Hydraulic Functions Slow Diagnostic Procedure JJ03229,000112C -19-30OCT15-2/10
• 1
Machine Operation
Verify machine operation. See Cycle Times Check. (Group 9005-10.)
YES: Checks complete.
Do cycle times meet specification?
NO: Go to Low Pilot Oil Pressure. JJ03229,000112C -19-30OCT15-3/10
• 2
Low Pilot Oil Pressure Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) Does pilot oil pressure meet specification?
YES: Go to Pump Control Pilot Pressure Signal Low. NO: Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) JJ03229,000112C -19-30OCT15-4/10
• 3
Pump Control Pilot Pressure Signal Low
Check pump control pilot pressure. Perform Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
YES: Go to Pilot Circuit Obstruction.
Does pump control pilot pressure meet specification?
NO: Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JJ03229,000112C -19-30OCT15-5/10
• 4
Pilot Circuit Obstruction
Check pilot circuit for obstructions. See Pilot System Operation. (Group 9025-05.)
YES: Go to Main Relief Valve Setting Too Low or Malfunctioning.
Are all lines and hoses straight and in good condition; not kinked, worn from rubbing, or NO: Repair or replace pilot weather checked? circuit. JJ03229,000112C -19-30OCT15-6/10
• 5
Main Relief Valve Setting Too Low or Malfunctioning
Verify proper main relief valve setting and operation. See Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Restricted Hydraulic Oil Tank Suction Screen.
Does main relief valve settings meet specification?
NO: Adjust, repair, or replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360).
Continued on next page
TM13345X19 (23APR18)
9025-15-1
JJ03229,000112C -19-30OCT15-7/10
160GLC Excavator 042318 PN=1001
Diagnostic Information
• 6
Restricted Hydraulic Oil Tank Suction Screen
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
YES: Go to Torque Control Solenoid Malfunction.
Is hydraulic oil tank suction screen free of restriction?
NO: Clean or replace hydraulic oil tank suction screen. JJ03229,000112C -19-30OCT15-8/10
• 7
Torque Control Solenoid Malfunction
Check torque control solenoid connection. Check torque control solenoid. See Electrical Component Specifications. (Group 9015-20.)
Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Worn Pump.
Does torque control solenoid and solenoid valve operate correctly?
NO: Repair or replace torque control solenoid and solenoid valve. JJ03229,000112C -19-30OCT15-9/10
• 8
Worn Pump
Check pump flow. See Pump Flow Test. (Group 9025-25.)
YES: Checks complete.
Does pump flow meet specification?
NO: Repair or replace pump. See Pump 1 and 2 Remove and Install. (Group 3360.) JJ03229,000112C -19-30OCT15-10/10
Hydraulic Oil Overheats DF89619,00B579C -19-08MAY15-1/11
Hydraulic Oil Overheats Diagnostic Procedure DF89619,00B579C -19-08MAY15-2/11
• 1
Low Hydraulic Oil Level
Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)
YES: Go to Cooling Package Check.
Is hydraulic oil at proper level?
NO: Fill hydraulic tank to proper level. DF89619,00B579C -19-08MAY15-3/11
• 2
Cooling Package Check
Inspect cooling package for missing or damaged baffles or seals.
YES: Repair or replace parts.
Are baffles or seals missing or damaged?
NO: Go to Restricted Hydraulic Oil Cooler.
Continued on next page
TM13345X19 (23APR18)
9025-15-2
DF89619,00B579C -19-08MAY15-4/11
160GLC Excavator 042318 PN=1002
Diagnostic Information
• 3
Restricted Hydraulic Oil Cooler
Inspect cooling package.
YES: Go to Fan Drive Malfunction.
Is cooling package free of debris?
NO: Clear debris from cooling package. DF89619,00B579C -19-08MAY15-5/11
• 4
Fan Drive Malfunction
Inspect fan drive. See Fan Speed Test. (Group 9025-25.)
YES: Go to Machine Lift Capacity Exceeded.
Does fan drive operate properly?
NO: Repair or replace fan drive. See Fan Drive Motor Remove and Install. (Group 3360.) DF89619,00B579C -19-08MAY15-6/11
• 5
Machine Lift Capacity Exceeded
Check machine lift capacity. See Miscellaneous—Specifications. (Operator's Manual.)
YES: Go to Main Relief Valve Setting Too Low or Malfunctioning.
Is amount of weight being lifted within machine lifting capacity?
NO: Reduce amount of weight being lifted. DF89619,00B579C -19-08MAY15-7/11
• 6
Main Relief Valve Setting Too Low or Malfunctioning
Verify proper main relief valve setting and operation. See Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Restricted Hydraulic Oil Return Filter.
Does main relief valve settings meet specification?
NO: Adjust, repair, or replace main relief valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360). DF89619,00B579C -19-08MAY15-8/11
• 7
Restricted Hydraulic Oil Return Filter
Check hydraulic oil return filter for restriction. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
YES: Replace hydraulic oil tank return filter.
Is hydraulic oil tank return filter restricted?
NO: Go to Oil Cooler Bypass Valve Stuck Open. DF89619,00B579C -19-08MAY15-9/11
• 8
Oil Cooler Bypass Valve Stuck Open
Inspect oil cooler bypass valve. See Hydraulic Oil Cooler Bypass Valve Remove and Install. (Group 3360.)
YES: Go to Restriction Valve Stuck Closed.
Does oil cooler bypass valve operate correctly?
NO: Replace oil cooler bypass valve.
Continued on next page
TM13345X19 (23APR18)
9025-15-3
DF89619,00B579C -19-08MAY15-10/11
160GLC Excavator 042318 PN=1003
Diagnostic Information
• 9
Restriction Valve Stuck Closed
Inspect restriction valve. See Restriction Valve Remove and Install. (Group 3360.)
YES: Checks complete.
Does restriction valve operate correctly?
NO: Replace restriction valve. DF89619,00B579C -19-08MAY15-11/11
No Hydraulic Functions DF89619,00B579D -19-06AUG14-1/8
No Hydraulic Functions Diagnostic Procedure DF89619,00B579D -19-06AUG14-2/8
• 1
Pilot Shutoff Lever Position
Check position of pilot shutoff lever.
YES: Go to Pilot Shutoff Solenoid Malfunction.
Is pilot shutoff lever in unlocked (DOWN) position?
NO: Place pilot shutoff lever in unlocked (DOWN) position. DF89619,00B579D -19-06AUG14-3/8
• 2
Pilot Shutoff Solenoid Malfunction
Check pilot shutoff solenoid. See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Pilot Shutoff Solenoid Voltage Check.
Does pilot shutoff solenoid operate correctly?
NO: Repair or replace solenoid. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.) DF89619,00B579D -19-06AUG14-4/8
• 3
Pilot Shutoff Solenoid Voltage Check
Key switch OFF.
Disconnect pilot shutoff solenoid. Key switch ON. Pilot shutoff lever in unlocked (DOWN) position. Measure voltage at pin 1 and pin 2 of pilot shutoff solenoid connector.
YES: Go to Pilot Shutoff Valve Pilot Pressure.
Is approximately 24 volts indicated?
NO: See No Hydraulic Functions—Electrical Checks. (Group 9025-15.) Continued on next page
TM13345X19 (23APR18)
9025-15-4
DF89619,00B579D -19-06AUG14-5/8
160GLC Excavator 042318 PN=1004
Diagnostic Information
• 4
Pilot Shutoff Valve Pilot Pressure
Measure pressure from solenoid valve manifold port PF to pilot shutoff valve at port P.
• See Pilot Shutoff Solenoid Valve Operation for pilot shutoff solenoid valve port identification. (Group 9025-05.)
• See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern for pilot shutoff solenoid valve line identification. (Group 9025-15.)
• See Pilot Pressure Regulating Valve Test and Adjustment for pilot pressure
YES: Go to next step in this check.
Does pressure meet specification?
NO: Verify proper operation of pilot pressure regulating valve. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)
specification. (Group 9025-25.)
Pilot shutoff lever in unlocked (DOWN) position. Measure pressure at pilot shutoff valve port A4.
• See Pilot Shutoff Solenoid Valve Operation for pilot shutoff solenoid valve port identification. (Group 9025-05.)
• See Pilot Pressure Regulating Valve Test and Adjustment for pilot pressure
YES: Go to Restricted Hydraulic Oil Tank Suction Screen.
Does pressure meet specification?
NO: Inspect pilot shutoff valve. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.)
specification. (Group 9025-25.)
Repair or replace as necessary. DF89619,00B579D -19-06AUG14-6/8
• 5
Restricted Hydraulic Oil Tank Suction Screen
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
YES: Go to Pump Drive Malfunction.
Is hydraulic oil tank suction screen free of restriction?
NO: Clean or replace hydraulic oil tank suction screen. DF89619,00B579D -19-06AUG14-7/8
• 6
Pump Drive Malfunction
Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install. (Group 0752.)
YES: Checks complete.
Does damper drive (flex coupling) operate correctly?
NO: Repair or replace damper drive (flex coupling). DF89619,00B579D -19-06AUG14-8/8
No Hydraulic Functions—Electrical Checks DF89619,00B57E3 -19-03FEB17-1/9
No Hydraulic Functions—Electrical Checks Diagnostic Procedure For more information, see Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) Continued on next page
TM13345X19 (23APR18)
9025-15-5
DF89619,00B57E3 -19-03FEB17-2/9
160GLC Excavator 042318 PN=1005
Diagnostic Information
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using monitor, Service ADVISOR™, or 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.)
YES: Diagnose DTC. See specific diagnostic procedure in Group 9001.
Are any DTCs present?
NO: Go to Fuse Check.
Service ADVISOR is a trademark of Deere & Company DF89619,00B57E3 -19-03FEB17-3/9
• 2
Fuse Check
Remove solenoid 20 A fuse (marked SOLENOID) (F4) from fuse block. See Fuse and Relay Specifications. (Group 9015-10.) Check fuse F4 for continuity.
YES: Go to Pilot Shutoff Switch Malfunction.
Is continuity indicated?
NO: Replace fuse. DF89619,00B57E3 -19-03FEB17-4/9
• 3
Pilot Shutoff Switch Malfunction
View Pilot Control Shut-Off Lever Switch position in monitor. See Monitoring. (Group 9015-16.) Move pilot shutoff lever to locked (UP) position and unlocked (DOWN) position.
YES: Go to Pilot Shutoff Solenoid Relay Malfunction.
Does lever position match monitor status?
NO: Inspect and repair pilot shutoff switch harness (W11). See Pilot Shutoff Switch Harness (W11) Component Location. (Group 9015-10.) DF89619,00B57E3 -19-03FEB17-5/9
• 4
Pilot Shutoff Solenoid Relay Malfunction
Test pilot shutoff solenoid relay (K2). See Electrical Component Checks. (Group 9015-20.)
YES: Go to Pilot Shutoff Solenoid Malfunction.
Is pilot shutoff solenoid relay OK?
NO: Replace pilot shutoff solenoid relay. DF89619,00B57E3 -19-03FEB17-6/9
• 5
Pilot Shutoff Solenoid Malfunction
Check pilot shutoff solenoid (Y10). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to Pilot Shutoff Solenoid Voltage Check.
Does pilot shutoff solenoid operate correctly?
NO: Replace pilot shutoff solenoid. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.)
Continued on next page
TM13345X19 (23APR18)
9025-15-6
DF89619,00B57E3 -19-03FEB17-7/9
160GLC Excavator 042318 PN=1006
Diagnostic Information
• 6
Pilot Shutoff Solenoid Voltage Check
Key switch OFF.
Disconnect pilot shutoff solenoid (Y10). Key switch ON. Pilot shutoff lever in unlocked (DOWN) position. Measure voltage at pin 1 and pin 2 of pilot shutoff solenoid connector.
YES: Repair or replace pilot shutoff valve. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.)
Is approximately 24 volts indicated?
NO: Go to Pilot Shutoff Circuit Check. DF89619,00B57E3 -19-03FEB17-8/9
• 7
Pilot Shutoff Circuit Check
Key switch OFF.
Disconnect pilot shutoff solenoid (Y10). Key switch ON. Pilot shutoff lever in unlocked (DOWN) position. Measure voltage at pin 1 and machine ground.
YES: Inspect pilot shutoff valve harness (W21) and cab harness (W1) for open ground circuit. See Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) See Pilot Shutoff Valve Harness (W21) Wiring Diagram and see Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
Is approximately 24 volts indicated?
NO: Inspect pilot shutoff valve harness (W21) and cab harness (W1) for open power circuit. See Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) See Pilot Shutoff Valve Harness (W21) Wiring Diagram and see Cab Harness (W1) Wiring Diagram. (Group 9015-10.) DF89619,00B57E3 -19-03FEB17-9/9
Function Does Not Stop When Control Lever Released DF89619,00B57A0 -19-06FEB17-1/7
Function Does Not Stop When Control Lever Released Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9025-15-7
DF89619,00B57A0 -19-06FEB17-2/7
160GLC Excavator 042318 PN=1007
Diagnostic Information
• 1
Cold Hydraulic Oil
Check hydraulic oil temperature. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
YES: Go to Mechanical Control Lever Pattern Selector—If Equipped.
Does hydraulic oil temperature meet specification?
NO: Perform hydraulic system warm-up procedure. DF89619,00B57A0 -19-06FEB17-3/7
• 2
Mechanical Control Lever Pattern Selector—If Equipped
Verify mechanical control lever pattern selector is properly positioned. See Mechanical Control Lever Pattern Selector—If Equipped. (Operator’s Manual.)
YES: Go to Pilot Circuit Obstruction.
Is mechanical control lever pattern selector properly positioned?
NO: Adjust mechanical control lever pattern selector position. DF89619,00B57A0 -19-06FEB17-4/7
• 3
Pilot Circuit Obstruction
Check pilot circuit for obstructions. See Pilot System Operation. (Group 9025-05.)
YES: Go to Pilot Control Valve Malfunction.
Are all lines and hoses straight and in good condition; not kinked, worn from rubbing, or NO: Repair or replace pilot weather checked? circuit. DF89619,00B57A0 -19-06FEB17-5/7
• 4
Pilot Control Valve Malfunction
Inspect pilot control valve spools. See Pilot Valve (Left and Right) Remove and Install or see Travel Pilot Valve Remove and Install. (Group 3360.)
YES: Go to Control Valve Spool Stuck.
Do pilot control valve spools move freely?
NO: Repair or replace pilot control valve. DF89619,00B57A0 -19-06FEB17-6/7
• 5
Control Valve Spool Stuck
Inspect control valve for stuck spool. See Control Valve Operation. (Group 9025-05.)
YES: Checks complete.
Do control valve spools move freely?
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.) DF89619,00B57A0 -19-06FEB17-7/7
Load Drifts Down When Control Lever is in Neutral Position DF89619,00B57A6 -19-06AUG14-1/8
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9025-15-8
DF89619,00B57A6 -19-06AUG14-2/8
160GLC Excavator 042318 PN=1008
Diagnostic Information
• 1
Cylinder Drift
Verify proper operation of machine cylinders. See Cylinder Drift Test—Boom, Arm, and Bucket. (Group 9025-25.)
YES: Checks complete.
Does cylinder drift meet specification?
NO: Go to Boom Manual Lower Screw Loose. DF89619,00B57A6 -19-06AUG14-3/8
• 2
Boom Manual Lower Screw Loose
Inspect boom manual lower screw. See Lower Boom With Engine Stopped. (Operator’s YES: Go to Circuit Relief Manual.) Valve Setting Too Low or Malfunctioning. Is boom manual lower screw tightened to specification?
NO: Tighten boom manual lower screw to specification. DF89619,00B57A6 -19-06AUG14-4/8
• 3
Circuit Relief Valve Setting Too Low or Malfunctioning
Check circuit relief valve drifting function. Swap circuit relief valves for a particular function.
YES: Go to Reduced Leakage Valve.
Does cylinder drift continue on same function?
NO: Adjust, repair, or replace circuit relief valve. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.) See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.) DF89619,00B57A6 -19-06AUG14-5/8
• 4
Reduced Leakage Valve
NOTE: Reduced leakage valve check should only be completed on machines showing symptoms of arm in or boom down cylinder drift.
Inspect reduced leakage valve pilot valve and poppet. For component identification, see YES: Replace reduced Control Valve Operation. (Group 9025-05.) See Control Valve (5-Spool) Disassemble leakage valve pilot valve or and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group poppet. 3360.) Is reduced leakage valve pilot valve or poppet scored or sticking?
NO: Go to Control Valve Leakage. DF89619,00B57A6 -19-06AUG14-6/8
• 5
Control Valve Leakage Inspect control valve for leakage. See Hydraulic System Component Location. (Group 9025-15.) Is control valve free of leaks?
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.) Continued on next page
TM13345X19 (23APR18)
YES: Go to Cylinder Leakage.
9025-15-9
DF89619,00B57A6 -19-06AUG14-7/8
160GLC Excavator 042318 PN=1009
Diagnostic Information
• 6
Cylinder Leakage
Inspect machine cylinders. See Boom Cylinder Remove and Install, see Arm Cylinder Remove and Install, and see Bucket Cylinder Remove and Install. (Group 3360.)
YES: Checks complete.
Are machine cylinders in proper working condition?
NO: Repair or replace cylinder. DF89619,00B57A6 -19-06AUG14-8/8
Load Falls When Control Valve is Actuated To Raise Load DF89619,00B57A7 -19-12JUN14-1/3
Load Falls When Control Valve is Actuated To Raise Load Diagnostic Procedure DF89619,00B57A7 -19-12JUN14-2/3
• 1
Lift Check Valve Leakage
Inspect control valve check valves and flow rate control valve poppets for leakage. See Control Valve Check Valves Identification and Operation and see Control Valve Operation. (Group 9025-05.)
YES: Checks complete.
Are check valve and flow rate control valve poppets operating correctly?
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.) DF89619,00B57A7 -19-12JUN14-3/3
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal DF89619,00B57C4 -19-18DEC15-1/7
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure For more information, see Engine Speed Control System Operation. (Group 9010-05.) DF89619,00B57C4 -19-18DEC15-2/7
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using monitor, Service ADVISOR™, or 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.)
YES: Diagnose DTC. See specific diagnostic procedure in Group 9001.
Are any DTCs present?
NO: Go to Work Mode.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9025-15-10
DF89619,00B57C4 -19-18DEC15-3/7
160GLC Excavator 042318 PN=1010
Diagnostic Information
• 2
Work Mode
Check work mode setting. See Main Menu—Work Mode. (Operator’s Manual.)
YES: Go to Machine Settings.
Is bucket mode enabled?
NO: Change work mode setting to bucket mode. DF89619,00B57C4 -19-18DEC15-4/7
• 3
Machine Settings
Verify H/P mode is enabled. See Machine Setting. (Group 9015-16.)
NOTE: H/P mode option can be disabled using MPDr, causing H/P mode selection to be disabled in monitor.
YES: Go to Slow Engine Speed.
Is H/P mode be enabled?
NO: Change machine setting using monitor or MPDr. DF89619,00B57C4 -19-18DEC15-5/7
• 4
Slow Engine Speed
Verify engine speed meets H/P mode requirements. See Engine Speed Control System YES: Go to Pressure Operation. (Group 9010-05.) Sensor Malfunction. Does engine speed meet specification?
NO: Select correct engine speed. Continued on next page
TM13345X19 (23APR18)
9025-15-11
DF89619,00B57C4 -19-18DEC15-6/7
160GLC Excavator 042318 PN=1011
Diagnostic Information
• 5
Pressure Sensor Malfunction
Check pressure readings of the following pressure sensors:
• Pump 1 Delivery Pressure • Pump 2 Delivery Pressure • Boom Raise Pilot Pressure • Arm Roll-In Pilot Pressure Pressure readings can be viewed using the monitor service menu. See Service Menu. (Group 9015-16.)
• Actuate arm in or boom up function to view reading.
YES: Checks complete.
Do pressure readings meet specification?
NO: Go to next step in this check.
- 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/Travel Speed 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.)
Install gauges to verify sensor readings. See Main Relief and Power Dig Valve Test and Adjustment and see Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.) Operate boom up and arm in functions.
YES: Inspect hydraulic plumbing. Repair or replace parts as necessary.
Do gauge readings match pressure sensor readings?
NO: Verify proper operation of sensors and harnesses. See 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input, see 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input, see 011302.04—Boom Up Pilot Pressure Sensor Circuit Low Input, or see 011303.04—Arm In Pressure Sensor Circuit Low Input. (Group 9001-10.) DF89619,00B57C4 -19-18DEC15-7/7
Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal MM16284,0001D1D -19-26FEB15-1/3
Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure If machine shows these characteristics repeatedly, submit a fluid sample to a designated regional lab for testing. See Fluid Sampling Test Ports—If Equipped. (Operator’s Manual.) Continued on next page
TM13345X19 (23APR18)
9025-15-12
MM16284,0001D1D -19-26FEB15-2/3
160GLC Excavator 042318 PN=1012
Diagnostic Information
• 1
Reduced Leakage Valve
Remove and set aside boom reduced leakage valve poppet and spring. See Control Valve Operation. (Group 9025-05.) See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.) Install boom reduced leakage valve pilot valve only. CAUTION: Prevent possible crushing injury from heavy component. Boom down drift will increase with reduced leakage valve poppet removed. Keep work area clear of bystanders. Operate machine.
YES: Replace boom reduced leakage valve components.
Does boom down function operate properly?
NO: Checks complete. MM16284,0001D1D -19-26FEB15-3/3
Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal DF89619,00B57D0 -19-06AUG14-1/6
Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure If machine shows these characteristics repeatedly, submit a fluid sample to a designated regional lab for testing. See Fluid Sampling Test Ports—If Equipped. (Operator’s Manual.) DF89619,00B57D0 -19-06AUG14-2/6
• 1
System Check
View pump 1 and pump 2 delivery pressure in monitor. See Monitoring. (Group 9015-16.) Perform controlled arm in function. Monitor pump 1 and pump 2 delivery pressure while arm is in motion.
YES: Go to Reduced Leakage Valve.
Are both pump 1 and pump 2 delivery pressures near main relief specification? See Main NO: Go to next step in this Relief and Power Dig Valve Test and Adjustment for specification. (Group 9025-25.) check. Perform controlled arm in function. Monitor pump 1 and pump 2 delivery pressure while arm is in motion.
YES: Go to Arm 1 Flow Rate Control Valve.
Is only pump 1 delivery pressure near main relief specification? See Main Relief and Power Dig Valve Test and Adjustment for specification. (Group 9025-25.)
NO: Go to Arm 2 Flow Rate Control Valve. DF89619,00B57D0 -19-06AUG14-3/6
• 2
Reduced Leakage Valve
Remove and set aside arm reduced leakage valve poppet and spring. See Control Valve Operation. (Group 9025-05.) See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) Install arm reduced leakage valve pilot valve only. CAUTION: Prevent possible crushing injury from heavy component. Arm in drift will increase with reduced leakage valve poppet removed. Keep work area clear of bystanders. Operate machine.
YES: Replace arm reduced leakage valve components.
Does arm in function operate properly?
NO: Checks complete. Continued on next page
TM13345X19 (23APR18)
9025-15-13
DF89619,00B57D0 -19-06AUG14-4/6
160GLC Excavator 042318 PN=1013
Diagnostic Information
• 3
Arm 1 Flow Rate Control Valve
Inspect arm 1 flow rate control valve components. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.)
YES: Repair or replace arm 1 flow rate control valve components.
Are arm 1 flow rate control valve components scored or sticking?
NO: Checks complete. DF89619,00B57D0 -19-06AUG14-5/6
• 4
Arm 2 Flow Rate Control Valve
Inspect arm 2 flow rate control valve components. See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)
YES: Repair or replace arm 2 flow rate control valve components.
Are arm 2 flow rate control valve components scored or sticking?
NO: Checks complete. DF89619,00B57D0 -19-06AUG14-6/6
Swing Speed Slow During Arm In Function DF89619,00B57D7 -19-01OCT14-1/4
Swing Speed Slow During Arm In Function Diagnostic Procedure DF89619,00B57D7 -19-01OCT14-2/4
• 1
Arm 1 Flow Rate Pilot Valve
Measure pressure from arm 1 flow rate pilot valve (port SE) during swing and arm in over relief.
• See Control Valve Spool Actuating Pilot Pressure Test for pressure specification. (Group 9025-25.)
• See Control Valve Line Identification for port identification. (Group 9025-15.) • See Pilot Signal Manifold-to-Control Valve Line Connection for line identification. (Group 9025-15.)
Does pilot pressure meet specification?
YES: Go to Arm 1 Flow Rate Control Valve. NO: Repair or replace arm 1 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) DF89619,00B57D7 -19-01OCT14-3/4
• 2
Arm 1 Flow Rate Control Valve
Inspect arm 1 flow rate control valve components. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.)
YES: Checks complete.
Are arm 1 flow rate control valve components scored or sticking?
NO: Repair or replace arm 1 flow rate control valve components. DF89619,00B57D7 -19-01OCT14-4/4
Boom Cannot Raise Track Off Ground DF89619,00B57D3 -19-01OCT14-1/8
Boom Cannot Raise Track Off Ground Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9025-15-14
DF89619,00B57D3 -19-01OCT14-2/8
160GLC Excavator 042318 PN=1014
Diagnostic Information
• 1
Function Test CAUTION: Avoid possible injury from unexpected machine movement. Machine could slide causing personal injury. Keep angle between boom and arm 90—110°. YES: Checks complete.
TX1152721 —UN—13FEB14
Machine Position Swing the upperstructure 90° and lower the bucket to raise track off ground. Keep angle between boom and arm 90—110°. Using boom down function, can track be raised?
NO: Go to Pilot Circuit Obstruction. DF89619,00B57D3 -19-01OCT14-3/8
• 2
Pilot Circuit Obstruction
Check pilot circuit for obstructions. See Pilot System Operation. (Group 9025-05.)
YES: Go to Pilot Control Valve Malfunction.
Are all lines and hoses straight and in good condition; not kinked, worn from rubbing, or NO: Repair or replace pilot weather checked? circuit. DF89619,00B57D3 -19-01OCT14-4/8
• 3
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Cylinder Drift.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair, or replace pilot control valve. See Pilot Valve (left and right) Remove and Install. (Group 3360.) DF89619,00B57D3 -19-01OCT14-5/8
• 4
Cylinder Drift
Verify proper operation of machine cylinders. See Cylinder Drift Test—Boom, Arm, and Bucket. (Group 9025-25.)
YES: Go to Boom Lower Meter-In Cut Valve Circuit.
Does cylinder drift meet specification?
NO: Repair or replace boom cylinders. See Boom Cylinder Remove and Install. (Group 3360.) Continued on next page
TM13345X19 (23APR18)
9025-15-15
DF89619,00B57D3 -19-01OCT14-6/8
160GLC Excavator 042318 PN=1015
Diagnostic Information
• 5
Boom Lower Meter-In Cut Valve Circuit
Install pressure gauge and measure boom down pilot pressure to boom lower meter-in cut valve during boom down operation.
• See Control Valve Spool Actuating Pilot Pressure Test for pressure specification. (Group 9025-25.)
• See Control Valve Operation for component identification. (Group 9025-05.) • See Control Valve Line Identification for port identification. (Group 9025-15.) • See Hydraulic System Schematic for more information. (Group 9025-15.) Does pressure meet specification?
YES: Go to next step in this check. NO: Inspect pilot circuit for obstruction.
Install pressure gauge and measure boom down pilot pressure from boom lower meter-in cut valve during boom down operation.
• See Control Valve Spool Actuating Pilot Pressure Test for pressure specification. (Group 9025-25.)
• See Control Valve Operation for component identification. (Group 9025-05.) • See Control Valve Line Identification for port identification. (Group 9025-15.) • See Hydraulic System Schematic for more information. (Group 9025-15.)
YES: Go to Bypass Shutoff Valve Circuit Check.
Does pressure meet specification?
NO: Go to next step in this check.
Inspect boom lower meter-in cut valve. See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)
YES: Repair or replace boom lower meter-in cut valve.
Is boom lower meter-in cut pilot valve scored or sticking?
NO: Inspect pilot circuit for obstruction. DF89619,00B57D3 -19-01OCT14-7/8
• 6
Bypass Shutoff Valve Circuit Check
Install pressure gauge and measure boom down pilot pressure from boom lower meter-in cut valve to bypass shutoff valve during boom down operation.
• See Control Valve Spool Actuating Pilot Pressure Test for pressure specification. (Group 9025-25.)
• See Control Valve Operation for component identification. (Group 9025-05.) • See Control Valve Line Identification for port identification. (Group 9025-15.) • See Hydraulic System Schematic for more information. (Group 9025-15.) Does pressure meet specification?
YES: Go to next step in this check. NO: Inspect pilot circuit for obstruction.
Inspect bypass shutoff valve. See Control Valve (4-Spool) Disassemble and Assemble. YES: Repair or replace (Group 3360.) bypass shutoff valve. Is bypass shutoff valve scored or sticking?
NO: Checks complete. DF89619,00B57D3 -19-01OCT14-8/8
Swing Function Does Not Operate in Both Directions DF89619,00B57DF -19-12JUN14-1/9
Swing Function Does Not Operate in Both Directions Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9025-15-16
DF89619,00B57DF -19-12JUN14-2/9
160GLC Excavator 042318 PN=1016
Diagnostic Information
• 1
Isolation Check Valve
Perform combined operation of bucket curl and swing.
YES: Repair or replace main relief isolation check valve (4-spool). See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)
Does swing function operate?
NO: Go to Left Travel Power Passage Check Valve. DF89619,00B57DF -19-12JUN14-3/9
• 2
Left Travel Power Passage Check Valve
Perform combined operation of left travel and swing.
YES: Repair or replace left travel power passage check valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.)
Does swing function operate?
NO: Go to Pilot Control Valve Malfunction. DF89619,00B57DF -19-12JUN14-4/9
• 3
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Control Valve Spool Stuck.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair, or replace pilot control valve. See Pilot Valve (left and right) Remove and Install. (Group 3360.) DF89619,00B57DF -19-12JUN14-5/9
• 4
Control Valve Spool Stuck
Inspect control valve for stuck spool. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Go to Swing Park Brake Pilot Valve.
Does swing valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) DF89619,00B57DF -19-12JUN14-6/9
• 5
Swing Park Brake Pilot Valve
View front attachment pressure sensor value in monitor. See Monitoring. (Group 9015-16.) Actuate a dig function.
YES: Go to Case Drain Leakage.
Does front attachment pressure sensor value change?
NO: Repair or replace swing park brake pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
Continued on next page
TM13345X19 (23APR18)
9025-15-17
DF89619,00B57DF -19-12JUN14-7/9
160GLC Excavator 042318 PN=1017
Diagnostic Information
• 6
Case Drain Leakage
Inspect swing motor for leakage. See Swing Motor Leakage Test. (Group 9025-25.)
YES: Go to Swing Park Brake Not Fully Released.
Does observed leakage meet specification?
NO: Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.) DF89619,00B57DF -19-12JUN14-8/9
• 7
Swing Park Brake Not Fully Released
Inspect swing park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)
YES: Checks complete.
Is swing park brake OK?
NO: Repair or replace swing park brake. DF89619,00B57DF -19-12JUN14-9/9
Swing Speed Slow in Both Directions JJ03229,000112D -19-26JUL16-1/8
Swing Speed Slow in Both Directions Diagnostic Procedure JJ03229,000112D -19-26JUL16-2/8
• 1
Machine Operation
Verify machine operation. See Cycle Times Check. (Group 9005-10.)
YES: Checks complete.
Do swing cycle times meet specification?
NO: Go to Pump 2 Flow Rate Pilot Valve. JJ03229,000112D -19-26JUL16-3/8
• 2
Pump 2 Flow Rate Pilot Valve
Check pump control pilot pressure. See Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
YES: Go to Isolation Check Valve.
Does pump control pilot pressure meet specification?
NO: Check pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JJ03229,000112D -19-26JUL16-4/8
• 3
Isolation Check Valve
Perform combined operation of bucket curl and swing.
YES: Repair or replace main relief isolation check valve (4-spool). See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)
Does swing speed increase?
NO: Go to Left Travel Neutral Passage Check Valve. Continued on next page
TM13345X19 (23APR18)
9025-15-18
JJ03229,000112D -19-26JUL16-5/8
160GLC Excavator 042318 PN=1018
Diagnostic Information
• 4
Left Travel Neutral Passage Check Valve
Perform combined operation of left travel and swing.
YES: Repair or replace left travel neutral passage check valve. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.)
Does swing speed increase?
NO: Go to Swing Motor Leakage. JJ03229,000112D -19-26JUL16-6/8
• 5
Swing Motor Leakage
Inspect swing motor for leakage. See Swing Motor Leakage Test. (Group 9025-25.)
YES: Go to Pump 2 Worn.
Does swing motor meet specification?
NO: Repair or replace swing motor. See Swing Motor and Park Brake Remove and Install. (Group 4360.) JJ03229,000112D -19-26JUL16-7/8
• 6
Pump 2 Worn
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.)
YES: Checks complete.
Do travel cycle times and pump flow meet specification?
NO: Repair or replace pump. See Pump 1 and 2 Remove and Install. (Group 3360.) JJ03229,000112D -19-26JUL16-8/8
Swing Speed Slow or Does Not Operate in One Direction DF89619,00B57A9 -19-20AUG15-1/6
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure DF89619,00B57A9 -19-20AUG15-2/6
• 1
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Swing Motor Crossover Relief Valve Malfunction.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair, or replace pilot control valve. See Pilot Valve (Left and Right) Remove and Install. (Group 3360.)
Continued on next page
TM13345X19 (23APR18)
9025-15-19
DF89619,00B57A9 -19-20AUG15-3/6
160GLC Excavator 042318 PN=1019
Diagnostic Information
• 2
Swing Motor Swap right swing motor crossover relief valve with left swing motor crossover relief Crossover Relief Valve valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. Malfunction (Group 4360.)
Is swing speed slow in same direction?
YES: Go to Swing Motor Make-Up Check Valve Leakage.
NO: Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) DF89619,00B57A9 -19-20AUG15-4/6
• 3
Swing Motor Make-Up Check Valve Leakage
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation. (Group 9025-05.)
YES: Go to Control Valve Sticking.
Are swing motor make-up check valves OK?
NO: Repair or replace swing motor make-up check valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) DF89619,00B57A9 -19-20AUG15-5/6
• 4
Control Valve Sticking
Inspect control valve for sticking spool. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Checks complete.
