245GLC Excavator Operation and Test (PIN: 1FF245GX_ _E600001— )
OPERATION & TEST TECHNICAL MANUAL 245GLC Excavator (PIN: 1FF245GX_ _E600001— ) TM12660 18APR18
(ENGLISH)
Worldwide Construction And Forestry Division PRINTED IN U.S.A.
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 -19-01DEC15-1/1
TM12660 (18APR18)
041818
PN=2
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
TM12660 (18APR18)
041818
PN=3
Introduction
TM12660 (18APR18)
041818
PN=4
Contents Section 9000—General Information Group 01—Safety
Section 9001—Diagnostics Group 10—Main Controller (MCZ) Diagnostic Trouble Codes Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Group 30—Monitor Controller (DSZ) Diagnostic Trouble Codes Group 40—Information Controller (ICZ) Diagnostic Trouble Codes Group 50—Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Section 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure
Section 9010—Engine Group 05—Theory of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Section 9015—Electrical System Group 05—System Information Group 10—System Diagrams Group 15—Sub-System Diagnostics Group 16—Monitor Operation Group 20—References
Section 9020—Power Train Group 05—Theory of Operation Group 15—Diagnostic Information
Section 9025—Hydraulic System Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests
Section 9031—Heating and Air Conditioning Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests
Section 9900—Dealer Fabricated Tools Group 99—Dealer Fabricated Tools
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 © 2013, 2014, 2015, 2016, 2017
TM12660 (18APR18)
i
041818
PN=1
Contents
TM12660 (18APR18)
ii
041818
PN=2
Contents
Section 9000 General Information
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 ............................................... 9000-01-3 Add Cab Guarding for Special Uses ...................................................... 9000-01-3 Inspect Machine ........................................ 9000-01-3 Stay Clear of Moving Parts........................ 9000-01-3 Avoid High-Pressure Fluids ....................... 9000-01-4 Avoid High-Pressure Oils .......................... 9000-01-4 Work In Ventilated Area............................. 9000-01-5 Prevent Fires ............................................. 9000-01-5 Prevent Battery Explosions ....................... 9000-01-6 Handle Chemical Products Safely.............. 9000-01-6 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 9000-01-7 Exhaust Filter Ash Handling and Disposal................................................. 9000-01-7 Prepare for Emergencies........................... 9000-01-7 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 ....................... 9000-01-8 Prevent Unintended Machine Movement.............................................. 9000-01-9 Avoid Work Site Hazards........................... 9000-01-9 Keep Riders Off Machine ........................ 9000-01-10 Avoid Backover Accidents ....................... 9000-01-10 Inspect and Maintain ROPS .................... 9000-01-10 Avoid Machine Tip Over .......................... 9000-01-11 Use Special Care When Lifting Objects ................................................ 9000-01-11 Add and Operate Attachments Safely................................................... 9000-01-12 Park and Prepare for Service Safely................................................... 9000-01-13 Service Cooling System Safely ............... 9000-01-13 Remove Paint Before Welding or Heating ................................................ 9000-01-14 Make Welding Repairs Safely ................. 9000-01-14 Drive Metal Pins Safely ........................... 9000-01-14 Clean Exhaust Filter Safely ..................... 9000-01-15
TM12660 (18APR18)
9000-1
041818
PN=1
Contents
TM12660 (18APR18)
9000-2
041818
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
TM12660 (18APR18)
9000-01-1
041818
PN=9
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 malfunctions 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.
TX1086762A —UN—11JAN11
Machines equipped with roll-over protective structure (ROPS) are tested in accordance with applicable international standards and are intended for the base machine model listed on the roll-over protective structure (ROPS) plate (1). The ROPS plate is located inside the cab on the front left cab frame. Do not use any attachment or make any modifications that increase the weight of the machine beyond the certified value listed on the ROPS plate.
Roll-Over Protective Structure (ROPS) Plate
1— Roll-Over Protective Structure (ROPS) Plate ER79617,0000DB1 -19-18SEP12-1/1
TM12660 (18APR18)
9000-01-2
041818
PN=10
Safety
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
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
TM12660 (18APR18)
9000-01-3
041818
PN=11
Safety
Avoid High-Pressure Fluids
X9811 —UN—23AUG88
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. DX,FLUID -19-12OCT11-1/1
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
TM12660 (18APR18)
9000-01-4
041818
PN=12
Safety
Work In Ventilated Area 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. TS220 —UN—15APR13
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
DX,AIR -19-17FEB99-1/1
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
TM12660 (18APR18)
9000-01-5
041818
PN=13
Safety
Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
TS204 —UN—15APR13
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
DX,SPARKS -19-03MAR93-1/1
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
TM12660 (18APR18)
9000-01-6
041818
PN=14
Safety
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
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
TM12660 (18APR18)
9000-01-7
041818
PN=15
Safety
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
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
TM12660 (18APR18)
9000-01-8
041818
PN=16
Safety
Prevent Unintended Machine Movement
T216779 —UN—22NOV05
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.
VD76477,000036D -19-19APR11-1/1
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
TM12660 (18APR18)
9000-01-9
041818
PN=17
Safety
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
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
TM12660 (18APR18)
9000-01-10
041818
PN=18
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
TM12660 (18APR18)
9000-01-11
041818
PN=19
Safety
Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability and may create a hazard for others near the machine. Machines equipped with roll-over protective structure (ROPS) are tested in accordance with applicable international standards and are intended for the base machine model listed on the roll-over protective structure (ROPS) plate (1). The ROPS plate is located inside the cab on the front left cab frame. Do not use any attachment or make any modifications that increase the weight of the machine beyond the certified value listed on the ROPS plate. 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. TX1086762A —UN—11JAN11
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. 1— Roll-Over Protective Structure (ROPS) Plate Roll-Over Protective Structure (ROPS) Plate
ER79617,0000DB2 -19-22FEB11-1/1
TM12660 (18APR18)
9000-01-12
041818
PN=20
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
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
TS281 —UN—15APR13
Explosive release of fluids from pressurized cooling system can cause serious burns.
DX,RCAP -19-04JUN90-1/1
TM12660 (18APR18)
9000-01-13
041818
PN=21
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
TM12660 (18APR18)
9000-01-14
041818
PN=22
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
TM12660 (18APR18)
9000-01-15
041818
PN=23
Safety
TM12660 (18APR18)
9000-01-16
041818
PN=24
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 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 Control Dial Sensor Circuit High Input ......................9001-10-5 Engine Control Dial Sensor Circuit High Input Diagnostic Procedure...................9001-10-6 011101.04 — Engine Control Dial Sensor Circuit Low Input .......................9001-10-7 Engine Control 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 011203.03 — Pump 3 Delivery Pressure Sensor Circuit High Input ....................................................9001-10-16 Pump 3 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-16 011203.04 — Pump 3 Delivery Pressure Sensor Circuit Low Input ....................................................9001-10-17 Pump 3 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-17 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input ....................................................9001-10-19 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-19 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input ....................................................9001-10-20 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-20 011207.03 — Pump 3 Flow Control Pressure Sensor Circuit High Input ....................................................9001-10-22
Continued on next page
TM12660 (18APR18)
9001-1
041818
PN=1
Contents
Page
Page
Pump 3 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-22 011207.04 — Pump 3 Flow Control Pressure Sensor Circuit Low Input ....................................................9001-10-23 Pump 3 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-23 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input ....................................................9001-10-25 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-25 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input ....................................................9001-10-26 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-26 011301.03 — Swing Pressure Sensor Circuit High Input.................................9001-10-28 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-28 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input .....................9001-10-29 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-29 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input ....................9001-10-30 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-30 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input .....................9001-10-32 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-32 011303.03 — Arm In Pressure Sensor Circuit High Input.................................9001-10-33 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-33 011303.04 — Arm In Pressure Sensor Circuit Low Input .................................9001-10-34 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-34 011304.03 — Travel Pilot Pressure Sensor Circuit High Input ....................9001-10-36 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-36 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input .....................9001-10-37
Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-37 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input ....................................................9001-10-39 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-39 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input ....................................................9001-10-40 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-40 011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input ....................................................9001-10-41 Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure............................................9001-10-41 011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input ....................................................9001-10-43 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................9001-10-43 011400.02 — Pump 2 Flow Rate Limit Solenoid Feedback Abnormal Feedback ............................................9001-10-44 Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-44 011400.03 — Pump 2 Flow Rate Limit Solenoid Feedback High Current ................................................9001-10-46 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure............................................9001-10-46 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current ................................................9001-10-47 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................................9001-10-47 011401.02 — Pump 1 and 2 Torque P/S Valve Abnormal Feedback ..................9001-10-49 Pump 1 and 2 Torque P/S Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-49 011401.03 — Pump 1 and 2 Torque P/S Valve Feedback High Current ................................................9001-10-51 Pump 1 and 2 Torque P/S Valve Feedback High Current Diagnostic Procedure............................................9001-10-51 011401.04 — Pump 1 and 2 Torque P/S Valve Feedback Low Current ..............9001-10-52 Continued on next page
TM12660 (18APR18)
9001-2
041818
PN=2
Contents
Page
Page
Pump 1 and 2 Torque P/S Valve Feedback Low Current Diagnostic Procedure............................................9001-10-52 011402.02 — 5-Spool Solenoid Valve Unit (SF) Abnormal Feedback ............................................9001-10-54 5-Spool Solenoid Valve Unit (SF) Abnormal Feedback Diagnostic Procedure............................................9001-10-54 011402.03 — 5-Spool Solenoid Valve Unit (SF) Feedback High Input ....................................................9001-10-56 5-Spool Solenoid Valve Unit (SF) Feedback High Input Diagnostic Procedure............................................9001-10-56 011402.04 — 5-Spool Solenoid Valve Unit (SF) Feedback Low Input ....................................................9001-10-57 5-Spool Solenoid Valve Unit (SF) Feedback Low Input Diagnostic Procedure............................................9001-10-57 011403.02 — 5-Spool Solenoid Valve Unit (SC) Abnormal Feedback ............................................9001-10-59 5-Spool Solenoid Valve Unit (SC) Abnormal Feedback Diagnostic Procedure............................................9001-10-59 011403.03 — 5-Spool Solenoid Valve Unit (SC) Feedback High Input ....................................................9001-10-61 5-Spool Solenoid Valve Unit (SC) Feedback High Input Diagnostic Procedure............................................9001-10-61 011403.04 — 5-Spool Solenoid Valve Unit (SC) Feedback Low Input ....................................................9001-10-62 5-Spool Solenoid Valve Unit (SC) Feedback Low Input Diagnostic Procedure............................................9001-10-62 011406.02 — Pump 3 Torque P/S Valve Abnormal Feedback ..................9001-10-64 Pump 3 Torque P/S Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-64 011406.03 — Pump 3 Torque P/S Valve Feedback High Current .......................9001-10-66 Pump 3 Torque P/S Valve Feedback High Current Diagnostic Procedure............................................9001-10-66 011406.04 — Pump 3 Torque P/S Valve Feedback Low Current ..............9001-10-67 Pump 3 Torque P/S Valve Feedback Low Current Diagnostic Procedure............................................9001-10-67 011407.02 — 5-Spool Solenoid Valve Unit (SI) Abnormal Feedback ............................................9001-10-69
5-Spool Solenoid Valve Unit (SI) Abnormal Feedback Diagnostic Procedure............................................9001-10-69 011407.03 — 5-Spool Solenoid Valve Unit (SI) Feedback High Input ....................................................9001-10-71 5-Spool Solenoid Valve Unit (SI) Feedback High Input Diagnostic Procedure............................................9001-10-71 011407.04 — 5-Spool Solenoid Valve Unit (SI) Feedback Low Input..............9001-10-72 5-Spool Solenoid Valve Unit (SI) Feedback Low Input Diagnostic Procedure............................................9001-10-72 011408.02 — 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback ............................................9001-10-74 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback Diagnostic Procedure............................................9001-10-74 011408.03 — 2-Spool Solenoid Valve Unit (SJ) Feedback High Input ....................................................9001-10-76 2-Spool Solenoid Valve Unit (SJ) Feedback High Input Diagnostic Procedure............................................9001-10-76 011408.04 — 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input ....................................................9001-10-77 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input Diagnostic Procedure............................................9001-10-77 011409.02 — 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback ............................................9001-10-79 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback Diagnostic Procedure............................................9001-10-79 011409.03 — 2-Spool Solenoid Valve Unit (SZ) Feedback High Input ....................................................9001-10-81 2-Spool Solenoid Valve Unit (SZ) Feedback High Input Diagnostic Procedure............................................9001-10-81 011409.04 — 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input ....................................................9001-10-82 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input Diagnostic Procedure............................................9001-10-82 011427.02 — 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback ............................................9001-10-84 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure............................................9001-10-84
Continued on next page
TM12660 (18APR18)
9001-3
041818
PN=3
Contents
Page
Page
011427.03 — 5-Spool Solenoid Valve Unit (SE) Feedback High Current ................................................9001-10-86 5-Spool Solenoid Valve Unit (SE) Feedback High Current Diagnostic Procedure............................................9001-10-86 011427.04 — 5-Spool Solenoid Valve Unit (SE) Feedback Low Current ................................................9001-10-87 5-Spool Solenoid Valve Unit (SE) Feedback Low Current Diagnostic Procedure............................................9001-10-87 011428.02 — 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback ............................................9001-10-88 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback Diagnostic Procedure............................................9001-10-89 011428.03 — 5-Spool Solenoid Valve Unit (SD) Feedback High Current ................................................9001-10-90 5-Spool Solenoid Valve Unit (SG) Feedback High Current Diagnostic Procedure............................................9001-10-90 011428.04 — 5-Spool Solenoid Valve Unit (SD) Feedback Low Current ................................................9001-10-91 5-Spool Solenoid Valve Unit (SD) Feedback Low Current Diagnostic Procedure............................................9001-10-91 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback ............................9001-10-93 Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-93 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current .......................9001-10-95 Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure............................................9001-10-95 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current........................9001-10-96 Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure............................................9001-10-96 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback ............................9001-10-98 Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure............................................9001-10-98
011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current .....................9001-10-100 Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure..........................................9001-10-100 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current......................9001-10-101 Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure..........................................9001-10-101 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback ..........................9001-10-103 Breaker Relief Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure........................9001-10-103 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current .....................9001-10-105 Breaker Relief Proportional Solenoid Valve Feedback High Current Diagnostic Procedure........................9001-10-105 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current......................9001-10-106 Breaker Relief Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure........................9001-10-106 011437.02 — 2-Spool Solenoid Valve Unit (A1) Abnormal Feedback ..........................................9001-10-107 2-Spool Solenoid Valve Unit (A1) Abnormal Feedback Diagnostic Procedure..........................................9001-10-107 011437.03 — 2-Spool Solenoid Valve Unit (A1) Feedback High Current ..............................................9001-10-109 2-Spool Solenoid Valve Unit (A1) Feedback High Current Diagnostic Procedure..........................................9001-10-109 011437.04 — 2-Spool Solenoid Valve Unit (A1) Feedback Low Current ..............................................9001-10-110 2-Spool Solenoid Valve Unit (A1) Feedback Low Current Diagnostic Procedure..........................................9001-10-110 011438.02 — 2-Spool Solenoid Valve Unit (A2) Abnormal Feedback ..........................................9001-10-112 2-Spool Solenoid Valve Unit (A2) Abnormal Feedback Diagnostic Procedure..........................................9001-10-112