Does control valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.) DF89619,00B57A9 -19-20AUG15-6/6
Upperstructure Drift With Swing Valve in Neutral DF89619,00B57AA -19-12JUN14-1/11
Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure DF89619,00B57AA -19-12JUN14-2/11
• 1
Upperstructure Drift Check
Measure upperstructure drift. See Upperstructure Drift Test. (Group 9025-25.)
YES: Checks complete.
Is upperstructure drift within specification?
NO: Go to Park Brake Operation. DF89619,00B57AA -19-12JUN14-3/11
• 2
Park Brake Operation
Inspect swing motor and park brake for proper application and release. See Swing Motor Park Brake Release Circuit Operation. (Group 9025-05.)
YES: Go to Swing Park Brake Pilot Valve.
Does swing continue to drift after releasing controller for 10 seconds?
NO: Go to Drift Direction.
Continued on next page
TM13345X19 (23APR18)
9025-15-20
DF89619,00B57AA -19-12JUN14-4/11
160GLC Excavator 042318 PN=1020
Diagnostic Information
• 3
Drift Direction
Operate machine and check for drift in both directions.
YES: Go to Case Drain Leakage.
Does drift occur in both directions?
NO: Go to Swing Motor Make-Up Check Valve Leakage. DF89619,00B57AA -19-12JUN14-5/11
• 4
Case Drain Leakage
Inspect swing motor for leakage. See Swing Motor Leakage Test. (Group 9025-25.)
YES: Go to Damper Valve Malfunction.
Does observed leakage meet specification?
NO: Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.) DF89619,00B57AA -19-12JUN14-6/11
• 5
Damper Valve Malfunction
Inspect swing motor dampener valves. See Swing Motor Damper Valve. (Group 9025-05.)
YES: Checks complete.
Are damper valves OK?
NO: Repair or replace damper valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) DF89619,00B57AA -19-12JUN14-7/11
• 6
Swing Motor Make-Up Check Valve Leakage
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation. (Group 9025-05.)
YES: Go to Swing Motor Crossover Relief Valve Malfunction.
Are swing motor make-up check valves OK?
NO: Repair or replace swing motor make-up check valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) DF89619,00B57AA -19-12JUN14-8/11
• 7
Swing Motor Remove crossover relief valves and install in opposite ports in park brake housing. See YES: Repair or replace Crossover Relief Valve Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) crossover relief valves. Malfunction See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) Does swing drift change directions?
NO: Checks complete. Continued on next page
TM13345X19 (23APR18)
9025-15-21
DF89619,00B57AA -19-12JUN14-9/11
160GLC Excavator 042318 PN=1021
Diagnostic Information
• 8
Swing Park Brake Pilot Valve
View front attachment pressure sensor value in monitor. See Monitoring. (Group 9015-16.) Actuate a dig function.
YES: Go to Swing Park Brake Not Fully Engaging.
Does front attachment pressure sensor value change?
NO: Repair or replace swing park brake pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) DF89619,00B57AA -19-12JUN14-10/11
• 9
Swing Park Brake Not Engaging
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.)
YES: Checks complete.
Is swing motor and park brake OK?
NO: Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.) DF89619,00B57AA -19-12JUN14-11/11
Machine Freewheels Down an Incline DF89619,00B57E1 -19-06AUG14-1/4
Machine Freewheels Down an Incline Diagnostic Procedure DF89619,00B57E1 -19-06AUG14-2/4
• 1
Park Brake Housing
Swap park brake housing with other travel motor. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) Operate travel functions.
YES: Go to Mechanical Malfunction of Travel Motor and Gear Case.
Does same track freewheel?
NO: Replace park brake housing. See Park Brake Valve Disassemble and Assemble. (Group 0260.) DF89619,00B57E1 -19-06AUG14-3/4
• 2
Mechanical Malfunction of Travel Motor and Gear Case
Check travel motor leakage. See Travel Motor Leakage Test. (Group 9025-25.)
YES: Checks complete.
Does motor leakage meet specification?
NO: Inspect gear case components. If no issues are found, repair or replace travel motor. See Travel Gear Case Remove and Install. (Group 0250.) DF89619,00B57E1 -19-06AUG14-4/4
Track Will Not Move in Either Direction Continued on next page
TM13345X19 (23APR18)
9025-15-22
DF89619,00B57AE -19-24JUL14-1/9
160GLC Excavator 042318 PN=1022
Diagnostic Information Track Will Not Move in Either Direction Diagnostic Procedure DF89619,00B57AE -19-24JUL14-2/9
• 1
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Control Valve Stuck.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair, or replace pilot control valve. See Travel Pilot Valve Remove and Install. (Group 3360.) DF89619,00B57AE -19-24JUL14-3/9
• 2
Control Valve Stuck
Inspect control valve for stuck travel valve spool. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Go to Travel Motor Leakage.
Does travel valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.) DF89619,00B57AE -19-24JUL14-4/9
• 3
Travel Motor Leakage
Check travel motor leakage. See Travel Motor Leakage Test. (Group 9025-25.)
YES: Go to Counterbalance Valve Spool Stuck.
Does motor leakage meet specification?
NO: Repair or replace travel motor. See Travel Gear Case Remove and Install. (Group 0250.) DF89619,00B57AE -19-24JUL14-5/9
• 4
Counterbalance Valve Spool Stuck
Inspect counterbalance valve.
YES: Go to Park Brake Housing.
Does counterbalance valve spool move freely?
NO: Repair or replace counterbalance valve. See Park Brake Valve Disassemble and Assemble. (Group 0260.) DF89619,00B57AE -19-24JUL14-6/9
• 5
Park Brake Housing
Swap park brake housing with other travel motor. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Go to Mechanical Malfunction of Travel Motor or Gear Case.
Operate travel functions. Does same track not move in either direction?
NO: Replace park brake housing.
Continued on next page
TM13345X19 (23APR18)
9025-15-23
DF89619,00B57AE -19-24JUL14-7/9
160GLC Excavator 042318 PN=1023
Diagnostic Information
• 6
Mechanical Malfunction of Travel Motor or Gear Case
Inspect travel motor and gear case for mechanical malfunction. See Travel Gear Case Remove and Install. (Group 0250.)
YES: Go to Center Joint Leakage.
Is travel motor and gear case OK?
NO: Repair or replace travel motor or gear case. DF89619,00B57AE -19-24JUL14-8/9
• 7
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 4360.)
YES: Checks complete.
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Remove and Install. (Group 4360.) DF89619,00B57AE -19-24JUL14-9/9
Machine Mistracks DF89619,00B6904 -19-06FEB18-1/11
Machine Mistracks Diagnostic Procedure DF89619,00B6904 -19-06FEB18-2/11
• 1
Machine Tracking
Check machine tracking. See Travel System Tracking Check. (Group 9005-10.)
YES: Checks complete.
Does tracking meet specification?
NO: Go to Incorrect Track Sag Adjustment. DF89619,00B6904 -19-06FEB18-3/11
• 2
Incorrect Track Sag Adjustment
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Fast Travel Check.
Is track sag within specification?
NO: Adjust track sag. DF89619,00B6904 -19-06FEB18-4/11
• 3
Fast Travel Check
Operate machine in fast and slow travel speeds.
YES: Go to Travel System Check.
Does machine mistrack at both speeds?
NO: Inspect travel speed change components. See Park Brake Valve Disassemble and Assemble. (Group 0260.) DF89619,00B6904 -19-06FEB18-5/11
• 4
Travel System Check
Swap left travel hoses with right travel hoses at top of center joint. See Travel Hydraulic System Line Connection. (Group 9025-15.) Operate travel functions.
YES: Go to Travel Motor Leakage.
Does machine mistrack in same direction?
NO: Go to Pilot Control Valve Malfunction.
Continued on next page
TM13345X19 (23APR18)
9025-15-24
DF89619,00B6904 -19-06FEB18-6/11
160GLC Excavator 042318 PN=1024
Diagnostic Information
• 5
Travel Motor Leakage
Check travel motor leakage. See Travel Motor Leakage Test. (Group 9025-25.)
YES: Go to Center Joint Leakage.
Does motor leakage meet specification?
NO: Repair or replace travel motor. See Travel Gear Case Remove and Install. (Group 0250.) DF89619,00B6904 -19-06FEB18-7/11
• 6
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 4360.)
YES: Repair or replace travel motor. See Travel Gear Case Remove and Install. (Group 0250.)
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Remove and Install. (Group 4360.) DF89619,00B6904 -19-06FEB18-8/11
• 7
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Pump Control Pilot Pressure Signal.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair, or replace pilot control valve. See Travel Pilot Valve Remove and Install. (Group 3360.) NO: For machines equipped with single pedal travel, inspect single pedal travel manifold for sticking or stuck shuttle valve. See Single Pedal Travel Operation—If Equipped. (Group 9025-05.) DF89619,00B6904 -19-06FEB18-9/11
• 8
Pump Control Pilot Pressure Signal
Check pump control pilot pressure. Perform Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
YES: Go to Worn Pump.
Does pump control pilot pressure meet specification?
NO: Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
Continued on next page
TM13345X19 (23APR18)
9025-15-25
DF89619,00B6904 -19-06FEB18-10/11
160GLC Excavator 042318 PN=1025
Diagnostic Information
• 9
Worn Pump
Slow cycle times may indicate a worn pump. Check cycle times. See Operational Checkout. (Group 9005-10.) If cycle times do not meet specification, check pump flow. See Pump Flow Test. (Group 9025-25.)
YES: Replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)
Do cycle times and pump flow meet specification?
NO: Repair or replace pump. See Pump 1 and 2 Remove and Install. (Group 3360.) DF89619,00B6904 -19-06FEB18-11/11
Machine Mistracks Left During Combined Travel and Dig Functions DF89619,00B57E0 -19-01OCT14-1/4
Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure NOTE: During combined travel and dig functions, hydraulic functions will be slow, but machine should not mistrack. DF89619,00B57E0 -19-01OCT14-2/4
• 1
Travel Flow Combiner Pilot Valve Stuck
Measure pressure from travel flow combiner pilot valve (port SL) during combined travel and dig functions.
• See Control Valve Spool Actuating Pilot Pressure Test for pressure specification. (Group 9025-25.)
• See Control Valve Line Identification for port identification. (Group 9025-15.) • See Pilot Signal Manifold-to-Control Valve Line Connection for line identification.
YES: Go to Travel Flow Combiner Valve and Check Valves Stuck.
Does pilot pressure meet specification?
NO: Repair or replace travel flow combiner pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
(Group 9025-15.)
DF89619,00B57E0 -19-01OCT14-3/4
• 2
Travel Flow Combiner Valve and Check Valves Stuck
Inspect travel flow combiner valve and check valves. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)
YES: Checks complete.
Does travel flow combiner valve and check valves move freely?
NO: Repair or replace control valve components. DF89619,00B57E0 -19-01OCT14-4/4
Machine Will Not Shift Into Fast (rabbit) Speed Continued on next page
TM13345X19 (23APR18)
9025-15-26
DF89619,00B5889 -19-06FEB17-1/13
160GLC Excavator 042318 PN=1026
Diagnostic Information Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure For more information, see Travel Motor Speed Circuit Operation. (Group 9025-05.) Also see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.) DF89619,00B5889 -19-06FEB17-2/13
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using monitor, Service ADVISOR™, or 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.)
YES: Diagnose DTC. See specific diagnostic procedure in Group 9001.
Are any DTCs present?
NO: Go to Fuse Check.
Service ADVISOR is a trademark of Deere & Company DF89619,00B5889 -19-06FEB17-3/13
• 2
Fuse Check
Remove solenoid 20 A fuse (marked SOLENOID) (F4) from fuse block. See Fuse and Relay Specifications. (Group 9015-10.) Check fuse F4 for continuity.
YES: Go to Travel Speed Function.
Is continuity indicated?
NO: Replace fuse. DF89619,00B5889 -19-06FEB17-4/13
• 3
Travel Speed Function NOTE: Fast (rabbit) travel speed function will not enabled if travel functions are held over relief. Travel mode switch in fast (rabbit) position. View Boost Pressure P/S Output in monitor. See Monitoring. (Group 9015-16.) Fully actuate travel functions.
YES: Go to Solenoid Check.
Is Boost Pressure P/S Output approximately 3.0 MPa?
NO: Go to Travel Mode Switch Check. DF89619,00B5889 -19-06FEB17-5/13
• 4
Solenoid Check
Verify proper operation of power dig/travel speed solenoid (marked SG) (Y24). See Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Travel Speed Circuit Check.
Does power dig valve pressure meet specification?
NO: Go to next step in this check.
Test power dig/travel speed solenoid (marked SG) (Y24). See Electrical Component Specifications. (Group 9015-20.)
YES: Go to next step in this check.
Is solenoid within specification?
NO: Replace solenoid.
Inspect power dig/travel speed solenoid valve for scoring or debris. See Solenoid Valve YES: Go to Harness Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), Check. and Dig Regenerative (SF) Valves. (Group 3360.) Is power dig/travel speed solenoid valve OK?
Continued on next page
TM13345X19 (23APR18)
9025-15-27
NO: Repair or replace power dig/travel speed solenoid valve. DF89619,00B5889 -19-06FEB17-6/13
160GLC Excavator 042318 PN=1027
Diagnostic Information
• 5
Harness Check
Check harness and harness connectors for damage, corrosion, or debris.
YES: Go to Travel Speed Circuit Check.
Are harness and harness connectors in good condition?
NO: Repair or repair harness as necessary. DF89619,00B5889 -19-06FEB17-7/13
• 6
Travel Speed Circuit Check
Inspect travel speed circuit.
• See Hydraulic System Schematic. (Group 9025-15.) • See Center Joint Operation. (Group 9025-05.) • See Travel Hydraulic System Line Connection. (Group 9025-05.)
YES: Checks complete.
Are all lines and hoses straight and in good condition; not kinked, worn from rubbing, or NO: Repair or replace lines weather checked? or hoses as necessary. DF89619,00B5889 -19-06FEB17-8/13
• 7
Travel Mode Switch Check
View Travel Mode Switch in monitor. See Monitoring. (Group 9015-16.)
Move travel mode switch to fast (rabbit) position and slow (turtle) position.
YES: Go to Front Attachment Pressure Sensor Check.
Does switch positions match monitor status?
NO: Repair or replace travel mode switch or harness. DF89619,00B5889 -19-06FEB17-9/13
• 8
Front Attachment Pressure Sensor Check
View Front ATT Pilot Pressure in monitor. See Monitoring. (Group 9015-16.)
Fully actuate dig function and return pilot control levers to neutral to view reading.
YES: Go to Travel Pressure Sensor Check.
Does indicated pressure rise above 3.0 MPa and return to 0.0 MPa?
NO: Test front attachment pressure sensor. See Electrical Component Specifications. (Group 9015-20.) DF89619,00B5889 -19-06FEB17-10/13
• 9
Travel Pressure Sensor Check
View Travel Pilot Pressure in monitor. See Monitoring. (Group 9015-16.)
Fully actuate travel function and return pilot control valve to neutral to view reading.
YES: Go to Pump Delivery Pressure Sensor Check.
Does indicated pressure rise above 3.0 MPa and return to 0.0 MPa?
NO: Test travel pressure sensor. See Electrical Component Specifications. (Group 9015-20.)
Continued on next page
TM13345X19 (23APR18)
9025-15-28
DF89619,00B5889 -19-06FEB17-11/13
160GLC Excavator 042318 PN=1028
Diagnostic Information
•
10 Pump Delivery Pressure Sensor Check
View Pump 1 Delivery Pressure and Pump 2 Delivery Pressure in monitor. See Monitoring. (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. (Group 9025-25.)
YES: Go to Pump Control Pressure Sensor Check.
Do pressure readings meet specification?
NO: Replace pump delivery pressure sensor. DF89619,00B5889 -19-06FEB17-12/13
•
11 Pump Control Pressure Sensor Check
Verify proper operation of pump control pressure sensors. See Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
YES: Checks complete.
Does pump control pilot pressure readings meet specification?
NO: Test pump control pressure sensors. See Electrical Component Specifications. (Group 9015-20.) DF89619,00B5889 -19-06FEB17-13/13
Pump 1, Pump 2, and Pilot Pump Line Identification 3 4
5
TX1107072 —UN—31JAN12
9
2 7 1 TX1107072
10
6
8
Pump 1, Pump 2, and Pilot Pump Line Identification 1— Pilot Pump Outlet Port 2— Pilot Pump Inlet Port 3— From Pilot Signal Manifold (port SA)
4— From Pilot Signal Manifold (port SB) 5— Pump 1 Outlet Port 6— Pump 2 Outlet Port
7— From Pilot Pressure Regulating Valve 8— Pumps 1 and 2 Inlet Port 9— Pump 1 Attenuator Port
10— Pump 2 Attenuator Port
JA66566,000267C -19-09AUG14-1/1
TM13345X19 (23APR18)
9025-15-29
160GLC Excavator 042318 PN=1029
Diagnostic Information
Control Valve Line Identification 12
7 93A
10
2
SG 31A
4 B31
51B 6 91A 36A
87B
63A
104A
52B
63B
TX1157035 —UN—02APR14
16B 73 DY
127B
43
74
DE 127A
52A
TX1157035 Left Control Valve (5-spool) 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) 16B— From Pump 2 31A— To Hydraulic Oil Tank 36A— To Hydraulic Oil Cooler
43— Arm 1 (swing priority) Flow 73— Right Control Valve (4-spool) 127B— Arm Cylinder (rod end) Rate Pilot Valve (port SE) 74— Left Control Valve (5-spool) B31— Arm In Pressure Sensor 51B— From Swing Device 87B— From Boom Lower Meter-In DE—To Solenoid Valve Manifold 52A— To Swing Motor (swing Cut Valve Port DE right) 91A— To Arm 2 Flow Rate Control DY—To Solenoid Valve Manifold 52B— To Swing Motor (swing left) Valve Port DY (2 used) 63A— Left Travel Motor (forward) 93A— To Bypass Shutoff Valve SG—From Power Dig Solenoid 63B— Left Travel Motor (reverse) 104A— To Boom 2 Spool Valve (SG) 127A— Arm Cylinder (head end) Continued on next page
TM13345X19 (23APR18)
9025-15-30
DF89619,00B574C -19-09APR14-1/3
160GLC Excavator 042318 PN=1030
Diagnostic Information
DH
SC 125A 87A 93A 81B
B31
73
126B
87B
46
104A
61B
74 DK
94B
15B
DD 16B
61A
126A
5
125B 3
1
SF
8
B30
9
11
TX1157034 —UN—02APR14
31A
44
DZ DN
TX1157034 Right Control Valve (4-spool)
61A— Right Travel Motor 1— Boom Up (pilot) 104A— To Boom 2 Spool DK—To Solenoid Valve Manifold (forward) 3— Arm Out (pilot) 125A— Boom Cylinder (head Port DK 61B— Right Travel Motor 5— Swing Left (pilot) end) DN—To Solenoid Valve Manifold (reverse) 8— Bucket Dump (pilot) 125B— Boom Cylinder (rod end) Port DN 73— Right Control Valve (4-spool) 126A— Bucket Cylinder (head 9— Left Travel Forward (pilot) DZ—To Solenoid Valve Manifold 11— Right Travel Forward (pilot) 74— Left Control Valve (5-spool) end) Port DZ 81B— From Boom 1 Spool 15B— From Pump 1 126B— Bucket Cylinder (rod end) SC—From Arm Regenerative 87A— To Boom Lower Meter-In 16B— From Pump 2 B30— Boom Up Pressure Sensor Solenoid Valve (SC) Cut Valve 31A— To Hydraulic Oil Tank B31— Arm In Pressure Sensor SF—From Dig Regenerative 44— Travel Flow Combiner Pilot 87B— From Boom Lower Meter-In DD—To Solenoid Valve Manifold Solenoid Valve (SF) Cut Valve Valve (port SL) Port DD 46— Bucket Flow Rate Pilot Valve 93A— To Bypass Shutoff Valve DH—To Solenoid Valve Manifold 94B— From Arm Regenerative (port SK) Port DH Valve Continued on next page
TM13345X19 (23APR18)
9025-15-31
DF89619,00B574C -19-09APR14-2/3
160GLC Excavator 042318 PN=1031
Diagnostic Information
74
73
TX1157037
TX1157037 —UN—01APR14
DN
Control Valve Line Identification (front) 73— Right Control Valve (4-spool) 74— Left Control Valve (5-spool)
DN—To Solenoid Valve Manifold Port DN DF89619,00B574C -19-09APR14-3/3
TM13345X19 (23APR18)
9025-15-32
160GLC Excavator 042318 PN=1032
Diagnostic Information
Swing Motor Line Identification 4— To Control Valve 5— From Pilot Signal Manifold (port SH) B32— Front Attachment Pressure Sensor
TX1107074A —UN—31JAN12
1— From Control Valve Swing Left 2— From Control Valve Swing Right 3— To Hydraulic Oil Tank
Swing Motor Line Identification MM16284,00011FF -19-19DEC13-1/1
TM13345X19 (23APR18)
9025-15-33
160GLC Excavator 042318 PN=1033
Diagnostic Information
TM13345X19 (23APR18)
9025-15-34
160GLC Excavator 042318 PN=1034
Diagnostic Information
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern TX1107543 —UN—06FEB12
C 41 40
A E D B
H F
G PI
P 3
T 2
1 4
39
A1 A3
5
A2 6
A4 P 3
4 T
2
T2
1
T3
T1
TX1107543 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern Continued on next page
TM13345X19 (23APR18)
9025-15-35
160GLC Excavator 042318 PN=1035
JA66566,000267F -19-03AUG12-1/2
Diagnostic Information
TM13345X19 (23APR18)
9025-15-36
160GLC Excavator 042318 PN=1036
Diagnostic Information 1— Port 1 39— Left Pilot Control Valve 2— Port 2 40— Right Pilot Control Valve 3— Port 3 41— Pilot Signal Manifold 4— Port 4 A—Port A 5— Pilot Control Shutoff Valve A1—To Travel Pilot Controller 6— From Solenoid Valve Manifold (port PE)
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
Right Pilot Lever
Pilot Signal Manifold Ports
Functions
Pilot Control Valve Ports
Bucket Dump
1
H
8
Boom Down
2
B
2
Bucket Curl
3
G
7
Boom Up
4
A
1
Pilot Control Valve Side
P
Pilot Shutoff Valve A2
T
Left Pilot Lever
Control Valve Side
Pilot Shutoff Valve T2
Swing Right
1
F
Arm Out
2
C
3
Swing Left
3
E
5
4
D
Arm In
6
4
P
Pilot Shutoff Valve A3
T
Pilot Shutoff Valve T3
NOTE: Letters and numbers are located on housings next to ports. Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern JA66566,000267F -19-03AUG12-2/2
TM13345X19 (23APR18)
9025-15-37
160GLC Excavator 042318 PN=1037
Diagnostic Information
TM13345X19 (23APR18)
9025-15-38
160GLC Excavator 042318 PN=1038
Diagnostic Information
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern TX1107545 —UN—06FEB12
A
C 41
40 E D
B
H F
G
PI
P
3
T 1 4 2 39
A1
5
A2 6
A3 A4 P 3
T
T2 1
TX1107545
T1
4
2 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern Continued on next page
TM13345X19 (23APR18)
T3
9025-15-39
160GLC Excavator 042318 PN=1039
JA66566,0002680 -19-03AUG12-1/2
Diagnostic Information
TM13345X19 (23APR18)
9025-15-40
160GLC Excavator 042318 PN=1040
Diagnostic Information 1— Port 1 39— Left Pilot Control Valve 2— Port 2 40— Right Pilot Control Valve 3— Port 3 41— Pilot Signal Manifold 4— Port 4 A—Port A 5— Pilot Control Shutoff Valve A1—To Travel Pilot Controller 6— From Solenoid Valve Manifold (port PE)
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
Right Pilot Lever
Pilot Signal Manifold Ports
Functions
Pilot Control Valve Ports
Bucket Dump
1
H
8
Arm Out
2
C
3
Bucket Curl
3
G
7
Arm In
4
D
4
Pilot Control Valve Side
P
Pilot Shutoff Valve A2
T
Left Pilot Lever
Control Valve Side
Pilot Shutoff Valve T2
Swing Right
1
F
Boom Down
2
B
2
Swing Left
3
E
5
4
A
Boom Up
6
1
P
Pilot Shutoff Valve A3
T
Pilot Shutoff Valve T3
NOTE: Letters and numbers are located on housings next to ports. Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern JA66566,0002680 -19-03AUG12-2/2
TM13345X19 (23APR18)
9025-15-41
160GLC Excavator 042318 PN=1041
Diagnostic Information
Pilot Signal Manifold-to-Control Valve Line Connection
41
2 4
SK 7
SE
6
10
12
TX1107077 —UN—31JAN12
73
TX1107077 Pilot Signal Manifold-to-Control Valve Line Connection—Top
Continued on next page
TM13345X19 (23APR18)
9025-15-42
JA66566,0002681 -19-03AUG12-1/4
160GLC Excavator 042318 PN=1042
Diagnostic Information 2— Port 2 to Boom Down Pilot 10— Port 10 to Left Travel Cap Reverse Pilot Cap 4— Port 4 to Arm In Pilot Cap 12— Port 12 to Right Travel 6— Port 6 to Swing Right Pilot Reverse Pilot Cap Cap 41— Control Valve Side of Pilot 7— Port 7 to Bucket Curl Pilot Cap Signal Manifold
73— Control Valve (top) SE—Port (SE) to Arm 1 (Swing Priority) Flow Rate Control Valve SK—Port (SK) to Bucket Flow Rate Pilot Valve
Continued on next page
TM13345X19 (23APR18)
9025-15-43
JA66566,0002681 -19-03AUG12-2/4
160GLC Excavator 042318 PN=1043
Diagnostic Information
1 41
3 S3 5 B33 8 11
9 SL
B34
TX1107076 —UN—31JAN12
TR
74
TX1107076 Pilot Signal Manifold-to-Control Valve Line Connection—Bottom
Continued on next page
TM13345X19 (23APR18)
9025-15-44
JA66566,0002681 -19-03AUG12-3/4
160GLC Excavator 042318 PN=1044
Diagnostic Information 1— Port 1 to Boom Up Pilot Cap 9— Port 9 to Left Travel Forward 3— Port 3 to Arm Out Pilot Cap Pilot Cap 5— Port 5 to Swing Left Pilot Cap 11— Port 11 to Right Travel 8— Port 8 to Bucket Dump Pilot Forward Pilot Cap Cap 41— Control Valve Side of Pilot Signal Manifold
74— Control Valve (bottom) TR—Travel Pressure Sensor Port B33— Swing Pressure Sensor B34— Travel Pressure Sensot S3— Swing Pressure Sensor Port SL—Port (SL) to Travel Flow Combiner Valve JA66566,0002681 -19-03AUG12-4/4
TM13345X19 (23APR18)
9025-15-45
160GLC Excavator 042318 PN=1045
Diagnostic Information
Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped
40 39
4
2
2
4
41
3
D
A
C D A 250 B
B
2 4
TX1248309 —UN—08DEC17
1 C
TX1248309 Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped 39— Left Pilot Control Valve 40— Right Pilot Control Valve
41— Pilot Signal Manifold 250— Pattern Selector Valve (if equipped) DB95148,000215E -19-16JAN18-1/1
Travel System Component Location For more information, see Hydraulic System Component Location. (Group 9015-15.) DF89619,00B68FC -19-31JAN18-1/1
TM13345X19 (23APR18)
9025-15-46
160GLC Excavator 042318 PN=1046
Diagnostic Information
Travel Hydraulic System Line Connections TX1251564 —UN—31JAN18
37
Y24 SG 31
P
4
T
38 1
3
74
2
T1 Y10
72 A1
73
141
9
41 L
12
B34
K
11
I J
61 10
63
SL
TX1251564 Travel Hydraulic System Line Connections Continued on next page
TM13345X19 (23APR18)
9025-15-47
160GLC Excavator 042318 PN=1047
DF89619,00B68FB -19-08FEB18-1/4
Diagnostic Information
TM13345X19 (23APR18)
9025-15-48
160GLC Excavator 042318 PN=1048
Diagnostic Information
31— Hydraulic Oil Tank 37— Solenoid Valve Manifold 38— Travel Pilot Control Valve 41— Pilot Signal Manifold
61— Right Travel Motor 74— Left Control Valve (5-spool) 63— Left Travel Motor 141— Pilot Shutoff Valve 72— Center Joint B34— Travel Pressure Sensor 73— Right Control Valve (4-spool) (marked TR)
Y10— Pilot Shutoff Solenoid Y24— Power Dig/Travel Speed Solenoid (marked SG)
• See Center Joint Operation. (Group 9025-05.)
For more information:
• See Hydraulic System Schematic. (Group 9025-15.) • See Hydraulic System Line Connections. (Group 9025-15.)
Continued on next page
TM13345X19 (23APR18)
9025-15-49
DF89619,00B68FB -19-08FEB18-2/4
160GLC Excavator 042318 PN=1049
Diagnostic Information
TM13345X19 (23APR18)
9025-15-50
160GLC Excavator 042318 PN=1050
Diagnostic Information
TX1251645 —UN—01FEB18
37
Y24 SG 31 251 38
P
P
T 2
3
T 2
74 1 SF
4
1
LF SR RF 72
RR 73
LR 252 141
VRF VLF
A1
Y10 T1
VLR
VRR
9
41
L
12
B34
K
11
I J
61 10
63
SL
TX1251645 Travel Hydraulic System Line Connections (with single pedal travel) Continued on next page
TM13345X19 (23APR18)
9025-15-51
160GLC Excavator 042318 PN=1051
DF89619,00B68FB -19-08FEB18-3/4
Diagnostic Information
TM13345X19 (23APR18)
9025-15-52
160GLC Excavator 042318 PN=1052
Diagnostic Information
31— Hydraulic Oil Tank 37— Solenoid Valve Manifold 38— Travel Pilot Control Valve 41— Pilot Signal Manifold 61— Right Travel Motor
63— Left Travel Motor 251— Single Pedal Travel Pilot 72— Center Joint Control Valve 73— Right Control Valve (4-spool) 252— Single Pedal Travel Pilot 74— Left Control Valve (5-spool) Manifold 141— Pilot Shutoff Valve B34— Travel Pressure Sensor (marked TR)
Y10— Pilot Shutoff Solenoid Y24— Power Dig/Travel Speed Solenoid (marked SG)
• See Center Joint Operation. (Group 9025-05.)
For more information:
• See Hydraulic System Schematic. (Group 9025-15.) • See Hydraulic System Line Connections. (Group 9025-15.)