Continued on next page
TM12660 (18APR18)
9001-4
041818
PN=4
Contents
Page
Page
011438.03 — 2-Spool Solenoid Valve Unit (A2) Feedback High Current ..............................................9001-10-113 2-Spool Solenoid Valve Unit (A2) Feedback High Current Diagnostic Procedure..........................................9001-10-113 011438.04 — 2-Spool Solenoid Valve Unit (A2) Feedback Low Current ..............................................9001-10-115 2-Spool Solenoid Valve Unit (A2) Feedback Low Current Diagnostic Procedure..........................................9001-10-115 011457.02 — 2-Speed Activation Solenoid Disconnected or Not Present..............................................9001-10-116 2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure........................9001-10-116 011458.02 — (Auxiliary) Discontinuity of Selector Valve ...............................9001-10-118 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure..........................................9001-10-118 011459.02 — Idle Stop Relay Circuit Malfunction........................................9001-10-120 Idle Stop Relay Circuit Malfunction Diagnostic Procedure........................9001-10-120 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)........................................9001-10-121 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure..........................................9001-10-121 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)........................................9001-10-122 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure..........................................9001-10-122 015016.03 — Right Analog Stroke Sensor Circuit High Input ..................9001-10-124 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure..........................................9001-10-124 015016.04 — Right Analog Stroke Sensor Circuit Low Input ...................9001-10-124 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure..........................................9001-10-125 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage......................................9001-10-126 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure..........................................9001-10-126
011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage.......................................9001-10-127 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure..........................................9001-10-127 011812.02 — OPT Electric Lever 1 Neutral Abnormal ..............................9001-10-128 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure........................9001-10-128 011813.02 — OPT Electric Lever 1 Abnormal Operation ..........................9001-10-129 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure..........................................9001-10-129 011816.02 — OPT Solenoid 1 Feedback Abnormal ..........................9001-10-131 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure..........................................9001-10-131 011816.03 — OPT Solenoid 1 Feedback Current High .....................9001-10-133 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure..........................................9001-10-133 011816.04 — OPT Solenoid 1 Feedback Current Low......................9001-10-135 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure..........................................9001-10-135 011817.02 — OPT Solenoid 2 Feedback Abnormal ..........................9001-10-137 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure..........................................9001-10-137 011817.03 — OPT Solenoid 2 Feedback Current High .....................9001-10-138 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure..........................................9001-10-139 011817.04 — OPT Solenoid 2 Feedback Current Low......................9001-10-140 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure..........................................9001-10-140 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input ..................................................9001-10-142 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure..........................................9001-10-142 Continued on next page
TM12660 (18APR18)
9001-5
041818
PN=5
Contents
Page
Page
011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input ..................................................9001-10-143 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure..........................................9001-10-143 020010.02 — Abnormal Exhaust Filter ..................................................9001-10-144 Abnormal Exhaust Filter Diagnostic Procedure..........................................9001-10-144 020011.02 — Electric Lever Alarm.................................................9001-10-144 Electric Control Lever Alarm Diagnostic Procedure..........................................9001-10-145 020012.02 — Line Filter Restriction Alarm.................................................9001-10-145 020303.02 — Electric Lever Pilot Cut Alarm.................................................9001-10-145 Attachment Pedal or Blade and Outrigger Control Lever Alarm Diagnostic Procedure........................9001-10-145
000100.03 — Engine Oil Pressure Sensor Circuit High Input (P0523) .................................................9001-20-2 000100.04 — Engine Oil Pressure Sensor Circuit Low Input (P0522) .................................................9001-20-2 000102.00 — Over Boost-Pressure (P0234) .................................................9001-20-2 000102.03 — Boost Pressure Sensor Circuit High Input (P0238).....................9001-20-3 000102.04 — Boost Pressure Sensor Circuit Low Input (P0237)......................9001-20-3 000105.03 — Boost Temperature Sensor Circuit High Input (P1113) ..................................................9001-20-3 000105.04 — Boost Temperature Sensor Circuit Low Input (P1112) ..................................................9001-20-3 000108.03 — Atmospheric Pressure Sensor Circuit High Input (P2229) .................................................9001-20-3 000108.04 — Atmospheric Pressure Sensor Circuit Low Input (P2228) .................................................9001-20-3 000110.00 — Overheat (P0217) .................................................9001-20-3 000110.03 — Engine Coolant Temperature Circuit High Input (P0118)..................................................9001-20-4 000110.04 — Engine Coolant Temperature Circuit Low Input (P0117)..................................................9001-20-4 000132.03 — Air Flow Sensor Circuit High Input (P0103) ................................9001-20-4 000132.04 — Air Flow Sensor Circuit Low Input (P0102).................................9001-20-4 000157.00 — Pressure Increase in Common Rail (Secondary) (P0088) .................................................9001-20-4 000157.03 — Common Rail Pressure Sensor Circuit High Input (P0193) .................................................9001-20-4 000157.04 — Common Rail Pressure Sensor Circuit Low Input (P0192) .................................................9001-20-4 000157.15 — Abnormal Common Rail Pressure (Over Pumping) (P0089) .................................................9001-20-5 000157.16 — Pressure Increase in Common Rail (Primary) (P0088) .................................................9001-20-5 000158.03 — Abnormally High Battery System Voltage (P0563) .......................9001-20-5 000172.03 — Intake Air Temperature Sensor Circuit High Input (P0113)..................................................9001-20-5
Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes ..................... 9001-20-1 000081.00 — High Exhaust Filter Differential Pressure (P2453) .................................................9001-20-1 000081.01 — Low Exhaust Filter Differential Pressure (P2452) .................................................9001-20-1 000081.02 — Zero-Point Calibration of Exhaust Filter Differential Pressure Sensor is Abnormal (P2456) .................9001-20-1 000081.03 — Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455) .................................................9001-20-1 000081.04 — Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454) .................................................9001-20-1 000091.02 — Accelerator Pedal Position Sensor 1-2 Correlation (P2138) .................................................9001-20-1 000091.03 — Accelerator Pedal Position Sensor 1 High Input (P2123) .................................................9001-20-2 000091.03 — Accelerator Pedal Position Sensor 2 High Input (P2128) .................................................9001-20-2 000091.04 — Accelerator Pedal Position Sensor 1 Low Input (P2122) .................................................9001-20-2 000091.04 — Accelerator Pedal Position Sensor 2 Low Input (P2127) .................................................9001-20-2
Continued on next page
TM12660 (18APR18)
9001-6
041818
PN=6
Contents
Page
Page
000172.04 — Intake Air Temperature Sensor Circuit Low Input (P0112)..................................................9001-20-5 000173.00 — Abnormally High Exhaust Temperature Sensor 1 (DPF Inlet) (P0426) .................................................9001-20-5 000173.03 — Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428) ........................................9001-20-5 000173.04 — Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427) ........................................9001-20-6 000174.03 — Combustion Temperature Sensor Circuit High Input (P0183) ........................................9001-20-6 000174.04 — Combustion Temperature Sensor Circuit Low Input (P0182) ........................................9001-20-6 000190.00 — Engine Overrun (P0219) .................................................9001-20-6 000628.02 — Abnormal ROM (P0601) .................................................9001-20-6 000633.07 — Common Rail Pressure Limiter Open (P0087)............................9001-20-6 000636.02 — Abnormal Cam Angle Sensor (No Signal) (P0340) ..................9001-20-6 000636.07 — Phase Difference Between Cam and Sensor (P0016) .................................................9001-20-7 000639.02 — Abnormal CAN Time-Out (U0101) .................................................9001-20-7 000639.19 — Abnormal CAN Bus (U0073) .................................................9001-20-7 000651.05 — Cylinder 1 Injector Circuit Open (P0201)........................................9001-20-7 000652.05 — Cylinder 2 Injector Circuit Open (P0202)........................................9001-20-7 000653.05 — Cylinder 3 Injector Circuit Open (P0203)........................................9001-20-7 000654.05 — Cylinder 4 Injector Circuit Open (P0204)........................................9001-20-7 000723.02 — Crank Position Sensor Failure (No Signal) (P0335) ..................9001-20-8 000723.02 — Crank Position Sensor Failure (Abnormal Signal) (P0336) .................................................9001-20-8 001077.02 — Abnormal CPU (P0606) .................................................9001-20-8 001079.02 — Abnormal 5V-Electric Power Circuit #1 (P0641) ......................9001-20-8 001080.02 — Abnormal 5V-Electric Power Circuit #2 (P0651) ......................9001-20-8 001131.03 — Manifold Temperature Sensor Circuit High Input (P041C).................................................9001-20-8 001131.04 — Manifold Temperature Sensor Circuit Low Input (P041D).................................................9001-20-8
001239.01 — Pressure Decline in Common Rail (No Pumping Pressure) (P0093).................................9001-20-9 001239.31 — Pressure Decline in Common Rail (No Pumping Pressure) (Fuel Temperature less than 5° C) (P0093) ................................9001-20-9 001239.17 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093).................................9001-20-9 001239.31 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (Fuel Temperature less than 5° C) (P1093) ................................9001-20-9 001347.03 — SCV Drive Circuit + Short Circuit B (P0092) .........................9001-20-9 001347.04 — SCV Drive Circuit Open or Short Circuited to GND (P0091) .................................................9001-20-9 001381.03 — Fuel Filter Restriction Sensor Circuit High Input (P1294) ...............................................9001-20-10 001381.04 — Fuel Filter Restriction Sensor Circuit Low Input (P1293) ...............................................9001-20-10 001485.05 — Abnormal Main Relay Circuit (Inactivation) (P0685)...............9001-20-10 001485.06 — Abnormal Main Relay Circuit (Kept Closed) (P0687) ...............................................9001-20-10 010001.02 — EGR Position Error (Brushless Type) (P0409) ...................9001-20-10 010001.13 — Abnormal EGR Zero-Point Calibration (P1404) ...............................................9001-20-10 010002.02 — Abnormal EGR Valve Control Circuit (P0404)........................9001-20-10 010003.02 — Abnormal Injector Common 1 Circuit (P2146)..................9001-20-11 010004.02 — Abnormal Injector Common 2 Circuit (P2149)..................9001-20-11 010005.01 — Abnormal Charge Circuit (Bank 1) (P1261).................................9001-20-11 010006.01 — Abnormal Charge Circuit (Bank 2) (P1262).................................9001-20-11 010007.02 — Abnormal CPU Monitor IC (P0606)...........................................9001-20-11 010008.02 — Abnormal A/D Converter (P060B) ...............................................9001-20-11 010009.02 — Abnormal 5V-Electric Power Circuit #3 (P0697) ....................9001-20-11 010010.02 — Abnormal 5V-Electric Power Circuit #4 (P1655) ....................9001-20-12 010012.02 — Abnormal 12V Circuit (P0560) ...............................................9001-20-12 010013.02 — Abnormal EEPROM/Abnormal HDEEPROM (P1621) ...............................................9001-20-12 Continued on next page
TM12660 (18APR18)
9001-7
041818
PN=7
Contents
Page
Page
010022.02 — Abnormal Intake Throttle Control Circuit (P0638)........................9001-20-12 010022.03 — Intake Throttle Position Sensor Circuit High Input (P0123) ...............................................9001-20-12 010022.04 — Intake Throttle Position Sensor Circuit Low Input (P0122) ...............................................9001-20-12 010023.02 — Abnormal CAN VNT Time-out/ISO-CAN VNT Communication Error (U0110) ...............................................9001-20-12 010023.12 — Abnormal VNT Turbo (P0045) ...............................................9001-20-13 010023.19 — VNT Communication Error (U0411) ......................................9001-20-13 010024.03 — Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)......................................9001-20-13 010024.04 — Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)......................................9001-20-13 010025.05 — Exhaust Filter Light Failure (P1669) ...................................9001-20-13 010026.00 — Exhaust Filter PM Over-Restriction 2 (P1455) .................9001-20-13 010026.15 — Exhaust Filter PM Over-Restriction (P242F) ....................9001-20-13 010027.00 — Exhaust Filter Cleaning Decision Error (P1471)........................9001-20-14 010028.00 — Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B) ...............................................9001-20-14 010029.00 — Over Frequent Exhaust Filter Regeneration Time-Out (P2458) ...............................................9001-20-14 010032.02 — QR Code Error (P0602) ...............................................9001-20-14 010033.02 — Abnormal RAM (P0604) ...............................................9001-20-14 010040.19 — Abnormal ISO-CAN Bus (U0001) ...............................................9001-20-14
013007.02 — Machine Controller (BCZ) Communication Error..................9001-30-1 020113.02 — System Error Alarm.....................................................9001-30-1
Group 30—Monitor Controller (DSZ) Diagnostic Trouble Codes Monitor Controller (DSZ) Diagnostic Trouble Codes ..................... 9001-30-1 013002.02 — ECU Communication Error ......................................................9001-30-1 013003.02 — Main Controller (MCZ) Communication Error 1 .........................9001-30-1 013004.02 — Main Controller (MCZ) Communication Error 2 .........................9001-30-1 013005.02 — Monitor Controller (DSZ) Communication Error 1 .........................9001-30-1 013006.02 — Monitor Controller (DSZ) Communication Error 2 .........................9001-30-1
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 013310.03 — Shorted Circuit in Coolant Temperature Sensor ................9001-40-2 Shorted Circuit in Coolant Temperature Sensor Diagnostic Procedure..............................................9001-40-2 013311.03 — Fuel Level Sensor Open Circuit ....................................................9001-40-2 Fuel Level Sensor Open Circuit Diagnostic Procedure............................9001-40-3 013311.04 — Fuel Level Sensor Shorted Circuit ......................................9001-40-4 Fuel Level Sensor Shorted Circuit Diagnostic Procedure............................9001-40-4 013334.02 — Radiator Coolant Error ......................................................9001-40-5 014001.02 — Flash Memory Read/Write Error ...................................9001-40-5 Flash Memory Read/Write Error Diagnostic Procedure............................9001-40-5 014002.02 — External RAM Read/Write Error ...................................9001-40-6 External RAM Read/Write Error Diagnostic Procedure............................9001-40-6 014003.02 — Abnormal EEPROM...............................................9001-40-6 Abnormal EEPROM Diagnostics Procedure..............................................9001-40-6 014006.02 — Communication Terminal:Communication Error ......................................................9001-40-6 Communication Terminal:Communication Error Diagnostic Procedure .......................................................9001-40-6 014008.02 — Abnormal Internal RAM ......................................................9001-40-7 Abnormal Internal RAM Diagnostic Procedure..............................................9001-40-7 014021.02 — Communication Terminal Security Error ........................................9001-40-7 014022.02 — SIM Card Error....................9001-40-8 014023.02 — Security Error ......................9001-40-8 020100.02 — Overheat Alarm...................9001-40-8 Continued on next page
TM12660 (18APR18)
9001-8
041818
PN=8
Contents
Page
Page
020101.02 — Engine Warning Alarm.....................................................9001-40-9 Engine Warming Alarm Diagnostic Procedure..............................................9001-40-9 020102.02 — Engine Oil Pressure Alarm...................................................9001-40-10 020105.02 — Hydraulic Oil Filter Restriction Alarm.................................9001-40-10 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure..........................9001-40-10 020106.02 — Air Cleaner Restriction Alarm...................................................9001-40-11 Air Cleaner Restriction Alarm Diagnostic Procedure..........................9001-40-11 020107.02 — Water Separator Alarm...................................................9001-40-12 Water-in-Fuel Separator Alarm................9001-40-12 020109.02 — Pilot Control Shut-Off Lever Alarm.........................................9001-40-13 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure..........................9001-40-13 020110.02 — Fuel Filter Restriction Alarm...................................................9001-40-14 Fuel Filter Restriction Alarm Diagnostic Procedure............................................9001-40-14 020114.02 — Overheat Alarm .................9001-40-16 Overheat Alarm .......................................9001-40-16 020137.02 — Exhaust Filter Alarm...................................................9001-40-17 020141.02 — Exhaust Temperature Alarm...................................................9001-40-17 020142.02 — Intake Air Temperature Alarm...................................................9001-40-17 020145.02 — Boost Temperature Increase Alarm ....................................9001-40-17 020146.02 — Fuel Temperature Increase Alarm ....................................9001-40-17 020149.02 — EGR Gas Temperature Alarm...................................................9001-40-18
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............................................9001-50-13 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
TM12660 (18APR18)
9001-9
041818
PN=9
Contents
TM12660 (18APR18)
9001-10
041818
PN=10
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. (Group 9015-20.) or See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application. (Group 9015-20.)