DF89619,00B68FB -19-08FEB18-4/4
TM13345X19 (23APR18)
9025-15-53
160GLC Excavator 042318 PN=1053
Diagnostic Information
TM13345X19 (23APR18)
9025-15-54
160GLC Excavator 042318 PN=1054
Diagnostic Information
Auxiliary Attachment Schematic TX1156310 —UN—27MAR14
P
A3 A2 A1
T4
T2 T1 T3
37
28 Y23
Y22
HT
PH
Y24 B34
9
I
10
J
TR
104
K 11
74
41 12
K
4
D
117 SA
107 SN
95
97
110 SP
3
C
2 B
118
SB
171 46 SK
47 604
A
1
609 81
90
SH
76
56 75
120
93
SL
44
45
164
42
SE
73
P T
B33
B60
8
H
7
G
6
F
S3
E
5 13
M
2
SM N
TX1156310 Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted) Continued on next page
TM13345X19 (23APR18)
1
14
9025-15-55
160GLC Excavator 042318 PN=1055
DF89619,00B5752 -19-19JUN14-1/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-56
160GLC Excavator 042318 PN=1056
Diagnostic Information 28— Pilot Pump 56— To Swing Park Brake 110— Left Travel Spool 37— Solenoid Valve Manifold 73— Right Control Valve (4-spool) 117— Main Relief 41— Pilot Signal Manifold 74— Left Control Valve (5-spool) 118— Auxiliary Function Flow 42— Boom Down Shockless 75— Right Travel Spool Combiner Valve Valve 76— Bucket Spool 120— Travel Flow Combiner 44— Travel Flow Combiner Pilot 81— Boom 1 Spool Valve Valve (port SL) 90— Arm 2 Spool 164— Auxiliary Pilot Control 45— Swing Park Brake Release 93— Bypass Shutoff Valve Valve Pilot Valve (port SH) 95— Swing Spool 171— To Pump 2 Flow Rate 46— Bucket Flow Rate Pilot Valve 97— Arm 1 Spool Solenoid Valve (port SK) 104— Boom 2 Spool 604— Return Oil 47— Pump 2 Flow Rate Pilot 107— Auxiliary Spool 609— Pilot Oil Valve (port SB) B33— Swing Pressure Sensor (marked S3) Continued on next page
TM13345X19 (23APR18)
9025-15-57
B34— Travel Pressure Sensor (marked TR) B60— Attachment Pressure Sensor Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
DF89619,00B5752 -19-19JUN14-2/14
160GLC Excavator 042318 PN=1057
Diagnostic Information
TM13345X19 (23APR18)
9025-15-58
160GLC Excavator 042318 PN=1058
Diagnostic Information
TX1156311 —UN—27MAR14
P
A3 A2 A1
T4
T2 T1 T3
37
28 Y23
Y22
HT
PH
Y24 B34
9
I
10
J
TR
104
K 11
74
41 12
K
4
D
117 SA
107 SN
95
97
110 SP
3
C
2 B SB
118
171 46 SK
149
47 A
1
81
90
SH
76
56 75
120
93
SL
44
45
42
SE
73
B33
B60
8
H
7
G
6
F
S3
E
5 13
M
604
SM N 14
TX1156311 Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted) Continued on next page
TM13345X19 (23APR18)
9025-15-59
160GLC Excavator 042318 PN=1059
148
609
DF89619,00B5752 -19-19JUN14-3/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-60
160GLC Excavator 042318 PN=1060
Diagnostic Information 28— Pilot Pump 56— To Swing Park Brake 117— Main Relief 37— Solenoid Valve Manifold 73— Right Control Valve (4-spool) 118— Auxiliary Function Flow 41— Pilot Signal Manifold 74— Left Control Valve (5-spool) Combiner Valve 42— Boom Down Shockless 75— Right Travel Spool 120— Travel Flow Combiner Valve 76— Bucket Spool Valve 44— Travel Flow Combiner Pilot 81— Boom 1 Spool 148— Auxiliary Pilot Solenoid Valve (port SL) 90— Arm 2 Spool Valve 45— Swing Park Brake Release 93— Bypass Shutoff Valve 149— Auxiliary Pilot Pressure Pilot Valve (port SH) 95— Swing Spool Reducing Valve 46— Bucket Flow Rate Pilot Valve 97— Arm 1 Spool 171— To Pump 2 Flow Rate (port SK) 104— Boom 2 Spool Solenoid Valve 47— Pump 2 Flow Rate Pilot 107— Auxiliary Spool 604— Return Oil Valve (port SB) 110— Left Travel Spool 609— Pilot Oil B33— Swing Pressure Sensor (marked S3) Continued on next page
TM13345X19 (23APR18)
9025-15-61
B34— Travel Pressure Sensor (marked TR) B60— Attachment Pressure Sensor Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)
DF89619,00B5752 -19-19JUN14-4/14
160GLC Excavator 042318 PN=1061
Diagnostic Information
TM13345X19 (23APR18)
9025-15-62
160GLC Excavator 042318 PN=1062
Diagnostic Information
TX1157670 —UN—11APR14
74
73
150 155 75
110
76 154
13
14 107
Y40
104
81
97
37
90
95 28
124 16
15
600
604
609
TX1157670 Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted) Continued on next page
TM13345X19 (23APR18)
9025-15-63
160GLC Excavator 042318 PN=1063
DF89619,00B5752 -19-19JUN14-5/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-64
160GLC Excavator 042318 PN=1064
Diagnostic Information
13— Auxiliary (pilot) 74— Left Control Valve (5-spool) 14— Auxiliary (pilot) 75— Right Travel Spool 15— Pump 1 76— Bucket Spool 16— Pump 2 81— Boom 1 Spool 28— Pilot Pump 90— Arm 2 Spool 37— Solenoid Valve Manifold 95— Swing Spool 73— Right Control Valve (4-spool) 97— Arm 1 Spool
104— Boom 2 Spool 107— Auxiliary Spool 110— Left Travel Spool 124— Oil Cooler Bypass Valve 150— Auxiliary Attachment 154— Selector Valve Solenoid Valve
Continued on next page
TM13345X19 (23APR18)
9025-15-65
155— Selector Valve 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil Y40— Selector Valve Solenoid Valve DF89619,00B5752 -19-19JUN14-6/14
160GLC Excavator 042318 PN=1065
Diagnostic Information
TM13345X19 (23APR18)
9025-15-66
160GLC Excavator 042318 PN=1066
Diagnostic Information
TX1148728 —UN—04DEC13
B61 Y44 157 156
143
Y43
B60
73
28 93 75
90 76
81 171 56 172 14
SM
13 5 S3
6
7
8
SE
SL SH
1
SK
SB
2
15
118
41
3
SP
SN
SA
4
12
D
K
11
TR 10
9
J
I
48
47 45
119
107
108 16
117 108 N
M
E
F
G
H
A
B
C
K
74
95
110 104
600
97
604 609 TX1148728 Two Pump Combined Flow Kit Schematic (Y43 energized and Y44 de-energized) Continued on next page
TM13345X19 (23APR18)
9025-15-67
160GLC Excavator 042318 PN=1067
DF89619,00B5752 -19-19JUN14-7/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-68
160GLC Excavator 042318 PN=1068
Diagnostic Information 15— Pump 1 75— Right Travel Spool 16— Pump 2 76— Bucket Spool 28— Pilot Pump 81— Boom 1 Spool 41— Pilot Signal Manifold 90— Arm 2 Spool 45— Swing Park Brake Release 93— Bypass Shutoff Valve Pilot Valve 95— Swing Spool 47— Pump 2 Flow Rate Pilot Valve 97— Arm 1 Spool 48— Pump 1 Flow Rate Pilot Valve 104— Boom 2 Spool 56— To Swing Park Brake 107— Auxiliary Spool 73— Right Control Valve (4-spool) 108— Auxiliary Flow Rate 74— Left Control Valve (5-spool) Control Valve (valve and poppet) 110— Left Travel Spool 117— Main Relief and Power Dig Valve
118— Auxiliary Function Flow 600— High-Pressure Oil Combiner Valve 604— Return Oil 119— Check Valve—Auxiliary 609— Pilot Oil Flow Combiner Valve B60— Attachment Pressure Circuit Sensor 143— Auxiliary Shuttle Valve B61— Arm Out Pressure Sensor 156— Flow Rate Select Solenoid Y43— 2-Speed Activation Valve Solenoid Valve 157— Flow Rate Select Reducing Y44— Flow Rate Adjustment Valve Solenoid Valve 171— To Pump 2 Flow Rate Solenoid Valve 172— To Torque Control Solenoid Valve
Continued on next page
TM13345X19 (23APR18)
9025-15-69
DF89619,00B5752 -19-19JUN14-8/14
160GLC Excavator 042318 PN=1069
Diagnostic Information
TM13345X19 (23APR18)
9025-15-70
160GLC Excavator 042318 PN=1070
Diagnostic Information
TX1156399 —UN—27MAR14
LEFT FORWARD
LEFT REVERSE
RIGHT FORWARD
10
9
11
RIGHT REVERSE
ARM OUT
ARM IN
3
4
12
BOOM DOWN
SWING LEFT
SWING RIGHT
6
5
BUCKET DUMP
BOOM UP
1
2
8
BUCKET CURL
7 164
R1 2
144
M P
3
T
P
T
4
2
1
2
P
T
4 1
3
2
P
T
4
1
1 AUX B1
AUX A1
14
13
3
B1
T
141
A3
A2
T2
A1
A4
TA
T1
T3 HT
41
PA
145 PD
PC
PG
PD
DH
PF
P
P
T4
I
J
9
10
K
L
D
12
4
C
B
A
H
G
F
E
M
8
7
6
S3 5 13
N
PH
PE
DE
PE
DP
DK DY
DN DS
DZ PF TR
B34
11
SA
SN
SP
3
2
SB
SK
1
SH SL
SE
SM
14
B33 37
DM
DD SC
SF
56
SG
600
604
606
609
TX1156399 Low Flow Kit Schematic (foot pedal operated) Continued on next page
TM13345X19 (23APR18)
9025-15-71
160GLC Excavator 042318 PN=1071
DF89619,00B5752 -19-19JUN14-9/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-72
160GLC Excavator 042318 PN=1072
Diagnostic Information
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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— Auxiliary A1 (pilot) 14— Auxiliary B1 (pilot) 37— Solenoid Valve Manifold
41— Pilot Signal Manifold 56— To Swing Park Brake 141— Pilot Shutoff Valve 144— Low Flow Control Valve 145— Pilot Low Flow Pump 164— Auxiliary Pilot Control Valve 600— High-Pressure Oil
Continued on next page
TM13345X19 (23APR18)
9025-15-73
604— Return Oil 606— Trapped Oil 609— Pilot Oil B33— Swing Pressure Sensor (marked S3) B34— Travel Pressure Sensor (marked TR)
DF89619,00B5752 -19-19JUN14-10/14
160GLC Excavator 042318 PN=1073
Diagnostic Information
TM13345X19 (23APR18)
9025-15-74
160GLC Excavator 042318 PN=1074
Diagnostic Information
TX1156400 —UN—26MAR14
LEFT FORWARD
LEFT REVERSE
RIGHT FORWARD
10
9
11
RIGHT REVERSE
ARM OUT
ARM IN
3
4
12
BOOM DOWN
SWING LEFT
SWING RIGHT
6
5
BUCKET DUMP
BOOM UP
1
2
8
BUCKET CURL
AUX B1
AUX A1
14
13
7 148
R1
144
M P
3
T
P
T
4
2
1
2
P
T
4 1
3
2
P
T
4
1
3
149 B1
141
A3
A2
T2
A1
A4
TA
T1
T3 HT
41
PA
145 PD
PC
PG
PD
DH
PF
P
T4
I
J
9
10
K
L
D
12
4
C
B
A
H
G
F
E
M
8
7
6
S3 5 13
N
PH
PE
DE
PE
DP
DK DY
DN DS
DZ PF TR
B34
11
SA
SN
SP
3
2
SB
SK
1
SH SL
SE
SM
14
B33 37
DM
DD SC
SF
56
SG
600
604
606
609
TX1156400 Low Flow Kit Schematic (solenoid operated) Continued on next page
TM13345X19 (23APR18)
9025-15-75
160GLC Excavator 042318 PN=1075
DF89619,00B5752 -19-19JUN14-11/14
Diagnostic Information
TM13345X19 (23APR18)
9025-15-76
160GLC Excavator 042318 PN=1076
Diagnostic Information
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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— Auxiliary A1 (pilot) 14— Auxiliary B1 (pilot) 37— Solenoid Valve Manifold 41— Pilot Signal Manifold
56— To Swing Park Brake 141— Pilot Shutoff Valve 144— Low Flow Control Valve 145— Pilot Low Flow Pump 148— Auxiliary Solenoid Valve 149— Auxiliary Pressure Reducing Valve 600— High-Pressure Oil
Continued on next page
TM13345X19 (23APR18)
9025-15-77
604— Return Oil 606— Trapped Oil 609— Pilot Oil B33— Swing Pressure Sensor (marked S3) B34— Travel Pressure Sensor (marked TR)
DF89619,00B5752 -19-19JUN14-12/14
160GLC Excavator 042318 PN=1077
Diagnostic Information
150
110 74
136
107 14
137 108
13 159
160 158
104
Y41
37
95
28
16 600
TX1148731
604
609
TX1148731 —UN—04DEC13
97
Secondary Auxiliary Relief Kit Schematic (auxiliary spool shifted)
Continued on next page
TM13345X19 (23APR18)
9025-15-78
DF89619,00B5752 -19-19JUN14-13/14
160GLC Excavator 042318 PN=1078
Diagnostic Information 13— Auxiliary (pilot) 14— Auxiliary (pilot) 16— Pump 2 28— Pilot Pump 37— Solenoid Valve Manifold 74— Left Control Valve (5-spool) 95— Swing Spool 97— Arm 1 Spool
104— Boom 2 Spool 137— Auxiliary Circuit Relief and 160— Secondary Auxiliary Relief 107— Auxiliary Spool Anticavitation Valve Control Valve 108— Auxiliary Flow Rate 150— Auxiliary Attachment 600— High-Pressure Oil Control Valve (valve and 158— Secondary Auxiliary Relief 604— Return Oil poppet) Valve Solenoid Valve 609— Pilot Oil 110— Left Travel Spool 159— Secondary Auxiliary Relief Y41— Secondary Relief Solenoid 136— Auxiliary Circuit Relief and Valve Valve Anticavitation Valve DF89619,00B5752 -19-19JUN14-14/14
TM13345X19 (23APR18)
9025-15-79
160GLC Excavator 042318 PN=1079
Diagnostic Information
TM13345X19 (23APR18)
9025-15-80
160GLC Excavator 042318 PN=1080
Diagnostic Information
Auxiliary System Line Connections TX1242575 —UN—02AUG17
74
31
150
155
29
Y40
37
28
154
TX1242575 High Flow Line Connections Continued on next page
TM13345X19 (23APR18)
9025-15-81
160GLC Excavator 042318 PN=1081
DF89619,00B565A -19-02AUG17-1/4
Diagnostic Information
TM13345X19 (23APR18)
9025-15-82
160GLC Excavator 042318 PN=1082
Diagnostic Information 28— Pilot Pump 37— Solenoid Valve Manifold 29— Pilot Filter and Bypass Valve 74— Left Control Valve (5-spool) 31— Hydraulic Oil Tank 150— Auxiliary Attachment
154— Selector Valve Solenoid Valve 155— Selector Valve Y40— Selector Valve Solenoid Valve
Continued on next page
TM13345X19 (23APR18)
9025-15-83
DF89619,00B565A -19-02AUG17-2/4
160GLC Excavator 042318 PN=1083
Diagnostic Information
TM13345X19 (23APR18)
9025-15-84
160GLC Excavator 042318 PN=1084
Diagnostic Information
TX1148768 —UN—04DEC13
41
73 Y43
Y44
74 156
31
73 74
143
29
37 157
28
TX1148768 Two Pump Combined Flow Kit Line Connections Continued on next page
TM13345X19 (23APR18)
9025-15-85
160GLC Excavator 042318 PN=1085
DF89619,00B565A -19-02AUG17-3/4
Diagnostic Information
TM13345X19 (23APR18)
9025-15-86
160GLC Excavator 042318 PN=1086
Diagnostic Information 28— Pilot Pump 41— Pilot Signal Manifold 156— Flow Rate Select Solenoid Y44— Flow Rate Adjustment 29— Pilot Filter and Bypass Valve 73— Right Control Valve (4-spool) Solenoid Valve Valve 31— Hydraulic Oil Tank 74— Left Control Valve (5-spool) 157— Flow Rate Select Reducing 37— Solenoid Valve Manifold 143— Auxiliary Shuttle Valve Valve Y43— 2-Speed Activation Solenoid Valve DF89619,00B565A -19-02AUG17-4/4
TM13345X19 (23APR18)
9025-15-87
160GLC Excavator 042318 PN=1087
Diagnostic Information
TM13345X19 (23APR18)
9025-15-88
160GLC Excavator 042318 PN=1088
Diagnostic Information
Hydraulic System Schematic TX1248216 —UN—14DEC17
38 TRAVEL PILOT CONTROL VALVE LEFT TRAVEL FORWARD
10
P
T
3
93
PD
77
98
108
RIGHT TRAVEL FORWARD
LEFT TRAVEL REVERSE
9
39 LEFT PILOT CONTROL VALVE RIGHT TRAVEL REVERSE
11
4
ARM OUT
ARM IN
SWING RIGHT
SWING LEFT
BOOM DOWN
BOOM UP
BUCKET DUMP
BUCKET CURL
3
4
6
5
2
1
8
7
12
2
1
40 RIGHT PILOT CONTROL VALVE
2
P
T
4
1
3
2
P
T
4
1
3
118 PILOT 41 SIGNAL MANIFOLD I
J
K
L
D
C
B
A
H
G
F
PH A3 PD
84B
DH
DE
PE
DP
DK
DY
A2
T2
A1
T1
E
M
N
49
T3
DN A4
DZ
42
129
HT
DS
50
Y10
PF
P
Y23
Y22
T4
Y24 141
DF
45 PI
SOLENOID 37 VALVE MANIFOLD
43 47
48 DD
SC
SG
SF
DM 9
10
TR
11
12
4
SA
SN
SP
66 B34 300 301
84A
117
3
2
SB
46
SK
1
SH
SL
44
SE
8
7
6
S3
5
13
SM
14
B33 604 609 TX1248216 Pilot Control Valves and Pilot Signal Manifold Schematic—Excavator Pattern Continued on next page
TM13345X19 (23APR18)
9025-15-89
160GLC Excavator 042318 PN=1089
DF89619,00B68D2 -19-14FEB18-1/12
Diagnostic Information
TM13345X19 (23APR18)
9025-15-90
160GLC Excavator 042318 PN=1090
Diagnostic Information
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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) 37— Solenoid Valve Manifold 38— Travel Pilot Control Valve 39— Left Pilot Control Valve 40— Right Pilot Control Valve 41— Pilot Signal Manifold
84A— To Dig Regenerative Valve 604— Return Oil 42— Boom Down Shockless 84B— From Dig Regenerative Valve 609— Pilot Oil Valve 43— Arm 1 Flow Rate Pilot Valve B33— Swing Pressure Sensor 93— From Bypass Shutoff Valve (port SE) (marked S3) 44— Travel Flow Combiner Pilot 98— From Arm 1 Flow Rate B34— Travel Pressure Sensor Control Valve (valve and Valve (port SL) (marked TR) poppet) 45— Swing Park Brake Release PD—From Pilot Filter and 108— From Auxiliary Flow Rate Pilot Valve (port SH) Regulator Valve Housing Control Valve (valve and 46— Bucket Flow Rate Pilot Valve (port PD) poppet) (port SK) Y10— Pilot Shutoff Solenoid 117— To Main Relief and Power Y22— Dig Regenerative Solenoid 47— Pump 2 Flow Rate Pilot Dig Valve Valve (port SB) (marked SF) 118— From Auxiliary Flow 48— Pump 1 Flow Rate Pilot Y23— Arm Regenerative Combiner Valve Valve (port SA) Solenoid (marked SC) 129— Orifice 49— Filter Screen (17 used) Y24— Power Dig/Travel Speed 141— Pilot Shutoff Valve 50— Shuttle Valve (17 used) Solenoid (marked SG) 300— From Arm 2 Flow Rate 66— To Travel Speed Change Control Valve and Boom Valve Lower Meter-In Cut Valve 77— From Bucket Flow Rate 301— To Arm Regenerative Valve Control Valve (valve and and Arm 2 Flow Rate poppet) Control Valve Continued on next page
TM13345X19 (23APR18)
9025-15-91
DF89619,00B68D2 -19-14FEB18-2/12
160GLC Excavator 042318 PN=1091
Diagnostic Information
TM13345X19 (23APR18)
9025-15-92
160GLC Excavator 042318 PN=1092
Diagnostic Information
TX1248217 —UN—14DEC17
38 TRAVEL PILOT CONTROL VALVE LEFT TRAVEL FORWARD
10
P
T
3
93
PD
98
77
108
RIGHT TRAVEL FORWARD
LEFT TRAVEL REVERSE
9
39 LEFT PILOT CONTROL VALVE RIGHT TRAVEL REVERSE
11
4
BOOM DOWN
BOOM UP
SWING RIGHT
SWING LEFT
ARM OUT
ARM IN
BUCKET DUMP
BUCKET CURL
2
1
6
5
3
4
8
7
12
2
1
40 RIGHT PILOT CONTROL VALVE
2
P
T
4
1
3
2
P
T
4
1
3
118 PILOT 41 SIGNAL MANIFOLD I
J
K
L
D
C
B
A
H
G
F
PH A3 PD
84B
DH
DE
PE
DP
DK
DY
A2
T2
A1
T1
E
M
N
49
T3
DN A4
DZ PF
50
42
129
HT
DS
Y10 P
Y23
Y22
T4
Y24 141
DF
45 PI
SOLENOID 37 VALVE MANIFOLD
43 47
48 DD
SC
SF
SG
DM 9
10
TR
11
12
4
SA
SN
SP
66 B34 300 301
84A
117
3
2
SB
46
SK
1
SH
SL
44
SE
8
7
6
S3
B33
5
13
SM
14
604 609
TX1248217 Pilot Control Valves and Pilot Signal Manifold Schematic—Backhoe Pattern Continued on next page
TM13345X19 (23APR18)
9025-15-93
160GLC Excavator 042318 PN=1093
DF89619,00B68D2 -19-14FEB18-3/12
Diagnostic Information
TM13345X19 (23APR18)
9025-15-94
160GLC Excavator 042318 PN=1094
Diagnostic Information
1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 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) 37— Solenoid Valve Manifold 38— Travel Pilot Control Valve 39— Left Pilot Control Valve 40— Right Pilot Control Valve 41— Pilot Signal Manifold
84A— To Dig Regenerative Valve 604— Return Oil 42— Boom Down Shockless 84B— From Dig Regenerative Valve 609— Pilot Oil Valve 43— Arm 1 Flow Rate Pilot Valve B33— Swing Pressure Sensor 93— From Bypass Shutoff Valve (port SE) (marked S3) 44— Travel Flow Combiner Pilot 98— From Arm 1 Flow Rate B34— Travel Pressure Sensor Control Valve (valve and Valve (port SL) (marked TR) poppet) 45— Swing Park Brake Release PD—From Pilot Filter and 108— From Auxiliary Flow Rate Pilot Valve (port SH) Regulator Valve Housing Control Valve (valve and 46— Bucket Flow Rate Pilot Valve (port PD) poppet) (port SK) Y10— Pilot Shutoff Solenoid 117— To Main Relief and Power Y22— Dig Regenerative Solenoid 47— Pump 2 Flow Rate Pilot Dig Valve Valve (port SB) (marked SF) 118— From Auxiliary Flow 48— Pump 1 Flow Rate Pilot Y23— Arm Regenerative Combiner Valve Valve (port SA) Solenoid (marked SC) 129— Orifice 49— Filter Screen (17 used) Y24— Power Dig/Travel Speed 141— Pilot Shutoff Valve 50— Shuttle Valve (17 used) Solenoid (marked SG) 300— From Arm 2 Flow Rate 66— To Travel Speed Change Control Valve and Boom Valve Lower Meter-In Cut Valve 77— From Bucket Flow Rate 301— To Arm Regenerative Valve Control Valve (valve and and Arm 2 Flow Rate poppet) Control Valve Continued on next page
TM13345X19 (23APR18)
9025-15-95
DF89619,00B68D2 -19-14FEB18-4/12
160GLC Excavator 042318 PN=1095
Diagnostic Information
LEFT PILOT 39 CONTROL VALVE
SWING RIGHT 6
2
P
T
A3 T3
4
1
F
RIGHT PILOT 40 CONTROL VALVE
SWING LEFT 5
BUCKET DUMP 8
3
2
P
T
4
A2 T2
E
1
H
BUCKET CURL 7
3
G
D C B A
4 3 2 1
4
3
2
1
604
D
C
B
A
609
TX1247390
TX1247390 —UN—20NOV17
250
Pilot Control Valves and Pattern Select Valve Schematic 1— Boom Up (pilot) 2— Boom Down (pilot) 3— Arm Out (pilot) 4— Arm In (pilot) 5— Swing Left (pilot) 6— Swing Right (pilot) 7— Bucket Curl (pilot) 8— Bucket Dump (pilot) 39— Left Pilot Control Valve
40— Right Pilot Control Valve 250— Pattern Select Valve (if equipped) 604— Return Oil 609— Pilot Oil A—To Pilot Signal Manifold (port A) A2—From Pilot Shutoff Valve (port A2) A3—From Pilot Shutoff Valve (port A3)
B—To Pilot Signal Manifold (port H—To Pilot Signal Manifold (port B) H) C—To Pilot Signal Manifold (port T2— To Pilot Shutoff Valve (port C) T2) D—To Pilot Signal Manifold (port T3— To Pilot Shutoff Valve (port D) T3) E—To Pilot Signal Manifold (port E) F— To Pilot Signal Manifold (port F) G—To Pilot Signal Manifold (port G)
Continued on next page
TM13345X19 (23APR18)
9025-15-96
DF89619,00B68D2 -19-14FEB18-5/12
160GLC Excavator 042318 PN=1096
Diagnostic Information
251 38 10
9
11
12 10 12
1 3
P
T
4
2
P
9 11
T
2
1
A1 T1
LR
LF
RR
RF
SF
SR
VLR
VLF
J
I
VRF
K
VRR
L
604 609
TX1247310
TX1247310 —UN—17NOV17
252
Single Pedal Travel Schematic 9— Left Travel Forward (pilot) 10— Left Travel Reverse (pilot) 11— Right Travel Forward (pilot) 12— Right Travel Reverse (pilot) 38— Travel Pilot Control Valve
251— Single Pedal Travel Pilot A1—From Pilot Shutoff Valve L— To Pilot Signal Manifold (port Control Valve (if equipped) (port A1) L) 252— Single Pedal Travel Pilot I— To Pilot Signal Manifold (port T1— To Pilot Shutoff Valve (port Manifold (if equipped) I) T1) 604— Return Oil J— To Pilot Signal Manifold (port 609— Pilot Oil J) K—To Pilot Signal Manifold (port K) Continued on next page
TM13345X19 (23APR18)
9025-15-97
DF89619,00B68D2 -19-14FEB18-6/12
160GLC Excavator 042318 PN=1097
Diagnostic Information
TM13345X19 (23APR18)
9025-15-98
160GLC Excavator 042318 PN=1098
Diagnostic Information
TX1248218 —UN—14DEC17
RIGHT TRAVEL MOTOR 61
8
SK SL
11
DK
B57
DZ
SF
1
B61
DD
DH
SC 126
15 PUMP 1
79
88
80
89
90
86
87
125 116 76
73
75
RIGHT CONTROL VALVE
124
92
82
78
77
85
81
93
83
91
120 84 121
122
123 94 2
12
51 SG
B31
7 B56
10
128
14
4
6
DN
36 118
119
114
110
74 LEFT CONTROL VALVE
HYDRAULIC OIL COOLER
117
115
104
107
113
100
97
95
108
112
105
111
114
98
96
101
99
LEFT TRAVEL MOTOR
103
127
102 52 SWING MOTOR
63
13
9
DY
B30
3
SE
DE
5
600 604 606
TX1248218 Control Valve Schematic Continued on next page
TM13345X19 (23APR18)
16 PUMP 2
9025-15-99
160GLC Excavator 042318 PN=1099
DF89619,00B68D2 -19-14FEB18-7/12
Diagnostic Information
TM13345X19 (23APR18)
9025-15-100
160GLC Excavator 042318 PN=1100
Diagnostic Information
1— Boom Up (pilot) 83— Boom Flow Rate Control 104— Boom 2 Spool 600— High-Pressure Oil 2— Boom Down (pilot) Valve (valve and poppet) 105— Check Valve (lift 604— Return Oil 3— Arm Out (pilot) 84— Dig Regenerative Valve check)—Boom 2 Power 606— Trapped Oil 4— Arm In (pilot) 85— Boom Reduced Leakage Circuit B30— Boom Up Pressure Sensor 5— Swing Left (pilot) Valve (valve and check 107— Auxiliary Spool (marked PI1) 6— Swing Right (pilot) valve) 108— Auxiliary Flow Rate B31— Arm In Pressure Sensor 7— Bucket Curl (pilot) 86— Orifice Control Valve (valve and (marked PI2) 8— Bucket Dump (pilot) 87— Boom Lower Meter-In Cut poppet) B56— Bucket Curl Pressure 9— Left Travel Forward (pilot) Valve 110— Left Travel Spool Sensor (marked BKC) (S.N. 10— Left Travel Reverse (pilot) 88— Boom Up Circuit Relief and 111— Check Valve (lift 057100— ) 11— Right Travel Forward (pilot) Anticavitation Valve check)—Left Travel Neutral B57— Bucket Dump Pressure 12— Right Travel Reverse (pilot) 89— Boom Down Circuit Relief Passage Sensor (marked BKD) (S.N. 13— Plug—Auxiliary (pilot) and Anticavitation Valve 112— Check Valve (lift 057100— ) 14— Plug—Auxiliary (pilot) 90— Arm 2 Spool check)—Left Travel Power B61— Arm Out Pressure Sensor 15— Pump 1 (4-spool) 91— Arm 2 Flow Rate Control Passage (S.N. 057100— ) 16— Pump 2 (5-spool) Valve (valve and poppet) 113— Orifice—Left Travel Power DD—To Solenoid Valve Manifold 36— Hydraulic Oil Cooler 92— Check Valve (lift Passage (port DD) 51— From Swing Device check)—Arm 2 Neutral 114— Orifice—Air Bleed (9 used) DE—To Solenoid Valve Manifold 52— Swing Motor Passage 115— Main Relief Valve Isolation (port DE) 61— Right Travel Motor 93— Bypass Shutoff Valve Check Valve (5-spool) DH—To Solenoid Valve Manifold 63— Left Travel Motor 94— Arm Regenerative Valve 116— Main Relief Valve Isolation (port DH) 73— Right Control Valve (4-spool) 95— Swing Spool Check Valve (4-spool) DK—To Solenoid Valve Manifold 74— Left Control Valve (5-spool) 96— Check Valve (lift 117— Main Relief and Power Dig (port DK) 75— Right Travel Spool check)—Swing Neutral Valve DN—To Solenoid Valve Manifold 76— Bucket Spool Passage 118— Auxiliary Flow Combiner (port DN) 77— Bucket Flow Rate Control 97— Arm 1 Spool Valve DY—To Solenoid Valve Manifold Valve (valve and poppet) 98— Arm 1 Flow Rate Control 119— Check Valve—Flow (port DY) 78— Bucket Regenerative Valve Valve (valve and poppet) Combiner Valve Circuit DZ—To Solenoid Valve Manifold 79— Bucket Dump Circuit Relief 99— Check Valve (lift 120— Travel Flow Combiner (port DZ) and Anticavitation Valve check)—Arm 1 Regenerative Valve SC—From Solenoid Valve 80— Bucket Curl Circuit Relief Circuit 121— Check Valve—Travel Flow Manifold (port SC) and Anticavitation Valve 100— Check Valve (lift Combiner Valve Circuit SE—From Pilot Signal Manifold 81— Boom 1 Spool check)—Dig Regenerative 122— Check Valve (lift (port SE) 82— Boom Regeneration Valve Circuit check)—Bucket SF—From Solenoid Valve 101— Arm Reduced Leakage 123— Orifice—Bucket Power Manifold (port SF) Valve (valve and poppet) Circuit SG—From Solenoid Valve 102— Arm In Circuit Relief and 124— Hydraulic Oil Cooler Manifold (port SG) Anticavitation Valve Bypass Valve SK—From Pilot Signal Manifold 103— Arm Out Circuit Relief and 125— Boom Cylinder (2 used) (port SK) Anticavitation Valve 126— Bucket Cylinder SL—From Pilot Signal Manifold 127— Arm Cylinder (port SL) 128— Restriction Valve Continued on next page
TM13345X19 (23APR18)
9025-15-101
DF89619,00B68D2 -19-14FEB18-8/12
160GLC Excavator 042318 PN=1101
Diagnostic Information
73 55 55
51 53
54
52 56
95A 95B
58
B32
45 604
TX1157113
TX1157113 —UN—08APR14
57
Swing Motor Schematic 45— Swing Park Brake Release 54— Swing Crossover Relief Pilot Valve (port SH) Valve (2 used) 51— Swing Device 55— Swing Dampener Valve (2 52— Swing Motor used) 53— Swing Motor Make-Up Check 56— Swing Park Brake Valve (2 used) 57— Orifice
58— Check Valve 73— To Right Control Valve (4-spool) 95A— From Swing Spool (swing right) 95B— From Swing Spool (swing left) Continued on next page
TM13345X19 (23APR18)
9025-15-102
604— Return Oil B32— Front Attachment Pressure Sensor (marked FRT)
DF89619,00B68D2 -19-14FEB18-9/12
160GLC Excavator 042318 PN=1102
Diagnostic Information
60
61 B
75B 75A SG A
72
64
64 B
65
66
67
A
68 70
62 604
69
606
TX1157114
TX1157114 —UN—08APR14
71 63
110A 110B
Travel Motor Schematic 60— Right Travel Device 61— Right Travel Motor 62— Left Travel Device 63— Left Travel Motor 64— Travel Park Brake (2 used) 65— 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 (2 used) 70— Orifice (2 used) 71— Counterbalance Valve (2 used)
72— Center Joint 75A— From Right Travel Spool (forward) 75B— From Right Travel Spool (reverse) 110A— From Left Travel Spool (forward) 110B— From Left Travel Spool (reverse) Continued on next page
TM13345X19 (23APR18)
9025-15-103
604— Return Oil 606— Trapped Oil SG—From Solenoid Valve Manifold (port SG)
DF89619,00B68D2 -19-14FEB18-10/12
160GLC Excavator 042318 PN=1103
Diagnostic Information
TM13345X19 (23APR18)
9025-15-104
160GLC Excavator 042318 PN=1104
Diagnostic Information
TX1248219 —UN—14DEC17
74B 74A
73A 73B
27
B37
HYDRAULIC OIL COOLER
124
73B DS DF 141
72
51
B35
PUMP 2 16
36
27
PILOT PUMP 28
PUMP 1 15
34
PA
35 32
HYDRAULIC 31 OIL TANK
29 PILOT FILTER AND BYPASS VALVE
185
PE
128
PF PG
PILOT PRESSURE REGULATING VALVE 30 Y20
Y26
PC PD
Y21
SA 18 PUMP 2 REGULATOR
SB
PUMP 1 17 REGULATOR
TA
PD B36
B38
600 604 609 TX1248219 Hydraulic Oil Pumps and Regulators Schematic Continued on next page
TM13345X19 (23APR18)
9025-15-105
160GLC Excavator 042318 PN=1105
DF89619,00B68D2 -19-14FEB18-11/12
Diagnostic Information
TM13345X19 (23APR18)
9025-15-106
160GLC Excavator 042318 PN=1106
Diagnostic Information
15— Pump 1 (4-spool) 72— From Center Joint 16— Pump 2 (5-spool) 73A— To Right Control Valve 17— Pump 1 Regulator (4-spool) 18— Pump 2 Regulator 73B— From Right Control Valve 27— Attenuator Hose (2 used) (4-spool) (2 used) 28— Pilot Pump 74A— To Left Control Valve 29— Pilot Filter and Bypass Valve (5-spool) 30— Pilot Pressure Regulating 74B— From Left Control Valve Valve (5-spool) 31— Hydraulic Oil Tank 124— Hydraulic Oil Cooler 32— Return Filter Bypass Valve 34— Filter Bypass 128— Restriction Valve 35— Suction Screen 141— From Pilot Shutoff Valve 36— Hydraulic Oil Cooler 185— Pilot Filter and Regulator 51— From Swing Device Valve Housing
600— High-Pressure Oil 604— Return Oil 609— Pilot Oil B35— Pump 1 Delivery Pressure Sensor (marked PP1) B36— Pump 1 Control Pressure Sensor (marked PC1) B37— Pump 2 Delivery Pressure Sensor (marked PP2) B38— Pump 2 Control Pressure Sensor (marked PC2) DF—From Pilot Signal Manifold (port DF) DS—From Solenoid Valve Manifold (port DS)
PD—To Solenoid Valve Manifold (port PD) SA—From Pilot Signal Manifold (port SA) SB—From Pilot Signal Manifold (port SB) Y20— Pump 2 Flow Rate Limit Solenoid (marked SB) Y21— Torque Control Solenoid (marked ST) Y26— Pump 1 Flow Rate Limit Solenoid (marked SA)
DF89619,00B68D2 -19-14FEB18-12/12
TM13345X19 (23APR18)
9025-15-107
160GLC Excavator 042318 PN=1107
Diagnostic Information
Hydraulic System Component Location
31
185 15
251 252
16
51
40
60
72
37
38 73 28 74
41
39
250
36
TX1251723 —UN—02FEB18
141
62 TX1251723 Hydraulic System Component Location 15— Pump 1 (4-spool) 16— Pump 2 (5-spool) 28— Pilot Pump 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 60— Right Travel Device 62— Left Travel Device 72— Center Joint
73— Right Control Valve (4-spool) 251— Single Pedal Travel Pilot 74— Left Control Valve (5-spool) Control Valve (if equipped) 141— Pilot Shutoff Valve 252— Single Pedal Travel Pilot 185— Pilot Filter and Regulator Manifold (if equipped) Valve Housing 250— Pattern Select Valve (if equipped) DF89619,00B6900 -19-02FEB18-1/1
TM13345X19 (23APR18)
9025-15-108
160GLC Excavator 042318 PN=1108
Diagnostic Information
Hydraulic System Line Connections TX1108090 —UN—11FEB12
73 74
31
127
125
41
SB 126 SA
SH 15
16
36 28 29
72 30
51
TX1108090 Hydraulic System Line Connections Continued on next page
TM13345X19 (23APR18)
9025-15-109
160GLC Excavator 042318 PN=1109
JA66566,0002686 -19-03AUG12-1/2
Diagnostic Information
TM13345X19 (23APR18)
9025-15-110
160GLC Excavator 042318 PN=1110
Diagnostic Information 15— Pump 1 36— Hydraulic Oil Cooler 74— Left Control Valve (5-spool) 16— Pump 2 41— Pilot Signal Manifold 125— Boom Cylinder (2 used) 28— Pilot Pump 51— Swing Device 126— Bucket Cylinder 29— Pilot Filter and Bypass Valve 72— Center Joint 127— Arm Cylinder 30— Pilot Pressure Regulating 73— Right Control Valve (4-spool) SA—Pump 1 Flow Rate Pilot Valve Valve Port 31— Hydraulic Oil Tank
SB—Pump 2 Flow Rate Pilot Valve Port SH—Swing Park Brake Release Port
JA66566,0002686 -19-03AUG12-2/2
TM13345X19 (23APR18)
9025-15-111
160GLC Excavator 042318 PN=1111
Diagnostic Information
TM13345X19 (23APR18)
9025-15-112
160GLC Excavator 042318 PN=1112
Diagnostic Information
Fan Drive Hydraulic System Component Location TX1161165 —UN—21MAY14
31
5
1 4
Y5015 2
135
133
Y5014
3
132
TX1161165 Fan Drive Hydraulic System Component Location (reversing fan shown) Continued on next page
TM13345X19 (23APR18)
9025-15-113
160GLC Excavator 042318 PN=1113
DF89619,00B57DD -19-11JUN14-1/2
Diagnostic Information
TM13345X19 (23APR18)
9025-15-114
160GLC Excavator 042318 PN=1114
Diagnostic Information
1— Case Drain Hose—Fan Drive Motor-to-Hydraulic Oil Tank 2— Sump Hose—Hydraulic Oil Tank-to-Fan Drive Pump 3— Supply Pressure Hose—Fan Pump-to-Fan Speed Control Valve
4— Return Line—Fan Speed 31— Hydraulic Oil Tank Control Valve-to-Hydraulic Oil 132— Fan Drive Pump Tank 133— Fan Drive Motor 5— Return Line—Hydraulic Oil 135— Fan Speed and Reversing Cooler-to-Hydraulic Oil Tank Control Valve Y5014—Variable Speed Fan Solenoid
Y5015—Reversing Fan Solenoid
DF89619,00B57DD -19-11JUN14-2/2
TM13345X19 (23APR18)
9025-15-115
160GLC Excavator 042318 PN=1115
Diagnostic Information
Fan Drive Hydraulic System Schematic
134
133 Y5014
B
A
132
36
34
31
600 604
TX1156892
TX1156892 —UN—21MAY14
32
Fan Drive Hydraulic System Schematic 31— Hydraulic Oil Tank 32— Return Filter 34— Filter Bypass 36— From Hydraulic Oil Cooler
132— Fan Drive Pump 133— Fan Drive Motor 134— Fan Speed Control Valve
600— High-Pressure Oil 604— Return Oil Y5005—Proportional Fan Speed Solenoid Valve Continued on next page
TM13345X19 (23APR18)
9025-15-116
DF89619,00B57C8 -19-07MAY14-1/2
160GLC Excavator 042318 PN=1116
Diagnostic Information
133
Y5015
Y5014
135
132
34 32 600 31 TX1156893
604
TX1156893 —UN—21MAY14
36
Fan Drive Hydraulic System Schematic—Reversing (if equipped) 31— Hydraulic Oil Tank 32— Return Filter 34— Filter Bypass 36— From Hydraulic Oil Cooler
132— Fan Drive Pump 600— High-Pressure Oil 133— Fan Drive Motor 604— Return Oil 135— Fan Speed and Reversing Y9— Reversing Fan Solenoid Control Valve—If Equipped Valve Y5005—Proportional Fan Speed Solenoid Valve DF89619,00B57C8 -19-07MAY14-2/2
TM13345X19 (23APR18)
9025-15-117
160GLC Excavator 042318 PN=1117
Diagnostic Information
TM13345X19 (23APR18)
9025-15-118
160GLC Excavator 042318 PN=1118
Group 25
Tests JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer
T6808CE —UN—28FEB89
1. Fasten temperature probe (A) to a bare metal hydraulic line using a tie band. 2. Wrap temperature probe and line with a shop towel. A—Temperature Probe B—Cable
C—JT05800 Digital Thermometer
CED,TX08227,2895 -19-19NOV97-1/1
JT02156A Digital Pressure and Temperature Analyzer Kit Installation SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Kit T8543AI —UN—25AUG95
JT02158 Digital Pressure and Temperature Analyzer JT02159 6 m (20 ft.) Cable with Couplers JT02161 3400 kPa (35 bar) (500 psi) Transducer JT02162 34 000 kPa (350 bar) (5000 psi) Transducer JT05969 Thermo-Coupler 312883 Carry Case JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)
Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a separate temperature reader.