Service ADVISOR is a trademark of Deere & Company RH60123,0000C5D -19-17AUG12-1/1
Controller Area Network 0 (CAN 0) Circuit Diagnostics There are four CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) RH60123,0000C5E -19-28FEB18-1/1
Controller Area Network 1 (CAN 1) Circuit Diagnostics There are four CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) RH60123,0000C5F -19-28FEB18-1/1
Interface Controller Area Network (N-CAN) Diagnostics There are four CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) RH60123,0000C60 -19-28FEB18-1/1
Engine Controller Area Network (Engine CAN) Diagnostics There are four CAN networks on this machine. For diagnostic information on CAN networks, see Controller Area Network (CAN) Circuit Test. (Group 9015-20.) MB00333,00003B8 -19-28FEB18-1/1
011000.02 — Abnormal EEPROM RH60123,0000C61 -19-12AUG15-1/4
Abnormal EEPROM Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-1
RH60123,0000C61 -19-12AUG15-2/4
041818
PN=35
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Code Check
Clear and check again for diagnostic trouble codes.
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. RH60123,0000C61 -19-12AUG15-3/4
• 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.) RH60123,0000C61 -19-12AUG15-4/4
011001.02 — Abnormal RAM RH60123,0000C62 -19-12AUG15-1/4
Abnormal RAM Diagnostic Procedure RH60123,0000C62 -19-12AUG15-2/4
• 1
Code Check
Clear and check again for diagnostic trouble codes.
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
TM12660 (18APR18)
9001-10-2
RH60123,0000C62 -19-12AUG15-3/4
041818
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.) RH60123,0000C62 -19-12AUG15-4/4
011002.02 — Abnormal A/D Converter RH60123,0000C63 -19-12AUG15-1/4
Abnormal A/D Converter Diagnostic Procedure RH60123,0000C63 -19-12AUG15-2/4
• 1
Code Check
Clear and check again for diagnostic trouble codes.
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. RH60123,0000C63 -19-12AUG15-3/4
• 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.) RH60123,0000C63 -19-12AUG15-4/4
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. RH60123,0000C64 -19-12AUG15-1/4
Abnormal Sensor Voltage Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-3
RH60123,0000C64 -19-12AUG15-2/4
041818
PN=37
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Sensor Check
Key switch: Off
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. RH60123,0000C64 -19-12AUG15-3/4
• 2
Continuity Check
Key switch: Off
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.) RH60123,0000C64 -19-12AUG15-4/4
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.)
RH60123,0000C65 -19-12AUG15-1/1
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.)
RH60123,0000C66 -19-12AUG15-1/1
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.)
RH60123,0000C67 -19-12AUG15-1/1
TM12660 (18APR18)
9001-10-4
041818
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.)
RH60123,0000C68 -19-12AUG15-1/1
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.)
RH60123,0000C69 -19-12AUG15-1/1
011100.02 — Abnormal Engine Speed Engine speed is 2500 rpm or faster. RH60123,0000C6A -19-31AUG12-1/3
Abnormal Engine Speed Diagnostic Procedure NOTE: The main controller (MCZ) receives engine speed via CAN from the engine control unit (ECU). RH60123,0000C6A -19-31AUG12-2/3
• 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 000190.00. See 190.0 — Engine Overrun (P0219). (Group 9001-20.)
Service ADVISOR is a trademark of Deere & Company RH60123,0000C6A -19-31AUG12-3/3
011101.03 — Engine Control Dial Sensor Circuit High Input
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
Engine control dial (R15) signal voltage is high. (Above 4.78 V) IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.
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
TM12660 (18APR18)
9001-10-5
RH60123,0000C6B -19-16APR18-1/6
041818
PN=39
Main Controller (MCZ) Diagnostic Trouble Codes Engine Control Dial Sensor Circuit High Input Diagnostic Procedure RH60123,0000C6B -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 26-pin connector F (X36). 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 connector. See appropriate harness.
(W2) Component Location. (Group 9015-10.)
RH60123,0000C6B -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. RH60123,0000C6B -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. RH60123,0000C6B -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. RH60123,0000C6B -19-16APR18-6/6
TM12660 (18APR18)
9001-10-6
041818
PN=40
Main Controller (MCZ) Diagnostic Trouble Codes
011101.04 — Engine Control Dial Sensor Circuit Low Input
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
Engine control sensor 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). RH60123,0000C6C -19-16APR18-1/6
Engine Control Dial Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C6C -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 26-pin connector E (X36). See Cab Harness (W1) 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 24-Pin connector E (X34). 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.)
RH60123,0000C6C -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. RH60123,0000C6C -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 24-pin connector D (X35). Disconnect cab harness-to-main controller 26-pin connector E (X36). Check for continuity between pin 5 of cab harness-to-switch panel connector 3 (X29) and pin 16 of cab harness-to-main controller 24-pin connector E (X35).
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check. Continued on next page
TM12660 (18APR18)
9001-10-7
RH60123,0000C6C -19-16APR18-5/6
041818
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. RH60123,0000C6C -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
TM12660 (18APR18)
9001-10-8
TK40086,000090D -19-08AUG16-4/7
041818
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
TM12660 (18APR18)
9001-10-9
TK40086,000090D -19-08AUG16-6/7
041818
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 (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.
RH60123,0000C6E -19-12AUG15-1/7
Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C6E -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 delivery pressure sensor (B35) and pump harness splice connector (X97). See Pump Harness (W8) Component Location. (Group 9015-10.)
• 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-10
RH60123,0000C6E -19-12AUG15-3/7
041818
PN=44
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component 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 connector (B35) to pump 2 delivery pressure sensor (B37). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011200.04—Pump 1 Delivery Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 1 delivery pressure sensor (B35) malfunction. Replace sensor. RH60123,0000C6E -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 delivery pressure sensor (B35). Turn key switch to ON position. Check pin 1 and pin 3 of pump 1 delivery pressure sensor connector (B35) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C6E -19-12AUG15-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 1 delivery pressure sensor (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 connector (B35) YES: Go to Short Circuit 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. RH60123,0000C6E -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 1 delivery pressure sensor (B35) disconnected. Check for continuity between pin 2 of pump 1 delivery pressure sensor connector (B35) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C6E -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-11
041818
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
TM12660 (18APR18)
9001-10-12
BG71862,00002AB -19-19JUL16-4/7
041818
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
TM12660 (18APR18)
9001-10-13
BG71862,00002AB -19-19JUL16-6/7
041818
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 (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.
RH60123,0000C70 -19-12AUG15-1/7
Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C70 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 delivery pressure sensor (B37) and pump harness splice connector (X97). 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-14
RH60123,0000C70 -19-12AUG15-3/7
041818
PN=48
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component 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 connector (B37) to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011202.04—Pump 2 Delivery Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 2 delivery pressure sensor (B37) malfunction. Replace sensor. RH60123,0000C70 -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 delivery pressure sensor (B37). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 delivery pressure sensor connector (B37) for approximately 5 V..
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C70 -19-12AUG15-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 2 delivery pressure sensor (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 connector (B37) YES: Go to Short Circuit 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. RH60123,0000C70 -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 2 delivery pressure sensor (B37) disconnected. Check for continuity between pin 2 of pump 2 delivery pressure sensor connector (B37) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C70 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-15
041818
PN=49
Main Controller (MCZ) Diagnostic Trouble Codes
011203.03 — Pump 3 Delivery Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 delivery pressure sensor (B56) 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.
RH60123,0000C71 -19-12AUG15-1/6
Pump 3 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C71 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 delivery pressure sensor (B56) and pump harness splice connector (X97). See Pump Harness (W8) 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.)
• 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 connector. See appropriate harness.
Component Location. (Group 9015-10.)
RH60123,0000C71 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 3 delivery pressure sensor (B56). Disconnect pump 1 delivery pressure sensor (B35). Connect pump 3 delivery pressure sensor connector (B56) to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011203.03—Pump 3 Delivery Pressure Sensor Circuit High Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 3 delivery pressure sensor (B56) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-16
RH60123,0000C71 -19-12AUG15-4/6
041818
PN=50
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 3 delivery pressure sensor (B56). Turn key switch to ON position. Check between pin 2 of pump 3 delivery pressure sensor connector (B56) and machine YES: Go to Harness ground for approximately 0.0 V. Check. Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C71 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 3 delivery pressure sensor (B56). Disconnect main controller connectors (X31—X36). Check for continuity between pin 27 of cab harness-to-main controller 30-pin connector YES: Repair or replace D (X34) to all pins on all main controller connectors. harness. See appropriate harness. Is continuity indicated between any circuits?
NO: Checks complete. RH60123,0000C71 -19-12AUG15-6/6
011203.04 — Pump 3 Delivery Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 delivery pressure sensor (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.
RH60123,0000C72 -19-12AUG15-1/7
Pump 3 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C72 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 delivery pressure sensor (B56) and pump harness splice connector (X97). See Pump Harness (W8) 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.)
• 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 connector. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-17
RH60123,0000C72 -19-12AUG15-3/7
041818
PN=51
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 3 delivery pressure sensor (B56). Disconnect pump 1 delivery pressure sensor (B35). Connect pump 3 delivery pressure sensor connector (B56) to pump 1 delivery pressure sensor (B35). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011203.04—Pump 2 Delivery Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 3 delivery pressure sensor (B56) malfunction. Replace sensor. RH60123,0000C72 -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 3 delivery pressure sensor (B56). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 3 delivery pressure sensor connector (B56) for approximately 5 V.
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C72 -19-12AUG15-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 3 delivery pressure sensor (B56) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of pump 3 delivery pressure sensor connector (B56) YES: Go to Short Circuit and pin 27 of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C72 -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 3 delivery pressure sensor (B56) disconnected. Check for continuity between pin 2 of pump 3 delivery pressure sensor connector (B56) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C72 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-18
041818
PN=52
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 (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.
RH60123,0000C73 -19-12AUG15-1/6
Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C73 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 control pressure sensor (B36) and pump harness splice connector (X97). See Pump Harness (W8) Component Location. (Group 9015-10.)
• 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
RH60123,0000C73 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 1 control pressure sensor (B36). Disconnect pump 2 control pressure sensor (B38). Connect pump 1 control pressure sensor connector (B36) to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011206.03—Pump 1 Flow Control Pressure Sensor Circuit High Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 1 control pressure sensor (B36) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-19
RH60123,0000C73 -19-12AUG15-4/6
041818
PN=53
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (B36). Turn key switch to ON position. Check between pin 2 of pump 1 control pressure sensor connector (B36) 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. RH60123,0000C73 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (B36). Disconnect main controller connectors (X31—X36). Check for continuity between pin 8 of cab harness-to-main controller 17-pin connector C (X33) to all pins on all main controller connectors.
YES: Circuit is short to power. Repair or replace harness. See appropriate harness.
Is continuity indicated between any circuits?
NO: Checks complete. RH60123,0000C73 -19-12AUG15-6/6
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 (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.
RH60123,0000C74 -19-12AUG15-1/7
Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C74 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 1 control pressure sensor (B36) and pump harness splice connector (X97). See Pump Harness (W8) Component Location. (Group 9015-10.)
• 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-20
RH60123,0000C74 -19-12AUG15-3/7
041818
PN=54
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 1 control pressure sensor (B36). Disconnect pump 2 control pressure sensor (B38). Connect pump 1 control pressure sensor connector (B36) to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011206.04—Pump 1 Flow Control Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 1 control pressure sensor (B36) malfunction. Replace sensor. RH60123,0000C74 -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 1 control pressure sensor (B36). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 1 control pressure sensor connector (B36) for approximately 5 V..
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C74 -19-12AUG15-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 1 control pressure sensor (B36) disconnected. Disconnect cab harness-to-main controller 26-pin connector F (X36). Check for continuity between pin 2 of pump 1 control pressure sensor 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. RH60123,0000C74 -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 1 control pressure sensor (B36) disconnected. Check for continuity between: pin 2 of pump 1 control pressure sensor connector (B33) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C74 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-21
041818
PN=55
Main Controller (MCZ) Diagnostic Trouble Codes
011207.03 — Pump 3 Flow Control Pressure Sensor Circuit High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 control pressure sensor (B57) 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.
RH60123,0000C75 -19-12AUG15-1/6
Pump 3 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C75 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 control pressure sensor (B57) and pump harness splice connector (X97). 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 connector. See appropriate harness.
Component Location. (Group 9015-10.)
RH60123,0000C75 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 3 control pressure sensor (B57). Disconnect pump 2 control pressure sensor (B38). Connect pump 3 control pressure sensor connector (B57) to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011207.03—Pump 3 Flow Control Pressure Sensor Circuit High Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 3 control pressure sensor (B57) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-22
RH60123,0000C75 -19-12AUG15-4/6
041818
PN=56
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 3 control pressure sensor (B57). Turn key switch to ON position. Check between pin 2 of pump 3 control pressure sensor connector (B57) 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. RH60123,0000C75 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 3 control pressure sensor (B57). Disconnect main controller connectors (X31—X36). Check for continuity between pin 28 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. RH60123,0000C75 -19-12AUG15-6/6
011207.04 — Pump 3 Flow Control Pressure Sensor Circuit Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 control pressure sensor (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.
RH60123,0000C76 -19-12AUG15-1/7
Pump 3 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C76 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 control pressure sensor (B57) and pump harness splice connector (X97). See Pump Harness (W8) 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.)
• 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 connector. See appropriate harness.
Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-23
RH60123,0000C76 -19-12AUG15-3/7
041818
PN=57
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 3 control pressure sensor (B57). Disconnect pump 2 control pressure sensor (B38). Connect pump 3 control pressure sensor connector (B57) to pump 2 control pressure sensor (B38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011207.04—Pump 3 Flow Control Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 3 control pressure sensor (B57) malfunction. Replace sensor. RH60123,0000C76 -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 3 control pressure sensor (B57). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 3 control pressure sensor connector (B57) for approximately 5 V..
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C76 -19-12AUG15-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 3 control pressure sensor (B57) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of pump 3 control pressure sensor connector (B57) and pin 28 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. RH60123,0000C76 -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 3 control pressure sensor (B57) disconnected. Check for continuity between pin 2 of pump 3 control pressure sensor connector (B57) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C76 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-24
041818
PN=58
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 (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.
RH60123,0000C77 -19-12AUG15-1/6
Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C77 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 control pressure sensor (B38) and pump harness splice connector (X97). 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
RH60123,0000C77 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 2 control pressure sensor (B38). Disconnect pump 1 control pressure sensor (B36). Connect pump 2 control pressure sensor connector (B38) to pump 1 control pressure sensor (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.03—Pump 2 Flow Control Pressure Sensor Circuit High Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 2 control pressure sensor (B38) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-25
RH60123,0000C77 -19-12AUG15-4/6
041818
PN=59
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (B38). Turn key switch to ON position. Check between pin 2 of pump 2 control pressure sensor connector (B38) 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. RH60123,0000C77 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (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. RH60123,0000C77 -19-12AUG15-6/6
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 (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. RH60123,0000C78 -19-20AUG12-1/7
Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C78 -19-20AUG12-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 control pressure sensor (B38) and pump harness splice connector (X97). 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) Component Location. (Group 9015-10.)
• Pump harness splice connector (X97). See Pump Harness (W8) Component
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-26
RH60123,0000C78 -19-20AUG12-3/7
041818
PN=60
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Disconnect pump 2 control pressure sensor (B38). Disconnect pump 1 control pressure sensor (B36). Connect pump 2 control pressure sensor connector (B38) to pump 1 control pressure sensor (B36). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011208.04—Pump 2 Flow Control Pressure Sensor Circuit Low Input.
YES: Go to Voltage Check.
Is code active?
NO: Pump 2 control pressure sensor (B38) malfunction. Replace sensor. RH60123,0000C78 -19-20AUG12-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect pump 2 control pressure sensor (B38). Turn key switch to ON position. Check voltage between pin 1 and pin 3 of pump 2 control pressure sensor connector (B38) for approximately 5 V..
YES: Go to Open Circuit Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C78 -19-20AUG12-5/7
• 4
Open Circuit Check
Key switch in OFF position.
Pump 2 control pressure sensor (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 connector (B38) and pin 13 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. RH60123,0000C78 -19-20AUG12-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Pump 2 control pressure sensor (B38) disconnected. Check for continuity between pin 2 of pump 2 control pressure sensor connector (B38) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C78 -19-20AUG12-7/7
TM12660 (18APR18)
9001-10-27
041818
PN=61
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.
RH60123,0000C79 -19-12AUG15-1/6
Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C79 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 30-pin connector D (X34). 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.)
RH60123,0000C79 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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 YES: Go to Voltage Check. Circuit High Input. Is code active?
NO: Swing pressure sensor (B33) malfunction. Replace sensor. RH60123,0000C79 -19-12AUG15-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect swing pressure sensor (B33). Turn key switch to ON position. Check between pin 2 of swing pressure sensor connector (B33) 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. Continued on next page
TM12660 (18APR18)
9001-10-28
RH60123,0000C79 -19-12AUG15-5/6
041818
PN=62
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. RH60123,0000C79 -19-12AUG15-6/6
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.
RH60123,0000C7A -19-12AUG15-1/7
Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C7A -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Swing pressure sensor (B33) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector E (X35). See Cab Harness (W1) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 30-pin connector D (X34). 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.)
RH60123,0000C7A -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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 YES: Go to Voltage Check. Circuit Low Input. Is code active?
NO: Swing pressure sensor (B33) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-29
RH60123,0000C7A -19-12AUG15-4/7
041818
PN=63
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 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. RH60123,0000C7A -19-12AUG15-5/7
• 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 E (X34).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C7A -19-12AUG15-6/7
• 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. RH60123,0000C7A -19-12AUG15-7/7
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.
RH60123,0000C7B -19-12AUG15-1/6
Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-30
RH60123,0000C7B -19-12AUG15-2/6
041818
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:
• Boom up pressure sensor (B30) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C7B -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Boom up pressure sensor (B30) malfunction. Replace sensor. RH60123,0000C7B -19-12AUG15-4/6
• 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: Go to Harness Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C7B -19-12AUG15-5/6
• 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. RH60123,0000C7B -19-12AUG15-6/6
TM12660 (18APR18)
9001-10-31
041818
PN=65
Main Controller (MCZ) Diagnostic Trouble Codes
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.
RH60123,0000C7C -19-12AUG15-1/7
Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C7C -19-12AUG15-2/7
• 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 (X98) and pump harness-to-machine harness
connector (X40). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C7C -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Boom up pressure sensor (B30) malfunction. Replace sensor. RH60123,0000C7C -19-12AUG15-4/7
• 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. Continued on next page
TM12660 (18APR18)
9001-10-32
RH60123,0000C7C -19-12AUG15-5/7
041818
PN=66
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. RH60123,0000C7C -19-12AUG15-6/7
• 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. RH60123,0000C7C -19-12AUG15-7/7
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.
RH60123,0000C7D -19-12AUG15-1/6
Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C7D -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-33
RH60123,0000C7D -19-12AUG15-3/6
041818
PN=67
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Arm in pressure sensor (B31) malfunction. Replace sensor. RH60123,0000C7D -19-12AUG15-4/6
• 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: Go to Harness Check.
Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C7D -19-12AUG15-5/6
• 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. RH60123,0000C7D -19-12AUG15-6/6
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.
RH60123,0000C7E -19-12AUG15-1/7
Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-34
RH60123,0000C7E -19-12AUG15-2/7
041818
PN=68
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm in pressure sensor (B31) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), 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 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C7E -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Arm in pressure sensor (B31) malfunction. Replace sensor. RH60123,0000C7E -19-12AUG15-4/7
• 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. RH60123,0000C7E -19-12AUG15-5/7
• 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. Continued on next page
TM12660 (18APR18)
9001-10-35
RH60123,0000C7E -19-12AUG15-6/7
041818
PN=69
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. RH60123,0000C7E -19-12AUG15-7/7
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.
RH60123,0000C7F -19-12AUG15-1/6
Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C7F -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C7F -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Travel pressure sensor (B34) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-36
RH60123,0000C7F -19-12AUG15-4/6
041818
PN=70
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 between pin 2 of travel pressure sensor connector (B34) 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. RH60123,0000C7F -19-12AUG15-5/6
• 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. RH60123,0000C7F -19-12AUG15-6/6
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.
RH60123,0000C80 -19-12AUG15-1/7
Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C80 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Travel pressure sensor (B34) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), 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 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-37
RH60123,0000C80 -19-12AUG15-3/7
041818
PN=71
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Travel pressure sensor (B34) malfunction. Replace sensor. RH60123,0000C80 -19-12AUG15-4/7
• 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. RH60123,0000C80 -19-12AUG15-5/7
• 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. RH60123,0000C80 -19-12AUG15-6/7
• 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. RH60123,0000C80 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-38
041818
PN=72
Main Controller (MCZ) Diagnostic Trouble Codes
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.
RH60123,0000C81 -19-12AUG15-1/6
Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure RH60123,0000C81 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C81 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Front attachment pressure sensor (B32) malfunction. Replace sensor. RH60123,0000C81 -19-12AUG15-4/6
• 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: Go to Harness ground for approximately 0.0 V. Check. Is correct voltage indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM12660 (18APR18)
9001-10-39
RH60123,0000C81 -19-12AUG15-5/6
041818
PN=73
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. RH60123,0000C81 -19-12AUG15-6/6
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.
RH60123,0000C82 -19-12AUG15-1/7
Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C82 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Front attachment pressure sensor (B32) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3), 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 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C82 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
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.
YES: Go to Voltage Check.
Is code active?
NO: Front attachment pressure sensor (B32) malfunction. Replace sensor. Continued on next page
TM12660 (18APR18)
9001-10-40
RH60123,0000C82 -19-12AUG15-4/7
041818
PN=74
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. RH60123,0000C82 -19-12AUG15-5/7
• 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 13 of cab harness-to-main controller 30-pin connector D (X34). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C82 -19-12AUG15-6/7
• 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. RH60123,0000C82 -19-12AUG15-7/7
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 in pressure sensor (B39) 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.
RH60123,0000C83 -19-12AUG15-1/6
Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-41
RH60123,0000C83 -19-12AUG15-2/6
041818
PN=75
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Bucket in pressure sensor (B39) and machine harness splice connector (X98). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and cab harness-to-main
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 30-pin connector D (X34). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C83 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Switch bucket in pressure sensor connector (B39) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011325.03—Bucket Roll-In Pilot Pressure YES: Go to Voltage Check. Sensor Circuit High Input. Is code active?
NO: Bucket in pressure sensor (B39) malfunction. Replace sensor. RH60123,0000C83 -19-12AUG15-4/6
• 3
Voltage Check
Key switch in OFF position.
Disconnect bucket in pressure sensor (B39). Turn key switch to ON position. Check between pin 2 of bucket in pressure sensor connector (B39) 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. RH60123,0000C83 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Disconnect bucket in pressure sensor (B39). 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. RH60123,0000C83 -19-12AUG15-6/6
TM12660 (18APR18)
9001-10-42
041818
PN=76
Main Controller (MCZ) Diagnostic Trouble Codes
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 in pressure sensor (B39) 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.
RH60123,0000C84 -19-12AUG15-1/7
Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure RH60123,0000C84 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Bucket in pressure sensor (B39) and machine harness splice connector (X98). 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 connector. See appropriate harness.
controller 30-pin connector D (X34), and cab harness-to-main controller 26-pin connector E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C84 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate sensors after check is completed.
Switch bucket in pressure sensor connector (B39) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011325.04—Bucket Roll-In Pilot Pressure YES: Go to Voltage Check. Sensor Circuit Low Input. Is code active?
NO: Bucket in pressure sensor (B39) malfunction. Replace sensor. RH60123,0000C84 -19-12AUG15-4/7
• 3
Voltage Check
Key switch in OFF position.
Disconnect bucket in pressure sensor (B39). Turn key switch to ON position. Check between pin 2 of bucket in pressure sensor connector (B39) 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. Continued on next page
TM12660 (18APR18)
9001-10-43
RH60123,0000C84 -19-12AUG15-5/7
041818
PN=77
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Open Circuit Check
Key switch in OFF position.
Bucket in pressure sensor connector (B39) disconnected. Disconnect cab harness-to-main controller 30-pin connector D (X34). Check for continuity between pin 2 of bucket in pressure sensor connector (B39) and pin 8 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. RH60123,0000C84 -19-12AUG15-6/7
• 5
Short Circuit Check
Key switch in OFF position.
Bucket in pressure sensor connector (B39) disconnected. Check for continuity between pin 2 of bucket in pressure sensor connector (B39) and machine ground.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. RH60123,0000C84 -19-12AUG15-7/7
011400.02 — Pump 2 Flow Rate Limit Solenoid Feedback Abnormal Feedback
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.
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.
RH60123,0000C85 -19-12AUG15-1/8
Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure RH60123,0000C85 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness
connector (X40). See Pump Harness (W8) 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
TM12660 (18APR18)
9001-10-44
RH60123,0000C85 -19-12AUG15-3/8
041818
PN=78
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 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid connector (Y20) to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.02—Pump 2 Flow Rate Limit Solenoid Feedback Abnormal.
YES: Go to Continuity Check.
Is code active?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. RH60123,0000C85 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid connector (Y20) to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid connector (Y20) to pin 6 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. RH60123,0000C85 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Pump 2 flow rate limit solenoid (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid connector (Y20) 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. RH60123,0000C85 -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 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.
Continued on next page
TM12660 (18APR18)
9001-10-45
RH60123,0000C85 -19-12AUG15-7/8
041818
PN=79
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. RH60123,0000C85 -19-12AUG15-8/8
011400.03 — Pump 2 Flow Rate Limit Solenoid 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.
RH60123,0000C86 -19-12AUG15-1/7
Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure RH60123,0000C86 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness
connector (X40). See Pump Harness (W8) 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.)
RH60123,0000C86 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid connector (Y20) to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.03—Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-46
RH60123,0000C86 -19-12AUG15-4/7
041818
PN=80
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid connector (Y20) to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid connector (Y20) to pin 6 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. RH60123,0000C86 -19-12AUG15-5/7
• 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. RH60123,0000C86 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. RH60123,0000C86 -19-12AUG15-7/7
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.
RH60123,0000C87 -19-12AUG15-1/7
Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-47
RH60123,0000C87 -19-12AUG15-2/7
041818
PN=81
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 2 flow rate limit solenoid (Y20) and pump harness-to-machine harness
connector (X40). See Pump Harness (W8) Component Location. (Group 9015-10.)
• Cab harness-to-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.)
RH60123,0000C87 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Disconnect torque control solenoid (marked ST) (Y21). Connect pump 2 flow rate limit solenoid connector (Y20) to torque control solenoid (Y21). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011400.04—Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. RH60123,0000C87 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Disconnect main controller connectors (X31). Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid connector (Y20) to pin 7 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 2 flow rate limit solenoid connector (Y20) to pin 6 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. Continued on next page
TM12660 (18APR18)
9001-10-48
RH60123,0000C87 -19-12AUG15-5/7
041818
PN=82
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Pump 2 flow rate limit solenoid (Y20) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 2 flow rate limit solenoid connector (Y20) 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. RH60123,0000C87 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 2 flow rate limit solenoid (Y20). Test pump 2 flow rate limit solenoid (Y20) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 2 flow rate limit solenoid (Y20) within specification?
NO: Pump 2 flow rate limit solenoid (Y20) malfunction. Replace solenoid. RH60123,0000C87 -19-12AUG15-7/7
011401.02 — Pump 1 and 2 Torque P/S Valve Abnormal Feedback Torque control solenoid (marked ST) (Y21) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000C88 -19-12AUG15-1/8
Pump 1 and 2 Torque P/S Valve Abnormal Feedback Diagnostic Procedure RH60123,0000C88 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location. (Group 9015-10.)
• Cab harness-to-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
TM12660 (18APR18)
9001-10-49
RH60123,0000C88 -19-12AUG15-3/8
041818
PN=83
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 torque control solenoid (marked ST) (Y21). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect torque control solenoid connector (Y21) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.02—Torque Control Solenoid Valve Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. RH60123,0000C88 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of torque control solenoid connector (Y21) to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid connector (Y21) to pin 2 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C88 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Torque control solenoid (Y21) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of torque control solenoid connector (Y21) 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. RH60123,0000C88 -19-12AUG15-6/8
• 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.
Continued on next page
TM12660 (18APR18)
9001-10-50
RH60123,0000C88 -19-12AUG15-7/8
041818
PN=84
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (Y21) within specification?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. RH60123,0000C88 -19-12AUG15-8/8
011401.03 — Pump 1 and 2 Torque P/S Valve Feedback High Current Torque control solenoid (marked ST) (Y21) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000C89 -19-12AUG15-1/7
Pump 1 and 2 Torque P/S Valve Feedback High Current Diagnostic Procedure RH60123,0000C89 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Torque control solenoid (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) Component Location. (Group 9015-10.)
• Cab harness-to-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.)
RH60123,0000C89 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
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 connector (Y21) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.03—Torque Control Solenoid Valve Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-51
RH60123,0000C89 -19-12AUG15-4/7
041818
PN=85
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of torque control solenoid connector (Y21) to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid connector (Y21) to pin 2 cab harness-to-main controller 31-pin connector A (X31).
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C89 -19-12AUG15-5/7
• 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. RH60123,0000C89 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (Y21) within specification?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. RH60123,0000C89 -19-12AUG15-7/7
011401.04 — Pump 1 and 2 Torque P/S Valve Feedback Low Current 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.
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.
RH60123,0000C8A -19-12AUG15-1/7
Pump 1 and 2 Torque P/S Valve Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-52
RH60123,0000C8A -19-12AUG15-2/7
041818
PN=86
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 (Y21) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) 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.)
RH60123,0000C8A -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
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 connector (Y21) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011401.04—Torque Control Solenoid Valve Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. RH60123,0000C8A -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Disconnect main controller connectors (X31 and X32). Check for continuity between:
• Pin 1 of torque control solenoid connector (Y21) to pin 3 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of torque control solenoid connector (Y21) to pin 2 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. Continued on next page
TM12660 (18APR18)
9001-10-53
RH60123,0000C8A -19-12AUG15-5/7
041818
PN=87
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Torque control solenoid (Y21) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of torque control solenoid connector (Y21) 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. RH60123,0000C8A -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect torque control solenoid (Y21). Test torque control solenoid (Y21) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is torque control solenoid (Y21) within specification?
NO: Torque control solenoid (Y21) malfunction. Replace solenoid. RH60123,0000C8A -19-12AUG15-7/7
011402.02 — 5-Spool Solenoid Valve Unit (SF) Abnormal Feedback
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.
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.
RH60123,0000C8B -19-12AUG15-1/8
5-Spool Solenoid Valve Unit (SF) Abnormal Feedback Diagnostic Procedure RH60123,0000C8B -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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
TM12660 (18APR18)
9001-10-54
RH60123,0000C8B -19-12AUG15-3/8
041818
PN=88
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 dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid connector (Y22) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.02—5-Spool Solenoid Valve Unit (SF) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. RH60123,0000C8B -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid connector (Y22) to pin 14 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C8B -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Dig regenerative solenoid (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (Y22) to machine ground. • Pin 17 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. RH60123,0000C8B -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) 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
TM12660 (18APR18)
9001-10-55
NO: Go to Solenoid Check. RH60123,0000C8B -19-12AUG15-7/8
041818
PN=89
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (Y22) within specification?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. RH60123,0000C8B -19-12AUG15-8/8
011402.03 — 5-Spool Solenoid Valve Unit (SF) Feedback High Input
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.
RH60123,0000C8C -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SF) Feedback High Input Diagnostic Procedure RH60123,0000C8C -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Dig regenerative solenoid (Y22) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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.)
RH60123,0000C8C -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid connector (Y22) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.03—5-Spool Solenoid Valve Unit (SF) Feedback High Input.
YES: Go to Continuity Check.
Is code active?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-56
RH60123,0000C8C -19-12AUG15-4/7
041818
PN=90
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid connector (Y22) to pin 14 cab harness-to-main
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C8C -19-12AUG15-5/7
• 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?
NO: Go to Solenoid Check. RH60123,0000C8C -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (Y22) within specification?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. RH60123,0000C8C -19-12AUG15-7/7
011402.04 — 5-Spool Solenoid Valve Unit (SF) Feedback Low Input
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.
RH60123,0000C8D -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SF) Feedback Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-57
RH60123,0000C8D -19-12AUG15-2/7
041818
PN=91
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 (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.)
RH60123,0000C8D -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect dig regenerative solenoid (marked SF) (Y22). Disconnect arm regenerative solenoid (marked SC) (Y23). Connect dig regenerative solenoid connector (Y22) to arm regenerative solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011402.04—5-Spool Solenoid Valve Unit (SF) Feedback Low Input.
YES: Go to Continuity Check.