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
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. DX,JT02156A -19-20JAN10-1/1
TM13345X19 (23APR18)
9025-25-1
160GLC Excavator 042318 PN=1119
Tests
General Hydraulic Oil Cleanup Procedure ESSENTIAL TOOLS JDG10712 Super Caddy™
TX1035521A —UN—25JAN08
This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter caddy 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.
Hydraulic Tank Cap
Oil contamination could result if filter caddy is used in dusty or wet conditions. Clean work practices and cleanliness of filter caddy and attachments are critical when filtering oil. TX1035522A —UN—25JAN08
NOTE: Filter oil should be at 27°C (80°F) or above for best Super Caddy performance. Reduce flow rate to filter oil below 27°C (80°F). Super Caddy requires a 20-amp electric circuit. Use of electrical extension cord is not recommended. 1. Park machine on a flat, level surface with attachments lowered to the ground and turn engine off. See Park and Prepare for Service Safely. (Group 0001.)
Hydraulic Tank and Wands 1— Hydraulic Oil Tank Pressure Release Button 2— Hydraulic Oil Tank Cap 3— Cover
CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.
4— Suction Wand 5— Discharge Wand
CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.
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.)
Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine while filter caddy is connected to machine.
3. Remove hydraulic oil tank cap (2). NOTE: When installing suction and discharge wands (4 and 5) into the hydraulic oil tank, locate the submerged ends of the wands as far away from each other as possible to ensure maximum oil movement during cleanup procedure.
8. Make sure machine is parked in an area that will allow all hydraulic functions to be operated. 9. Fill hydraulic oil tank to operating level.
4. Install JDG10712 Super Caddy discharge wand (5) and suction wand (4) into hydraulic oil tank. 5. Cover the wands and tank openings with a plastic tarp to prevent contamination.
10. Run machine at slow idle. Operate each circuit a minimum of 2 minutes in each direction to flush any remaining contaminants back through hydraulic system filters.
6. Remove residual oil contaminants using JDG10712 Super Caddy.
11. Stop engine. Install Super Caddy to machine as before.
7. When cleaning process is done, disconnect Super Caddy from machine. Continued on next page
TM13345X19 (23APR18)
9025-25-2
JS20420,0000B51 -19-27AUG14-1/2
160GLC Excavator 042318 PN=1120
Tests
12. Repeat Super Caddy operation procedure until contaminant value is at specifications. Refer to operator’s manual included with Super Caddy or see Super Caddy in Service ADVISOR™ for operating procedure.
NOTE: Instrument cleanliness and clean work practices are critical when taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing can affect results.
13. When oil reaches an acceptable level of cleanliness, disconnect Super Caddy from machine.
16. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the filter when oil is warm.
14. Install new hydraulic oil filters.
17. Fill hydraulic oil tank to proper operating level.
15. Clean hydraulic oil tank pressure release button and install hydraulic oil tank cap.
18. Return machine to service.
Super Caddy is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company JS20420,0000B51 -19-27AUG14-2/2
TM13345X19 (23APR18)
9025-25-3
160GLC Excavator 042318 PN=1121
Tests
Hydraulic Component Failure Cleanup Procedure
11. Replace oil cooler and system accumulators. Some manifolds cannot be cleaned. Replace manifolds as required.
IMPORTANT: Oil types and filters must not be intermixed. To avoid intermixing of oils, use filter element in same type oil.
12. Install new hydraulic oil filters. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter. (Operator’s Manual.)
Avoid operating Super Caddy™ in dusty or wet conditions. Oil contamination could result.
IMPORTANT: Ultra Clean process must have all T-fittings disconnected. Lines or hoses with T-fittings must be cleaned individually.
NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing affect results.
13. Locate and disconnect all circuit hoses and lines from pumps, motors, valves, manifolds, and T-fittings. NOTE: To minimize contamination, close all line and component openings using caps ot plugs.
1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)
14. Clean all lines and hoses using Ultra Clean hose kit. Install all removed lines and hoses.
IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates.
15. Fill hydraulic oil tank to operating level. See Drain and Refill Hydraulic Tank Oil and Clean Suction Screen. (Operator’s Manual.)
2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.)
CAUTION: Avoid entanglement and possible electrocution from Super Caddy™ power cord. Do not operate machine while Super Caddy™ is connected to machine.
3. Clean all machine components and surrounding areas. CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.
Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine. 16. Make sure that area is clear and large enough to operate all functions of machine.
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.)
IMPORTANT: Do not operate hydraulic functions over relief.
5. Remove and clean fill cap and strainer. In sealed plastic bag, store fill cap and strainer.
17. To prevent component damage during start-up, perform start-up and bleed procedures for components:
6. Cover fill tube with plastic bag or all purpose tape.
• See Hydraulic Cylinder Bleed Procedure. (Group
7. To remove oil contaminants before hydraulic oil tank is drained, use Super Caddy™. See General Hydraulic Oil Cleanup Procedure. (Group 3160.)
• See Travel Motor and Park Brake Start-Up
8. Use Super Caddy™ to transfer oil from hydraulic oil tank to a clean container or drain hydraulic oil tank. See Drain and Refill Hydraulic Tank Oil and Clean Suction Screen. (Operator’s Manual.)
• See Swing Gear Case Start-Up Procedure. (Group
Procedure. (Group 0260.)
• See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
4350.)
• See Swing Motor and Park Brake Start-Up Procedure. (Group 4360.)
9. Remove, disassemble, clean, and inspect system components.
18. Check hydraulic oil level. Fill tank to proper level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)
10. Repair or replace damaged components. Install all components. IMPORTANT: Oil cooler and accumulators cannot be cleaned of contamination and must be replaced. System manifolds cannot always be cleaned of contamination and must be replaced.
3360.)
IMPORTANT: Trapped air suddenly compressed in a cylinder makes enough heat to ignite the oil used for assembly, causing cap seal and ring damage. Start with cylinder rod retracted and the rod end filled with clean oil. Operate function to extend rod. Procedure eliminates most of the air and reduces the possibility of damage.
Continued on next page
TM13345X19 (23APR18)
9025-25-4
DV53278,0000876 -19-21JUN16-1/2
160GLC Excavator 042318 PN=1122
Tests Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing affect results.
19. Run machine at slow idle. To move air and contaminants back through machine’s oil filter, operate each circuit a minimum of 2 minutes in each direction. 20. Cycle cylinders an additional 10 times to be sure that air is eliminated from circuit. 21. Operate all functions for 3—5 minutes in each direction. 22. Filter oil until Super Caddy™ shuts off and contaminant value is to specification. Refer to operator's manual included with Super Caddy™ or see Super Caddy™ in Service ADVISOR™ for operating procedure. 23. Install new hydraulic oil filters. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter. (Operator’s Manual.)
24. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter when oil is warm. 25. Check hydraulic oil level. Fill tank to proper level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 26. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 27. Return machine to service. 28. After 100 hours of service, obtain oil sample for fluid analysis. Confirm oil is within specification.
NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Super Caddy is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company DV53278,0000876 -19-21JUN16-2/2
Hydraulic Oil Tank Pressure Release Procedure 1. Park machine on level surface. T6811AI —UN—18OCT88
2. Position machine with arm cylinder fully retracted and bucket cylinder fully extended. 3. Lower boom until bucket is resting on ground. 4. Shut engine off.
MM16284,0000FA7 -19-12MAR11-1/2
5. Press pressure release button (1) to relieve pressure. 2— Hydraulic Oil Tank Cover
TX1089386A —UN—14MAR11
1— Pressure Release Button
Hydraulic Oil Tank Cover MM16284,0000FA7 -19-12MAR11-2/2
TM13345X19 (23APR18)
9025-25-5
160GLC Excavator 042318 PN=1123
Tests
Hydraulic Oil Warm-Up Procedure Select the following items from the monitor display: - Coolant Temperature - Hydraulic Oil Temperature - Actual Engine Speed
SPECIFICATIONS Engine Speed
1300—1400 rpm if below -18°C 1300—1400 rpm if below 0°F 1750—1850 rpm if above -18°C 1750—1850 rpm if above 0°F
Power Mode Button Position
ECO (economy) Mode if below -18°C ECO (economy) Mode if below 0°F H/P (high power) Mode if above -18°C H/P (high power) Mode if above 0°F
Work Mode Switch Position
Bucket Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Slow (turtle)
Hydraulic Oil Temperature
45—55°C 110—130°F
CAUTION: Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all bystanders before doing the warm-up procedure. 2. Clear the area of all bystanders to allow for machine movement. 3. Run machine at specification for approximately 5 minutes before operating any functions.
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 Application for instruction. (Group 9015-20.)
Specification Engine—Speed...................................... 1300—1400 rpm if below -18°C 1300—1400 rpm if below 0°F 1750—1850 rpm if above -18°C 1750—1850 rpm if above 0°F Power Mode Button—Position............................ ECO (economy) Mode if below -18°C ECO (economy) Mode if below 0°F H/P (high power) Mode if above -18°C H/P (high power) Mode if above 0°F Work Mode Switch—Position................................................................. Bucket Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position................................................................... Slow (turtle)
4. Slowly turn upperstructure so boom is to the side. CAUTION: Avoid possible serious injury from machine sliding backwards. Keep angle between boom and arm at 90—110°. 5. 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). IMPORTANT: Holding a function over relief for more than 10 seconds can cause damage due to hot spots in the control valve. 8. 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.
Continued on next page
TM13345X19 (23APR18)
9025-25-6
DF89619,00B58B7 -19-26SEP14-1/2
160GLC Excavator 042318 PN=1124
Tests
10. Continue procedure until oil temperature is within specifications.
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
Service ADVISOR is a trademark of Deere & Company DF89619,00B58B7 -19-26SEP14-2/2
TM13345X19 (23APR18)
9025-25-7
160GLC Excavator 042318 PN=1125
Tests
Pilot Pressure Regulating Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle and Slow Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Pilot System Pressure (slow idle)
3.800—4.800 MPa 3805—4805 kPa 39.00—49.00 bar 552—697 psi
Pilot System Pressure (fast idle)
3.500—5.000 MPa 3509—5012 kPa 36.00—51.00 bar 509—727 psi
Pilot Pressure Regulating Valve Shim (approximate per 0.25 mm [0.010 in] shim)
0.078 MPa 78 kPa 0.78 bar 11 psi
Pilot Pressure Regulating Valve Shim (approximate per 0.50 mm [0.020 in] shim)
0.160 MPa 160 kPa 1.60 bar 22 psi
Pilot Pressure Regulating Valve Shim (approximate per 1.00 mm [0.040 in] shim)
0.31 MPa 304 kPa 3.10 bar 44 psi
Pilot Pressure Regulating Valve Housing Plug
25 N·m 220 lb·in
TX1089155A —UN—10MAR11
Hydraulic Oil Temperature
Pilot Pressure Regulating Valve and Test Port 1— Test Port 2— Adapter 3— JT02162 Transducer
4— Oil Sample Port (if equipped) 30— Pilot Pressure Regulating Valve
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)
• Monitor application. For instruction to actuate the
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - 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 from the menu: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, See MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of test is to ensure there is enough pilot pressure to operate all the pilot system functions and to adjust the pressure as necessary. The pilot pressure regulating valve is used to regulate the 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. Remove plug from test port (1).
3. Install Adapter (2). NOTE: The monitor can be used to make a quick check of the pilot system pressure using the arm in function. The pressure reading displayed is from the arm in pressure senor located in the pilot cap 4. Connect the JT02162 Transducer (3) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter.
5. Monitor arm in pilot pressure with the engine at 1750--1850 rpm and then actuate arm in function over relief. 6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed. Continued on next page TM13345X19 (23APR18)
9025-25-8
DF89619,00B58B8 -19-13AUG15-1/3
160GLC Excavator 042318 PN=1126
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed....................................................Fast Idle and Slow Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
8. Compare pressure readings to specification. Make adjustments as necessary.
Specification Pilot System Pressure (slow idle)—Pressure................................................. 3.800—4.800 MPa 3805—4805 kPa 39.00—49.00 bar 552—697 psi Pilot System Pressure (fast idle)—Pressure................................................... 3.500—5.000 MPa 3509—5012 kPa 36.00—51.00 bar 509—727 psi
9. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank.
Service ADVISOR is a trademark of Deere & Company DF89619,00B58B8 -19-13AUG15-2/3
10. Remove pilot pressure regulating valve (30). Add shims to increase pressure. Remove shims to decrease pressure.
11. Tighten pilot pressure regulating valve plug to specification.
TX1089155A —UN—10MAR11
Specification 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 psi Pilot Pressure Regulating Valve Shim (approximate per 0.50 mm [0.020 in] shim)—Pressure Change....................................................................................0.160 MPa 160 kPa 1.6 bar 22 psi Pilot Pressure Regulating Valve Shim (approximate per 1.00 mm [0.040 in] shim)—Pressure......................................................................0.310 MPa 304 kPa 3.1 bar 44 psi
Pilot Pressure Regulating Valve and Test Port 1— Test Port 2— 4200465 Adapter 3— JT02162 Transducer
4— Oil Sample Port (if equipped) 30— Pilot Pressure Regulating Valve
12. Check the pressure settings again.
Specification Plug to Pilot Pressure Regulating Valve Housing—Torque...........................................................................25 N·m 220 lb·in DF89619,00B58B8 -19-13AUG15-3/3
TM13345X19 (23APR18)
9025-25-9
160GLC Excavator 042318 PN=1127
Tests
Control Valve Spool Actuating Pilot Pressure Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle and Slow Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Fast (rabbit)
Control Valve Spool Actuating Pressure
3.4—4.0 MPa 3432—4021 kPa 34.3—40.2 bar 495—583 psi
TX1002098A —UN—07JAN06
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS 203836 (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37° ) Tee Gauge 7000 kPa (70 bar) (1000 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Control Valve Spool Actuating Pilot Pressure Test
Purpose of test is to ensure that the pilot pressure to the valve spools is enough to completely shift the spools.
1— 203836 Tee
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.)
• MPDr application. See MPDr Application for
instruction. (Group 9015-20.) Select the following items from the monitor display: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed
NOTE: Spool actuating pressure can be checked for each function by installing a tee and gauge in pilot line and then actuating that function. 2. Install 203836 Tee in pilot line for function being tested. 3. Install JT02162 Transducer and Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge.
5. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 6. Run machine at specifications.
NOTE: Spool actuating pressure for boom up, arm in, left and right swing, and all travel functions can also be measured with the monitor. 4. Connect one of the following test equipment to monitor pressure reading, 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: - Arm Roll-In Pilot Pressure - 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: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position...................................................................Fast (rabbit)
7. Actuate the function to be checked to full stroke. Record pressure. 8. Compare pressure to specifications. Specification Control Valve Spool Actuating—Pressure.......................................................... 3.4—4.0 MPa 3432—4021 kPa 34.3—40.2 bar 495—583 psi Continued on next page
TM13345X19 (23APR18)
2— JT02162 Transducer
9025-25-10
DF89619,00B58B9 -19-29JUL15-1/2
160GLC Excavator 042318 PN=1128
Tests
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 then check pressure at the solenoid valve manifold, pilot control shutoff solenoid valve, pilot controllers, and pilot signal manifold.
Service ADVISOR is a trademark of Deere & Company DF89619,00B58B9 -19-29JUL15-2/2
TM13345X19 (23APR18)
9025-25-11
160GLC Excavator 042318 PN=1129
Tests
Dig Regenerative Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Dig Regenerative Solenoid Valve (port SF) Pressure
Monitor Reading ± 0.200 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.00 bar Monitor Reading ± 29 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.069 MPa 69 kPa 0.69 bar 10 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
3.0 N·m 27 lb·in
TX1106358A —UN—25JAN12
Hydraulic Oil Temperature
Solenoid Valve Manifold Location
Y23
Y24
Y22
37 SERVICE EQUIPMENT AND TOOLS Adapter Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)
2
JT02156A Digital Pressure/Temperature Analyzer
1
TX1104725 —UN—17JAN12
3
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of this test is to check the output pressure for the dig regenerative solenoid valve (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.)
Solenoid Valve Manifold Detail
2. Remove the dig regenerative solenoid valve fitting (2) from dig regenerative solenoid valve (Y22). 3. Install adapter tee in place of dig regenerative solenoid valve fitting. Connect line to adapter tee.
1— Power Dig/Travel Speed Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 3— Arm Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
Y22— Dig Regenerative Solenoid Valve (port SF) Y23— Arm Regenerative Solenoid Valve (port SC) Y24— Power Dig/Travel Speed Solenoid Valve (port SG)
• 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
5. Connect one of the following test equipment to monitor the dig regenerative valve 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
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Continued on next page
TM13345X19 (23APR18)
9025-25-12
BG71631,00009BD -19-13AUG15-1/3
160GLC Excavator 042318 PN=1130
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. 8. Operate boom up and arm in over relief. Record monitor and gauge pressure readings.
10. Verify that the actual reading from gauge is within the calculated pressure range from monitor. Specification Dig Regenerative Solenoid Valve (port SF)—Pressure.............................................. Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
NOTE: An example of monitor reading is given in the chart below for the dig regenerative solenoid valve. Example of Calculated Reading From Monitor Example Monitor Reading
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.
Actuated
Non Actuated
3.19 MPa 3190 kPa 31.9 bar 463 psi
0.03 MPa 30 kPa 0.3 bar 4 psi
Service ADVISOR is a trademark of Deere & Company BG71631,00009BD -19-13AUG15-2/3
11. Adjust solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than 2 turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) in (clockwise) to increase pressure setting; turn adjusting screw out (counterclockwise) to decrease pressure setting. The length from end of adjusting screw to nut must not exceed 4 mm (0.157 in). Solenoid Adjustment Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................0.069 MPa 69 kPa 0.69 bar 10 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in
4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................3.0 N·m 27 lb·in
12. Check the pressure setting again.
c. Hold adjusting screw and tighten nut to specification. BG71631,00009BD -19-13AUG15-3/3
TM13345X19 (23APR18)
9025-25-13
160GLC Excavator 042318 PN=1131
Tests
Arm Regenerative Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Arm Regenerative Solenoid Valve (port SC) Pressure
Monitor Reading ± 0.200 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.00 bar Monitor Reading ± 29 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.069 MPa 69 kPa 0.69 bar 10 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
3.0 N·m 27 lb·in
TX1106358A —UN—25JAN12
Hydraulic Oil Temperature
Solenoid Valve Manifold Location
Y23
Y24
Y22
37 SERVICE EQUIPMENT AND TOOLS Adapter Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)
2
JT02156A Digital Pressure/Temperature Analyzer
1
TX1104725 —UN—17JAN12
3
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of this test is to check the output pressure for the arm regenerative solenoid valve (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.)
Solenoid Valve Manifold Detail
2. Remove the arm regenerative solenoid valve fitting (3) from arm regenerative solenoid valve (Y23). 3. Install adapter tee in place of arm regenerative solenoid valve fitting. Connect line to adapter tee.
1— Power Dig/Travel Speed Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 3— Arm Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
Y22— Dig Regenerative Solenoid Valve (port SF) Y23— Arm Regenerative Solenoid Valve (port SC) Y24— Power Dig/Travel Speed Solenoid Valve (port SG)
• 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
5. Connect one of the following test equipment to monitor the arm regeneration proportional valve 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
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Continued on next page
TM13345X19 (23APR18)
9025-25-14
BG71631,00009BE -19-13AUG15-1/3
160GLC Excavator 042318 PN=1132
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. 8. Operate arm in over relief. Record monitor and gauge pressure readings.
10. Verify that the actual reading from gauge is within the calculated pressure range from monitor. Specification Arm Regenerative Solenoid Valve (port SC)—Pressure............................................. Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
NOTE: An example of monitor reading is given in the chart below for the arm regenerative solenoid valve. Example of Calculated Reading From Monitor Example Monitor Reading
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.
Actuated
Non Actuated
3.19 MPa 3190 kPa 31.9 bar 463 psi
1.19 MPa 1190 kPa 11.9 bar 173 psi
Service ADVISOR is a trademark of Deere & Company BG71631,00009BE -19-13AUG15-2/3
11. Adjust solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than 2 turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) in (clockwise) to increase pressure setting; turn adjusting screw out (counterclockwise) to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification. Solenoid Adjustment Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................0.069 MPa 69 kPa 0.69 bar 10 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in
4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................3.0 N·m 27 lb·in
12. Check the pressure setting again.
c. Hold adjusting screw and tighten nut to specification. BG71631,00009BE -19-13AUG15-3/3
TM13345X19 (23APR18)
9025-25-15
160GLC Excavator 042318 PN=1133
Tests
Power Dig/Travel Speed Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Power Dig/Travel Speed Solenoid Valve (port SG) Pressure
Monitor Reading ± 0.200 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.00 bar Monitor Reading ± 29 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.069 MPa 69 kPa 0.69 bar 10 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
3.0 N·m 27 lb·in
TX1106358A —UN—25JAN12
Hydraulic Oil Temperature
Solenoid Valve Manifold Location
Y23
Y24
Y22
37 SERVICE EQUIPMENT AND TOOLS Adapter Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°)
2
JT02156A Digital Pressure/Temperature Analyzer
1
TX1104725 —UN—17JAN12
3
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of this test is to check the output pressure from the power dig/travel speed solenoid valve (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.)
Solenoid Valve Manifold Detail 1— Power Dig/Travel Speed Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 3— Arm Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold
2. Remove the power dig/travel speed solenoid valve fitting (1) from power dig/travel speed solenoid valve (Y24). 3. Install adapter tee in place of power dig/travel speed solenoid valve fitting. Connect line to adapter tee.
• Service ADVISOR™ application. For instruction,
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
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
5. Connect one of the following test equipment to monitor the power dig/travel speed control 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: - 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.)
Continued on next page
TM13345X19 (23APR18)
Y22— Dig Regenerative Solenoid Valve (port SF) Y23— Arm Regenerative Solenoid Valve (port SC) Y24— Power Dig/Travel Speed Solenoid Valve (port SG)
9025-25-16
BG71631,00009BF -19-19AUG15-1/3
160GLC Excavator 042318 PN=1134
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. 8. Turn power dig switch ON and OFF. Record monitor and gauge pressure readings.
10. Verify that the actual reading from gauge is within the calculated pressure range from monitor. Specification Power Dig/Travel Speed Solenoid Valve (port SG)—Pressure......................................... Monitor Reading ± 0.200 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.00 bar Monitor Reading ± 29 psi 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 valve. Example of Calculated Reading From Monitor Example Monitor Reading
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.
Actuated
Non Actuated
2.99 MPa 2990 kPa 29.9 bar 434 psi
0.71 MPa 710 kPa 7.1 bar 103 psi
Service ADVISOR is a trademark of Deere & Company BG71631,00009BF -19-19AUG15-2/3
11. Adjust solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than 2 turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) in (clockwise) to increase pressure setting; turn adjusting screw out (counterclockwise) to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification. Solenoid Adjustment Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................0.069 MPa 69 kPa 0.69 bar 10 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in
4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................3.0 N·m 27 lb·in
12. Check the pressure setting again.
c. Hold adjusting screw and tighten nut to specification. BG71631,00009BF -19-19AUG15-3/3
TM13345X19 (23APR18)
9025-25-17
160GLC Excavator 042318 PN=1135
Tests
Torque Control Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Torque Control Solenoid Valve Pressure
Monitor Reading ± 0.200 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.00 bar Monitor Reading ± 29 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
TX1089550A —UN—16MAR11
Hydraulic Oil Temperature
Adjusting Screw Pressure Change 0.069 MPa 69 kPa (approximate per 1/4 turn) 0.69 bar 10 psi End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in
Adjusting Screw-to-Housing Nut Torque
3 N·m 27 lb·in
Pump 1 and Pump 2 Regulators 1— Test Port 2— 4200465 Adapter 3— Pump 1 Regulator 4— Pump 2 Regulator
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
5— Torque Control Solenoid Valve 6— Nut 7— Adjusting Screw
JT02156A Digital Pressure/Temperature Analyzer
Select the following items from monitoring list: - Pumps 1 Torque P/S O/P - Pumps 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 from the menu: - Pumps 1 Torque P/S O/P - Pumps 2 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pumps 1 Torque P/S O/P - Pumps 2 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed
Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of test is to check that the output pressure from the torque control solenoid valve 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. Remove plug from torque control solenoid valve test port (1) in pump 1 regulator (3). 3. Install 4200465 Adapter (2). 4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter. 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. 5. Connect one of the following test equipment to monitor the pump torque proportional valve pressure reading, hydraulic oil temperature, and actual engine speed.
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
• Monitor application. For instruction to actuate the
service menu on monitor in cab, see Service Menu. (Group 9015-16.)
Continued on next page
TM13345X19 (23APR18)
9025-25-18
DF89619,00B58BA -19-25AUG15-1/2
160GLC Excavator 042318 PN=1136
Tests Example of Calculated Reading From Monitor
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Example Monitor Reading
Specification Torque Control Solenoid Valve—Pressure........................................... Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
NOTE: An example of monitor reading is given in the chart below for the pump torque proportional valve (torque control solenoid valve). When a function is actuated, the readings starts to decrease. The reading will vary depending on the load on the function.
3.79 MPa 3850 kPa 38.5 bar 558 psi
0.33 MPa 330 kPa 3.3 bar 48 psi
IMPORTANT: Turning adjusting screw out too far may cause oil leakage because the O-ring has come off its seat. a. Loosen nut (6). b. Turn adjusting screw (7) out to increase pressure setting; turn adjusting screw in to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification.
Record the pressure readings from monitor and gauge.
NOTE: Check that the actual reading from gauge is within the pressure range.
Actuated
10. Adjust the torque control solenoid valve (5) as needed.
8. Return all control levers and pedals to the neutral position.
9. Calculate the pressure range using calculated reading from monitor and specify tolerance.
Neutral (Non Actuated)
Specification Adjusting Screw—Pressure Change (approximate per 1/4 turn).............................................................................0.069 MPa 69 kPa 0.69 bar 10 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in
c. Hold adjusting screw. Tighten nut to specification. Specification Adjusting Screw-toHousing Nut—Torque......................................................................3 N·m 27 lb·in
Service ADVISOR is a trademark of Deere & Company DF89619,00B58BA -19-25AUG15-2/2
TM13345X19 (23APR18)
9025-25-19
160GLC Excavator 042318 PN=1137
Tests
Pump Control Pilot Pressure Signal Test
- Pump 1 Pump Control Pressure - Pump 2 Pump Control Pressure - Hydraulic Oil Temperature - Actual Engine Speed
SPECIFICATIONS Hydraulic Oil Temperature
45—55° C 110—130° F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
2. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 3. Run machine at specification.
Pump 1 and Pump 2 Pump Control 1.03 MPa 1030 kPa Pressure in Neutral Pressure 10.3 bar (approximate) 149 psi Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate)
3.70 MPa 3700 kPa 37.0 bar 537 psi
The function of the pump 1 and pump 2 flow rate pilot valves (port SA and SB) is to send a regulated pilot control pressure signal to its respective pump regulator to change pump flow in response to the actuation of pilot control valves to shift the control valve spools. The purpose of test is to check that the regulated pump control pilot pressure signal from the flow rate pilot valves to the remote control spool in pump 1 and pump 2 regulators 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.
4. Return all control levers and pedals to the neutral position. Check that pilot shutoff lever is in the unlock (DOWN) position. 5. Record the pressure readings from monitor. Specification Pump 1 and Pump 2 Pump Control Pressure in Neutral—Pressure (approximate)............................................................................1.03 MPa 1030 kPa 10.3 bar 149 psi
See Pilot Signal Manifold Operation for the flow rate pilot valves. (Group 9025-05.) See Pump 1 and Pump 2 Regulator Operation for the remote control spools. (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. See Service Menu for instruction
to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items from monitoring list: - Pump 1 Pump Control Pressure - Pump 2 Pump Control Pressure - 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: - Pump 1 Pump Control Pressure - Pump 2 Pump Control Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Application for instruction. (Group 9015-20.) Select the following items from the monitor display:
Specification Hydraulic Oil—Temperature.....................................................................45—55° C 110—130° F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
6. Slowly actuate the 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 the control lever at full stroke. Record the pressure readings from monitor. Specification 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 the hoses from the pilot signal manifold to the pump 1 and pump 2 regulators for damage.
• See Electrical Component Specifications to check pump 1 and pump 2 control pressure sensors. (Group 9015-20.)
Continued on next page
TM13345X19 (23APR18)
9025-25-20
JA66566,000339C -19-03FEB17-1/2
160GLC Excavator 042318 PN=1138
Tests
• See Pilot Signal Manifold Disassemble and
Assemble for instruction to remove and inspect the
pump 1 and pump 2 flow rate pilot valves. (Group 3360.)
Service ADVISOR is a trademark of Deere & Company JA66566,000339C -19-03FEB17-2/2
TM13345X19 (23APR18)
9025-25-21
160GLC Excavator 042318 PN=1139
Tests
Main Relief and Power Dig Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Main Relief Valve Pressure
33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4900—5260 psi
Power Dig Valve Pressure
37.5—40.0 MPa 37 500—40 000 kPa 375—400 bar 5450—5800 psi
TX1089395A —UN—14MAR11
Hydraulic Oil Temperature
7.1 MPa Second Adjusting Plug Pressure Change (approximate per 1/4 turn) 7100 kPa 71 bar 1030 psi 32 mm Nut Torque
83 N·m 61 lb·ft
First Adjusting Plug Pressure 5.3 MPa Change (approximate per 1/4 turn) 5300 kPa 53 bar 768 psi 27 mm Nut Torque
Pump 1 and Pump 2 Test Ports
64 N·m 47 lb·ft
1— Pump 1 Test Port 2— Pump 2 Test Port
3— Adapter 4— JT02160 Transducer
SERVICE EQUIPMENT AND TOOLS
Select the following items from the menu: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Pressure Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi) Combination Wrenches 17, 27, and 32 mm
The 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. Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed.