Is code active?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. RH60123,0000C8D -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (Y22) to pin 15 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of dig regenerative solenoid connector (Y22) to pin 14 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
Continued on next page
TM12660 (18APR18)
9001-10-58
RH60123,0000C8D -19-12AUG15-5/7
041818
PN=92
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Dig regenerative solenoid (Y22) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of dig regenerative solenoid connector (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. RH60123,0000C8D -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect dig regenerative solenoid (Y22). Test dig regenerative solenoid (Y22) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is dig regenerative solenoid (Y22) within specification?
NO: Dig regenerative solenoid (Y22) malfunction. Replace solenoid. RH60123,0000C8D -19-12AUG15-7/7
011403.02 — 5-Spool Solenoid Valve Unit (SC) Abnormal Feedback
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.
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.
RH60123,0000C8E -19-12AUG15-1/8
5-Spool Solenoid Valve Unit (SC) Abnormal Feedback Diagnostic Procedure RH60123,0000C8E -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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
TM12660 (18APR18)
9001-10-59
RH60123,0000C8E -19-12AUG15-3/8
041818
PN=93
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 arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid connector (Y23) to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.02—5-Spool Solenoid Valve Unit (SC) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. RH60123,0000C8E -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid connector (Y23) to pin 10 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C8E -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Arm regenerative solenoid (Y23) disconnected. Cab harness-to-main controller 31-pin connector A disconnected. Check for continuity between:
• Pin 1 of arm regenerative solenoid connector (Y23) to machine ground. • Pin 10 of cab harness-to-main controller 31-pin connector A to machine ground. Is continuity indicated?
YES: Short to ground. Repair or replace harness. See appropriate harness. NO: Go to Harness Check. RH60123,0000C8E -19-12AUG15-6/8
• 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? Continued on next page
TM12660 (18APR18)
9001-10-60
NO: Go to Solenoid Check. RH60123,0000C8E -19-12AUG15-7/8
041818
PN=94
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (Y23) within specification?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. RH60123,0000C8E -19-12AUG15-8/8
011403.03 — 5-Spool Solenoid Valve Unit (SC) Feedback High Input
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.
RH60123,0000C8F -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SC) Feedback High Input Diagnostic Procedure RH60123,0000C8F -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm regenerative solenoid (Y23) and cab harness-to-machine harness 100-pin
connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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.)
RH60123,0000C8F -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid connector (Y23) to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.03—5-Spool Solenoid Valve Unit (SC) Feedback High Input.
YES: Go to Continuity Check.
Is code active?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-61
RH60123,0000C8F -19-12AUG15-4/7
041818
PN=95
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid connector (Y23) to pin 10 cab harness-to-main controller 31-pin connector A (X31).
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C8F -19-12AUG15-5/7
• 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?
NO: Go to Solenoid Check. RH60123,0000C8F -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (Y23) within specification?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. RH60123,0000C8F -19-12AUG15-7/7
011403.04 — 5-Spool Solenoid Valve Unit (SC) Feedback Low Input
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.
RH60123,0000C90 -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SC) Feedback Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-62
RH60123,0000C90 -19-12AUG15-2/7
041818
PN=96
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 (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.)
RH60123,0000C90 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm regenerative solenoid (marked SC) (Y23). Disconnect dig regenerative solenoid (marked SF) (Y22). Connect arm regenerative solenoid connector (Y23) to dig regenerative solenoid (Y22). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011403.04—5-Spool Solenoid Valve Unit (SC) Feedback Low Input.
YES: Go to Continuity Check.
Is code active?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. RH60123,0000C90 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm regenerative solenoid connector (Y23) to pin 11 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm regenerative solenoid 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. Continued on next page
TM12660 (18APR18)
9001-10-63
RH60123,0000C90 -19-12AUG15-5/7
041818
PN=97
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Arm regenerative solenoid (Y23) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm regenerative solenoid 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. RH60123,0000C90 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect arm regenerative solenoid (Y23). Test arm regenerative solenoid (Y23) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is arm regenerative solenoid (Y23) within specification?
NO: Arm regenerative solenoid (Y23) malfunction. Replace solenoid. RH60123,0000C90 -19-12AUG15-7/7
011406.02 — Pump 3 Torque P/S Valve Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 torque control solenoid (marked SU) (Y28) 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.
RH60123,0000C91 -19-12AUG15-1/8
Pump 3 Torque P/S Valve Abnormal Feedback Diagnostic Procedure RH60123,0000C91 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 torque control solenoid (Y28) and pump harness-to-machine harness
connector (X40). See Pump Harness (W8) 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
TM12660 (18APR18)
9001-10-64
RH60123,0000C91 -19-12AUG15-3/8
041818
PN=98
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 3 torque control solenoid (marked SU) (Y28). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect pump 3 torque control solenoid connector (Y28) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011406.02—Pump 3 Torque P/S Valve Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Pump 3 torque control solenoid (Y28) malfunction. Replace solenoid. RH60123,0000C91 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 3 torque control solenoid (marked SU) (Y28). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 3 torque control solenoid connector (Y28) to pin 4 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 3 torque control solenoid connector (Y28) to pin 5 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. RH60123,0000C91 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Pump 3 torque control solenoid (marked SU) (Y28) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 3 torque control solenoid connector (Y28) to machine ground. • Pin 5 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. RH60123,0000C91 -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 5 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
TM12660 (18APR18)
9001-10-65
RH60123,0000C91 -19-12AUG15-7/8
041818
PN=99
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Pump 3 torque control solenoid (marked SU) (Y28) disconnected. Test pump 3 torque control solenoid (marked SU) (Y28) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 3 torque control solenoid (marked SU) (Y28) within specification?
NO: Pump 3 torque control solenoid (marked SU) (Y28) malfunction. Replace solenoid. RH60123,0000C91 -19-12AUG15-8/8
011406.03 — Pump 3 Torque P/S Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 torque control solenoid (marked SU) (Y28) 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.
RH60123,0000C92 -19-12AUG15-1/7
Pump 3 Torque P/S Valve Feedback High Current Diagnostic Procedure RH60123,0000C92 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 torque control solenoid (marked SU) (Y28) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) 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.)
RH60123,0000C92 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 3 torque control solenoid (marked SU) (Y28). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect pump 3 torque control solenoid (Y28) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011406.03—Pump 3 Torque P/S Valve Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 3 torque control solenoid (Y28) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-66
RH60123,0000C92 -19-12AUG15-4/7
041818
PN=100
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 3 torque control solenoid (Y28). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 3 torque control solenoid (Y28) to pin 4 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 3 torque control solenoid (Y28) to pin 5 cab harness-to-main controller YES: Go to Harness 31-pin connector A (X31). Check. Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C92 -19-12AUG15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 5 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. RH60123,0000C92 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect pump 3 torque control solenoid (Y28). Test pump 3 torque control solenoid (Y28) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 3 torque control solenoid (Y28) within specification?
NO: Pump 3 torque control solenoid (Y28) malfunction. Replace solenoid. RH60123,0000C92 -19-12AUG15-7/7
011406.04 — Pump 3 Torque P/S Valve Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Pump 3 torque control solenoid (marked SU) (Y28) 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.
RH60123,0000C93 -19-12AUG15-1/7
Pump 3 Torque P/S Valve Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-67
RH60123,0000C93 -19-12AUG15-2/7
041818
PN=101
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Pump 3 torque control solenoid (marked SU) (Y28) and pump harness-to-machine harness connector (X40). See Pump Harness (W8) 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.)
RH60123,0000C93 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect pump 3 torque control solenoid (marked SU) (Y28). Disconnect pump 2 flow rate limit solenoid (marked SB) (Y20). Connect pump 3 torque control solenoid connector (Y28) to pump 2 flow rate limit solenoid (Y20). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011406.04—Pump 3 Torque P/S Valve Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Pump 3 torque control solenoid (Y28) malfunction. Replace solenoid. RH60123,0000C93 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect pump 3 torque control solenoid (marked SU) (Y28). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of pump 3 torque control solenoid connector (Y28) to pin 4 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of pump 3 torque control solenoid connector (Y28) to pin 5 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. Continued on next page
TM12660 (18APR18)
9001-10-68
RH60123,0000C93 -19-12AUG15-5/7
041818
PN=102
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Pump 3 torque control solenoid (marked SU) (Y28) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of pump 3 torque control solenoid connector (Y28) to machine ground. • Pin 5 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. RH60123,0000C93 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Pump 3 torque control solenoid (marked SU) (Y28) disconnected. Test pump 3 torque control solenoid (Y28) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is pump 3 torque control solenoid (Y28) within specification?
NO: Pump 3 torque control solenoid (marked SU) (Y28) malfunction. Replace solenoid. RH60123,0000C93 -19-12AUG15-7/7
011407.02 — 5-Spool Solenoid Valve Unit (SI) Abnormal Feedback Power dig solenoid (marked SI) (Y24) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000C94 -19-12AUG15-1/8
5-Spool Solenoid Valve Unit (SI) Abnormal Feedback Diagnostic Procedure RH60123,0000C94 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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
TM12660 (18APR18)
9001-10-69
RH60123,0000C94 -19-12AUG15-3/8
041818
PN=103
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 power dig solenoid (marked SI) (Y24). Disconnect arm solenoid (marked SC) (Y23). Connect power dig solenoid connector (Y24) to arm solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.02—5-Spool Solenoid Valve Unit (SI) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. RH60123,0000C94 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of power dig solenoid connector (Y24) to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig solenoid connector (Y24) to pin 13 cab harness-to-main controller
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
31-pin connector A (X31).
RH60123,0000C94 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Power dig solenoid (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of power dig solenoid connector (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. RH60123,0000C94 -19-12AUG15-6/8
• 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? Continued on next page
TM12660 (18APR18)
9001-10-70
NO: Go to Solenoid Check. RH60123,0000C94 -19-12AUG15-7/8
041818
PN=104
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid YES: Checks complete. Test. (Group 9015-20.) Is power dig solenoid (Y24) within specification?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. RH60123,0000C94 -19-12AUG15-8/8
011407.03 — 5-Spool Solenoid Valve Unit (SI) Feedback High Input Power dig solenoid (marked SI) (Y24) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000C95 -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SI) Feedback High Input Diagnostic Procedure RH60123,0000C95 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Power dig solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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.)
RH60123,0000C95 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect power dig solenoid (marked SI) (Y24). Disconnect arm solenoid (marked SC) (Y23). Connect power dig solenoid connector (Y24) to arm solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.03—5-Spool Solenoid Valve Unit (SI) Feedback High Input.
YES: Go to Continuity Check.
Is code active?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-71
RH60123,0000C95 -19-12AUG15-4/7
041818
PN=105
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of power dig solenoid connector (Y24) to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig solenoid connector (Y24) to pin 13 cab harness-to-main controller
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
31-pin connector A (X31).
RH60123,0000C95 -19-12AUG15-5/7
• 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?
NO: Go to Solenoid Check. RH60123,0000C95 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid YES: Checks complete. Test. (Group 9015-20.) Is power dig solenoid (Y24) within specification?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. RH60123,0000C95 -19-12AUG15-7/7
011407.04 — 5-Spool Solenoid Valve Unit (SI) Feedback Low Input Power dig solenoid (marked SI) (Y24) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in. RH60123,0000C96 -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SI) Feedback Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-72
RH60123,0000C96 -19-12AUG15-2/7
041818
PN=106
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 solenoid (Y24) and cab harness-to-machine harness 100-pin connector (X3). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 31-pin connector A (X31). See Cab Harness (W1)
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.)
RH60123,0000C96 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect power dig solenoid (marked SI) (Y24). Disconnect arm solenoid (marked SC) (Y23). Connect power dig solenoid connector (Y24) to arm solenoid (Y23). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011407.04—5-Spool Solenoid Valve Unit (SI) Feedback Low Input.
YES: Go to Continuity Check.
Is code active?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. RH60123,0000C96 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of power dig solenoid connector (Y24) to pin 12 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of power dig solenoid connector (Y24) to pin 13 cab harness-to-main controller
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
31-pin connector A (X31).
Continued on next page
TM12660 (18APR18)
9001-10-73
RH60123,0000C96 -19-12AUG15-5/7
041818
PN=107
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Power dig solenoid (Y24) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of power dig solenoid connector (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. RH60123,0000C96 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect power dig solenoid (Y24). Test power dig solenoid (Y24) and compare to specification. See Proportional Solenoid YES: Checks complete. Test. (Group 9015-20.) Is power dig solenoid (Y24) within specification?
NO: Power dig solenoid (Y24) malfunction. Replace solenoid. RH60123,0000C96 -19-12AUG15-7/7
011408.02 — 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback
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.
Exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
RH60123,0000C97 -19-12AUG15-1/8
2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback Diagnostic Procedure RH60123,0000C97 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Exhaust filter regulator solenoid (marked SJ) (Y13) 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.)
Continued on next page
TM12660 (18APR18)
9001-10-74
RH60123,0000C97 -19-12AUG15-3/8
041818
PN=108
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 exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Connect exhaust filter regulator solenoid connector (marked SJ) (Y13) to exhaust filter regulator solenoid (marked SZ) (Y12). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011408.02—2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. RH60123,0000C97 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 16 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 17 cab
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check.
harness-to-main controller 31-pin connector A (X31).
RH60123,0000C97 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Exhaust filter regulator solenoid (marked SJ) (Y13) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SJ) (Y13) to machine ground. • Pin 17 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. RH60123,0000C97 -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 17 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
TM12660 (18APR18)
9001-10-75
NO: Go to Solenoid Check. RH60123,0000C97 -19-12AUG15-7/8
041818
PN=109
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Test exhaust filter regulator solenoid (marked SJ) (Y13) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SJ) (Y13) within specification?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. RH60123,0000C97 -19-12AUG15-8/8
011408.03 — 2-Spool Solenoid Valve Unit (SJ) Feedback High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) current above 920 mA.
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.
RH60123,0000C98 -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (SJ) Feedback High Input Diagnostic Procedure RH60123,0000C98 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Exhaust filter regulator solenoid (marked SJ) (Y13) 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.)
RH60123,0000C98 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Connect exhaust filter regulator solenoid connector (marked SJ) (Y13) to exhaust filter regulator solenoid (marked SZ) (Y12). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011408.03—2-Spool Solenoid Valve Unit (SJ) Feedback High Input.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-76
RH60123,0000C98 -19-12AUG15-4/7
041818
PN=110
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect main controller connectors (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 16 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 17 cab harness-to-main controller 31-pin connector A (X31).
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check. RH60123,0000C98 -19-12AUG15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 17 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. RH60123,0000C98 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Test exhaust filter regulator solenoid (marked SJ) (Y13) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SJ) (Y13) within specification?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. RH60123,0000C98 -19-12AUG15-7/7
011408.04 — 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) current below 70 mA.
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.
RH60123,0000C99 -19-21MAY15-1/7
2-Spool Solenoid Valve Unit (SJ) Feedback Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-77
RH60123,0000C99 -19-21MAY15-2/7
041818
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.
• Exhaust filter regulator solenoid (marked SJ) (Y13) 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.)
RH60123,0000C99 -19-21MAY15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Connect exhaust filter regulator solenoid connector (marked SJ) (Y13) to exhaust filter regulator solenoid (marked SZ) (Y12). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 11408.04—2-Spool Solenoid Valve Unit (SJ) Feedback Low Input.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. RH60123,0000C99 -19-21MAY15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Disconnect main controller connectors (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 16 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SJ) (Y13) to pin 17 cab harness-to-main controller 31-pin connector A (X31).
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check. Continued on next page
TM12660 (18APR18)
9001-10-78
RH60123,0000C99 -19-21MAY15-5/7
041818
PN=112
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Exhaust filter regulator solenoid (marked SJ) (Y13) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SJ) (Y13) to machine ground. • Pin 17 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. RH60123,0000C99 -19-21MAY15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Test exhaust filter regulator solenoid (marked SJ) (Y13) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SJ) (Y13) within specification?
NO: Exhaust filter regulator solenoid (marked SJ) (Y13) malfunction. Replace solenoid. RH60123,0000C99 -19-21MAY15-7/7
011409.02 — 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Exhaust filter regulator solenoid (pump 1) (marked SZ) (Y12) 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.