2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank.
• Monitor application. For instruction to actuate the
3. Remove the plug from pump 1 test port and pump 2 test port (1 and 2).
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - 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.)
4. Install adapter (3). 5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) pressure gauge to adapter. 6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Continued on next page
TM13345X19 (23APR18)
9025-25-22
DF89619,00B58BB -19-06APR18-1/3
160GLC Excavator 042318 PN=1140
Tests Auto-Idle Switch—Position............................................................................... OFF
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode
8. Actuate arm out function over relief. Record main relief pressure reading. 9. Actuate arm out function over relief while pressing power dig switch. Record power dig pressure reading.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9025-25-23
DF89619,00B58BB -19-06APR18-2/3
160GLC Excavator 042318 PN=1141
Tests
NOTE: If pressure setting cannot be raised by adjusting main relief and power dig valve, arm out circuit relief valve pressure setting may be low. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)
1 2
10. Adjust the main relief and power dig valve (7) pressures as needed.
3
Specification Main Relief Valve—Pressure............................................................. 33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4900—5260 psi Power Dig Valve—Pressure............................................................. 37.5—40.0 MPa 37 500—40 000 kPa 375—400 bar 5450—5800 psi
4
5 6
7
11. Loosen 17 mm nut (1) to prevent twisting power dig pilot line. Tighten nut before starting engine. TX1000964 —UN—01DEC05
12. Loosen 27 mm nut (3). 13. Turn first adjusting plug (2) in until piston (6) is against bottom of bore in second adjusting plug (4). Tighten nut finger tight. 14. Loosen 32 mm nut (5). 15. Start the engine.
TX1000964
16. Actuate arm in function over relief.
Main Relief and Power Dig Valve
17. Turn second adjusting plug (4) in to increase power dig relief pressure; turn adjusting plug out to decrease pressure. Specification Second Adjusting Plug—Pressure Change (approximate per 1/4 turn).............................................................................................7.1 MPa 7100 kPa 71 bar 1030 psi
Hold second adjusting plug. Tighten 32 mm nut to specification. Specification 32 mm Nut—Torque......................................................................83 N·m 60 lb·ft
1— 17 mm Nut 2— First Adjusting Plug 3— 27 mm Nut 4— Second Adjusting Plug
5— 32 mm Nut 6— Piston 7— Main Relief and Power Dig Valve
Specification First Adjusting Plug—Pressure Change (approximate per 1/4 turn).............................................................................................5.3 MPa 5300 kPa 53 bar 770 psi
21. Hold first adjusting plug. Tighten 27 mm nut to specification. Specification 27 mm Nut—Torque......................................................................64 N·m 47 lb·ft
18. Loosen 27 mm nut (3). 19. Actuate the arm in function over relief. 20. Turn the first adjusting plug (2) out to decrease pressure to get the specified pressure for main relief valve.
22. Tighten 17 mm nut (1) on the elbow. 23. Check the pressures again. DF89619,00B58BB -19-06APR18-3/3
TM13345X19 (23APR18)
9025-25-24
160GLC Excavator 042318 PN=1142
Tests
Circuit Relief Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed (approximate)
1300 rpm
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Bucket Curl Pressure
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
Bucket Dump Pressure
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
Arm In Pressure
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
Arm Out Pressure
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
Boom Up Pressure
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
Boom Down Pressure
TX1089395A —UN—14MAR11
Hydraulic Oil Temperature
Pump 1 and Pump 2 Test Ports 1— Pump 1 Test Port 2— Pump 2 Test Port
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
- Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. For instruction, see Service ADVISOR™ Connection Procedure. (Group 9015-20.) Select the following items from the menu: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, See MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
5.2 MPa Circuit Relief Valve Pressure Change (approximate per 1/4 turn) 5200 kPa 52 bar 754 psi Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque
29.5 N·m 22 lb·ft
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)
The purpose of circuit relief valves is to relieve high-pressure spikes caused by external forces when functions are in neutral. The valves are checked and adjusted to specification to protect components from damage.
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.)
1. 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
3. Remove the plug from pump 1 test port and pump 2 test port (1 and 2).
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure
4. Install the 4200465 Adapter (3). 5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter.
Continued on next page
TM13345X19 (23APR18)
3— 4200465 Adapter 4— JT02160 Transducer
9025-25-25
DF89619,00B58BC -19-19AUG15-1/3
160GLC Excavator 042318 PN=1143
Tests
6. Turn second adjusting plug of main relief and power dig valve in 1/2 turn to increase pressure setting. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.) 7. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 8. Run machine at specification.
Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9025-25-26
DF89619,00B58BC -19-19AUG15-2/3
160GLC Excavator 042318 PN=1144
Tests
117
103
88
79
102
89 80
5-Spool Side Circuit Relief and Anticavitation Valves 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
9. Actuate the function over relief for circuit relief valve (79, 80, 88, 89, 102, and 103) being checked. Record pressure reading. Specification Bucket Curl—Pressure................................................... 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi Bucket Dump—Pressure................................................................................ 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi Arm In—Pressure........................................................... 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi Arm Out—Pressure........................................................ 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi Boom Up—Pressure...................................................... 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi Boom Down—Pressure.................................................. 39.2—40.2 MPa 39 200—40 200 kPa 392—4024 bar 5685—5830 psi
TX1001112 —UN—03DEC05
TX1001113 —UN—03DEC05
117
4-Spool Side Circuit Relief and Anticavitation Valves 102— Arm In Circuit Relief and 117— Main Relief and Power Dig Anticavitation Valve Valve 103— Arm Out Circuit Relief and Anticavitation Valve
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. Specification Circuit Relief Valve—Pressure Change (approximate per 1/4 turn).............................................................................................5.2 MPa 5200 kPa 52 bar 754 psi Circuit Relief Valve Adjusting Screw-to-Plug Nut—Torque...............................................................................29.5 N·m 22 lb·ft
11. Check pressures again. 12. Turn second adjusting plug of main relief and power dig valve out to its original setting. Check main pressure setting. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
DF89619,00B58BC -19-19AUG15-3/3
TM13345X19 (23APR18)
9025-25-27
160GLC Excavator 042318 PN=1145
Tests
Swing Motor Crossover Relief Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed (approximate)
1300 rpm
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Swing Motor Crossover Relief Valve Pressure
32.8—35.6 MPa 32 852—36 308 kPa 335—363 bar 4767—5174 psi
Crossover Relief Valve Shim Pressure Change (per 0.1 mm [0.004 in])
0.62 MPa 620 kPa 6.2 bar 90 psi
Crossover Relief Valve Plug Torque
118 N·m 90 lb·ft
TX1104353A —UN—10JAN12
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Pump 1 and Pump 2 Test Ports
Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Gauge 70 000 kPa (700 bar) (10 000 psi)
1— Pump 1 Test Port 2— Pump 2 Test Port
JT02156A Digital Pressure/Temperature Analyzer
3— 4200465 Adapter 4— JT02160 Transducer
JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)
Purpose of test is to check that the swing motor crossover relief valve pressures are within specification.
- Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
The swing motor crossover relief valves limit system pressure in the swing circuit. The valves protect swing components from high stresses generated during the starting and stopping of upperstructure. The valves also protect the components from pressure spikes from external forces when the control valve is in neutral.
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.)
1. Connect one of the following test equipment to monitor pump 2 delivery pressure, hydraulic oil temperature, and actual engine speed.
4. Install adapter (3).
3. Remove plug from pump 2 test port (2).
• 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
5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter. 6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Continued on next page
TM13345X19 (23APR18)
9025-25-28
BG71631,00009C9 -19-14AUG15-1/3
160GLC Excavator 042318 PN=1146
Tests
8. Actuate the swing function over relief. Record pressure reading. Repeat for opposite direction. Make adjustments as necessary.
Specification Swing Motor Crossover Relief Valve—Pressure.................................................. 32.8—35.1 MPa 32 852—35 108 kPa 328—351 bar 4765—5090 psi
Service ADVISOR is a trademark of Deere & Company BG71631,00009C9 -19-14AUG15-2/3
9. Stop and turn off machine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. Add or remove shims (7) by removing plug (10), sleeve (9), and piston (8) to increase or decrease pressure. Specification Crossover Relief Valve Shim—Pressure Change.................................................. 0.62 MPa per 0.1 mm (0.004 in) 620 kPa per 0.1 mm (0.004 in) 6.21 bar per 0.1 mm (0.004 in) 90 psi per 0.1 mm (0.004 in) TX1162156A —UN—20JUN14
10. Tighten plug (10) to specification. Specification Crossover Relief Valve Plug—Torque............................................................................... 118 N·m 90 lb·ft
11. Actuate the swing function over relief to check adjustment. 9— Sleeve 10— Plug 54A— Left Swing Crossover Relief Valve 54B— Right Swing Crossover Relief Valve
Swing Crossover Relief Valve Location
TX1163358 —UN—17JUN14
5— Spring 6— Spring Seat 7— Shim (as needed) 8— Piston
Swing Crossover Relief Valve Shims BG71631,00009C9 -19-14AUG15-3/3
TM13345X19 (23APR18)
9025-25-29
160GLC Excavator 042318 PN=1147
Tests
Travel Motor Crossover Relief Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed (approximate)
1300 rpm
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Motor Crossover Relief Valve Pressure
34.9—36.3 MPa 34 855—36 300 kPa 349—363 bar 5055—5265 psi
Crossover Relief Valve Shim Pressure Change (per 0.5 mm [0.02 in])
0.9 MPa 900 kPa 9 bar 130 psi
Crossover Relief Valve Torque
310 N·m 230 lb·ft
TX1089395A —UN—14MAR11
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer Pump 1 and Pump 2 Test Ports
JT02160 Transducer, 70 000 kPa (700 bar) (10 000 psi) 76.2 mm (3 in) OD Pin or Round Bar Stock (2 used)
Purpose of test is to check that the travel motor crossover relief valve pressure is within specification.
1— Pump 1 Test Port 2— Pump 2 Test Port
- Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
1. 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
3— 4200465 Adapter 4— JT02160 Transducer
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - 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.) Or select the following items from the menu: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pump 1 Delivery Pressure
2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Remove the plugs from pump 1 and pump 2 test ports (1 and 2). 4. Install 4200465 Adapter (3). 5. Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) gauge. 6. Turn second adjusting plug of main relief and power dig valve in 1/2 turn to increase pressure setting. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.) 7. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9025-25-30
DF89619,00B58BD -19-05OCT16-1/4
160GLC Excavator 042318 PN=1148
Tests
8. Install 76.2 mm (3 in) OD pin (5) or round bar stock between the sprocket and track frame to stall travel motor. 9. Run machine at specification.
TX1089540A —UN—23MAR11
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF 5— 76.2 mm (3 in) OD Pin
Travel Motor Stalled Using Pin DF89619,00B58BD -19-05OCT16-2/4
10. Slowly actuate the travel function for the crossover relief valve (68A or 68B) being checked. Record the pressure reading. Make adjustments as necessary. Specification Travel Motor Crossover Relief Valve—Pressure.................................................. 34.9—36.3 MPa 34 855—36 300 kPa 349—363 bar 5055—5265 psi
68A— Forward Crossover Relief Valve
TX1089491A —UN—16MAR11
11. Stop engine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. 68B— Reverse Crossover Relief Valve
Travel Motor Crossover Relief Valve Location Continued on next page
TM13345X19 (23APR18)
9025-25-31
DF89619,00B58BD -19-05OCT16-3/4
160GLC Excavator 042318 PN=1149
Tests
22
24
25
TX1000689 —UN—29NOV05
23
TX1000689 Travel Motor Crossover Relief Valve Shims 22— Poppet 23— Spring Seat
24— Shim (as needed)
25— Spring
12. Remove crossover relief valve. Add or remove shims (24) to adjust pressure. Specification Crossover Relief Valve Shim—Pressure Change (per 0.5 mm [0.02 in])..................................................................0.9 MPa 900 kPa 9 bar 130 psi
13. Install crossover relief valve. Tighten to specification.
Specification Crossover Relief Valve—Torque.............................................................................310 N·m 230 lb·ft
14. Actuate the travel function at stall to check adjustment. 15. Turn second adjusting plug of main relief and power dig valve out to its original setting. Check main pressure setting. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.) DF89619,00B58BD -19-05OCT16-4/4
TM13345X19 (23APR18)
9025-25-32
160GLC Excavator 042318 PN=1150
Tests
Pump Regulator Test and Adjustment—Minimum Flow SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Slow (turtle)
One Revolution of Raised Track Cycle Time (with pump regulator pilot line disconnected)
34.7—36.7 seconds TX1089633A —UN—16MAR11
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS 7/16-20 M 37° (Parker No. 03CP-4) Plug (2 used) Stop Watch 17 mm Combination Wrench Flat Blade Screwdriver
The purpose of 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.)
Hydraulic Pump Regulator Pilot Lines 1— Hydraulic Pump 1 Pilot Line 2— Hydraulic Pump 2 Pilot Line
2. Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.
the fittings on regulator open. Lay a shop towel over the fittings.
• 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: - 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: - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Application for instruction. (Group 9015-20.) Select the following items from the monitor display: - Hydraulic Oil Temperature - Actual Engine Speed
3. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
3— Hydraulic Pump 1 Regulator 4— Hydraulic Pump 2 Regulator
6. Run machine at specifications: Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position................................................................... Slow (turtle)
7. Raise the left track off ground for pump 2 or the right track for pump 1. 8. Actuate travel function to full speed. Record the cycle time for one revolution.
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 5. Disconnect pump regulator pilot lines (1 and 2) at pump regulators (3 and 4). Install plugs in lines. LeaveContinued on next page TM13345X19 (23APR18)
9025-25-33
DF89619,00B58BE -19-19JUN14-1/3
160GLC Excavator 042318 PN=1151
Tests Service ADVISOR is a trademark of Deere & Company DF89619,00B58BE -19-19JUN14-2/3
9. Adjust the minimum flow adjusting screw (E) as needed to obtain the specified cycle time. Turn screw in to decrease the cycle time (flow rate increases); turn screw out to increase the cycle time (flow rate decreases). Hold the screw and tighten the 17 mm nut (F). Specification One Revolution of Raised Track (with pump regulator pilot line disconnected)—Cycle Time.......................................................................... 34.7—36.7 seconds
10. Repeat procedure for other pump. Adjust regulators so cycle times are approximately the same for each track. F— 17 mm Nut
T103502 —UN—24AUG98
E—Minimum Flow Adjusting Screw
DF89619,00B58BE -19-19JUN14-3/3
TM13345X19 (23APR18)
9025-25-34
160GLC Excavator 042318 PN=1152
Tests
Pump Regulator Test and Adjustment—Maximum Flow
- Actual Engine Speed 3. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
SPECIFICATIONS Hydraulic Oil Temperature
45—55°C 113—131°F
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
Hydraulic Oil End of Maximum Flow Adjusting Screw to 13 mm Nut Distance
3 mm
End of Maximum Flow Adjusting Screw to 13 mm Nut
0.125 in (1/8 in.)
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Fast (rabbit)
Track Raised—3 Revolutions From a Running Start Cycle Time
24.7—28.7 s
4. Check the distance from the end of maximum flow adjusting screw (2) to the 13 mm nut (3) for both pump 1 and pump 2 regulators. Adjust screw to specification as needed. Specification End of Maximum Flow Adjusting Screw to 13 mm Nut—Distance.......................................................................... 3 mm 0.125 in (1/8 in)
5. Run machine at specifications:
SERVICE EQUIPMENT AND TOOLS
Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position...................................................................Fast (rabbit)
13 mm Combination Wrench Flat Blade Screwdriver Stop Watch 30 mm Combination Wrench
Purpose of test is to check and adjust the maximum flow rate of pump 1 and 2 using the cycle time for travel are approximately the same. Maximum flow rate cannot be significantly increased by turning out the flow adjusting cartridge. 1. Check and adjust track sag. See Maintenance—Check Track Sag in operator’s manual. 2. Connect one of the following test equipment to monitor 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: - 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: - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Application for instruction. (Group 9015-20.) Select the following items from the monitor display: - Hydraulic Oil Temperature
6. Raise the left track off ground for pump 2 or the right track for pump 1. 7. Actuate travel function to full speed for the raised track. Record track cycle time for three revolutions. Repeat procedure for the other pump. 8. Adjust flow adjusting cartridge (track cycle time) (4) on pump 1 and pump 2 regulators so track cycle times are within the specification and approximately the same. Specification Track Raised—3 Revolutions From a Running Start—Cycle Time......................................................................................24.7—28.7 s
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.
Continued on next page
TM13345X19 (23APR18)
9025-25-35
MM16284,0001E6E -19-02NOV15-1/2
160GLC Excavator 042318 PN=1153
T143804 —UN—10JUL01
Tests
1— Distance 2— Maximum Flow Adjusting Screw 3— 13 mm Nut
4— Flow Adjusting Cartridge (track cycle time) 5— 30 mm Nut
Service ADVISOR is a trademark of Deere & Company MM16284,0001E6E -19-02NOV15-2/2
TM13345X19 (23APR18)
9025-25-36
160GLC Excavator 042318 PN=1154
Tests
Pump Flow Test SPECIFICATIONS Hydraulic Oil Temperature
Purpose of this test is to determine the pump condition. Test should be performed only if a comparison of actual machine cycle times to specified cycle times indicates low pump flow. Perform the following appropriate procedures before continuing test:
45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
• See Torque Control Solenoid Valve Test and
Pump 1 or Pump 2 Flow Rate (approximate at 2000 rpm)
50 L/min 13 gal/min
• See Pump Control Pilot Pressure Signal Test. (Group
Adjustment. (Group 9025-25.)
9025-25.)
SERVICE EQUIPMENT AND TOOLS Elbow Fitting (-16 M BSPP ORB x -16 M ORFS) Flowmeter T107068 Flange Fitting Split Clamp Half (code 62) Test Hose (1020 mm [40 in] x 1 in hose with 90° flange fitting end, code 62)
Continued on next page
TM13345X19 (23APR18)
9025-25-37
JA66566,0000D16 -19-08NOV17-1/2
160GLC Excavator 042318 PN=1155
Tests
73 74
1
18 17 15
2
TX1173618 —UN—08OCT14
16
TX1173618 Pump Flow Test 1— Pump 1 Delivery Port 2— Pump 2 Delivery Port 15— Pump 1 (4-spool)
16— Pump 2 (5-spool) 17— Pump 1 Regulator 18— Pump 2 Regulator
73— Right Control Valve (4-spool) 74— Left Control Valve (5-spool)
1. Release hydraulic oil tank pressure. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)
4. Connect the flowmeter. If available, connect flowmeters to both pumps as shown.
2. Connect vacuum pump to hydraulic oil tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)
5. Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed.
3. Disconnect pump-to-control valve line from pump 1 delivery port (1) and/or pump 2 delivery port (2).
• Monitor application. For instruction to activate the
service menu on monitor in cab, see Service Menu. (Group 9015-16.) JA66566,0000D16 -19-08NOV17-2/2
TM13345X19 (23APR18)
9025-25-38
160GLC Excavator 042318 PN=1156
Tests Select the following items from monitoring list: - 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 from the menu: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
10. Verify main relief valve setting is to specification. For specification, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.) CAUTION: Avoid possible serious injury from machine movement. Clear the area of all bystanders before performing this procedure. 11. Actuate arm in function over relief. Record actual engine speed and flow rate. 12. Stop engine. NOTE: Formula is used to standardize measured flow rate due to engine speed variations. 13. Convert measured flow rate to those at specified engine speed by using formula and compare value to specification.
• Qc = 2000 x Q/Ne • Qc : Converted pump flow rate • Q : Measured pump flow rate • 2000 : Specified engine speed • Ne : Measured engine speed
6. Disconnect vacuum pump. 7. Verify flowmeter loading valve is open. 8. Warm the hydraulic oil to specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
9. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Specification Pump 1 or Pump 2—Flow Rate (approximate at 2000 rpm)................................................................................... 50 L/min 13 gal/min
14. If pump flow rate does not meet specification, inspect pump regulator for signs of adjustment.
• If signs of adjustment are indicated, see
Comprehensive Pump Flow Test. (Group 9025-25.)
• If no signs of adjustment are indicated, replace
hydraulic pump. See Pump 1 and 2 Remove and Install. (Group 3360.)
Service ADVISOR is a trademark of Deere & Company JA66566,0000D16 -19-08NOV17-3/2
TM13345X19 (23APR18)
9025-25-39
160GLC Excavator 042318 PN=1157
Tests
Comprehensive Pump Flow Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Maximum Flow Rate Adjusting Screw 13 mm Nut Torque
10 N·m 89 lb·in
Load Adjusting Cartridge 30 mm Nut Torque
30 N·m 22 lb·ft
Load Adjusting Screw 17 mm Nut Torque
10 N·m 89 lb·in
TX1243429A —UN—17AUG17
Hydraulic Oil Temperature
NOTE: This procedure is designed to follow pump flow test procedure to perform comprehensive pump flow testing and adjust pump regulators as required. Complete pump flow test before beginning this procedure. See Pump Flow Test. (Group 9025-25.) 1. Release hydraulic oil tank pressure. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 2. Remove plug and install drain hose to a torque control port (3). 3. Place opposite end of drain hose in suitable container. 4. 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 activate the
Pump Regulators 3— Torque Control Port (2 used) 17— Pump 1 Regulator
18— Pump 2 Regulator Y21— Torque Control Solenoid (marked ST)
5. Warm the hydraulic oil to specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
6. Run machine at specification.
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - 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 from the menu: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
7. Adjust main relief valve to specified pump flow pressures used in Points on PQ Curve table. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.) CAUTION: Avoid possible serious injury from machine movement. Clear the area of all bystanders before performing this procedure. 8. Actuate arm in function over relief. Record actual engine speed and flow rate. 9. Repeat steps to obtain flow rates for additional pressures. 10. Stop engine.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM13345X19 (23APR18)
9025-25-40
DF89619,00B6844 -19-27SEP17-1/4
160GLC Excavator 042318 PN=1158
Tests
A B
C
D
E
TX1206780 —UN—13JAN16
F
Q P TX1206780 PQ Curve P—Pressure
Q—Flow Rate
11.
Convert measured flow rates to those at specified engine speed by using formula:
Points on PQ Curve P
Q
Delivery Pressure MPa (bar) [psi]
Flow Rate* L/min (gal/min)
A
3.9 (39) [566]
164 (43)
B
13.7 (137) [1987]
162 (43)
C
15.7 (157) [2277]
141 (37)
D
18.7 (157) [2712]
111 (29)
E
21.4 (214) [3104]
101 (27)
F
34.3 (343) [4975]
50 (13)
• Qc = 2000 x Q/Ne • Qc : Converted pump flow rate • Q : Measured pump flow rate • 2000 : Specified engine speed • Ne : Measured engine speed 12. Adjust pump 1 or pump 2 regulators as needed. See adjustments later in this procedure:
• Maximum flow rate • Load adjusting cartridge (pressure to flow
*Approximate at 2000 rpm
control-torque adjustment)
• Load adjusting screw (pressure to flow control-torque
NOTE: Formula is used to standardize measured flow rates due to engine speed variations.
adjustment)
Continued on next page
TM13345X19 (23APR18)
9025-25-41
DF89619,00B6844 -19-27SEP17-2/4
160GLC Excavator 042318 PN=1159
Tests Adjustments
1 2
3 4
5 6
TX1243428 —UN—05OCT17
1 5 Q
Q P
4
Q P
P
TX1243428 Pump 1 and Pump 2 Regulator Adjustment 1— Maximum Flow Adjusting Screw 2— 13 mm Nut 3— 17 mm Nut 4— Load Adjusting Screw (pressure to flow control-torque adjustment)
6— 30 mm Nut P—Pressure Q—Flow Rate
5— Load Adjusting Cartridge (pressure to flow control-torque adjustment)
Maximum Flow Rate (PQ Curve Point A)
1. Loosen 30 mm nut (6).
IMPORTANT: Do not increase the maximum pump flow rate over maximum flow specifications.
2. Turn load adjusting cartridge (5) clockwise to increase flow rate.
Do not turn adjusting screw (1) more than 2 turns. Pump damage can occur.
3. Hold load adjusting cartridge. Tighten 30 mm nut to specification.
1. Loosen 13 mm nut (2). 2. Turn maximum flow adjusting screw (1) clockwise to decrease maximum pump flow.
Specification Load Adjusting Cartridge 30 mm Nut—Torque......................................................................30 N·m 22 lb·ft
3. Hold adjusting screw. Tighten 13 mm nut to specification.
Load Adjusting Screw (Pressure to Flow Control-Torque Adjustment)
Specification Maximum Flow Rate Adjusting Screw 13 mm Nut—Torque..................................................................................10 N·m 89 lb·in
IMPORTANT: Do not turn adjusting screw (4) more than 1 turn. Pump damage can occur. 1. Loosen 17 mm nut (3). 2. Turn load adjusting screw (4) clockwise to increase flow rate.
Load Adjusting Cartridge (Pressure to Flow Control-Torque Adjustment) IMPORTANT: Do not turn adjusting cartridge (5) more than 1 turn. Pump damage can occur.
Continued on next page
TM13345X19 (23APR18)
9025-25-42
DF89619,00B6844 -19-27SEP17-3/4
160GLC Excavator 042318 PN=1160
Tests
Specification Load Adjusting Screw 17 mm Nut—Torque...........................................................................10 N·m 89 lb·in
3. Hold adjusting screw. Tighten 17 mm nut to specification.
DF89619,00B6844 -19-27SEP17-4/4
Control Pressure Pump Flow Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
30 mm Nut Torque
30 N·m 22 lb·ft
13 mm Nut Torque
10 N·m 89 lb·in
2 1
SERVICE EQUIPMENT AND TOOLS
TX1252286 —UN—13FEB18
Hydraulic Oil Temperature
28
AT186623 Pressure Reducing Valve JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
3
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
1. Release hydraulic oil tank pressure. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 2. Connect vacuum pump to hydraulic oil tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)
Hydraulic Pump Regulator Hoses 1— Regulator Hose (pump 1) 2— Regulator Hose (pump 2)
3— Pilot Supply Hose 28— Pilot Pump
3. Install pump flow testing equipment. See Pump Flow Test. (Group 9025-25.) 4. Install identification tag and disconnect pump regulator hose (1 or 2) from regulator for pump being tested. Install cap or plug to open hose. Continued on next page
TM13345X19 (23APR18)
9025-25-43
DF89619,00B6927 -19-13FEB18-1/4
160GLC Excavator 042318 PN=1161
Tests
5. Install test hose (4) to open port of regulator. 6. Connect opposite end of test hose (4) to tee (5) and to output pressure port of pressure reducing valve (6).
301 7
7. Connect the JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
6
8. Disconnect pilot supply hose from pilot pump (28). 9. Install tee fitting to pilot pump.
5
10. Connect pilot supply hose and test hose (7) to tee fitting.
8
11. Connect opposite end of test hose (7) to input pressure port of pressure reducing valve.
302
12. Install drain hose (8) from pressure reducing valve to open port of hydraulic oil tank or hydraulic return manifold.
300
13. Disconnect vacuum pump. 14. Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.
• Monitor application. For instruction to activate the
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. For instruction, see Service ADVISOR™ Connection Procedure. (Group 9015-20.) Select the following items from the menu: - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Application. (Group 9015-20.) Select the following items from the monitor display: - Hydraulic Oil Temperature - Actual Engine Speed
Pressure Reducing Valve 4— Test Hose (pressure reducing valve to pump regulator) 5— Tee 6— Pressure Reducing Valve 7— Test Hose (pilot pump to pressure reducing valve)
8— Drain Hose (pressure reducing valve to hydraulic oil tank) 300— To Hydraulic Pump Regulator 301— From Pilot Pump 302— To Hydraulic Oil Tank
18. Adjust pressure reducing valve set pressure to each pressure point used in Points on PQ Curve. Record actual engine speed and flow rate. 19. Stop engine. Points on PQ Curve P
Q
Pilot Control Pressure MPa (bar) [psi]
Flow Rate* L/min (gal/min)
15. Verify flowmeter loading valve is open.
A
1.9 (19) [276]
70 (18)
16. Warm the hydraulic oil to specification.
B
3.4 (34) [493]
152 (40)
C
2.9 (29) [421]
164 (43)**
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
17. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
*Approximate at 2000 rpm **Maximum flow rate
NOTE: Formula is used to standardize measured flow rates due to engine speed variations. 20. Convert measured flow rates to those at specified engine speed by using formula:
• Qc = 2000 x Q/Ne • Qc : Converted pump flow rate • Q : Measured pump flow rate • 2000 : Specified engine speed • Ne : Measured engine speed
Continued on next page
TM13345X19 (23APR18)
TX1251995 —UN—12FEB18
4
9025-25-44
DF89619,00B6927 -19-13FEB18-2/4
160GLC Excavator 042318 PN=1162
Tests
• Flow adjusting cartridge (track cycle time) • Maximum flow rate
21. Adjust pump 1 or pump 2 regulators as needed. See adjustments later in this procedure: Service ADVISOR is a trademark of Deere & Company
DF89619,00B6927 -19-13FEB18-3/4
Adjustments
1 2 4
TX1251957 —UN—12FEB18
3
4 2
Q
Q P
P TX1251957
Pump 1 and Pump 2 Regulator Adjustment 1— 30 mm Nut 2— Flow Adjusting Cartridge
3— 13 mm Nut 4— Maximum Flow Adjusting Screw
Flow Adjusting Cartridge (Track Cycle Time)
Maximum Flow Rate
1. Loosen 30 mm nut (1).
1. Loosen 13 mm nut (3).
NOTE: When adjusting cartridge (2) is adjusted, maximum flow rate is also changed.
2. Turn maximum flow adjusting screw (4) clockwise to decrease maximum pump flow.
2. Turn adjusting cartridge (2) clockwise to decrease flow rate.
3. Hold adjusting screw. Tighten 13 mm nut to specification.
3. Hold adjusting cartridge. Tighten 30 mm nut to specification.
Specification 13 mm Nut—Torque......................................................................10 N·m 89 lb·in
Specification 30 mm Nut—Torque......................................................................30 N·m 22 lb·ft
DF89619,00B6927 -19-13FEB18-4/4
TM13345X19 (23APR18)
9025-25-45
160GLC Excavator 042318 PN=1163
Tests
Swing Motor Leakage Test SPECIFICATIONS Hydraulic Oil Temperature
45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Swing Motor Swinging Leakage
0.2—0.5 L/min. 0.05—0.08 gpm
Swing Motor Stalled Leakage
2.0—5.0 L/min. 0.5—1.3 gpm
SERVICE EQUIPMENT AND TOOLS TX1162154A —UN—05JUN14
JT03023 (9/16-18 F 37°) (Parker No. 06CP-6) Cap Calibrated Container
1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
2. Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Disconnect swing motor drain line (1) from the return manifold. Install a JT03023 Cap on fitting in return manifold. Put drain line in a calibrated container. 4. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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 doing test. 5. Raise and lower boom to pressurize hydraulic oil tank. 6. Operate swing function for 1 minute. Record amount of leakage. Repeat for swing in opposite direction. Record amount of leakage. Compare amount of leakage for each direction to specification.
Swing Motor Drain Line 1— Swing Motor Drain Line
Specification Swing Motor Swinging—Leakage.........................................................0.2—0.5 L/min. 0.05—0.08 gpm
7. Stall swing function for 1 minute. Record the amount of leakage. Repeat procedure by stalling the motor in several different positions. Record the amount of leakage for each position. Repeat procedure in the opposite direction. Take an average of the readings. Compare amount of leakage to specification. Specification Swing Motor Stalled—Leakage.............................................................2.0—5.0 L/min. 0.5—1.3 gpm
8. Swing motor leakage over specified allowable amount can be caused by a malfunction in the swing motor crossover relief valves. See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) 9. 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.) BG71631,00009C4 -19-19JUN14-1/1
TM13345X19 (23APR18)
9025-25-46
160GLC Excavator 042318 PN=1164
Tests
Travel Motor Leakage Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Position
OFF
Travel Speed Switch Position
Fast (rabbit)
Travel Motor with Track Raised Leakage (maximum)
10.0 L/min 2.6 gpm
Travel Motor Stalled Leakage (maximum)
15.0 L/min 4.0 gpm
TX1089572A —UN—16MAR11
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS JT03025 (3/4-16 F 37°) (Parker No. 06CP—8) Cap Calibrated Container 76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used) JT03221 (3/4-16 M 37°) (Parker No. 03CP—8) Plug Center Joint
1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
2. Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Disconnect travel motor drain line (1) at return manifold. Put line in a calibrated container. Install cap on return manifold fitting.
1— Travel Motor Drain Line
Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle—Position............................................................................ OFF Travel Speed Switch—Position...................................................................Fast (rabbit)
6. For travel motor being checked, actuate travel forward function at full speed for 1 minute. Record amount of leakage. Repeat procedure for reverse. Compare leakage to specification. Repair or replace travel motor as necessary.
4. Raise track off the ground for side being checked. 5. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode
Specification Travel Motor with Track Raised—Leakage.........................................................10.0 L/min or less 2.6 gpm or less
Continued on next page
TM13345X19 (23APR18)
9025-25-47
DF89619,00B58C1 -19-15MAR16-1/3
160GLC Excavator 042318 PN=1165
Tests
7. To check travel motor for leakage at stall, install pin (5) or round bar stock between the sprocket and track frame on the side being tested. 8. Actuate the forward travel function being checked to full stroke for one minute. Record the amount of leakage. Repeat procedure by stalling the motor in several different positions and then take an average of readings. Repeat procedure for reverse.
TX1089540A —UN—23MAR11
Specification Travel Motor Stalled—Leakage (maximum).............................................................................. 15.0 L/min 4.0 gpm 5— 76.2 mm (3 in.) OD Pin
Travel Motor Stalled Using Pin DF89619,00B58C1 -19-15MAR16-2/3
9. 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. Disconnect travel motor drain line (6) at travel motor. Install JT03221 Plug in the line.
T144148 —UN—19JUL01
6
7
Connect a line (7) to fitting on travel motor. Put line in a calibrated container (8).
8
Repeat test. 10. 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.)
Travel Motor Drain Line 6— Travel Motor Drain Line 7— Line
8— Calibrated Container
11. 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.) DF89619,00B58C1 -19-15MAR16-3/3
TM13345X19 (23APR18)
9025-25-48
160GLC Excavator 042318 PN=1166
Tests
Cylinder Drift Test—Boom, Arm, and Bucket SPECIFICATIONS Hydraulic Oil Temperature
45—55°C 110—130°F
Boom Cylinder Drift (maximum allowable for 5 minutes)
10 mm 0.39 in
Arm Cylinder Drift (maximum allowable for 5 minutes)
20 mm 0.79 in
Bucket Cylinder Drift (maximum allowable for 5 minutes)
15 mm 0.59 in
TX1095487 —UN—28JUN13
Bucket Load Weight (approximate) 825 kg 1819 lb
Bottom of Bucket-to-Ground Drift 100 mm (maximum allowable for 5 minutes) 3.94 in Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
Machine Position—Bucket Loaded
5 mm 0.20 in
4. Position bucket cylinder so rod is retracted 50 mm (2 in) from the extended position.
Arm Cylinder—Bucket Empty Drift 15 mm (maximum allowable for 5 minutes) 0.59 in Bucket Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
10 mm 0.39 in
Arm Tip-to-Ground—Bucket Empty Drift (maximum allowable for 5 minutes)
110 mm 4.33 in
5. Position the 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.
SERVICE EQUIPMENT AND TOOLS Tape Measure
Procedure is used to check leakage past the cylinder piston seals, control valve spools, circuit relief valves, boom reduced leakage valve, and arm reduced leakage valve. Drift Test—Bucket Filled 1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
Specification Boom Cylinder—Drift (maximum allowable for 5 minutes)...................................................................................... 10 mm 0.39 in Arm Cylinder—Drift (maximum allowable for 5 minutes)...................................................................................... 20 mm 0.79 in Bucket Cylinder—Drift (maximum allowable for 5 minutes)...................................................................................... 15 mm 0.59 in Bottom of Bucket-toGround—Drift (maximum allowable for 5 minutes).............................................................. 100 mm 3.94 in
2. Fill bucket with material to specification. Specification Bucket Load—Weight (approximate)................................................................................ 825 kg 1819 lb
3. Position arm cylinder so rod is extended approximately 50 mm (2 in) from the retracted position. Continued on next page
TM13345X19 (23APR18)
9025-25-49
JJ03229,0001125 -19-22OCT15-1/2
160GLC Excavator 042318 PN=1167
Tests
TX1109902 —UN—28JUN13
Drift Test—Bucket Empty 1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 2. Empty bucket of material. 3. Position arm and bucket so rod is fully extended. 4. Lower boom until arm tip position above ground 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. Specification Boom Cylinder—Bucket Empty—Drift (maximum allowable for 5 minutes).................................................................. 5 mm 0.20 in Arm Cylinder—Bucket Empty—Drift (maximum allowable for 5 minutes)................................................................ 15 mm 0.59 in
Machine Position—Bucket Empty Bucket Cylinder—Bucket Empty—Drift (maximum allowable for 5 minutes)................................................................ 10 mm 0.39 in Arm Tip-toGround—Bucket Empty—Drift (maximum allowable for 5 minutes)...............................................................110 mm 4.33 in
JJ03229,0001125 -19-22OCT15-2/2
TM13345X19 (23APR18)
9025-25-50
160GLC Excavator 042318 PN=1168
Tests
Upperstructure Drift Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Switch Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Loaded Bucket Weight (approximate)
825 kg 1819 lb
Upperstructure Drift Distance (maximum)
100 mm 4 in
TX1162186 —UN—04JUN14
Hydraulic Oil Temperature
Machine Position
SERVICE EQUIPMENT AND TOOLS Tape Measure
The purpose of this test is to determine if swing and swing park brake components are operating properly. 1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
2. Operate machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Switch—Position.......................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
3. Fill bucket with material to specification. Specification Loaded Bucket—Weight (approximate)................................................................................ 825 kg 1819 lb
4. Position arm cylinder so rod is fully retracted. 5. Position bucket cylinder so rod is fully extended. 6. Position the boom cylinders so bucket pivot pin is at the same height as the boom-to-main frame pin. 7. Raise pilot shutoff lever and wait at least 15 seconds for swing park brake to apply. Continued on next page
TM13345X19 (23APR18)
9025-25-51
JJ03229,0001124 -19-12OCT15-1/2
160GLC Excavator 042318 PN=1169
Tests
8. Apply a mark across upper and lower swing bearing race (1 and 2).
3
9. Lower pilot shutoff lever and operate bucket curl over relief for 1 minute.
4
1
10. Raise pilot shutoff lever and wait at least 15 seconds for swing park brake to apply. 11. Measure distance (3) between lower swing bearing race mark (4) and upper swing bearing mark (5).
2
12. Repeat procedure 3 times and calculate average. 13. Rotate upperstructure 180° and repeat procedure.
TX1162107 —UN—05JUN14
5
Swing Bearing
14. Compare measurements to specification. Specification Upperstructure Drift—Distance (maximum).................................................................................. 100 mm 4 in
1— Upper Swing Bearing Race 2— Lower Swing Bearing Race 3— Distance
4— Lower Swing Bearing Race Mark 5— Upper Swing Bearing Race Mark
15. If measurements are not within specification, see Upperstructure Drift With Swing Valve in Neutral. (Group 9025-15.) JJ03229,0001124 -19-12OCT15-2/2
TM13345X19 (23APR18)
9025-25-52
160GLC Excavator 042318 PN=1170
Tests
Fan Drive Pump Flow Test SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
New, Typical Flow Rate
42 L/min. 11 gpm
Used, Minimum Flow Rate
36 L/min. 9.5 gpm
Fan Drive Circuit Pressure
20.7—21.0 MPa 20 700—21 000 kPa 207—210 bar 3000—3050 psi
TX1161627A —UN—29MAY14
Hydraulic Oil Temperature
Fan Speed and Reversing Control Valve 1— Pump Pressure Line 2— Return Line (fan control valve-to-hydraulic oil tank) 133— Fan Drive Motor
SERVICE EQUIPMENT AND TOOLS JT05984 Flowmeter Test Hose (2 used)
Use this procedure when diagnosing system overheating problems. See Fan Drive Hydraulic System Operation. (Group 9025-05.)
NOTE: When the variable speed fan solenoid (Y5014) is disconnected all hydraulic oil is forced through fan motor with the exception of a small portion is sent over circuit relief to tank. This nonadjustable circuit relief valve is built into the proportional solenoid.
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. Disconnect pump pressure line (1) coming from fan drive pump and connect JT05984 Flowmeter in-line using test hoses containing. 3. Connect one of the following test equipment to display hydraulic oil temperature and actual engine speed. 1. 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: - Hydraulic Oil Temperature - Actual Engine Speed 2. Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items from the menu: - Hydraulic Oil Temperature - Actual Engine Speed 3. MPDr application. See MPDr Application for instruction. (Group 9015-20.) Select the following items from the monitor display: - Hydraulic Oil Temperature - Actual Engine Speed 4. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
5. Disconnect variable speed fan solenoid (Y5014). 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 test temperatures. 6. Run engine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
7. Record fan drive pump flow and compare to specification. Specification New, Typical—Flow Rate........................................................................................... 42 L/min. 11 gpm Used, Minimum—Flow Rate........................................................................................... 36 L/min. 9.5 gpm Fan Drive Circuit—Pressure........................................................... 20.7—21.0 MPa 20 700—21 000 kPa 207—210 bar 3000—3050 psi
Continued on next page
TM13345X19 (23APR18)
135— Fan Speed and Reversing Control Valve Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid
9025-25-53
DF89619,00B5886 -19-19JUN14-1/2
160GLC Excavator 042318 PN=1171
Tests
8. If fan drive circuit testing pressure is not to specifications, change variable speed fan solenoid which contains a built in relief valve. If pump flow is below minimum specification, replace cooling fan drive pump.
If pump flow is within specification and overheating persists, perform the following:
• Check variable fan speed solenoid valve. • Check hydraulic lines to and from fan drive motor. • Replace fan drive motor.
Service ADVISOR is a trademark of Deere & Company DF89619,00B5886 -19-19JUN14-2/2
TM13345X19 (23APR18)
9025-25-54
160GLC Excavator 042318 PN=1172
Tests
Fan Speed Test SPECIFICATIONS 50—60°C 120—140°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Engine Fan Speed
1500 rpm
TX1161628A —UN—29MAY14
Hydraulic Oil Temperature
Engine Fan Speed (above 1660 m 1500 rpm [5450 ft] altitude) Fan Speed and Reversing Control Valve
SERVICE EQUIPMENT AND TOOLS JT05709 Reflective Tape JT05719 Handheld Digital Tachometer
Use this procedure when diagnosing system overheating problems. See Hydraulic Oil Overheats. (Group 9025-15.)
1— Pump Pressure Line 2— Return Line (fan control valve to hydraulic oil tank) 3— Fan Blade 4— JT05709 Reflective Tape
1. Install JT05709 Reflective Tape (4) on one fan blade (3). 2. Use one of the following to display hydraulic oil temperature and actual engine speed. 1. 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: - Hydraulic Oil Temperature - Actual Engine Speed - Engine Fan Speed 2. Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items from the menu: - Hydraulic Oil Temperature - Actual Engine Speed - Engine Fan Speed 3. MPDr application. See MPDr Application for instruction. (Group 9015-20.) Select the following items from the monitor display: - Hydraulic Oil Temperature - Actual Engine Speed - Engine Fan Speed 3. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................50—60°C 120—140°F
4. Disconnect engine coolant temperature sensor (B5208). See Front Engine Harness (W7) Component Location. (Group 9015-10.)
133— Fan Drive Motor 135— Fan Speed and Reversing Control Valve Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid
Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
6. Measure fan speed with JT05719 Handheld Digital Tachometer. Record result. 7. Compare reading to specification. Specification Engine Fan—Speed.................................................................. 1500 rpm Engine Fan—Speed (above 1660 m [5450 ft] altitude)...................................................................................... 1500 rpm
8. Verify with monitor that fan speed sensor (B5303) reading matches actual measured fan speed within 3 percent. 9. If fan speed is below specification, see Fan Drive Pump Flow Test. (Group 9025-25.) If fan drive pump flow is in specification, check variable speed fan solenoid (Y5014). See Electrical Component Specifications. (Group 9015-20.) 10. Connect engine coolant temperature sensor (B5208). See Front Engine Harness (W7) Component Location. (Group 9015-10.)
5. Operate engine at specification. Service ADVISOR is a trademark of Deere & Company JL58967,0000650 -19-20SEP16-1/1
TM13345X19 (23APR18)
9025-25-55
160GLC Excavator 042318 PN=1173
Tests
TM13345X19 (23APR18)
9025-25-56
160GLC Excavator 042318 PN=1174
Section 9031 Heating and Air Conditioning Contents Page Page
Group 05—Theory of Operation Air Conditioning System Cycle of Operation............................................... 9031-05-1 Group 15—Diagnostic Information Air Conditioning System Does Not Operate .................................................9031-15-1 Air Conditioning System Does Not Operate Diagnostic Procedure..............................................9031-15-1 Air Conditioning System Does Not Cool Interior of Cab ...............................9031-15-3 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure..............................................9031-15-3 Air Conditioning System Runs Constantly, Too Cold .............................9031-15-4 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure..............................................9031-15-4 Heating System Does Not Operate .................................................9031-15-5 Heating System Does Not Operate Diagnostic Procedure............................9031-15-5 Heating System Does Not Warm Interior of Cab .......................................9031-15-6 Heating System Does Not Warm Interior of Cab Diagnostic Procedure..............................................9031-15-6 Interior Windows Continue to Fog ........................................................9031-15-8 Interior Windows Continue to Fog Using Heater Diagnostic Procedure..............................................9031-15-8 Heater and Air Conditioner Component Location ........................... 9031-15-10
Air Conditioner Freeze Control Switch Test ............................................ 9031-25-6 Air Conditioning System Test..................... 9031-25-7 Operating Pressure Diagnostic Chart...................................................... 9031-25-9
Group 25—Tests R134a Refrigerant Cautions and Proper Handling..................................... 9031-25-1 R134a Oil Charge Capacity....................... 9031-25-1 R134a Refrigerant Charge Capacity................................................. 9031-25-1 Heater and Air Conditioner Operational Checks ............................... 9031-25-2 Visual Inspection of Components .....................................................9031-25-2 Air Conditioner Compressor Clutch Test ........................................................ 9031-25-3 R134a Refrigerant Leak Test..................... 9031-25-3 R134a Refrigerant Hoses and Tubing Inspection .................................. 9031-25-4 Air Conditioner High/Low-Pressure Switch Test ............................................ 9031-25-5 TM13345X19 (23APR18)
9031-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9031-2
160GLC Excavator 042318 PN=2
Group 05
Theory of Operation Air Conditioning System Cycle of Operation
1
2
4 5 4
3
7
6 TX1153371 —UN—11FEB14
8 9 10 11 TX1153371 Refrigerant System Cycle of Operation 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
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.
Continued on next page
TM13345X19 (23APR18)
11— Air Flow
9031-05-1
DF89619,00B5732 -19-16APR15-1/2
160GLC Excavator 042318 PN=1177
Theory of Operation
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.
is drained away through drain tubes connected to a drain pan under evaporator.
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
For location of machine heater and air conditioning components, see Heater and Air Conditioner Component Location. (Group 9031-15.)
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 18°C (64°F) and air conditioner is on.
DF89619,00B5732 -19-16APR15-2/2
TM13345X19 (23APR18)
9031-05-2
160GLC Excavator 042318 PN=1178
Group 15
Diagnostic Information Air Conditioning System Does Not Operate DF89619,00B5742 -19-29OCT15-1/12
Air Conditioning System Does Not Operate Diagnostic Procedure NOTE: On machines equipped with a reversing cooling fan, the air conditioning will be momentarily disabled during a reversing cooling fan cycle. DF89619,00B5742 -19-29OCT15-2/12
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using Service ADVISOR™. See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application. (Group 9015-25.)
YES: Diagnose code. See specific code diagnostic procedure in Group 9001.
Are any DTCs present?
NO: Go to Machine Settings Check.
Service ADVISOR is a trademark of Deere & Company DF89619,00B5742 -19-29OCT15-3/12
• 2
Machine Settings Check
Check machine settings for proper air conditioner control mode setting. See Cab Heater and Air Conditioner. (Operator’s Manual.)
YES: Go to Fuse Check.
Is correct setting selected?
NO: Select correct setting. DF89619,00B5742 -19-29OCT15-4/12
• 3
Fuse Check
Remove air conditioner and heater 20 A fuse (marked HEATER) (F3). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuse (F3).
YES: Go to Blower Motor Speed Switch Check.
Is continuity indicated?
NO: Replace fuse (F3). DF89619,00B5742 -19-29OCT15-5/12
• 4
Blower Motor Speed Switch Check
Verify proper operation of blower motor speed switch (S21). See Cab Heater and Air Conditioner. (Operator’s Manual.)
Press blower motor speed switch. Does air conditioner display change on monitor? See Monitor. (Operator’s Manual.) Rotate blower motor speed switch.
YES: Go to Air Conditioner and Heater Blower Motor Check.
Does fan speed indicator change on monitor? See Monitor. (Operator’s Manual.)
NO: Replace blower motor speed switch.
Continued on next page
TM13345X19 (23APR18)
9031-15-1
DF89619,00B5742 -19-29OCT15-6/12
160GLC Excavator 042318 PN=1179
Diagnostic Information
• 5
Air Conditioner and Heater Blower Motor Check
Disconnect air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Supply battery voltage to pin 1 and ground to pin 2 air conditioner and heater blower motor connector. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Go to Air Conditioner Freeze Control Switch Check.
Does motor run?
NO: Replace air conditioner and heater blower motor. DF89619,00B5742 -19-29OCT15-7/12
• 6
Air Conditioner Freeze Test air conditioner freeze control switch (B41). See Air Conditioner Freeze Control Control Switch Check Switch Test. (Group 9031-25.)
Does air conditioner freeze control switch test good?
YES: Go to Air Conditioner High/Low-Pressure Switch Check. NO: Replace switch. DF89619,00B5742 -19-29OCT15-8/12
• 7
Air Conditioner High/Low-Pressure Switch Check
Test air conditioner high/low-pressure switch (B20). See Air Conditioner High/Low-Pressure Switch Test. (Group 9031-25.)
YES: Go to Air Conditioner Compressor Clutch Check.
Does air conditioner high/low-pressure switch test good?
NO: Replace switch. DF89619,00B5742 -19-29OCT15-9/12
• 8
Air Conditioner Compressor Clutch Check
Test air conditioner compressor clutch (Y11). See Air Conditioner Compressor Clutch Test. (Group 9031-25.)
YES: Go to Air Conditioner and Heater Blower Motor Relay Check.
Does air conditioner compressor clutch test good?
NO: Replace air conditioner compressor clutch solenoid. DF89619,00B5742 -19-29OCT15-10/12
• 9
Air Conditioner and Heater Blower Motor Relay Check
Remove air conditioner and heater blower motor relay (K17). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test air conditioner and heater blower motor relay. See Electrical Component Checks. (Group 9015-20.)
YES: Go to Wiring Harness Check.
Does air conditioner and heater blower motor relay test good?
NO: Replace air conditioner and heater blower motor relay. DF89619,00B5742 -19-29OCT15-11/12
•
10 Wiring Harness Check Check heater and air conditioning system wiring for open and short circuits. For additional information, see System Functional Schematic. (Group 9015-10.) Does heater and air conditioning system contain open or short circuits?
YES: Repair or replace heater and air conditioner system wiring. NO: Checks complete. DF89619,00B5742 -19-29OCT15-12/12
TM13345X19 (23APR18)
9031-15-2
160GLC Excavator 042318 PN=1180
Diagnostic Information
Air Conditioning System Does Not Cool Interior of Cab DF89619,00B5743 -19-06FEB17-1/10
Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure NOTE: On machines equipped with a reversing cooling fan, the air conditioning will be momentarily disabled during a reversing cooling fan cycle. DF89619,00B5743 -19-06FEB17-2/10
• 1
Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
YES: Clean or replace cab fresh air filter.
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. DF89619,00B5743 -19-06FEB17-3/10
• 2
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions. See Clean Cab Fresh YES: Clean or replace cab Air and Cab Recirculating Air Filters. (Operator’s Manual.) recirculating air filter.
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Cab Seals Check. DF89619,00B5743 -19-06FEB17-4/10
• 3
Cab Seals Check
Check windows and doors to make sure seals are in good condition.
YES: Go to Refrigerant Hose Restriction Check.
Are seals on all windows and doors in good condition?
NO: Repair or replace damaged or malfunctioning seals. DF89619,00B5743 -19-06FEB17-5/10
• 4
Refrigerant Hose Restriction Check
Check refrigerant hoses. See R134a Refrigerant Hoses and Tubing Inspection. (Group YES: Reroute or re-index 9031-25.) hoses. Replace kinked or collapsed hoses. See Heater and Air Conditioner Component Location. (Group 9031-15.) Are any hoses kinked, pinched, or collapsed?
NO: Go to Condenser Air Flow Restriction Check. DF89619,00B5743 -19-06FEB17-6/10
• 5
Condenser Air Flow Restriction Check
Check condenser fins for air flow restrictions.
YES: Clean condenser fins.
Are condenser fins clogged with debris?
NO: Go to Evaporator Core Air Flow Restriction Check. Continued on next page
TM13345X19 (23APR18)
9031-15-3
DF89619,00B5743 -19-06FEB17-7/10
160GLC Excavator 042318 PN=1181
Diagnostic Information
• 6
Evaporator Core Air Flow Restriction Check
Check evaporator core fins for restrictions.
YES: Clean evaporator fins.
Are the evaporator core fins clogged with debris?
NO: Go to Air Conditioner Compressor Belt Check. DF89619,00B5743 -19-06FEB17-8/10
• 7
Air Conditioner Compressor Belt Check
Check air conditioner compressor belt for proper pulley alignment and damage. See Inspect Serpentine Belt. (Operator’s Manual.)
YES: Go to System Operating Pressures Check.
Is belt properly aligned and in good condition?
NO: Adjust or replace belt. DF89619,00B5743 -19-06FEB17-9/10
• 8
System Operating Pressures Check
Check air conditioner system operating pressures. See Air Conditioning System Test. (Group 9031-25.)
YES: Checks complete.
Are air conditioner system operating pressures within specification?
NO: Check conditions. See Operating Pressure Diagnostic Chart. (Group 9031-25.) DF89619,00B5743 -19-06FEB17-10/10
Air Conditioning System Runs Constantly, Too Cold DF89619,00B5744 -19-30JAN17-1/8
Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure DF89619,00B5744 -19-30JAN17-2/8
• 1
Air Conditioning System Check
Check air conditioning system for proper operation. See Heater and Air Conditioner Operational Checks. (Group 9031-25.)
YES: Go to Evaporator Core Component Check.
Is the air conditioning system operating correctly?
NO: See Air Conditioning System Does Not Operate. (Group 9031-15.) DF89619,00B5744 -19-30JAN17-3/8
• 2
Evaporator Core Component Check
Check evaporator core fins for frosting or freezing.
YES: Go to Air Conditioner Freeze Control Switch Check.
Is there any ice or frost on evaporator core fins?
NO: Go to Air Conditioner Compressor Clutch Check.
Continued on next page
TM13345X19 (23APR18)
9031-15-4
DF89619,00B5744 -19-30JAN17-4/8
160GLC Excavator 042318 PN=1182
Diagnostic Information
• 3
Air Conditioner Freeze Test air conditioner freeze control switch (B41). See Air Conditioner Freeze Control Control Switch Check Switch Test. (Group 9031-25.)
Does air conditioner freeze control switch test good?
YES: Go to Air Conditioner Compressor Clutch Check.
NO: Replace air conditioner freeze control switch. DF89619,00B5744 -19-30JAN17-5/8
• 4
Air Conditioner Compressor Clutch Check
Test air conditioner compressor clutch (Y11). See Air Conditioner Compressor Clutch Test. (Group 9031-25.)
YES: Go to Air Conditioner and Heater Blower Motor Relay Check.
Does air conditioner compressor clutch test good?
NO: Replace solenoid. DF89619,00B5744 -19-30JAN17-6/8
• 5
Air Conditioner and Heater Blower Motor Relay Check
Remove air conditioner and heater blower motor relay (K17). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test air conditioner and heater blower motor relay. See Electrical Component Checks. (Group 9015-20.)
YES: Go to Wiring Harness Check.
Does air conditioner and heater blower motor relay test good?
NO: Replace relay. DF89619,00B5744 -19-30JAN17-7/8
• 6
Wiring Harness Check Check heater and air conditioner system harnesses for open and short circuits. For additional information, see System Functional Schematic. (Group 9015-10.)
YES: Checks complete.
Is heater and air conditioner harness in good condition?
NO: Repair or replace harnesses. DF89619,00B5744 -19-30JAN17-8/8
Heating System Does Not Operate DF89619,00B5745 -19-19JUN14-1/9
Heating System Does Not Operate Diagnostic Procedure DF89619,00B5745 -19-19JUN14-2/9
• 1
Diagnostic Trouble Code Check
Check for active diagnostic trouble codes (DTCs) using Service ADVISOR™. See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application. (Group 9015-25.)
YES: Diagnose code. See specific code diagnostic procedure in Group 9001.
Are any DTCs present?
NO: Go to Machine Settings Check.
Service ADVISOR is a trademark of Deere & Company DF89619,00B5745 -19-19JUN14-3/9
• 2
Machine Settings Check
Check machine settings for proper air conditioner control mode setting. See Cab Heater and Air Conditioner. (Operator’s Manual.)
YES: Go to Fuse Check.
Is the correct setting selected?
NO: Select the correct setting. Continued on next page
TM13345X19 (23APR18)
9031-15-5
DF89619,00B5745 -19-19JUN14-4/9
160GLC Excavator 042318 PN=1183
Diagnostic Information
• 3
Fuse Check
Remove Air Conditioner and Heater 20 A Fuse (marked HEATER) (F3). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuse (F3).
YES: Go to Blower Motor Speed Switch Check.
Is continuity indicated?
NO: Replace fuse (F3). DF89619,00B5745 -19-19JUN14-5/9
• 4
Blower Motor Speed Switch Check
Verify proper operation of blower motor speed switch (S21). See Cab Heater and Air Conditioner. (Operator’s Manual.)
Press blower motor speed switch. Does air conditioner display change on monitor? See Monitor. (Operator’s Manual.) Rotate blower motor speed switch.
YES: Go to Air Conditioner and Heater Blower Motor Check.
Does fan speed indicator change on monitor? See Monitor. (Operator’s Manual.)
NO: Replace blower motor speed switch. DF89619,00B5745 -19-19JUN14-6/9
• 5
Air Conditioner and Heater Blower Motor Check
Disconnect air conditioner and heater blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Supply battery voltage to pin 1 and ground to pin 2 air conditioner and heater blower motor connector. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Go to Air Conditioner and Heater Blower Motor Relay Check.
Does motor run?
NO: Replace blower motor. DF89619,00B5745 -19-19JUN14-7/9
• 6
Air Conditioner and Heater Blower Motor Relay Check
Remove air conditioner and heater blower motor relay (K17). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test air conditioner and heater blower motor relay. See Electrical Component Checks. (Group 9015-20.)
YES: Go to Wiring Harness Check.
Does air conditioner and heater blower motor relay test good?
NO: Replace air conditioner and heater blower motor relay. DF89619,00B5745 -19-19JUN14-8/9
• 7
Wiring Harness Check Check heater and air conditioning system wiring for open and short circuits. For additional information, see System Functional Schematic. (Group 9015-10.) Does heater and air conditioning system contain open or short circuits?
YES: Repair or replace heating and air conditioning system wiring. NO: Checks complete. DF89619,00B5745 -19-19JUN14-9/9
Heating System Does Not Warm Interior of Cab DF89619,00B5746 -19-26MAR14-1/10
Heating System Does Not Warm Interior of Cab Diagnostic Procedure Continued on next page
TM13345X19 (23APR18)
9031-15-6
DF89619,00B5746 -19-26MAR14-2/10
160GLC Excavator 042318 PN=1184
Diagnostic Information
• 1
Heater Check
Check heater system for proper operation. See Heater and Air Conditioner Operational YES: Go to Coolant Check. Checks. (Group 9031-25.) Is the heater system operating correctly?
NO: See Heating System Does Not Operate. (Group 9031-15.) DF89619,00B5746 -19-26MAR14-3/10
• 2
Coolant Check
Check engine coolant level. See Check Engine Coolant Level. (Operator’s Manual.)
YES: Go to Cab Fresh Air Filter Restriction Check.
Is engine coolant full?
NO: Fill with proper coolant to specification. DF89619,00B5746 -19-26MAR14-4/10
• 3
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
YES: Clean or replace cab fresh air filter.
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. DF89619,00B5746 -19-26MAR14-5/10
• 4
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions. See Clean Cab Fresh YES: Clean or replace cab Air and Cab Recirculating Air Filters. (Operator’s Manual.) recirculating air filter.
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Cab Seals Check. DF89619,00B5746 -19-26MAR14-6/10
• 5
Cab Seals Check
Check windows and doors to make sure seals are in good condition.
YES: Go to Heater Hose Restriction Check.
Are seals on all windows and doors in good condition?
NO: Repair or replace damaged or malfunctioning seals. DF89619,00B5746 -19-26MAR14-7/10
• 6
Heater Hose Restriction Check
Check heater hoses. See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Reroute or re-index hoses. Replace kinked or collapsed hoses.
Are any hoses kinked, pinched or collapsed?
NO: Go to Heater Door Servo Motor Check. DF89619,00B5746 -19-26MAR14-8/10
• 7
Heater Door Servo Motor Check
Inspect heater servo motor and door. See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Go to Heater Core Air Flow Restriction Check.
Is servo motor and door operating correctly?
NO: Repair or replace servo motor or door.
Continued on next page
TM13345X19 (23APR18)
9031-15-7
DF89619,00B5746 -19-26MAR14-9/10
160GLC Excavator 042318 PN=1185
Diagnostic Information
• 8
Heater Core Air Flow Restriction Check
Check heater core fins for debris. See Heater and Air Conditioner Component Location. YES: Clean heater core (Group 9031-15.) fins.
Are heater core fins clogged with debris?
NO: Checks complete. DF89619,00B5746 -19-26MAR14-10/10
Interior Windows Continue to Fog DF89619,00B5747 -19-26MAR14-1/7
Interior Windows Continue to Fog Using Heater Diagnostic Procedure DF89619,00B5747 -19-26MAR14-2/7
• 1
Machine Settings Check
Check machine settings for proper air conditioner control mode setting. See Cab Heater and Air Conditioner. (Operator’s Manual.)
YES: Go to Air Filter Restriction Check.
Is the correct setting selected?
NO: Select the correct setting. DF89619,00B5747 -19-26MAR14-3/7
• 2
Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
YES: Clean or replace cab fresh air filter.
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. DF89619,00B5747 -19-26MAR14-4/7
• 3
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions. See Clean Cab Fresh YES: Clean or replace cab Air and Cab Recirculating Air Filters. (Operator’s Manual.) recirculating air filter.
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Heater Door Servo Motor Check. DF89619,00B5747 -19-26MAR14-5/7
• 4
Heater Door Servo Motor Check
Inspect heater servo motor and door. See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Go to Air Conditioner Check.
Is servo motor and door operating correctly?
NO: Repair or replace servo motor or door. DF89619,00B5747 -19-26MAR14-6/7
• 5
Air Conditioner Check
Verify air conditioner is working properly.
YES: Checks complete.
Is air conditioner working properly?
NO: Correct air conditioner problem. See Air Conditioning System Does Not Operate. (Group 9031-15.) DF89619,00B5747 -19-26MAR14-7/7
TM13345X19 (23APR18)
9031-15-8
160GLC Excavator 042318 PN=1186
Diagnostic Information
TM13345X19 (23APR18)
9031-15-9
160GLC Excavator 042318 PN=1187
Diagnostic Information
Heater and Air Conditioner Component Location
3 Y11 4
B20
5
6 8 7 2 A7
1
9
TX1106543 —UN—27JAN12
M7
TX1106543 Heater and Air Conditioner Component Location
Continued on next page
TM13345X19 (23APR18)
9031-15-10
JA66566,00016ED -19-20FEB12-1/2
160GLC Excavator 042318 PN=1188
Diagnostic Information 1— Heater and Air Conditioner Unit 2— Heater Return Line 3— Heater Supply Line 4— Evaporator-to-Compressor Low Pressure Line
9— Evaporator-to-Receiver-Dryer M7—Air Conditioner and Heater 5— Condenser Line 6— Receiver-Dryer Blower Motor 7— Condenser-to-Receiver-Dryer A7—Air Conditioner Controller Y11— Air Conditioner (ACF) High Pressure Line Compressor B20— Air Conditioner High/Low 8— Compressor-to-Condenser Pressure Switch Line JA66566,00016ED -19-20FEB12-2/2
TM13345X19 (23APR18)
9031-15-11
160GLC Excavator 042318 PN=1189
Diagnostic Information
TM13345X19 (23APR18)
9031-15-12
160GLC Excavator 042318 PN=1190
Group 25
Tests R134a Refrigerant Cautions and Proper Handling
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.
SERVICE EQUIPMENT AND TOOLS Refrigerant Identifier
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.
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. Do not mix refrigerants, hoses, fittings, components, or refrigerant oils.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials.
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. Refrigerant identifier should be used before any testing or repair to system is performed.
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 bare hands. Skin may freeze to container. Wear gloves.
AS79221,00005A0 -19-03MAR16-1/2
Refrigerant Identifier
Used to safely and correctly identify type and check purity of refrigerant prior to recovery, recycling, and charging of air conditioning systems. AS79221,00005A0 -19-03MAR16-2/2
R134a Oil Charge Capacity IMPORTANT: Prevent possible air conditioner compressor damage. Only use polyakyleneglycol (PAG) oil or equilivant. Item
Measurement
Specification
System (total)
Capacity
250 mL 8.5 fl oz JJ03229,0001132 -19-08JUL15-1/1
R134a Refrigerant Charge Capacity Item
Measurement
Specification
Refrigerant Charge
Capacity
0.75—0.85 kg 1.65—1.87 lb JJ03229,0001133 -19-08JUL15-1/1
TM13345X19 (23APR18)
9031-25-1
160GLC Excavator 042318 PN=1191
Tests
Heater and Air Conditioner Operational Checks DF89619,00B5736 -19-19MAR14-1/9
Visual Inspection of Components DF89619,00B5736 -19-19MAR14-2/9
Lines and Hoses Check
Inspect all lines and hoses. LOOK/FEEL: Are all lines and hoses straight and in good condition, not kinked, worn from rubbing, or weather checked? LOOK/FEEL: Are hose and line connections clean and not showing signs of leakage, such as dirt, oil, or refrigerant dye?
YES: Go to next check.
LOOK/FEEL: Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to prevent damage to hoses or lines?
NO: Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that will require replacement. DF89619,00B5736 -19-19MAR14-3/9
Air Conditioner Compressor Check
Inspect air conditioner compressor. LOOK/FEEL: Is belt in good condition, not frayed, worn, or glazed? LOOK/FEEL: Is belt properly tensioned? LOOK/FEEL: Is belt tensioner in good condition, not worn or damaged? LOOK/FEEL: Is compressor pulley in good condition and properly aligned with belt drive pulley on engine? LOOK/FEEL: Are compressor mounting brackets in good condition, and is mounting hardware properly tightened?
YES: Go to next check.
LOOK/FEEL: Are electrical connections to compressor clean and tight? Is wiring in good condition?
NO: Repair or replace components as necessary. DF89619,00B5736 -19-19MAR14-4/9
Condenser Check
Inspect condenser core. LOOK/FEEL: Is core free of dirt and debris? LOOK/FEEL: Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye? YES: Go to next check. LOOK/FEEL: Are fins of core straight, not bent or damaged?
NO: Clean and straighten fins if necessary. Repair or replace components as necessary. DF89619,00B5736 -19-19MAR14-5/9
Engine Fan Check
Inspect engine fan. LOOK/FEEL: Are fan blades in good condition, not worn, bent, broken, or missing?
YES: Go to next check.
LOOK/FEEL: Is fan securely installed?
NO: Repair or replace components as necessary. Continued on next page
TM13345X19 (23APR18)
9031-25-2
DF89619,00B5736 -19-19MAR14-6/9
160GLC Excavator 042318 PN=1192
Tests Heater/Evaporator Core Check
Inspect heater/evaporator core. LOOK/FEEL: Is core free of dirt and debris? LOOK/FEEL: Is core not showing signs of leakage, such as dirt, oil, or refrigerant dye? LOOK/FEEL: Are fins of core straight, not bent or damaged?