RH60123,0000C9A -19-12AUG15-1/8
2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback Diagnostic Procedure RH60123,0000C9A -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Exhaust filter regulator solenoid (marked SZ) (Y12) 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.)
Continued on next page
TM12660 (18APR18)
9001-10-79
RH60123,0000C9A -19-12AUG15-3/8
041818
PN=113
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 exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Connect exhaust filter regulator solenoid connector (marked SZ) (Y12) to exhaust filter regulator solenoid (marked SJ) (Y13). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011409.02—2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. RH60123,0000C9A -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 19 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 18 cab
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check.
harness-to-main controller 31-pin connector A (X31).
RH60123,0000C9A -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Exhaust filter regulator solenoid (marked SZ) (Y12) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SZ) (Y12) to machine ground. • Pin 18 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. RH60123,0000C9A -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 18 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
TM12660 (18APR18)
9001-10-80
NO: Go to Solenoid Check. RH60123,0000C9A -19-12AUG15-7/8
041818
PN=114
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Test exhaust filter regulator solenoid (marked SZ) (Y12) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SZ) (Y12) within specification?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. RH60123,0000C9A -19-12AUG15-8/8
011409.03 — 2-Spool Solenoid Valve Unit (SZ) Feedback High Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Exhaust filter regulator solenoid (pump 1) (marked SZ) (Y12) 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.
RH60123,0000C9B -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (SZ) Feedback High Input Diagnostic Procedure RH60123,0000C9B -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Exhaust filter regulator solenoid (marked SZ) (Y12) 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.)
RH60123,0000C9B -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Connect exhaust filter regulator solenoid connector (marked SZ) (Y12) to exhaust filter regulator solenoid (marked SJ) (Y13). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011409.03—2-Spool Solenoid Valve Unit (SZ) Feedback High Input.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-81
RH60123,0000C9B -19-12AUG15-4/7
041818
PN=115
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 19 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 18 cab
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check.
harness-to-main controller 31-pin connector A (X31).
RH60123,0000C9B -19-12AUG15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 18 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. RH60123,0000C9B -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Test exhaust filter regulator solenoid (marked SZ) (Y12) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SZ) (Y12) within specification?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. RH60123,0000C9B -19-12AUG15-7/7
011409.04 — 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input
Over torquing will result in permanent damage to connector. Torque only to specification.
Exhaust filter regulator solenoid (pump 1) (marked SZ) (Y12) 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.
RH60123,0000C9C -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (SZ) Feedback Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-82
RH60123,0000C9C -19-12AUG15-2/7
041818
PN=116
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris.
• Exhaust filter regulator solenoid (marked SZ) (Y12) 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.)
RH60123,0000C9C -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect exhaust filter regulator solenoid (marked SJ) (Y13). Connect exhaust filter regulator solenoid connector (marked SZ) (Y12) to exhaust filter regulator solenoid (marked SJ) (Y13). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011409.04—2-Spool Solenoid Valve Unit (SZ) Feedback Low Input.
YES: Go to Continuity Check.
Is code active?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. RH60123,0000C9C -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 19 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of exhaust filter regulator solenoid (marked SZ) (Y12) to pin 18 cab
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check.
harness-to-main controller 31-pin connector A (X31).
Continued on next page
TM12660 (18APR18)
9001-10-83
RH60123,0000C9C -19-12AUG15-5/7
041818
PN=117
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Exhaust filter regulator solenoid (marked SZ) (Y12) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of exhaust filter regulator solenoid (marked SZ) (Y12) to machine ground. • Pin 18 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. RH60123,0000C9C -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect exhaust filter regulator solenoid (marked SZ) (Y12). Test exhaust filter regulator solenoid (marked SZ) (Y12) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is exhaust filter regulator solenoid (marked SZ) (Y12) within specification?
NO: Exhaust filter regulator solenoid (marked SZ) (Y12) malfunction. Replace solenoid. RH60123,0000C9C -19-12AUG15-7/7
011427.02 — 5-Spool Solenoid Valve Unit (SE) Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 1 flow control solenoid (marked SE) (Y29) 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.
RH60123,0000C9D -19-12AUG15-1/7
5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure RH60123,0000C9D -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 1 flow control solenoid (Y29). 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-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
TM12660 (18APR18)
9001-10-84
RH60123,0000C9D -19-12AUG15-3/7
041818
PN=118
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 arm 1 flow control solenoid (marked SE) (Y29). Disconnect arm 2 flow control solenoid (marked SD) (Y27). Connect arm 1 flow control solenoid (Y29) to arm 2 flow control solenoid (Y27). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011427.02—5-Spool Solenoid Valve Unit (SE) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm 1 flow control solenoid (Y29) malfunction. Replace solenoid. RH60123,0000C9D -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 1 flow control solenoid (Y29). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 1 flow control solenoid connector (Y29) to pin 20 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 1 flow control solenoid connector (Y29) to pin 21 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C9D -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Arm 1 flow control solenoid (Y29) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm 1 flow control solenoid connector (Y29) to machine ground. • Pin 2 of arm 1 flow control solenoid connector (Y29) to machine ground. Is continuity indicated?
YES: Short to ground. Repair or replace harness. See appropriate harness. NO: Go to Harness Check. RH60123,0000C9D -19-12AUG15-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 21 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: Checks complete. RH60123,0000C9D -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-85
041818
PN=119
Main Controller (MCZ) Diagnostic Trouble Codes
011427.03 — 5-Spool Solenoid Valve Unit (SE) Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 1 flow control solenoid (marked SE) (Y29) 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.
RH60123,0000C9E -19-12AUG15-1/6
5-Spool Solenoid Valve Unit (SE) Feedback High Current Diagnostic Procedure RH60123,0000C9E -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 1 flow control solenoid (Y29). 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-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.)
RH60123,0000C9E -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 1 flow control solenoid (marked SE) (Y29). Disconnect arm 2 flow control solenoid (marked SD) (Y27). Connect arm 1 flow control solenoid (Y29) to arm 2 flow control solenoid (Y27). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011427.03—5-Spool Solenoid Valve Unit (SE) Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Arm 1 flow control solenoid (Y29) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-86
RH60123,0000C9E -19-12AUG15-4/6
041818
PN=120
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 1 flow control solenoid (Y29). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 1 flow control solenoid connector (Y29) to pin 20 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 1 flow control solenoid connector (Y29) to pin 21 cab harness-to-main controller 31-pin connector A (X31).
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000C9E -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 21 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: Checks complete. RH60123,0000C9E -19-12AUG15-6/6
011427.04 — 5-Spool Solenoid Valve Unit (SE) Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 1 flow control solenoid (marked SE) (Y29) 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.
RH60123,0000C9F -19-21MAY15-1/6
5-Spool Solenoid Valve Unit (SE) Feedback Low Current Diagnostic Procedure RH60123,0000C9F -19-21MAY15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 1 flow control solenoid (Y29). 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-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
TM12660 (18APR18)
9001-10-87
RH60123,0000C9F -19-21MAY15-3/6
041818
PN=121
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 arm 1 flow control solenoid (marked SE) (Y29). Disconnect arm 2 flow control solenoid (marked SD) (Y27). Connect arm 1 flow control solenoid (Y29) to arm 2 flow control solenoid (Y27). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011427.04—5-Spool Solenoid Valve Unit (SE) Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Arm 1 flow control solenoid (Y29) malfunction. Replace solenoid. RH60123,0000C9F -19-21MAY15-4/6
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 1 flow control solenoid (Y29). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 1 flow control solenoid connector (Y29) to pin 20 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 1 flow control solenoid connector (Y29) to pin 21 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
RH60123,0000C9F -19-21MAY15-5/6
• 4
Short Circuit Check
Key switch in OFF position.
Arm 1 flow control solenoid (Y29) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm 1 flow control solenoid connector (Y29) to machine ground. • Pin 2 of arm 1 flow control solenoid connector (Y29) to machine ground. Is continuity indicated?
YES: Short to ground. Repair or replace harness. See appropriate harness. NO: Checks complete. RH60123,0000C9F -19-21MAY15-6/6
011428.02 — 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
Continued on next page
TM12660 (18APR18)
9001-10-88
RH60123,0000CA0 -19-12AUG15-1/7
041818
PN=122
Main Controller (MCZ) Diagnostic Trouble Codes 5-Spool Solenoid Valve Unit (SD) Abnormal Feedback Diagnostic Procedure RH60123,0000CA0 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 2 flow control solenoid (Y27). 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-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.)
RH60123,0000CA0 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm 1 flow control solenoid (marked SE) (Y29). Connect arm 2 flow control solenoid (Y27) to arm 1 flow control solenoid (Y29). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.02—5-Spool Solenoid Valve Unit (SD) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid. RH60123,0000CA0 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 2 flow control solenoid (Y27). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 2 flow control solenoid connector (Y27) to pin 8 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 2 flow control solenoid connector (Y27) to pin 9 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 31-pin connector A (X31).
Continued on next page
TM12660 (18APR18)
9001-10-89
RH60123,0000CA0 -19-12AUG15-5/7
041818
PN=123
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Arm 2 flow control solenoid (Y27) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm 2 flow control solenoid connector (Y27) to machine ground. • Pin 2 of arm 2 flow control solenoid connector (Y27) to machine ground. Is continuity indicated?
YES: Short to ground. Repair or replace harness. See appropriate harness. NO: Go to Harness Check. RH60123,0000CA0 -19-12AUG15-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 9 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: Checks complete. RH60123,0000CA0 -19-12AUG15-7/7
011428.03 — 5-Spool Solenoid Valve Unit (SD) Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 2 flow control solenoid (marked SD) (Y27) current above 920 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000CA1 -19-12AUG15-1/6
5-Spool Solenoid Valve Unit (SG) Feedback High Current Diagnostic Procedure RH60123,0000CA1 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 2 flow control solenoid (Y27). 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-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
TM12660 (18APR18)
9001-10-90
RH60123,0000CA1 -19-12AUG15-3/6
041818
PN=124
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 arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm 1 flow control solenoid (marked SE) (Y29). Connect arm 2 flow control solenoid (Y27) to arm 1 flow control solenoid (Y29). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.03—5-Spool Solenoid Valve Unit (SG) Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid. RH60123,0000CA1 -19-12AUG15-4/6
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 2 flow control solenoid (Y27). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 2 flow control solenoid connector (Y27) to pin 8 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 2 flow control solenoid connector (Y27) to pin 9 cab harness-to-main
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Harness Check.
controller 31-pin connector A (X31).
RH60123,0000CA1 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between pin 9 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: Checks complete. RH60123,0000CA1 -19-12AUG15-6/6
011428.04 — 5-Spool Solenoid Valve Unit (SD) Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 2 flow control solenoid (marked SD) (Y27) current below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in.
RH60123,0000CA2 -19-12AUG15-1/6
5-Spool Solenoid Valve Unit (SD) Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-91
RH60123,0000CA2 -19-12AUG15-2/6
041818
PN=125
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 2 flow control solenoid (Y27). 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-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.)
RH60123,0000CA2 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 2 flow control solenoid (marked SD) (Y27). Disconnect arm 1 flow control solenoid (marked SE) (Y29). Connect arm 2 flow control solenoid (Y27) to arm 1 flow control solenoid (Y29). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011428.04—5-Spool Solenoid Valve Unit (SD) Feedback Low Current.
YES: Go to Continuity Check.
Is code active?
NO: Arm 2 flow control solenoid (Y27) malfunction. Replace solenoid. RH60123,0000CA2 -19-12AUG15-4/6
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 2 flow control solenoid (Y27). Disconnect main controller connector (X31). Check for continuity between:
• Pin 1 of arm 2 flow control solenoid connector (Y27) to pin 8 cab harness-to-main controller 31-pin connector A (X31).
• Pin 2 of arm 2 flow control solenoid connector (Y27) to pin 9 cab harness-to-main
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Go to Short Circuit Check.
controller 31-pin connector A (X31).
Continued on next page
TM12660 (18APR18)
9001-10-92
RH60123,0000CA2 -19-12AUG15-5/6
041818
PN=126
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Arm 2 flow control solenoid (Y27) disconnected. Cab harness-to-main controller 31-pin connector A (X31) disconnected. Check for continuity between:
• Pin 1 of arm 2 flow control solenoid connector (Y27) to machine ground. • Pin 2 of arm 2 flow control solenoid connector (Y27) to machine ground. Is continuity indicated?
YES: Checks complete. NO: Short to ground. Repair or replace harness. See appropriate harness. RH60123,0000CA2 -19-12AUG15-6/6
011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback
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.
Attachment relief solenoid (Y38) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
RH60123,0000CA3 -19-12AUG15-1/8
Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure RH60123,0000CA3 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Attachment relief solenoid (Y38) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CA3 -19-12AUG15-3/8
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect attachment relief solenoid (Y38). Disconnect attachment relief solenoid 2 (Y39). Connect attachment relief solenoid (Y38) to attachment relief solenoid 2 (Y39). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011434.02—Attachment Relief 1 (Upper) YES: Go to Continuity Proportional Solenoid Valve Abnormal Feedback. Check. Is code active?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-93
RH60123,0000CA3 -19-12AUG15-4/8
041818
PN=127
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid (Y38). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of attachment relief solenoid (Y38) connector to pin 16 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid (Y38) connector to pin 15 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. RH60123,0000CA3 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Attachment relief solenoid (Y38) disconnected. Cab harness-to-main controller 24-pin connector B (X33) disconnected. Check for continuity between:
• Pin 1 of attachment relief solenoid (Y38) connector to machine ground. • Pin 15 of cab harness-to-main controller 24-pin connector A (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,0000CA3 -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X33) disconnected. Check for continuity between pin 15 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,0000CA3 -19-12AUG15-7/8
• 6
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid (Y38) disconnected. Test attachment relief solenoid (Y38) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid (Y38) within specification?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. RH60123,0000CA3 -19-12AUG15-8/8
TM12660 (18APR18)
9001-10-94
041818
PN=128
Main Controller (MCZ) Diagnostic Trouble Codes
011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Attachment relief solenoid (Y38) 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.
RH60123,0000CA4 -19-12AUG15-1/7
Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure RH60123,0000CA4 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Attachment relief solenoid (Y38) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CA4 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect attachment relief solenoid (Y38). Disconnect attachment relief solenoid 2 (Y39). Connect attachment relief solenoid (Y38) to attachment relief solenoid 2 (Y39). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011434.03—Attachment Relief 1 (Upper) YES: Go to Continuity Proportional Solenoid Valve Feedback High Current. Check. Is code active?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-95
RH60123,0000CA4 -19-12AUG15-4/7
041818
PN=129
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid (Y38). Disconnect cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of attachment relief solenoid (Y38) connector to pin 16 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid (Y38) connector to pin 15 cab harness-to-main controller 24-pin connector B (X32).
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000CA4 -19-12AUG15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 16 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,0000CA4 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid (Y38) disconnected. Test attachment relief solenoid (Y38) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid (Y38) within specification?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. RH60123,0000CA4 -19-12AUG15-7/7
011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Attachment relief solenoid (Y38) 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.
RH60123,0000CA5 -19-12AUG15-1/7
Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-96
RH60123,0000CA5 -19-12AUG15-2/7
041818
PN=130
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Attachment relief solenoid (Y38) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CA5 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect attachment relief solenoid (Y38). Disconnect attachment relief solenoid 2 (Y39). Connect attachment relief solenoid (Y38) to attachment relief solenoid 2 (Y39). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011434.04—Attachment Relief 1 (Upper) YES: Go to Continuity Proportional Solenoid Valve Feedback Low Current. Check. Is code active?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. RH60123,0000CA5 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid (Y38). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of attachment relief solenoid (Y38) connector to pin 16 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid (Y38) connector to pin 15 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
TM12660 (18APR18)
9001-10-97
RH60123,0000CA5 -19-12AUG15-5/7
041818
PN=131
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Attachment relief solenoid (Y38) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of attachment relief solenoid (Y38) connector to machine ground. • Pin 15 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. RH60123,0000CA5 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid (Y38) disconnected. Test attachment relief solenoid (Y38) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid (Y38) within specification?
NO: Attachment relief solenoid (Y38) malfunction. Replace solenoid. RH60123,0000CA5 -19-12AUG15-7/7
011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback
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.
Attachment relief solenoid 2 (Y39) current above 920 mA and below 70 mA. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools.
RH60123,0000CA6 -19-12AUG15-1/8
Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure RH60123,0000CA6 -19-12AUG15-2/8
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Attachment relief solenoid 2 (Y39) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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
TM12660 (18APR18)
9001-10-98
RH60123,0000CA6 -19-12AUG15-3/8
041818
PN=132
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 attachment relief solenoid 2 (Y39). Disconnect attachment relief solenoid (Y38). Connect attachment relief solenoid 2 (Y39) to attachment relief solenoid (Y38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011435.02—Attachment Relief 2 (Lower) YES: Go to Continuity Proportional Solenoid Valve Abnormal Feedback. Check. Is code active?
NO: Attachment relief solenoid 2 (Y39) malfunction. Replace solenoid. RH60123,0000CA6 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid 2 (Y39). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of attachment relief solenoid 2 (Y39) connector to pin 22 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid 2 (Y39) connector to pin 21 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. RH60123,0000CA6 -19-12AUG15-5/8
• 4
Short Circuit Check
Key switch in OFF position.
Attachment relief solenoid 2 (Y39) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of attachment relief solenoid 2 (Y39) connector to machine ground. • Pin 21 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,0000CA6 -19-12AUG15-6/8
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 21 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins? Continued on next page
TM12660 (18APR18)
9001-10-99
NO: Go to Solenoid Check. RH60123,0000CA6 -19-12AUG15-7/8
041818
PN=133
Main Controller (MCZ) Diagnostic Trouble Codes
• 6
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid 2 (Y39) disconnected. Test attachment relief solenoid 2 (Y39) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid 2 (Y39) within specification?
NO: Attachment relief solenoid (Y39) malfunction. Replace solenoid. RH60123,0000CA6 -19-12AUG15-8/8
011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Attachment relief solenoid (Y38) 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.
RH60123,0000CA7 -19-12AUG15-1/7
Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current Diagnostic Procedure RH60123,0000CA7 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Attachment relief solenoid 2 (Y39) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CA7 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect attachment relief solenoid 2 (Y39). Disconnect attachment relief solenoid (Y38). Connect attachment relief solenoid 2 (Y39) to attachment relief solenoid (Y38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011435.03—Attachment Relief 2 (Lower) YES: Go to Continuity Proportional Solenoid Valve Feedback High Current. Check. Is code active?
NO: Attachment relief solenoid 2 (Y39) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-100
RH60123,0000CA7 -19-12AUG15-4/7
041818
PN=134
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid 2 (Y39). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of attachment relief solenoid 2 (Y39) connector to pin 22 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid 2 (Y39) connector to pin 21 cab harness-to-main controller 24-pin connector B (X32).
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000CA7 -19-12AUG15-5/7
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 21 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Go to Solenoid Check. RH60123,0000CA7 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid 2 (Y39) disconnected. Test attachment relief solenoid 2 (Y39) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid 2 (Y39) within specification?
NO: Attachment relief solenoid (Y39) malfunction. Replace solenoid. RH60123,0000CA7 -19-12AUG15-7/7
011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current RH60123,0000CA8 -19-12AUG15-1/7
Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-101
RH60123,0000CA8 -19-12AUG15-2/7
041818
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:
• Attachment relief solenoid 2 (Y39) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CA8 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect attachment relief solenoid 2 (Y39). Disconnect attachment relief solenoid (Y38). Connect attachment relief solenoid 2 (Y39) to attachment relief solenoid (Y38). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011435.04—Attachment Relief 2 (Lower) YES: Go to Continuity Proportional Solenoid Valve Feedback Low Current. Check. Is code active?
NO: Attachment relief solenoid 2 (Y39) malfunction. Replace solenoid. RH60123,0000CA8 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect attachment relief solenoid 2 (Y39). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of attachment relief solenoid 2 (Y39) connector to pin 22 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of attachment relief solenoid 2 (Y39) connector to pin 21 cab harness-to-main
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
controller 24-pin connector B (X32).
Continued on next page
TM12660 (18APR18)
9001-10-102
RH60123,0000CA8 -19-12AUG15-5/7
041818
PN=136
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Short Circuit Check
Key switch in OFF position.
Attachment relief solenoid 2 (Y39) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of attachment relief solenoid 2 (Y39) connector to machine ground. • Pin 21 of cab harness-to-main controller 24-pin connector A (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. RH60123,0000CA8 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Attachment relief solenoid 2 (Y39) disconnected. Test attachment relief solenoid 2 (Y39) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is attachment relief solenoid 2 (Y39) within specification?
NO: Attachment relief solenoid (Y39) malfunction. Replace solenoid. RH60123,0000CA8 -19-12AUG15-7/7
011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Secondary relief solenoid valve (Y41) current above 920 mA and below 70 mA.
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.
RH60123,0000CA9 -19-12AUG15-1/7
Breaker Relief Proportional Solenoid Valve Abnormal Feedback Diagnostic Procedure RH60123,0000CA9 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Secondary relief solenoid valve (Y41) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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
TM12660 (18APR18)
9001-10-103
RH60123,0000CA9 -19-12AUG15-3/7
041818
PN=137
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Test secondary relief solenoid valve (Y41) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Go to Continuity Check.
Is secondary relief solenoid valve (Y41) within specification?
NO: Secondary relief solenoid valve (Y41) malfunction. Replace solenoid. RH60123,0000CA9 -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of secondary relief solenoid valve (Y41) connector to pin 23 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of secondary relief solenoid valve (Y41) connector to pin 24 cab harness-to-main YES: Go to Short Circuit controller 24-pin connector B (X32).
Is continuity indicated?
Check. NO: Repair or replace harness. See appropriate harness. RH60123,0000CA9 -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Secondary relief solenoid valve (Y41) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of secondary relief solenoid valve (Y41) connector to machine ground. • Pin 24 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,0000CA9 -19-12AUG15-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 24 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Checks complete. RH60123,0000CA9 -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-104
041818
PN=138
Main Controller (MCZ) Diagnostic Trouble Codes
011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Secondary relief solenoid valve (Y41) 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.
RH60123,0000CAA -19-12AUG15-1/6
Breaker Relief Proportional Solenoid Valve Feedback High Current Diagnostic Procedure RH60123,0000CAA -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Secondary relief solenoid valve (Y41) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CAA -19-12AUG15-3/6
• 2
Component Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Test secondary relief solenoid valve (Y41) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Go to Continuity Check.
Is secondary relief solenoid valve (Y41) within specification?
NO: Secondary relief solenoid valve (Y41) malfunction. Replace solenoid. RH60123,0000CAA -19-12AUG15-4/6
• 3
Continuity Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of secondary relief solenoid valve (Y41) connector to pin 23 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of secondary relief solenoid valve (Y41) connector to pin 24 cab harness-to-main YES: Go to Harness controller 24-pin connector B (X32).
Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. Continued on next page
TM12660 (18APR18)
9001-10-105
RH60123,0000CAA -19-12AUG15-5/6
041818
PN=139
Main Controller (MCZ) Diagnostic Trouble Codes
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 24 of cab harness-to-main controller 24-pin connector YES: Short to power. B (X32) to all other pins on connector. Repair or replace harness. See appropriate harness. Is continuity indicated between any pins?
NO: Checks complete. RH60123,0000CAA -19-12AUG15-6/6
011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Secondary relief solenoid valve (Y41) 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. RH60123,0000CAB -19-12AUG15-1/6
Breaker Relief Proportional Solenoid Valve Feedback Low Current Diagnostic Procedure RH60123,0000CAB -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Secondary relief solenoid valve (Y41) and attachment connector (X46). See Attachment Harness (W17) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32). 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.)
RH60123,0000CAB -19-12AUG15-3/6
• 2
Component Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Test secondary relief solenoid valve (Y41) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Go to Continuity Check.
Is secondary relief solenoid valve (Y41) within specification?
NO: Secondary relief solenoid valve (Y41) malfunction. Replace solenoid.
Continued on next page
TM12660 (18APR18)
9001-10-106
RH60123,0000CAB -19-12AUG15-4/6
041818
PN=140
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect secondary relief solenoid valve (Y41). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of secondary relief solenoid valve (Y41) connector to pin 23 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of secondary relief solenoid valve (Y41) connector to pin 24 cab harness-to-main YES: Go to Short Circuit controller 24-pin connector B (X32).
Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. RH60123,0000CAB -19-12AUG15-5/6
• 4
Short Circuit Check
Key switch in OFF position.
Secondary relief solenoid valve (Y41) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of secondary relief solenoid valve (Y41) connector to machine ground. • Pin 24 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Short to ground. Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Checks complete. RH60123,0000CAB -19-12AUG15-6/6
011437.02 — 2-Spool Solenoid Valve Unit (A1) Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Boom 3 spool control solenoid (marked A1) (Y32) 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.
RH60123,0000CAC -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (A1) Abnormal Feedback Diagnostic Procedure RH60123,0000CAC -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Boom 3 spool control solenoid (marked A1) (Y32) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-107
RH60123,0000CAC -19-12AUG15-3/7
041818
PN=141
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 boom 3 spool control solenoid (marked A1) (Y32). Disconnect arm 3 spool control solenoid (marked A2) (Y31). Connect boom 3 spool control solenoid (marked A1) (Y32) to arm 3 spool control solenoid (marked A2) (Y31). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011437.02—2-Spool Solenoid Valve Unit (A1) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Boom 3 spool control solenoid (marked A1) (Y32) malfunction. Replace solenoid. RH60123,0000CAC -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect boom 3 spool control solenoid (marked A1) (Y32). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 5 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 4 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 24-pin connector B (X32).
RH60123,0000CAC -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Boom 3 spool control solenoid (marked A1) (Y32) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to machine ground.
• Pin 4 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,0000CAC -19-12AUG15-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 4 of cab harness-to-main controller 24-pin connector B (X32) to all other pins on connector.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Checks complete. RH60123,0000CAC -19-12AUG15-7/7
TM12660 (18APR18)
9001-10-108
041818
PN=142
Main Controller (MCZ) Diagnostic Trouble Codes
011437.03 — 2-Spool Solenoid Valve Unit (A1) Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Boom 3 spool control solenoid (marked A1) (Y32) 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.
RH60123,0000CAD -19-12AUG15-1/6
2-Spool Solenoid Valve Unit (A1) Feedback High Current Diagnostic Procedure RH60123,0000CAD -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Boom 3 spool control solenoid (marked A1) (Y32) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000CAD -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect boom 3 spool control solenoid (marked A1) (Y32). Disconnect arm 3 spool control solenoid (marked A2) (Y31). Connect boom 3 spool control solenoid (marked A1) (Y32) to arm 3 spool control solenoid (marked A2) (Y31). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011437.03—2-Spool Solenoid Valve Unit (A1) Feedback High Current.
YES: Go to Continuity Check.
Is code active?
NO: Boom 3 spool control solenoid (Y32) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-109
RH60123,0000CAD -19-12AUG15-4/6
041818
PN=143
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect boom 3 spool control solenoid (marked A1) (Y32). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 5 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 4 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. RH60123,0000CAD -19-12AUG15-5/6
• 4
Short Circuit Check
Key switch in OFF position.
Boom 3 spool control solenoid (marked A1) (Y32) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to machine ground.
• Pin 4 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Checks complete. RH60123,0000CAD -19-12AUG15-6/6
011437.04 — 2-Spool Solenoid Valve Unit (A1) Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Boom 3 spool control solenoid (marked A1) (Y32) 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.
RH60123,0000CAE -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (A1) Feedback Low Current Diagnostic Procedure RH60123,0000CAE -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Boom 3 spool control solenoid (marked A1) (Y32) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-110
RH60123,0000CAE -19-12AUG15-3/7
041818
PN=144
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 boom 3 spool control solenoid (marked A1) (Y32). Disconnect arm 3 spool control solenoid (marked A2) (Y31). Connect boom 3 spool control solenoid (marked A1) (Y32) to arm 3 spool control solenoid (marked A2) (Y31). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011437.02—2-Spool Solenoid Valve Unit (A1) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Boom 3 spool control solenoid (marked A1) (Y32) malfunction. Replace solenoid. RH60123,0000CAE -19-12AUG15-4/7
• 3
Continuity Check
Key switch in OFF position.
Disconnect boom 3 spool control solenoid (marked A1) (Y32). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 5 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of boom 3 spool control solenoid (marked A1) (Y32) connector to pin 4 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 24-pin connector B (X32).
RH60123,0000CAE -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Boom 3 spool control solenoid (marked A1) (Y32) disconnected. Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of boom 3 spool control solenoid (marked A1) (Y32) connector to machine ground.
• Pin 24 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. Continued on next page
TM12660 (18APR18)
9001-10-111
RH60123,0000CAE -19-12AUG15-6/7
041818
PN=145
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Solenoid Check
Key switch in OFF position.
Disconnect boom 3 spool control solenoid (marked A1) (Y32). Test boom 3 spool control solenoid (marked A1) (Y32) and compare to specification. See Proportional Solenoid Test. (Group 9015-20.)
YES: Checks complete.
Is boom 3 spool control solenoid (marked A1) (Y32) within specification?
NO: Boom 3 spool control solenoid (marked A1) (Y32) malfunction. Replace solenoid. RH60123,0000CAE -19-12AUG15-7/7
011438.02 — 2-Spool Solenoid Valve Unit (A2) Abnormal Feedback
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 3 spool control solenoid (marked A2) (Y31) 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.
RH60123,0000C34 -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (A2) Abnormal Feedback Diagnostic Procedure RH60123,0000C34 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 3 spool control solenoid (marked A2) (Y31) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000C34 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect boom 3 spool control solenoid (marked A1) (Y32). Connect arm 3 spool control solenoid (marked A2) (Y31) to boom 3 spool control solenoid (marked A1) (Y32). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011438.02—2-Spool Solenoid Valve Unit (A2) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm 3 spool control solenoid (marked A2) (Y31) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-112
RH60123,0000C34 -19-12AUG15-4/7
041818
PN=146
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 6 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 7 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 24-pin connector B (X32).
RH60123,0000C34 -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of arm 3 spool control solenoid (marked A2) (Y31) connector to machine ground. • Pin 7 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Harness Check. RH60123,0000C34 -19-12AUG15-6/7
• 5
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 7 of cab harness-to-main controller 24-pin connector B (X32) to all other pins on connector.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Checks complete. RH60123,0000C34 -19-12AUG15-7/7
011438.03 — 2-Spool Solenoid Valve Unit (A2) Feedback High Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 3 spool control solenoid (marked A2) (Y31) 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.
RH60123,0000CB0 -19-12AUG15-1/6
2-Spool Solenoid Valve Unit (A2) Feedback High Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-113
RH60123,0000CB0 -19-12AUG15-2/6
041818
PN=147
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 3 spool control solenoid (marked A2) (Y31) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000CB0 -19-12AUG15-3/6
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect boom 3 spool control solenoid (marked A1) (Y32). Connect arm 3 spool control solenoid (marked A2) (Y31) to boom 3 spool control solenoid (marked A1) (Y32). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011438.02—2-Spool Solenoid Valve Unit (A2) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm 3 spool control solenoid (marked A2) (Y31) malfunction. Replace solenoid. RH60123,0000CB0 -19-12AUG15-4/6
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 6 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 7 cab
YES: Go to Harness Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 24-pin connector B (X32).
RH60123,0000CB0 -19-12AUG15-5/6
• 4
Harness Check
Key switch in OFF position.
Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between pin 7 of cab harness-to-main controller 24-pin connector B (X32) to all other pins on connector.
YES: Repair or replace harness. See appropriate harness.
Is continuity indicated between any pins?
NO: Checks complete. RH60123,0000CB0 -19-12AUG15-6/6
TM12660 (18APR18)
9001-10-114
041818
PN=148
Main Controller (MCZ) Diagnostic Trouble Codes
011438.04 — 2-Spool Solenoid Valve Unit (A2) Feedback Low Current
Over torquing will result in permanent damage to connector. Torque only to specification.
Arm 3 spool control solenoid (marked A2) (Y31) 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.