YES: Go to next check.
LOOK/FEEL: Is condensation drain hose attached and in good condition; not kinked, damaged, or clogged?
NO: Clean and straighten fins if necessary. Repair or replace components as necessary. DF89619,00B5736 -19-19MAR14-7/9
Cab Air Filter Check
Inspect cab air filter.
YES: Go to next check.
LOOK/FEEL: Is cab air filter clean and free of debris?
NO: Replace cab air filter. DF89619,00B5736 -19-19MAR14-8/9
Cab Door and Windows Check
Open and close cab door and windows. Inspect seals. LOOK/FEEL: Are seals present, properly installed, and in good condition?
YES: Checks complete.
LOOK/FEEL: Do door and windows contact seals evenly?
NO: Adjust door and windows if necessary. Repair or replace components as necessary. DF89619,00B5736 -19-19MAR14-9/9
Air Conditioner Compressor Clutch Test 1. Disconnect machine harness (W2) from air conditioner compressor clutch (Y11). See Machine Harness (W2) Component Location. (Group 9015-10.) 2. Connect battery voltage to air conditioner compressor clutch connector.
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 does not engage when connected to machine, check machine harness. See Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
3. Clutch solenoid should engage and a click may be heard. DF89619,00B5737 -19-30SEP14-1/1
R134a Refrigerant Leak Test
NOTE: Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
SPECIFICATIONS Leak Detector Probe Speed
25 mm per second 1 in per second
1. Inspect all lines, fittings, and components for oily or dusty conditions or for traces of refrigerant dye.
CAUTION: Refrigerant is under high pressure and system must be serviced by qualified personnel only. Improper service methods may cause injury. If accidental system discharge occurs, ventilate the work area before resuming work. Avoid breathing in the air conditioner refrigerant and lubricant vapor or mist. Exposure may irritate the eyes, nose, and throat. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. NOTE: When refrigerant leaks from a system, a small amount of oil is carried out with it.
2. Spray a soap and water solution on refrigerant lines and components to cause bubbles to form at source of 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. Specification Leak Detector Probe Speed—Speed........................................................... 25 mm per second 1 in per second
AS79221,000058E -19-06AUG15-1/1
TM13345X19 (23APR18)
9031-25-3
160GLC Excavator 042318 PN=1193
Tests
R134a Refrigerant Hoses and Tubing Inspection
tubing, or fittings and cannot be removed by cleaning, then replace parts.
IMPORTANT: Hoses used for air conditioning systems contain special barriers in its walls to prevent migration of refrigerant gas.
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.
Do not use hydraulic hoses as replacement hoses in the air conditioning system. Only use certified hose meeting SAE J2064 requirements. 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,
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. AS79221,000058F -19-16FEB15-1/1
TM13345X19 (23APR18)
9031-25-4
160GLC Excavator 042318 PN=1194
Tests
Air Conditioner High/Low-Pressure Switch Test
Specification Switch Closes—Low Pressure............................................................................ 177—206 kPa 1.77—2.06 bar 26—29 psi
SPECIFICATIONS Switch Closes—Low Pressure
177—206 kPa 1.77—2.06 bar 26—29 psi
Switch Opens—Low Pressure
177—206 kPa 1.77—2.06 bar 26—29 psi
Switch Opens—High Pressure
2350—2940 kPa 23.5—29.4 bar 341—426 psi
Switch Closes—High Pressure
2350—2940 kPa 23.5—29.4 bar 341—426 psi
between terminals until pressure increases to switch closing (low) pressure specification.
11. Slowly release pressure. Air conditioner high/low-pressure switch must have continuity until pressure decreases to switch opening (low) pressure specification. Specification Switch Opens—Low Pressure............................................................................ 177—206 kPa 1.77—2.06 bar 26—29 psi
ESSENTIAL TOOLS JT02148 Straight Connector SERVICE EQUIPMENT AND TOOLS Multimeter
NOTE: Air conditioner high/low-pressure switch is normally open when removed from machine. When installed, the switch becomes closed due to normal system pressure. 1. Power machine ON, but do not start engine. 2. Turn blower motor speed switch to ON position. 3. Turn temperature control switch to the maximum cooling position. 4. Disconnect harness from air conditioner high/low-pressure switch (B20). Air conditioner compressor clutch (Y11) must disengage (“click”). 5. Connect harness to air conditioner high/low-pressure switch. Air conditioner compressor clutch must engage (“click”). 6. Disconnect harness from air conditioner high/low-pressure switch.
12. Slowly increase pressure. Air conditioner high/low-pressure switch must have continuity between terminals until pressure increases to switch opening (high) pressure specification. Specification Switch Opens—High Pressure........................................................................ 2350—2940 kPa 23.5—29.4 bar 341—426 psi
13. Slowly release pressure. Air conditioner high/low-pressure switch must not have continuity until pressure decreases to switch closing (high) pressure specification. Specification Switch Closes—High Pressure........................................................................ 2350—2940 kPa 23.5—29.4 bar 341—426 psi
NOTE: The air conditioner high/low-pressure switch can also be checked when installed in air conditioning system; however, pressure is slow to increase to test specification.
NOTE: Refrigerant line is equipped with valve at the air conditioner high/low-pressure switch port to prevent system from discharging when switch is removed.
a. Connect an air conditioner gauge set to service fittings at compressor.
7. Remove high/low-pressure switch from refrigerant line.
b. Cover condenser with paper or plastic to stop air flow.
8. Connect harness to air conditioner high/low-pressure switch. Air conditioner compressor clutch must not engage (“click”). 9. Connect air conditioner high/low-pressure switch to regulated air supply or dry nitrogen using JT02148 Straight Connector.
c. Operate air conditioning on maximum cooling. d. Note high side pressure when high-pressure switch opens and then closes. If switch does not operate within specifications, replace air conditioner high/low-pressure switch.
10. Slowly apply pressure. Air conditioner high/low-pressure switch must not have continuity DF89619,00B680D -19-24AUG17-1/1
TM13345X19 (23APR18)
9031-25-5
160GLC Excavator 042318 PN=1195
Tests
Air Conditioner Freeze Control Switch Test SPECIFICATIONS Air Conditioner Freeze Control Switch Resistance (approximate) at 6.0°C (43°F)
4.8 kΩ
Air Conditioner Freeze Control Switch Resistance (approximate) at 1.5°C (35°F)
5.8 kΩ
Specification Air Conditioner Freeze Control Switch—Resistance (approximate) at 6.0°C (43°F).............................................................................................4.8 kΩ
4. Measure resistance of air conditioner freeze control switch at specification.
SERVICE EQUIPMENT AND TOOLS Multimeter
1. Disconnect and remove air conditioner freeze control switch (B41). 2. Connect terminals to multimeter and test for resistance between terminals. 3. Measure resistance of air conditioner freeze control switch at specification.
Specification Air Conditioner Freeze Control Switch—Resistance (approximate) at 1.5°C (35°F).............................................................................................5.8 kΩ
5. Compare resistance readings to specification. If measured resistance is not within specification, replace switch. DF89619,00B680E -19-27SEP17-1/1
TM13345X19 (23APR18)
9031-25-6
160GLC Excavator 042318 PN=1196
Tests
Air Conditioning System Test
NOTE: Follow manufacturer's instructions when operating refrigerant recovery, recycling, and charging station.
SPECIFICATIONS Engine Speed
Fast Idle
Auto-Idle Switch Position
OFF
Power Mode Button Setting
PWR (power) Mode
Auto Fan Reversing (if equipped) Position
OFF
6. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 7. Open both low and high-pressure valves on refrigerant recovery, recycling, and charging station.
SERVICE EQUIPMENT AND TOOLS Thermometer
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.) CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
8. Disconnect engine coolant temperature sensor (B5208). See Engine Harness (W4) Component Location. (Group 9015-10.) 9. Start engine and run at specification. Specification Engine—Speed.......................................................................... Fast Idle Auto-Idle Switch—Position............................................................................... OFF Power Mode Button—Setting.........................................................PWR (power) Mode Auto Fan Reversing (if equipped)—Position.......................................................................... OFF
10. Press the blower motor speed switch to turn the air conditioner ON. See Cab Heater and Air Conditioner. (Operator's Manual.) 11. Turn the temperature control/mode switch to maximum cooling position. 12. Turn blower motor speed switch to high. 13. Open cab door and windows.
4. Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling. (Group 9031-25.) 5. Identify refrigerant type using refrigerant identifier.
14. Run machine for at least 5 minutes. 15. Measure and record air temperature at condenser air inlet and at air ducts in cab. Compare to specifications.
Ambient Air Temperature
Expected Air Duct Temperature
16—18°C 61—64°F
8—12°C 46—54°F
19—21°C 66—70°F
9—13°C 48—55°F
22—24°C 72—76°F
9—13°C 48—55°F
25—26°C 77—79°F
10—14°C 50—57°F
27—29°C 81—85°F
10—14°C 50—57°F
30—32°C 86—90°F
12—16°C 54—61°F
33—35°C 92—95°F
14—18°C 57—64°F
36—38°C 97—101°F
17—21°C 63—70°F
39—40°C 103—104°F
19—23°C 66—73°F
41—43°C 106—110°F
22—26°C 72—79°F Continued on next page
TM13345X19 (23APR18)
9031-25-7
DF89619,00B6810 -19-25OCT17-1/2
160GLC Excavator 042318 PN=1197
Tests 16. Observe low side pressure and high side pressure on gauges.
17. Compare pressures to specifications shown.
Ambient Air Temperature
Low Side Pressure
High Side Pressure
16—18°C 61—64°F
138—201 kPa 1.38—2.01 bar 20—29 psi
649—951 kPa 6.49—9.51 bar 94—138 psi
19—21°C 66—70°F
102—150 kPa 1.02—1.50 bar 15—22 psi
782—1147 kPa 7.82—11.47 bar 113—166 psi
22—24°C 72—76°F
100—146 kPa 1.00—1.46 bar 15—21 psi
867—1270 kPa 8.67—12.70 bar 126—184 psi
25—26°C 77—79°F
85—125 kPa 0.85—1.25 bar 12—18 psi
972—1426 kPa 9.72—14.26 bar 141—207 psi
27—29°C 81—85°F
69—102 kPa 0.69—1.02 bar 10—15 psi
1105—1619 kPa 11.05—16.19 bar 160—235 psi
30—32°C 86—90°F
77—114 kPa 0.77—1.14 bar 11—17 psi
1256—1841 kPa 12.56—18.41 bar 182—267 psi
33—35°C 92—95°F
91—133 kPa 0.91—1.33 bar 13—19 psi
1377—2017 kPa 13.77—20.17 bar 200—293 psi
36—38°C 97—101°F
110—160 kPa 1.10—1.60 bar 16—23 psi
1527—2237 kPa 15.27—23.37 bar 221—324 psi
39—40°C 103—104°F
126—185 kPa 1.26—1.85 bar 18—27 psi
1672—2450 kPa 16.72—24.50 bar 243—355 psi
41—43°C 106—110°F
143—210 kPa 1.43—2.10 bar 21—30 psi
1819—2666 kPa 18.19—26.66 bar 264—387 psi
18. If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart. (Group 9031-25.) DF89619,00B6810 -19-25OCT17-2/2
TM13345X19 (23APR18)
9031-25-8
160GLC Excavator 042318 PN=1198
Tests
Operating Pressure Diagnostic Chart Condition
Low Side kPa High Side kPa (bar) (psi) (bar) (psi)
Sight Glass
Suction Line
ReceiverDryer
Liquid Line
Discharge Line
Discharge Air
Lack of Refrigerant
Very Low
Very Low
Clear
Slightly Cool
Slightly Warm
Loss of Refrigerant
Low
Low
Bubbles
Cool
Warm to Hot
Warm
Warm to Hot
Slightly Cool
High Side Restriction
Low
Low
Clear
Cool
Cool, Sweating, or Frosting
Cool, Sweating, or Frosting
Hot to Point of Restriction
Slightly Cool
Warm
Warm
Hot
Slightly Cool
Slightly Warm Slightly Warm
Warm
Expansion Valve Closed
Low
Low
Clear
Cold, Sweating, or Frosting Heavily at Valve Outlet
Loose Belt or Compressor Malfunction
High
Low
Clear
Cool
Warm
Warm
Warm
Slightly Cool
Condenser Malfunction
High
High
Clear to Occasional Bubbles
Slightly Cool to Warm
Hot
Hot
Hot
Warm
Refrigerant Contaminated and Air in System
High
High
Bubbles
Warm to Hot
Warm
Warm
Hot
Warm
Warm
Warm
Hot
Slightly Cool
Expansion Valve Open
High
High
Clear
Cold, Sweating, or Frosting Heavily
Plugged Condenser, Overcharge of Refrigerant
Normal
High
Clear
Cool
Warm
Warm
Hot
Slightly Cool
Moisture in System
Normal (may drop)
Normal (may drop)
Clear
Cool
Warm
Warm
Hot
Cool to Warm
Heater Valve Stuck Open
Normal
Normal
Clear
Cool
Warm
Warm
Hot
Warm
Lack of Refrigerant and Air in System
Normal (no drop)
Normal
Occasional Bubbles
Warm to Hot
Warm
Warm
Warm
Slightly Cool
AS79221,0000594 -19-16FEB15-1/1
TM13345X19 (23APR18)
9031-25-9
160GLC Excavator 042318 PN=1199
Tests
TM13345X19 (23APR18)
9031-25-10
160GLC Excavator 042318 PN=1200
Contents
Section 9900 Dealer Fabricated Tools
Page
Group 99—Dealer Fabricated Tools DFT1218 Split Flange Hose Cap............... 9900-99-1
TM13345X19 (23APR18)
9900-1
160GLC Excavator 042318 PN=1
Contents
TM13345X19 (23APR18)
9900-2
160GLC Excavator 042318 PN=2
Group 99
Dealer Fabricated Tools
T142036 —UN—10MAY01
DFT1218 Split Flange Hose Cap
Split Flange Hose Cap
Split Flange Hose Cap is used with split clamp halves to close 1 in. split flange.
Material required is 9.5 mm (3/8 in.) steel plate. MM16284,0000FA9 -19-03DEC14-1/1
TM13345X19 (23APR18)
9900-99-1
160GLC Excavator 042318 PN=1203
Dealer Fabricated Tools
TM13345X19 (23APR18)
9900-99-2
160GLC Excavator 042318 PN=1204
Index Page Page
A Aftertreatment inlet nox sensor Theory of operation...................................... 9015-15-64 Aftertreatment outlet nox sensor Theory of operation...................................... 9015-15-64 Air conditioner Component location ..................................... 9031-15-10 Freeze control switch test .............................. 9031-25-6 Operating pressure diagnostic chart ............................................................. 9031-25-9 Operational checks ........................................ 9031-25-2 Air conditioner compressor clutch Test ................................................................ 9031-25-3 Air conditioner controller (ACF) diagnostics trouble codes Diagnostic trouble codes air conditioner controller (ACF)............................................ 9001-50-1 Air conditioning Binary pressure switch test ............................ 9031-25-5 Hoses and tubing inspection.......................... 9031-25-4 R134a oil charge capacity.............................. 9031-25-1 R134a refrigerant charge capacity................. 9031-25-1 R134a system test ......................................... 9031-25-7 Refrigerant cautions and proper handling........................................................ 9031-25-1 Refrigerant charge capacity ........................... 9031-25-1 Refrigerant leak test....................................... 9031-25-3 System cycle of operation.............................. 9031-05-1 Alarm setting Setting alarm................................................ 9015-16-13 Alternator Test .............................................................. 9015-20-20 Alternator fuse Check........................................................... 9015-20-24 Anticavitation valve Operation ..................................................... 9025-05-65 Arm 1 flow rate circuit Operation ..................................................... 9025-05-95 Arm 1 flow rate pilot valve Operation ..................................................... 9025-05-20 Arm 2 flow rate control valve circuit Operation ..................................................... 9025-05-99 Arm cylinder Drift test........................................................ 9025-25-49 Operation ................................................... 9025-05-143 Arm reduced leakage valve Operation ..................................................... 9025-05-92 Arm regenerative Valve operation ............................................ 9025-05-83 Arm regenerative solenoid valve Test and adjustment..................................... 9025-25-14 Attachment Control circuit theory of operation .............. 9015-15-116 Attachment harness (W17) Component location ................................... 9015-10-210 Wiring diagram........................................... 9015-10-213
Attachment interface harness Wiring diagram........................................... 9015-10-223 Attachment Interface Harness (W25) Component location ................................... 9015-10-222 Attachments Adding safely ............................................... 9000-01-13 Operating safely........................................... 9000-01-13 Auto-acceleration System operation ......................................... 9010-05-18 Auto-idle circuit Operational check ........................................ 9005-10-25 Auto-idle control Operation ..................................................... 9010-05-18 Auto-warming up control Operation ..................................................... 9010-05-18 Auxiliary Control circuit theory of operation .............. 9015-15-116 System operation ....................................... 9025-05-145 Auxiliary 3-button cancel switch harness (W22) Component location ................................... 9015-10-218 Wiring diagram........................................... 9015-10-219 Auxiliary attachment Schematic .................................................... 9025-15-55 Auxiliary flow combiner valve Operation ..................................................... 9025-05-69 Auxiliary flow rate control valve circuit Operation ................................................... 9025-05-112 Auxiliary function lever (AFL) harness (W75) Component location ................................... 9015-10-294 Wiring diagram........................................... 9015-10-297 Auxiliary function lever (AFL) solenoid harness (W76) Component location ................................... 9015-10-301 Wiring diagram........................................... 9015-10-304 Auxiliary high flow line kit Operation ................................................... 9025-05-161 Auxiliary pilot control valve Operation ................................................... 9025-05-145 Auxiliary shuttle valve Operation ................................................... 9025-05-160 Auxiliary solenoid harness (W61) Component location ................................... 9015-10-285 Wiring diagram........................................... 9015-10-286 Auxiliary system Line connections .......................................... 9025-15-81 Operation ................................................... 9025-05-145 Avoid static electricity risk when fueling .............................................................. 9000-01-5
B Backhoe pattern Control lever pattern check .......................... 9005-10-29 Backover Accidents ......................................... 9000-01-11 Battery Remove and install ...................................... 9015-20-30 Continued on next page
TM13345X19 (23APR18)
Index-1
160GLC Excavator 042318 PN=1
Index
Page
Page
Battery disconnect indicator light Theory of operation...................................... 9015-15-29 Battery fuse Check........................................................... 9015-20-24 Battery relay Check........................................................... 9015-20-23 Battery voltage Check........................................................... 9015-20-23 Bent track shoe Diagnostic procedure ..................................... 9020-15-2 Boom cylinder Drift test........................................................ 9025-25-49 Operation ................................................... 9025-05-143 Boom down shockless valve Operation ..................................................... 9025-05-20 Boom flow rate control valve circuit Operation ................................................... 9025-05-107 Boom lower meter-in cut valve Operation ..................................................... 9025-05-73 Boom reduced leakage valve Operation ..................................................... 9025-05-92 Boom regenerative valve circuit Operation ..................................................... 9025-05-75 Bucket cylinder Drift test........................................................ 9025-25-49 Operation ................................................... 9025-05-143 Bucket flow rate control valve circuit Operation ................................................... 9025-05-103 Bucket flow rate pilot valve Operation ..................................................... 9025-05-20 Bucket regenerative valve circuit Operation ..................................................... 9025-05-89 Bypass shut-off valve operation ...................................................... 9025-05-69 Bypass valve Return filter, operation................................ 9025-05-144
CAN circuit Test ................................................................ 9015-20-7 Center joint Operation ................................................... 9025-05-128 Charge air cooler outlet temperature sensor Theory of operation...................................... 9015-15-29 Charge capacity R134a oil........................................................ 9031-25-1 Charging Theory of operation........................................ 9015-15-9 Check valve Control valve, identification and operation .................................................... 9025-05-58 Travel motor, operation .............................. 9025-05-130 Chipped link rails Diagnostic procedure ..................................... 9020-15-4 Circuit Lighting, theory of operation ...................... 9015-15-101 Machine controller (BCZ), theory of operation .................................................... 9015-15-95 Pilot shutoff, theory of operation ................ 9015-15-113 Windshield wiper and washer, theory of operation .................................................... 9015-15-97 Circuit relief valve Operation ..................................................... 9025-05-65 Test and adjustment..................................... 9025-25-25 Cleanup procedure General hydraulic oil ...................................... 9025-25-2 Hydraulic component failure .......................... 9025-25-4 Component failure Hydraulic, cleanup procedure ........................ 9025-25-4 Component location 2-Speed harness (W32)............................. 9015-10-226 Attachment harness (W17) ........................ 9015-10-210 Attachment interface harness (W25) ....................................................... 9015-10-222 Auxiliary 3-button cancel switch harness (W22) ....................................................... 9015-10-218 Auxiliary function lever (AFL) harness (W75) ....................................................... 9015-10-294 Auxiliary function lever (AFL) solenoid harness (W76).......................................... 9015-10-301 Auxiliary solenoid harness (W61) .............. 9015-10-285 Cab harness (W1)........................................ 9015-10-79 Cab roof light 1 relay harness (W46) ....................................................... 9015-10-245 Cab roof light 2 relay harness (W47) ....................................................... 9015-10-246 Cab roof light harness (W44) ..................... 9015-10-243 Cab roof light jumper harness (W45) ....................................................... 9015-10-244 Diesel Exhaust Fluid .................................... 9010-05-14 Diesel exhaust fluid (DEF) harness (W54) ....................................................... 9015-10-261 Diesel particulate filter (DPF) harness (W62) ....................................................... 9015-10-288 Engine cooling system ................................... 9010-05-7 Engine fuel system......................................... 9010-05-3
C Cab harness (W1) Component location ..................................... 9015-10-79 Wiring diagram............................................. 9015-10-87 Cab roof light 1 relay harness (W46) Component location ................................... 9015-10-245 Wiring diagram........................................... 9015-10-246 Cab roof light 2 relay harness (W47) Component location ................................... 9015-10-246 Wiring diagram........................................... 9015-10-247 Cab roof light harness (W44) Component location ................................... 9015-10-243 Wiring diagram........................................... 9015-10-244 Cab roof light jumper harness (W45) Component location ................................... 9015-10-244 Wiring diagram........................................... 9015-10-245 Camshaft position sensor Theory of operation...................................... 9015-15-29 CAN bus terminator Check.......................................9015-20-28, 9015-20-29
Continued on next page
TM13345X19 (23APR18)
Index-2
160GLC Excavator 042318 PN=2
Index
Page
Page
Engine harness (W4) ................................. 9015-10-145 Engine interface harness (W5) .................. 9015-10-153 Engine light harness (W58)........................ 9015-10-283 Exhaust aftertreatment harness (W53) ....................................................... 9015-10-253 Exhaust filter parked cleaning switch harness (W9)............................................ 9015-10-195 Fan harness (W57) .................................... 9015-10-277 Front engine harness (W7) ........................ 9015-10-181 Fuel injector harness (W38)....................... 9015-10-229 Glow plug harness (W40) .......................... 9015-10-235 Heated air seat harness (W14) .................. 9015-10-202 Heater and air conditioner harness (W41) ....................................................... 9015-10-239 Heater and air conditioner relay harness (W51) ....................................................... 9015-10-248 Hydraulic system........................................ 9025-15-108 Information ..................................................... 9015-05-1 Machine harness (W2)............................... 9015-10-119 Monitor harness (W3) ................................ 9015-10-140 Multi-function pilot control lever harness (W15) ....................................................... 9015-10-204 Pilot shutoff switch harness (W11)............. 9015-10-197 Pilot shutoff valve harness (W21) .............. 9015-10-217 Premium seat harness (W87) .................... 9015-10-311 Pump harness (W8) ................................... 9015-10-189 Rear cab light harness (W86) .................... 9015-10-309 Rear cab light relay harness (W85) ........... 9015-10-308 Rear cab light switch harness (W84) ....................................................... 9015-10-307 Rear camera harness (W19)...................... 9015-10-215 Reversing fan switch harness (W23) ....................................................... 9015-10-219 Satellite (SAT) harness (W6003) ............... 9015-10-315 Seat heater switch harness (W24)............. 9015-10-220 Service ADVISOR remote (SAR) switch harness (W10).......................................... 9015-10-195 Starter switch harness (W29)..................... 9015-10-225 Travel alarm cancel switch harness (W16) ....................................................... 9015-10-209 Travel alarm harness (W26) ...................... 9015-10-224 Travel system............................................... 9025-15-46 USB harness (W82) ................................... 9015-10-305 USB jumper harness (W83) ....................... 9015-10-305 Compressor clutch Air conditioner, test ........................................ 9031-25-3 Control lever pattern check - backhoe pattern Operational check ........................................ 9005-10-29 Control lever pattern check - excavator pattern Operational check ........................................ 9005-10-28 Control pattern................................................... 9000-01-2 Control pressure flow test Pump............................................................ 9025-25-43 Control valve Arm 2 flow rate, circuit operation ................. 9025-05-99 Auxiliary flow rate, circuit operation ........... 9025-05-112 Boom flow rate, circuit operation................ 9025-05-107
Bucket flow rate, circuit operation .............. 9025-05-103 Check valves identification and operation .................................................... 9025-05-58 Circuit relief and anticavitation valve operation .................................................... 9025-05-65 Line identification, 4-spool ........................... 9025-15-30 Line identification, 5-spool ........................... 9025-15-30 Line identification, front ................................ 9025-15-30 Operation ..................................................... 9025-05-40 Pilot operation .............................................. 9025-05-17 Spool, actuating pilot pressure test.............. 9025-25-10 Control valve lift check valve Operational check ........................................ 9005-10-37 Controller area network (CAN) Circuit test ...................................................... 9015-20-7 Theory of operation........................................ 9015-15-1 Controller version Monitor operation ........................................... 9015-16-5 Coolant pressure sensor Theory of operation...................................... 9015-15-29 Cooling fan motor Component location ................................... 9025-15-113 Cooling system Service safely............................................... 9000-01-14 Counterbalance valve Travel motor, operation .............................. 9025-05-130 Cracked track link Diagnostic procedure ..................................... 9020-15-3 Crankshaft position sensor Theory of operation...................................... 9015-15-29 Crossover relief valve Operation ................................................... 9025-05-116 Swing motor, test and adjustment................ 9025-25-28 Travel motor, operation .............................. 9025-05-130 Travel motor, test and adjustment................ 9025-25-30 Cycle times check Operational check ........................................ 9005-10-43 Cylinder Boom, arm, and bucket, operation............. 9025-05-143 Cylinder drift Boom, arm, and bucket................................ 9025-25-49
D Damper valve Swing motor, operation .............................. 9025-05-119 Diagnostic connection MPDr. ............................................................. 9015-20-6 Service ADVISOR.......................................... 9015-20-2 Diagnostic trouble code check Operational check .......................................... 9005-10-1 Diagnostic trouble codes Information controller (ICZ) ............................ 9001-40-1 MPDr.............................................................. 9015-20-5 Premium seat controller (PSC) ...................... 9001-60-1 Reading, monitor display ............................... 9015-20-1 Reading, Service ADVISOR .......................... 9015-20-3 Service ADVISOR™ ...................................... 9015-20-1 Continued on next page
TM13345X19 (23APR18)
Index-3
160GLC Excavator 042318 PN=3
Index
Page
Page
Diagnostic trouble codes air conditioner controller (ACF) Air conditioner controller (ACF) diagnostic trouble codes................................................ 9001-50-1 Diagnostic trouble codes engine control unit (ECU) Engine control unit (ECU) diagnostic trouble codes................................................ 9001-20-1 Diagnostic trouble codes main controller (MCZ) Main controller (MCZ) diagnostic trouble codes............................................................ 9001-10-1 Diagnostic trouble codes monitor controller (DSZ) Monitor controller (DSZ) diagnostic trouble codes............................................................ 9001-30-1 Diagram fan drive system Fan system diagram ...................................... 9025-05-2 Diesel exhaust fluid (DEF) circuit Theory of operation...................................... 9015-15-64 Diesel exhaust fluid (DEF) harness (W54) Component location ................................... 9015-10-261 Wiring diagram........................................... 9015-10-269 Diesel oxidation catalyst (DOC) circuit Theory of operation...................................... 9015-15-64 Diesel oxidation catalyst (DOC) inlet temperature sensor Theory of operation...................................... 9015-15-64 Diesel oxidation catalyst (DOC) outlet temperature sensor Theory of operation...................................... 9015-15-64 Diesel particulate filter (DPF) circuit Theory of operation...................................... 9015-15-64 Diesel particulate filter (DPF) harness (W62) Component location ................................... 9015-10-288 Diesel particulate filter (DPF) inlet pressure sensor Theory of operation...................................... 9015-15-64 Diesel particulate filter (DPF) outlet pressure sensor Theory of operation...................................... 9015-15-64 Diesel particulate filter (DPF) outlet temperature sensor Theory of operation...................................... 9015-15-64 Dig function drift Operational check ....................9005-10-34, 9005-10-35 Dig regenerative Solenoid valve test and adjustment ............. 9025-25-12 Valve operation ............................................ 9025-05-77 Digital thermometer installation ......................... 9025-25-1 Diode Check........................................................... 9015-20-26 Display and clear trouble codes Operational check .......................................... 9005-10-1 Drift test Upperstructure ............................................. 9025-25-51 Drive gear case, pump 1 and pump 2 Operation ..................................................... 9025-05-30
E E (economy) mode Operational check ........................................ 9005-10-23 Economy mode Operation ..................................................... 9010-05-18 Electrical Component specifications............................ 9015-20-17 Fuse and relay specifications......................... 9015-10-1 Schematic, wiring diagram, and component location information ................... 9015-05-1 Electrical component check............................. 9015-20-21 Electrical diagnostic procedures Key switch check ......................................... 9015-20-21 Electronic injector (cylinder 1) Theory of operation...................................... 9015-15-29 Electronic injector (cylinder 2) Theory of operation...................................... 9015-15-29 Electronic injector (cylinder 3) Theory of operation...................................... 9015-15-29 Electronic injector (cylinder 4) Theory of operation...................................... 9015-15-29 Engine Cold weather starting aid ............................. 9010-05-17 Cooling system, component location......................................................... 9010-05-7 (DEF), component location .......................... 9010-05-14 Identification................................................... 9010-05-1 Theory of operation..................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine control unit (ECU) Theory of operation...................................... 9015-15-29 Engine control unit (ECU) diagnostics trouble codes Diagnostic trouble codes engine control unit (ECU) .................................................... 9001-20-1 Engine coolant loss level sensor Theory of operation...................................... 9015-15-29 Engine coolant service level sensor Theory of operation...................................... 9015-15-29 Engine coolant temperature sensor Theory of operation...................................... 9015-15-29 Engine fuel system Component location ....................................... 9010-05-3 Engine harness (W4) Component location ................................... 9015-10-145 Wiring diagram........................................... 9015-10-148 Engine interface harness (W5) Component location ................................... 9015-10-153 Wiring diagram........................................... 9015-10-161 Engine light harness (W58) Component location ................................... 9015-10-283 Wiring diagram........................................... 9015-10-283 Engine oil pressure sensor Theory of operation...................................... 9015-15-29 Engine speed Specifications............................................... 9010-05-18 Continued on next page
TM13345X19 (23APR18)
Index-4
160GLC Excavator 042318 PN=4
Index
Page
Page
Engine speed control Heater control .............................................. 9010-05-18 System operation ......................................... 9010-05-18 Engine speed dial Operation ..................................................... 9010-05-18 Operational check ........................................ 9005-10-22 Engine speed sensing control circuit Operation ..................................................... 9025-05-38 Excavator pattern Control lever pattern check .......................... 9005-10-28 Excessive oil leakage from carrier rollers Diagnostic procedure ..................................... 9020-15-2 Excessive oil leakage from front idler Diagnostic procedure ..................................... 9020-15-2 Excessive oil leakage from track rollers Diagnostic procedure ..................................... 9020-15-2 Exhaust aftertreatment circuit Theory of operation...................................... 9015-15-64 Exhaust aftertreatment harness (W53) Component location ................................... 9015-10-253 Wiring diagram.....................9015-10-256, 9015-10-290 Exhaust filter...................................................... 9000-01-7 Monitor operation ......................................... 9015-16-13 Exhaust filter delta pressure sensor Theory of operation...................................... 9015-15-64 Exhaust filter parked cleaning switch Theory of operation...................................... 9015-15-29 Exhaust filter parked cleaning switch harness (W9) Component location ................................... 9015-10-195 Wiring diagram........................................... 9015-10-195 Exhaust Filter, Safety Safety, Exhaust Filter ................................... 9000-01-16 Exhaust gas recirculation (EGR) delta pressure sensor Theory of operation...................................... 9015-15-29 Exhaust gas recirculation (EGR) temperature sensor Theory of operation...................................... 9015-15-29 Exhaust gas recirculation (EGR) valve Theory of operation...................................... 9015-15-29 Exhaust manifold pressure sensor Theory of operation...................................... 9015-15-29
Filter Pilot, operation ............................................... 9025-05-5 Return, operation ....................................... 9025-05-144 Fire prevention................................................... 9000-01-5 Flex power controller (FPC) Theory of operation...................................... 9015-15-29 Flow rate control valve Arm 2, circuit operation ................................ 9025-05-99 Auxiliary, circuit operation .......................... 9025-05-112 Boom, circuit operation .............................. 9025-05-107 Bucket, circuit operation............................. 9025-05-103 Flow rate pressure reducing valve Operation ................................................... 9025-05-157 Flow rate select solenoid valve Operation ................................................... 9025-05-156 Flow test Pump........................................9025-25-37, 9025-25-40 Frequent track chain sag adjustment Diagnostic procedure ..................................... 9020-15-2 Front engine harness (W7) Component location ................................... 9015-10-181 Wiring diagram........................................... 9015-10-185 Fuel gauge Operational check .......................................... 9005-10-3 Fuel injector harness (W38) Component location ................................... 9015-10-229 Wiring diagram........................................... 9015-10-231 Fuel rail pressure sensor Theory of operation...................................... 9015-15-29 Fuel temperature sensor Theory of operation...................................... 9015-15-29 Fuel transfer pump Theory of operation...................................... 9015-15-29 Fuse Specification................................................... 9015-10-1
F Fan Fan speed test ............................................. 9025-25-55 Pump flow .................................................... 9025-25-53 Fan drive system Component location ................................... 9025-15-113 Fan operation................................................. 9025-05-2 Fan harness (W57) Component location ................................... 9015-10-277 Wiring diagram........................................... 9015-10-280 Fan reversing switch Operational check ........................................ 9005-10-21
G Gear case Pump 1, pump 2 and drive, operation .................................................... 9025-05-30 Swing reduction, operation ........................ 9025-05-115 Travel operation ............................................. 9020-05-2 General hydraulic oil Cleanup procedure ........................................ 9025-25-2 Glow plug harness (W40) Component location ................................... 9015-10-235 Wiring diagram........................................... 9015-10-238 Glow plug relay Check........................................................... 9015-20-25
H Hazards Avoiding ....................................................... 9000-01-10 Heated air seat harness (W14) Component location ................................... 9015-10-202 Continued on next page
TM13345X19 (23APR18)
Index-5
160GLC Excavator 042318 PN=5
Index
Page
Page
Wiring diagram........................................... 9015-10-203 Heater Component location ..................................... 9031-15-10 Operational checks ........................................ 9031-25-2 Heater and air conditioner Component location ..................................... 9031-15-10 Heater and air conditioner controls check Operational check ........................................ 9005-10-46 Heater and air conditioner harness (W41) Component location ................................... 9015-10-239 Wiring diagram........................................... 9015-10-241 Heater and air conditioner relay harness (W51) Component location ................................... 9015-10-248 Wiring diagram........................................... 9015-10-250 Heater and air conditioning circuit check Operational check ........................................ 9005-10-45 Heater control Disable and enable ...................................... 9015-20-35 High power mode Operation ..................................................... 9010-05-18 High/low-pressure switch Test ................................................................ 9031-25-5 Horn circuit Operational check .......................................... 9005-10-2 Hoses and tubing inspection Air conditioning .............................................. 9031-25-4 Hour meter Operational check .......................................... 9005-10-3 HP (high power) mode Operational check ........................................ 9005-10-24 Hydraulic Component failure cleanup procedure ..................................................... 9025-25-4 Schematic .................................................... 9025-15-89 Hydraulic fan Component location ................................... 9025-15-113 Hydraulic oil General, cleanup procedure .......................... 9025-25-2 Warm-up procedure ....................................... 9025-25-6 Hydraulic oil tank Pressure release procedure........................... 9025-25-5 Hydraulic oil tank pressurization Operational check ........................................ 9005-10-28 Hydraulic pump Regulator minimum flow test........................ 9025-25-33 Regulator operation ..................................... 9025-05-33 Hydraulic system Component location ................................... 9025-15-108 Diagram and operation .................................. 9025-05-1 Line connections ........................................ 9025-15-109
Individual undercarriage component wear Diagnsotic procedure ..................................... 9020-15-5 Information controller (ICZ) Diagnostic trouble codes................................ 9001-40-1 Inlet fuel pressure sensor Theory of operation...................................... 9015-15-29 Intake air sensor Theory of operation...................................... 9015-15-29 Intake air throttle Theory of operation...................................... 9015-15-29 Intake manifold pressure sensor Theory of operation...................................... 9015-15-29 Issued warning record Monitor operation ........................................... 9015-16-5
I Identification Manual ....................................................................... --3 Idle speed up control Operation ..................................................... 9010-05-18
J JT02156A digital pressure and temperature analyzer Installation...................................................... 9025-25-1 JT05800 digital thermometer installation........................................................ 9025-25-1
K Key switch Check........................................................... 9015-20-21 Key switch off, engine off Operational check .......................................... 9005-10-1 Key switch on, engine off Operational check .......................................... 9005-10-4 Key switch on, engine on Operational check ........................................ 9005-10-17 Kit Auxiliary high flow ...................................... 9025-05-161
L Leakage test Swing motor ................................................. 9025-25-46 Travel motor................................................. 9025-25-47 Legend System functional schematic, wiring diagram, and component location ................ 9015-10-5 Lifting objects Special care ................................................. 9000-01-12 Light circuit Operational check ........................................ 9005-10-11 Lighting Circuit theory of operation.......................... 9015-15-101 Line connection Pilot signal manifold to control valve........................................................... 9025-15-42 Travel system............................................... 9025-15-47 Line connections Auxiliary system ........................................... 9025-15-81 Hydraulic system........................................ 9025-15-109 Continued on next page
TM13345X19 (23APR18)
Index-6
160GLC Excavator 042318 PN=6
Index
Page
Page
Line identification Pump 1, pump 2, and pilot pump ................. 9025-15-29 Swing motor ................................................. 9025-15-33 Low flow kit Operation ................................................... 9025-05-177
Monitor harness (W3) Component location ................................... 9015-10-140 Wiring diagram........................................... 9015-10-142 Monitor setting Monitor operation ......................................... 9015-16-11 Monitor start up Operational check .......................................... 9005-10-5 Monitor warning alarm Check........................................................... 9015-20-27 Monitor, gauges and battery relay Operational check .......................................... 9005-10-6 Monitoring Monitor operation ........................................... 9015-16-2 Motor Swing crossover relief valve test and adjustment.................................................. 9025-25-28 Swing, leakage test...................................... 9025-25-46 Swing, operation ........................................ 9025-05-116 Travel, leakage test...................................... 9025-25-47 Travel, operation ........................................ 9025-05-130 Travel, speed circuit operation................... 9025-05-139 MPDr Overview ........................................................ 9015-20-5 MPDr. Connection procedure.................................... 9015-20-6 Multi-function pilot control lever harness (W15) Component location ................................... 9015-10-204 Wiring diagram........................................... 9015-10-207
M Machine controller (BCZ) circuit Theory of operation...................................... 9015-15-95 Machine harness (W2) Component location ................................... 9015-10-119 Wiring diagram........................................... 9015-10-123 Machine modifications Avoid .............................................................. 9000-01-2 Machine movement Unintended..................................................... 9000-01-9 Machine setting Monitor operation ........................................... 9015-16-7 Machine tip over Avoiding ....................................................... 9000-01-12 Machine,inspect................................................. 9000-01-3 Main controller Remove and install ...................................... 9015-20-34 Main controller (MCZ) Theory of operation...................................... 9015-15-79 Main controller (MCZ) diagnostics trouble codes Diagnostic trouble codes main controller (MCZ) ........................................................... 9001-10-1 Main relief Circuit operation........................................... 9025-05-61 Main relief valve Test and adjustment..................................... 9025-25-22 Main Relief Valve Circuit Operation .......................................... 9025-05-61 Make-up check valve Operation ................................................... 9025-05-116 Manifold Pilot signal, operation................................... 9025-05-20 Manifold air temperature sensor Theory of operation...................................... 9015-15-29 Manual Identification............................................................... --3 Manual boom lower screw Operation ..................................................... 9025-05-92 Monitor Reading diagnostic trouble codes.................. 9015-20-1 Monitor and gauge circuit Operational check ........................................ 9005-10-18 Monitor controller Remove and install ...................................... 9015-20-35 Monitor controller (DSZ) circuit Theory of operation...................................... 9015-15-19 Monitor controller (DSZ) diagnostics trouble codes Diagnostic trouble codes monitor controller (DSZ)............................................ 9001-30-1
N Noisy or loose track chain Diagnostic procedure ..................................... 9020-15-1
O Oil charge capacity Air conditioning .............................................. 9031-25-1 Oil tank, hydraulic Pressure release procedure........................... 9025-25-5 Operating pressure diagnostic chart Air conditioner ................................................ 9031-25-9 Operation Auxiliary high flow line kit ........................... 9025-05-161 Auxiliary pilot control valve......................... 9025-05-145 Auxiliary shuttle valve ................................ 9025-05-160 Auxiliary system ......................................... 9025-05-145 Flow rate select solenoid valve .................. 9025-05-156 Low flow kit ................................................ 9025-05-177 Monitor operation ........................................... 9015-16-6 Secondary auxiliary relief valve ................. 9025-05-158 Secondary pilot relief pressure control solenoid valve .......................................... 9025-05-157 Selector valve ............................................ 9025-05-159 Selector valve solenoid valve..................... 9025-05-159 Two pump combined flow kit...................... 9025-05-169 Continued on next page
TM13345X19 (23APR18)
Index-7
160GLC Excavator 042318 PN=7
Index
Page
Page
Two way solenoid kit .................................. 9025-05-165 Operation qualification....................................... 9000-01-1 Operational check Auto-idle circuit ............................................ 9005-10-25 Control lever pattern check - backhoe pattern ........................................................ 9005-10-29 Control lever pattern check - excavator pattern ........................................................ 9005-10-28 Control valve lift check valve........................ 9005-10-37 Cycle times check ........................................ 9005-10-43 Diagnostic trouble code check ....................... 9005-10-1 Dig function drift .......................9005-10-34, 9005-10-35 Display and clear trouble codes..................... 9005-10-1 E (economy) mode....................................... 9005-10-23 Engine speed dial ........................................ 9005-10-22 Fan reversing switch .................................... 9005-10-21 Fuel gauge ..................................................... 9005-10-3 Heater and air conditioner controls check.......................................................... 9005-10-46 Heater and air conditioning circuit check.......................................................... 9005-10-45 Horn circuit..................................................... 9005-10-2 Hour meter ..................................................... 9005-10-3 HP (high power) mode ................................. 9005-10-24 Hydraulic oil tank pressurization .................. 9005-10-28 Key switch off, engine off ............................... 9005-10-1 Key switch on, engine off ............................... 9005-10-4 Key switch on, engine on ............................. 9005-10-17 Light circuit................................................... 9005-10-11 Monitor and gauge circuit............................. 9005-10-18 Monitor start up .............................................. 9005-10-5 Monitor, gauges and battery relay.................. 9005-10-6 Pilot shutoff circuit........................................ 9005-10-19 PWR (standard) mode ................................. 9005-10-23 Rear cab light............................................... 9005-10-12 Rear camera .................................................. 9005-10-8 Swing dynamic braking ................................ 9005-10-30 Swing park brake and circuit drift................. 9005-10-32 Swing power check ...................................... 9005-10-33 Swing priority circuit ..................................... 9005-10-36 Travel alarm ................................................. 9005-10-26 Travel alarm cancel switch circuit ................ 9005-10-27 Travel lever and pedal ................................. 9005-10-10 Travel speed selection ................................. 9005-10-38 Travel system maneuverability .................... 9005-10-42 Travel system tracking ................................. 9005-10-39 Travel system tracking while operating a dig function................................................. 9005-10-41 Windshield washer circuit ............................ 9005-10-17 Windshield washer control ........................... 9005-10-14 Windshield wiper circuit ............................... 9005-10-15 Windshield wiper controls ............................ 9005-10-13
Park brake valve and travel motor Operation ................................................... 9025-05-130 Parts, moving Stay clear ....................................................... 9000-01-3 Pattern Selector Valve Line Connection Pilot Control Lever.................................... 9025-15-46 Pilot control valve Operation ....................................................... 9025-05-9 Travel operation ........................................... 9025-05-12 Pilot control valve-to-pilot signal mainifold component location Excavator pattern......................................... 9025-15-35 Pilot control valve-to-pilot signal mainifold component location Backhoe pattern........................................... 9025-15-39 Pilot filter Operation ....................................................... 9025-05-5 Pilot pressure regulating valve Operation ....................................................... 9025-05-5 Test and adjustment....................................... 9025-25-8 Pilot pump Operation ....................................................... 9025-05-5 Pilot shutoff Circuit theory of operation.......................... 9015-15-113 Pilot shutoff circuit Operational check ........................................ 9005-10-19 Pilot shutoff lever ............................................... 9000-01-9 Pilot shutoff solenoid valve Operation ....................................................... 9025-05-6 Pilot shutoff switch harness (W11) Component location ................................... 9015-10-197 Wiring diagram........................................... 9015-10-199 Pilot shutoff valve harness (W21) Component location ................................... 9015-10-217 Wiring diagram........................................... 9015-10-218 Pilot signal manifold Operation ..................................................... 9025-05-20 Port identification ......................................... 9025-05-20 Pilot signal manifold-to-control valve Line connection............................................ 9025-15-42 Pilot signal manifold-to-pilot control valve Line identification backhoe pattern .............. 9025-15-39 Line identification excavator pattern ........................................................ 9025-15-35 Pilot system Operation ....................................................... 9025-05-4 Pins, metal Drive safely .................................................. 9000-01-15 "Popping" of track Diagnostic procedure ..................................... 9020-15-3 Power dig Valve test and adjustment............................ 9025-25-22 Power dig/travel speed solenoid valve Test and adjustment..................................... 9025-25-16 Premium seat controller (PSC) Diagnostic trouble codes................................ 9001-60-1
P Park brake Swing motor, release circuit operation .................................................. 9025-05-127
Continued on next page
TM13345X19 (23APR18)
Index-8
160GLC Excavator 042318 PN=8
Index
Page
Page
Premium seat harness (W87) Component location ................................... 9015-10-311 Wiring diagram........................................... 9015-10-313 Pressure reducing valve operation Flow rate .................................................... 9025-05-157 Pressure regulating vavle Operation ....................................................... 9025-05-5 Pressure release procedure Hydraulic oil tank............................................ 9025-25-5 Pump Control pressure flow test ............................ 9025-25-43 Fan, flow ...................................................... 9025-25-53 Flow test...................................9025-25-37, 9025-25-40 Hydraulic, regulator minimum flow test ............................................................. 9025-25-33 Hydraulic, regulator operation...................... 9025-05-33 Pilot, operation ............................................... 9025-05-5 Regulator test, maximum flow...................... 9025-25-35 Pump 1, pump 2 and drive gear case Operation ..................................................... 9025-05-30 Pump 1, pump 2, and pilot pump Line identification ......................................... 9025-15-29 Pump control pilot pressure Signal test .................................................... 9025-25-20 Pump flow rate pilot valve Operation ..................................................... 9025-05-20 Pump harness (W8) Component location ................................... 9015-10-189 Wiring diagram........................................... 9015-10-193 Pump regulator Test maximum flow ...................................... 9025-25-35 PWR (standard) mode Operational check ........................................ 9005-10-23
Rear camera harness (W19) Component location ................................... 9015-10-215 Wiring diagram........................................... 9015-10-216 Rear cover Remove and install ...................................... 9015-20-32 Recognize Safety, information ......................................... 9000-01-1 Refrigerant cautions and proper handling Air conditioning .............................................. 9031-25-1 Refrigerant leak Test ................................................................ 9031-25-3 Refueling, avoid static electricity risk................. 9000-01-5 Regulator Hydraulic pump, operation ........................... 9025-05-33 Minimum flow test, hydraulic pump.............. 9025-25-33 Pump, test maximum flow............................ 9025-25-35 Relay Battery, check .............................................. 9015-20-23 Specification................................................... 9015-10-1 Relay check ..................................................... 9015-20-21 Relief valve Circuit, test and adjustment ......................... 9025-25-25 Return filter Operation ................................................... 9025-05-144 Reversing fan solenoid Theory of operation...................................... 9015-15-29 Reversing fan switch Theory of operation...................................... 9015-15-29 Reversing fan switch harness (W23) Component location ................................... 9015-10-219 Wiring diagram........................................... 9015-10-220 Riding machine................................................ 9000-01-10 ROPS Inspect ......................................................... 9000-01-11 Maintain ....................................................... 9000-01-11
R R134a air conditioning System test .................................................... 9031-25-7 R134a oil charge capacity Air conditioning .............................................. 9031-25-1 R134a refrigerant charge capacity Air conditioning .............................................. 9031-25-1 Reading diagnostic trouble codes Service ADVISOR.......................................... 9015-20-3 Rear cab light Operational check ........................................ 9005-10-12 Rear cab light harness (W86) Component location ................................... 9015-10-309 Wiring diagram........................................... 9015-10-310 Rear cab light relay harness (W85) Component location ................................... 9015-10-308 Wiring diagram........................................... 9015-10-309 Rear cab light switch harness (W84) Component location ................................... 9015-10-307 Wiring diagram........................................... 9015-10-308 Rear camera Operational check .......................................... 9005-10-8
S Safety Add cab guarding for special uses............................................9000-01-1, 9000-01-2 Clean debris from machine ............................ 9000-01-8 Fire................................................................. 9000-01-6 Operator's seat .............................................. 9000-01-8 Protective equipment ..................................... 9000-01-2 Safety hazards Travel ........................................................... 9000-01-13 Safety, high-pressure fluids Avoid high-pressure fluids.............................. 9000-01-3 Safety, information Recognize ...................................................... 9000-01-1 Satellite (SAT) harness (W6003) Component location ................................... 9015-10-315 Wiring diagram........................................... 9015-10-315 Schematic Auxiliary attachment..................................... 9025-15-55 Electrical ...................................................... 9015-10-13 Hydraulic ...................................................... 9025-15-89 Continued on next page
TM13345X19 (23APR18)
Index-9
160GLC Excavator 042318 PN=9
Index
Page
Page
Information ..................................................... 9015-05-1 Screw, manual boom lower Operation ..................................................... 9025-05-92 Seat heater switch harness Wiring diagram........................................... 9015-10-221 Seat heater switch harness (W24) Component location ................................... 9015-10-220 Secondary auxiliary relief valve Operation ................................................... 9025-05-158 Secondary pilot relief Pressure control valve operation ............... 9025-05-158 Secondary pilot relief pressure control solenoid valve Operation ................................................... 9025-05-157 Secondary pilot relief pressure control valve Operation ................................................... 9025-05-158 Selective catalytic reducition (SCR) circuit Theory of operation...................................... 9015-15-64 Selective catalytic reduction (SCR) inlet nox sensor Theory of operation...................................... 9015-15-64 Selective catalytic reduction (SCR) inlet temperature sensor Theory of operation...................................... 9015-15-64 Selective catalytic reduction (SCR) outlet nox sensor Theory of operation...................................... 9015-15-64 Selective catalytic reduction (SCR) outlet temperature sensor Theory of operation...................................... 9015-15-64 Selector valve Operation ................................................... 9025-05-159 Selector valve solenoid valve Operation ................................................... 9025-05-159 Service ADVISOR Connection procedure.................................... 9015-20-2 Reading diagnostic trouble codes.................. 9015-20-3 Service ADVISOR™ Overview ........................................................ 9015-20-1 Service ADVISOR remote (SAR) switch Theory of operation...................................... 9015-15-29 Service ADVISOR remote (SAR) switch harness (W10) Component location ................................... 9015-10-195 Wiring diagram........................................... 9015-10-196 Service menu Monitor operation ........................................... 9015-16-1 Shuttle valve Pilot signal manifold operation ..................... 9025-05-20 Single pedal travel Operation ..................................................... 9025-05-14 Slow speed sensing Operation ..................................................... 9025-05-38 Solenoid Pilot shutoff valve, operation.......................... 9025-05-6 Solenoid valve Arm regenerative, test and adjustment.................................................. 9025-25-14
Dig regenerative, test and adjustment ........................................................... 9025-25-12 Engine speed sensing control circuit.......................................................... 9025-05-38 Power dig/travel speed, test and adjustment.................................................. 9025-25-16 Torque control, test ...................................... 9025-25-18 Specification Fuse ............................................................... 9015-10-1 Relay.............................................................. 9015-10-1 Specifications Electrical components.................................. 9015-20-17 Spool Valve, actuating pilot pressure test .............. 9025-25-10 Standard mode Operation ..................................................... 9010-05-18 Starter switch harness (W29) Component location ................................... 9015-10-225 Wiring diagram........................................... 9015-10-226 Starting aid Cold weather................................................ 9010-05-17 Starting and charging circuit Theory of operation........................................ 9015-15-9 Steps Use correctly Handholds .................................................. 9000-01-8 Suction control valve Theory of operation...................................... 9015-15-29 Swing bearing Measure wear ................................................ 9020-15-6 Swing dynamic braking Operational check ........................................ 9005-10-30 Swing motor Crossover relief valve test and adjustment.................................................. 9025-25-28 Damper valve operation............................. 9025-05-119 Leakage test ................................................ 9025-25-46 Line identification ......................................... 9025-15-33 Operation ................................................... 9025-05-116 Swing motor park brake release circuit Operation ................................................... 9025-05-127 Swing park brake and circuit drift Operational check ........................................ 9005-10-32 Swing park brake release pilot valve Operation ..................................................... 9025-05-20 Swing power check Operational check ........................................ 9005-10-33 Swing priority circuit Operational check ........................................ 9005-10-36 Swing reduction gear case Operation ................................................... 9025-05-115 Switch Binary pressure, test ...................................... 9031-25-5 System cycle of operation Air conditioning .............................................. 9031-05-1 System functional schematic ........................... 9015-10-13 Information ..................................................... 9015-05-1
Continued on next page
TM13345X19 (23APR18)
Index-10
160GLC Excavator 042318 PN=10
Index
Page
Page
System functional schematic, wiring diagram, and component location legend .............................................................. 9015-10-5
Exhaust manifold pressure sensor............... 9015-15-29 Flex power controller (FPC) ......................... 9015-15-29 Fuel rail pressure sensor ............................. 9015-15-29 Fuel temperature sensor.............................. 9015-15-29 Fuel transfer pump....................................... 9015-15-29 Inlet fuel pressure sensor............................. 9015-15-29 Intake air sensor .......................................... 9015-15-29 Intake air throttle .......................................... 9015-15-29 Intake manifold pressure sensor.................. 9015-15-29 Lighting circuit ............................................ 9015-15-101 Machine controller (BCZ) circuit................... 9015-15-95 Main controller (MCZ) .................................. 9015-15-79 Manifold air temperature sensor .................. 9015-15-29 Monitor controller (DSZ) cirucit .................... 9015-15-19 Pilot shutoff circuit...................................... 9015-15-113 Reversing fan solenoid ................................ 9015-15-29 Reversing fan switch.................................... 9015-15-29 Selective catalytic reduction (SCR) circuit.......................................................... 9015-15-64 Selective catalytic reduction (SCR) inlet nox sensor.................................................. 9015-15-64 Selective catalytic reduction (SCR) inlet temperature sensor .................................... 9015-15-64 Selective catalytic reduction (SCR) outlet nox sensor.................................................. 9015-15-64 Selective catalytic reduction (SCR) outlet temperature sensor .................................... 9015-15-64 Service ADVISOR remote (SAR) switch ......................................................... 9015-15-29 Starting and charging circuit .......................... 9015-15-9 Suction control valve.................................... 9015-15-29 Travel alarm circuit..................................... 9015-15-110 Turbocharger actuator ................................. 9015-15-29 Turbocharger speed sensor......................... 9015-15-29 Variable speed fan solenoid......................... 9015-15-29 Water in fuel sensor ..................................... 9015-15-29 Windshield wiper and washer circuit.......................................................... 9015-15-97 Thermometer installation, digital........................ 9025-25-1 Tight track chain Diagnostic procedure ..................................... 9020-15-1 Tip over Avoiding ....................................................... 9000-01-12 Torque control solenoid valve Control circuit operation ............................... 9025-05-38 Test and adjustment..................................... 9025-25-18 Track Adjuster and recoil spring operation ............................................................... 9020-05-1 Track adjuster and recoil spring Operation ....................................................... 9020-05-1 Travel Single pedal, operation ................................ 9025-05-14 Travel alarm Check........................................................... 9015-20-27 Operational check ........................................ 9005-10-26 Travel alarm cancel switch circuit Operational check ........................................ 9005-10-27
T Test Alternator ..................................................... 9015-20-20 Binary pressure switch................................... 9031-25-5 Theory of operation Aftertreatment inlet nox sensor .................... 9015-15-64 Aftertreatment outlet nox sensor.................. 9015-15-64 Battery disconnect indicator light ................. 9015-15-29 Camshaft position sensor ............................ 9015-15-29 Charge air cooler outlet temperature sensor ........................................................ 9015-15-29 Controller area network (CAN)....................... 9015-15-1 Coolant pressure sensor.............................. 9015-15-29 Crankshaft position sensor .......................... 9015-15-29 Diesel exhaust fluid (DEF) circuit................. 9015-15-64 Diesel oxidation catalyst (DOC) circuit.......................................................... 9015-15-64 Diesel oxidation catalyst (DOC) inlet temperature sensor .................................... 9015-15-64 Diesel oxidation catalyst (DOC) outlet temperature sensor .................................... 9015-15-64 Diesel particulate filter (DPF) circuit.......................................................... 9015-15-64 Diesel particulate filter (DPF) inlet pressure sensor ......................................... 9015-15-64 Diesel particulate filter (DPF) outlet pressure sensor ......................................... 9015-15-64 Diesel particulate filter (DPF) outlet temperature sensor .................................... 9015-15-64 Electronic injector (cylinder 1)...................... 9015-15-29 Electronic injector (cylinder 2)...................... 9015-15-29 Electronic injector (cylinder 3)...................... 9015-15-29 Electronic injector (cylinder 4)...................... 9015-15-29 Engine......................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine control unit (ECU) ............................ 9015-15-29 Engine coolant loss level sensor.................. 9015-15-29 Engine coolant service level sensor ........................................................ 9015-15-29 Engine coolant temperature sensor ........................................................ 9015-15-29 Engine oil pressure sensor .......................... 9015-15-29 Exhaust aftertreatment circuit ...................... 9015-15-64 Exhaust filter delta pressure sensor ........................................................ 9015-15-64 Exhaust filter parked cleaning switch ......................................................... 9015-15-29 Exhaust gas recirculation (EGR) delta pressure sensor ......................................... 9015-15-29 Exhaust gas recirculation (EGR) temperature sensor .................................... 9015-15-29 Exhaust gas recirculation (EGR) valve........................................................... 9015-15-29
Continued on next page
TM13345X19 (23APR18)
Index-11
160GLC Excavator 042318 PN=11
Index
Page
Page
Travel alarm cancel switch harness (W16) Component location ................................... 9015-10-209 Wiring diagram........................................... 9015-10-209 Travel alarm circuit Theory of operation.................................... 9015-15-110 Travel alarm harness (W26) Component location ................................... 9015-10-224 Wiring diagram........................................... 9015-10-225 Travel flow combiner pilot valve Operation ..................................................... 9025-05-20 Travel flow combiner valve Operation ..................................................... 9025-05-66 Travel gear case Operation ....................................................... 9020-05-2 Travel high power mode Operation ..................................................... 9010-05-18 Travel lever and pedal Operational check ........................................ 9005-10-10 Travel motor Check valve operation ............................... 9025-05-130 Counterbalance valve operation ................ 9025-05-130 Crossover relief valve operation ................ 9025-05-130 Crossover relief valve test and adjustment.................................................. 9025-25-30 Leakage test ................................................ 9025-25-47 Travel motor and park brake valve Operation ................................................... 9025-05-130 Travel motor speed circuit Operation ................................................... 9025-05-139 Travel pilot control valve Operation ..................................................... 9025-05-12 Travel speed selection Operational check ........................................ 9005-10-38 Travel system Component location ..................................... 9025-15-46 Line connection............................................ 9025-15-47 Travel system maneuverability Operational check ........................................ 9005-10-42 Travel system tracking Operational check ........................................ 9005-10-39 Travel system tracking while operating a dig function Operational check ........................................ 9005-10-41 Travel torque-up control Operation ..................................................... 9025-05-38 Troubleshooting Monitor operation ........................................... 9015-16-1 Turbocharger actuator Theory of operation...................................... 9015-15-29 Turbocharger speed sensor Theory of operation...................................... 9015-15-29 Two pump combined flow kit Operation ................................................... 9025-05-169 Two way solenoid kit Operation ................................................... 9025-05-165
U Upperstructure Drift Test....................................................... 9025-25-51 USB harness (W82) Component location ................................... 9015-10-305 Wiring diagram........................................... 9015-10-305 USB jumper harness (W83) Component location ................................... 9015-10-305 Wiring diagram........................................... 9015-10-306
V Valve Arm 1 flow rate pilot, operation .................... 9025-05-20 Arm 1 flow rate, operation............................ 9025-05-95 Arm 2 flow rate control, circuit operation .................................................... 9025-05-99 Arm reduced leakage, operation.................. 9025-05-92 Arm regenerative operation ......................... 9025-05-83 Arm regenerative solenoid test and adjustment.................................................. 9025-25-14 Auxiliary flow combiner, operation ............... 9025-05-69 Auxiliary flow rate control, circuit operation .................................................. 9025-05-112 Boom down shockless, operation ................ 9025-05-20 Boom flow rate control, circuit operation .................................................. 9025-05-107 Boom lower meter-in cut, operation ............................................................. 9025-05-73 Boom reduced leakage, operation ............... 9025-05-92 Boom regenerative, circuit operation ............................................................. 9025-05-75 Bucket flow rate control, circuit operation .................................................. 9025-05-103 Bucket flow rate pilot, operation................... 9025-05-20 Bucket regenerative, circuit operation .................................................... 9025-05-89 Bypass shut-off, operation ........................... 9025-05-69 Circuit relief and anticavitation, operation .................................................... 9025-05-65 Circuit relief, test and adjustment................. 9025-25-25 Control, check valves identification and operation .................................................... 9025-05-58 Control, operation ........................................ 9025-05-40 Crossover relief, operation......................... 9025-05-116 Dig regenerative operation........................... 9025-05-77 Dig regenerative solenoid test and adjustment.................................................. 9025-25-12 Main relief , circuit operation ........................ 9025-05-61 Main relief and power dig, test and adjustment.................................................. 9025-25-22 Make-up check, operation.......................... 9025-05-116 Pilot control, operation ................................... 9025-05-9 Pilot operation of control .............................. 9025-05-17 Pilot pressure regulating, operation ............................................................... 9025-05-5 Continued on next page
TM13345X19 (23APR18)
Index-12
160GLC Excavator 042318 PN=12
Index
Page
Page
Pilot pressure regulating, test and adjustment.................................................... 9025-25-8 Pilot shutoff solenoid, operation..................... 9025-05-6 Power dig/travel speed solenoid test and adjustment.................................................. 9025-25-16 Pump flow rate pilot, operation .................... 9025-05-20 Return filter bypass, operation ................... 9025-05-144 Shuttle, pilot signal manifold operation .................................................... 9025-05-20 Swing motor crossover relief, test and adjustment.................................................. 9025-25-28 Swing motor damper, operation ................. 9025-05-119 Swing park brake release pilot, operation .................................................... 9025-05-20 Torque control solenoid, test ........................ 9025-25-18 Travel flow combiner pilot, operation ............................................................. 9025-05-20 Travel flow combiner, operation ................... 9025-05-66 Travel motor and park brake, operation .................................................. 9025-05-130 Travel motor check, operation ................... 9025-05-130 Travel motor counterbalance, operation .................................................. 9025-05-130 Travel motor crossover relief, operation .................................................. 9025-05-130 Travel motor crossover relief, test and adjustment.................................................. 9025-25-30 Travel pilot control, operation....................... 9025-05-12 Valve spool Actuating pilot pressure test......................... 9025-25-10 Variable speed fan solenoid Theory of operation...................................... 9015-15-29 Voltage Battery, check .............................................. 9015-20-23
Auxiliary function lever (AFL) harness (W75) ....................................................... 9015-10-297 Auxiliary function lever (AFL) solenoid harness (W76).......................................... 9015-10-304 Auxiliary solenoid harness (W61) .............. 9015-10-286 Cab harness (W1)........................................ 9015-10-87 Cab roof light 1 relay harness (W46) ....................................................... 9015-10-246 Cab roof light 2 relay harness (W47) ....................................................... 9015-10-247 Cab roof light harness (W44) ..................... 9015-10-244 Cab roof light jumper harness (W45) ....................................................... 9015-10-245 Diesel exhaust fluid (DEF) harness (W54) ....................................................... 9015-10-269 Engine harness (W4) ................................. 9015-10-148 Engine interface harness (W5) .................. 9015-10-161 Engine light harness (W58)........................ 9015-10-283 Exhaust aftertreatment harness (W53) .................................9015-10-256, 9015-10-290 Exhaust filter parked cleaning switch harness (W9)............................................ 9015-10-195 Fan harness (W57) .................................... 9015-10-280 Front engine harness (W7) ........................ 9015-10-185 Fuel injector harness (W38)....................... 9015-10-231 Glow plug harness (W40) .......................... 9015-10-238 Heated air seat harness (W14) .................. 9015-10-203 Heater and air conditioner harness (W41) ....................................................... 9015-10-241 Heater and air conditioner relay harness (W51) ....................................................... 9015-10-250 Information ..................................................... 9015-05-1 Machine harness (W2)............................... 9015-10-123 Monitor harness (W3) ................................ 9015-10-142 Multi-function pilot control lever harness (W15) ....................................................... 9015-10-207 Pilot shutoff switch harness (W11)............. 9015-10-199 Pilot shutoff valve harness (W21) .............. 9015-10-218 Premium seat harness (W87) .................... 9015-10-313 Rear cab light harness (W86) .................... 9015-10-310 Rear cab light relay harness (W85) ........... 9015-10-309 Rear cab light switch harness (W84) ....................................................... 9015-10-308 Rear camera harness (W19)...................... 9015-10-216 Reversing fan switch harness (W23) ....................................................... 9015-10-220 Satellite (SAT) harness (W6003) ............... 9015-10-315 Seat heater switch harness (W24)............. 9015-10-221 Service ADVISOR remote (SAR) switch harness (W10).......................................... 9015-10-196 Starter switch harness (W29)..................... 9015-10-226 Travel alarm cancel switch harness (W16) ....................................................... 9015-10-209 Travel alarm harness (W26) ...................... 9015-10-225 USB harness (W82) ................................... 9015-10-305 USB jumper harness (W83) ....................... 9015-10-306 Wiring diagram (W8) Pump harness............................................ 9015-10-193 Work site hazards Avoid ............................................................ 9000-01-10
W Warm-up procedure Hydraulic oil ................................................... 9025-25-6 Water in fuel sensor Theory of operation...................................... 9015-15-29 Welding repairs................................................ 9000-01-15 Windshield washer circuit Operational check ........................................ 9005-10-17 Windshield washer control Operational check ........................................ 9005-10-14 Windshield wiper and washer circuit Theory of operation...................................... 9015-15-97 Windshield wiper circuit Operational check ........................................ 9005-10-15 Windshield wiper controls Operational check ........................................ 9005-10-13 Wire markings.................................................... 9015-10-1 Wiring diagram 2-Speed harness (W32)............................. 9015-10-228 Attachment harness (W17) ........................ 9015-10-213 Attachment interface harness .................... 9015-10-223 Auxiliary 3-button cancel switch harness (W22) ....................................................... 9015-10-219
TM13345X19 (23APR18)
Index-13
160GLC Excavator 042318 PN=13
Index
TM13345X19 (23APR18)
Index-14
160GLC Excavator 042318 PN=14
Index
TM13345X19 (23APR18)
Index-15
160GLC Excavator 042318 PN=15