RH60123,0000CB1 -19-12AUG15-1/7
2-Spool Solenoid Valve Unit (A2) Feedback Low Current Diagnostic Procedure RH60123,0000CB1 -19-12AUG15-2/7
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Arm 3 spool control solenoid (marked A2) (Y31) and spool control interface
harness-to-spool control harness connector (X53). See Spool Control Harness (W43) Component Location. (Group 9015-10.)
• Cab harness-to-main controller 24-pin connector B (X32) and cab harness-to-spool
YES: Go to Component Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
control harness connector (X49). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000CB1 -19-12AUG15-3/7
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
Key switch in OFF position. Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect boom 3 spool control solenoid (marked A1) (Y32). Connect arm 3 spool control solenoid (marked A2) (Y31) to boom 3 spool control solenoid (marked A1) (Y32). Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011438.02—2-Spool Solenoid Valve Unit (A2) Abnormal Feedback.
YES: Go to Continuity Check.
Is code active?
NO: Arm 3 spool control solenoid (marked A2) (Y31) malfunction. Replace solenoid. Continued on next page
TM12660 (18APR18)
9001-10-115
RH60123,0000CB1 -19-12AUG15-4/7
041818
PN=149
Main Controller (MCZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Disconnect main controller connector (X32). Check for continuity between:
• Pin 1 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 6 cab harness-to-main controller 24-pin connector B (X32).
• Pin 2 of arm 3 spool control solenoid (marked A2) (Y31) connector to pin 7 cab
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
harness-to-main controller 24-pin connector B (X32).
RH60123,0000CB1 -19-12AUG15-5/7
• 4
Short Circuit Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Cab harness-to-main controller 24-pin connector B (X32) disconnected. Check for continuity between:
• Pin 1 of arm 3 spool control solenoid (marked A2) (Y31) connector to machine ground. • Pin 7 of cab harness-to-main controller 24-pin connector B (X32) to machine ground. YES: Repair or replace harness. See appropriate harness. Is continuity indicated?
NO: Go to Solenoid Check. RH60123,0000CB1 -19-12AUG15-6/7
• 5
Solenoid Check
Key switch in OFF position.
Disconnect arm 3 spool control solenoid (marked A2) (Y31). Test arm 3 spool control solenoid (marked A2) (Y31) and compare to specification. See YES: Checks complete. Proportional Solenoid Test. (Group 9015-20.) Is arm 3 spool control solenoid (marked A2) (Y31) within specification?
NO: Arm 3 spool control solenoid (marked A2) (Y31) malfunction. Replace solenoid. RH60123,0000CB1 -19-12AUG15-7/7
011457.02 — 2-Speed Activation Solenoid Disconnected or Not Present
present. Switch machine to dig mode or to an attachment mode that is not set up for combined pump flow, then clear the DTC. Operate machine and verify the DTC does not reappear. If the machine has this solenoid, continue with 2-speed activation solenoid diagnostic procedure.
NOTE: The 2-speed activation solenoid is part of the combined pump flow kit. If the machine does not have this kit installed, the solenoid will not be
MB00333,0000163 -19-12AUG15-1/8
2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-116
MB00333,0000163 -19-12AUG15-2/8
041818
PN=150
Main Controller (MCZ) Diagnostic Trouble Codes
• 1
Fuse Check
Ignition OFF.
Remove fuse F5 from fuse box F50. See Cab Harness (W1) Component Location and see Cab Harness (W1) Wiring Diagram. (Group 9015-10.) Check fuse F5 for continuity.
YES: Go to Solenoid Check.
Is continuity indicated?
NO: Replace fuse. MB00333,0000163 -19-12AUG15-3/8
• 2
Solenoid Check
Ignition OFF.
Disconnect harness from 2-speed activation solenoid. See 2-Speed Harness (W32) Component Location. (Group 9015-10.) Test solenoid. See Proportional Solenoid Test. (Group 9015-20.)
YES: Go to 2-Speed Harness Continuity Check.
Is 2-speed activation solenoid within specification?
NO: Solenoid malfunction. Replace solenoid. MB00333,0000163 -19-12AUG15-4/8
• 3
2-Speed Harness Continuity Check
Ignition OFF.
Disconnect attachment harness-to-2-speed harness connector (X87). See Attachment Harness (W17) Component Location. (Group 9015-10.) Check continuity between 2-speed activation solenoid valve (Y43) connector pin 1 and attachment harness-to-2-speed harness connector (X87) pin 4. Check continuity between 2-speed activation solenoid valve (Y43) pin 2 and attachment YES: Go to Attachment harness-to-2-speed harness connector (X87) pin 5. See 2-Speed Harness (W32) Harness Continuity Check. Wiring Diagram. (Group 9015-10.) Is continuity indicated in both circuits?
NO: Open circuit in 2-speed harness. Repair or replace harness. MB00333,0000163 -19-12AUG15-5/8
• 4
Attachment Harness Continuity Check
Disconnect attachment connector (X46). See Machine Harness (W2) Component Location. (Group 9015-10.)
Check for continuity between attachment harness-to-2-speed harness connector (X87) pin 4 and attachment connector (X46) pin 13. Check continuity between attachment harness-to-2-speed harness connector (X87) pin 5 and attachment connector (X46) pin 17. See Attachment Harness (W17) Wiring Diagram. (Group 9015-10.)
YES: Go to Machine Harness Continuity Check.
Is continuity indicated in both circuits?
NO: Open circuit in attachment harness. Repair or replace harness. Continued on next page
TM12660 (18APR18)
9001-10-117
MB00333,0000163 -19-12AUG15-6/8
041818
PN=151
Main Controller (MCZ) Diagnostic Trouble Codes
• 5
Machine Harness Continuity Check
Disconnect cab harness-to-machine harness 100-pin connector (X3). See Cab Harness (W1) Component Location. (Group 9015-10.)
Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin E2 and attachment connector (X46) pin 13. Check continuity between cab harness-to-machine harness 100-pin connector (X3) pin C6 and attachment connector (X46) pin 17. See Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
YES: Go to Cab Harness Continuity Check.
Is continuity indicated in both circuits?
NO: Open circuit in machine harness. Repair or replace harness. MB00333,0000163 -19-12AUG15-7/8
• 6
Cab Harness Continuity Check
Disconnect cab harness-to-main controller 17-pin connector (X33). See Cab Harness (W1) Component Location. (Group 9015-10.)
Check for continuity between cab harness-to-machine harness 100-pin connector (X3) pin E2 and cab harness-to-main controller 17-pin connector (X33) pin 3. Check continuity between cab harness-to-machine harness 100-pin connector (X3) pin YES: Main controller (MCZ) C6 and fuse F5. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) malfunction. Replace main controller. See Main Controller (MCZ) Remove and Install. (Group 9015-20.) Is continuity indicated in both circuits?
NO: Open circuit in cab harness. Repair or replace cab harness. MB00333,0000163 -19-12AUG15-8/8
011458.02 — (Auxiliary) Discontinuity of Selector Valve 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—(Auxiliary) Discontinuity of Selector Valve. If machine does not have selector valve solenoid valve (Y40), switch machine to dig mode and clear DTC. Operate machine and verify DTC is cleared.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb.-in. RH60123,0000CB2 -19-12AUG15-1/8
5-Spool Solenoid Valve Unit (SE) Abnormal Feedback Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-118
RH60123,0000CB2 -19-12AUG15-2/8
041818
PN=152
Main Controller (MCZ) Diagnostic Trouble Codes
• 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.)
• 2-speed activation solenoid valve (if equipped) (Y43). See 2-Speed Harness (W32) 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.)
RH60123,0000CB2 -19-12AUG15-3/8
• 2
Component Check
NOTE: Return connectors to appropriate solenoids after check is completed.
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. Operate machine. Check for active MCZ diagnostic trouble code 011458.02—(Auxiliary) Discontinuity of Selector Valve.
YES: Go to Continuity Check.
Is code active?
NO: Selector valve solenoid valve (Y40) malfunction. Replace solenoid. RH60123,0000CB2 -19-12AUG15-4/8
• 3
Continuity Check
Key switch in OFF position.
Disconnect selector valve solenoid valve (Y40). Disconnect main controller connector (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. RH60123,0000CB2 -19-12AUG15-5/8
• 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. Continued on next page
TM12660 (18APR18)
9001-10-119
RH60123,0000CB2 -19-12AUG15-6/8
041818
PN=153
Main Controller (MCZ) Diagnostic Trouble Codes
• 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: Checks complete. RH60123,0000CB2 -19-12AUG15-7/8
• 6
Component Check
Test selector valve solenoid valve (Y40) and compare to specification. See Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is selector valve solenoid valve (Y40) within specification?
NO: Selector valve solenoid valve (Y40) malfunction. Replace solenoid valve. RH60123,0000CB2 -19-12AUG15-8/8
011459.02 — Idle Stop Relay Circuit Malfunction
NOTE: For additional information, see auto-shutdown circuit. See Starting and Charging Circuit Theory of Operation. (Group 9015-15.) RH60123,00027CC -19-02JUN16-1/6
Idle Stop Relay Circuit Malfunction Diagnostic Procedure RH60123,00027CC -19-02JUN16-2/6
• 1
Fuse Check
Key switch in OFF position.
Remove idle stop 5 A fuse (marked IDLE STOP) (F18) from fuse box 1 (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. RH60123,00027CC -19-02JUN16-3/6
• 2
Voltage Check
Install idle stop 5 A fuse (marked IDLE STOP) (F18) in fuse box 1 (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. Continued on next page
TM12660 (18APR18)
9001-10-120
RH60123,00027CC -19-02JUN16-4/6
041818
PN=154
Main Controller (MCZ) Diagnostic Trouble Codes
• 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). RH60123,00027CC -19-02JUN16-5/6
• 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 monitor controller 12-pin connector C (X23) pin 5. Check for continuity between idle stop relay (K11) connector pin 3 and monitor controller 12-pin connector C (X23) 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: Checks complete.
Is continuity indicated in all circuits?
NO: Open circuit in cab harness. Repair or replace harness. RH60123,00027CC -19-02JUN16-6/6
015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)
Secondary hydraulic oil temperature sensor (B68) voltage is high (above 4.35 V). DF89619,00B5D9C -19-21JAN16-1/6
Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure DF89619,00B5D9C -19-21JAN16-2/6
• 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-machine harness 100-pin connector (X3). - 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 (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).
Continued on next page
TM12660 (18APR18)
9001-10-121
DF89619,00B5D9C -19-21JAN16-3/6
041818
PN=155
Main Controller (MCZ) Diagnostic Trouble Codes
• 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 Temperature Sensor Test. (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. DF89619,00B5D9C -19-21JAN16-4/6
• 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. DF89619,00B5D9C -19-21JAN16-5/6
• 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). 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).
DF89619,00B5D9C -19-21JAN16-6/6
015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)
Secondary hydraulic oil temperature sensor low (below 0.23 V). DF89619,00B5D9D -19-21JAN16-1/6
Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-122
DF89619,00B5D9D -19-21JAN16-2/6
041818
PN=156
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-machine harness 100-pin connector (X3). - 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 (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).
DF89619,00B5D9D -19-21JAN16-3/6
• 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 Temperature Sensor Test. (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. DF89619,00B5D9D -19-21JAN16-4/6
• 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 less than 0.1 V.
YES: Checks complete.
Is correct voltage indicated?
NO: Go to Harness Check. DF89619,00B5D9D -19-21JAN16-5/6
• 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. DF89619,00B5D9D -19-21JAN16-6/6
TM12660 (18APR18)
9001-10-123
041818
PN=157
Main Controller (MCZ) Diagnostic Trouble Codes
015016.03 — Right Analog Stroke Sensor Circuit High Input
Auxiliary function lever (AFL) proportional control switch (S29) voltage is high (above 4.5 V). DF89619,00B5D9E -19-21JAN16-1/5
Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure DF89619,00B5D9E -19-21JAN16-2/5
• 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-machine harness 100-pin connector (X3). - 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) right grip harness connector (marked R_LEVER) (X538) - Auxiliary function lever (AFL) connector (X574).
DF89619,00B5D9E -19-21JAN16-3/5
• 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. DF89619,00B5D9E -19-21JAN16-4/5
• 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. DF89619,00B5D9E -19-21JAN16-5/5
015016.04 — Right Analog Stroke Sensor Circuit Low Input
Auxiliary function lever (AFL) proportional control switch (S29) voltage is low (below 0.1 V). Continued on next page
TM12660 (18APR18)
9001-10-124
DF89619,00B5D9F -19-21JAN16-1/6
041818
PN=158
Main Controller (MCZ) Diagnostic Trouble Codes Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure DF89619,00B5D9F -19-21JAN16-2/6
• 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-machine harness 100-pin connector (X3). - 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) right grip harness connector (marked R_LEVER) (X538) - Auxiliary function lever (AFL) connector (X574).
DF89619,00B5D9F -19-21JAN16-3/6
• 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. DF89619,00B5D9F -19-21JAN16-4/6
• 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 13 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).
Continued on next page
TM12660 (18APR18)
9001-10-125
DF89619,00B5D9F -19-21JAN16-5/6
041818
PN=159
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. DF89619,00B5D9F -19-21JAN16-6/6
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). DF89619,00B5DA0 -19-22JAN16-1/6
Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure DF89619,00B5DA0 -19-22JAN16-2/6
• 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-machine harness 100-pin connector (X3). - 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 (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).
DF89619,00B5DA0 -19-22JAN16-3/6
• 2
Component Check
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011810.03—Electric Lever Operating Pressure Sensor 1 High Voltage. Is code active?
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.
Continued on next page
TM12660 (18APR18)
9001-10-126
DF89619,00B5DA0 -19-22JAN16-4/6
041818
PN=160
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. DF89619,00B5DA0 -19-22JAN16-5/6
• 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. DF89619,00B5DA0 -19-22JAN16-6/6
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). DF89619,00B5DA1 -19-22JAN16-1/7
Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure DF89619,00B5DA1 -19-22JAN16-2/7
• 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-machine harness 100-pin connector (X3). - 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 (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
TM12660 (18APR18)
9001-10-127
DF89619,00B5DA1 -19-22JAN16-3/7
041818
PN=161
Main Controller (MCZ) Diagnostic Trouble Codes
• 2
Component Check
Switch AFL solenoid pressure sensor (marked PS1) (B85) to another properly working pressure sensor. Clear MCZ diagnostic trouble codes. Operate machine. Check for active MCZ diagnostic trouble code 011810.04—Electric Lever Operating Pressure Sensor 1 Low Voltage. Is code active?
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. DF89619,00B5DA1 -19-22JAN16-4/7
• 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. DF89619,00B5DA1 -19-22JAN16-5/7
• 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. DF89619,00B5DA1 -19-22JAN16-6/7
• 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. DF89619,00B5DA1 -19-22JAN16-7/7
011812.02 — OPT Electric Lever 1 Neutral Abnormal
Secondary pilot shutoff solenoid (marked PiC) (Y66) signal voltage 0.1 V or less. DF89619,00B5DA2 -19-22JAN16-1/5
OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-128
DF89619,00B5DA2 -19-22JAN16-2/5
041818
PN=162
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).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Optional connector (X26). - Auxiliary function lever (AFL) connector (X574).
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.
YES: Go to Continuity 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).
DF89619,00B5DA2 -19-22JAN16-3/5
• 2
Continuity Check
Key switch in OFF position.
Disconnect secondary pilot shutoff solenoid (marked PiC) (Y66). Disconnect cab harness-to-main controller 17-pin connector C (X33). Check for continuity between:
• Pin 1 of secondary pilot shutoff solenoid (marked PiC) (Y66) connector to pin 6 of cab YES: Go to Solenoid harness-to-main controller 17-pin connector C (X33).
Is continuity indicated?
Check. NO: Repair or replace harness. See appropriate harness. DF89619,00B5DA2 -19-22JAN16-4/5
• 3
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 Solenoid Test. (Group 9015-20.) Is secondary pilot shutoff solenoid (marked PiC) (Y66) within specification?
NO: Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid. DF89619,00B5DA2 -19-22JAN16-5/5
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. DF89619,00B5DA3 -19-22JAN16-1/8
OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-129
DF89619,00B5DA3 -19-22JAN16-2/8
041818
PN=163
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).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Optional connector (X26). - Auxiliary function lever (AFL) connector (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).
DF89619,00B5DA3 -19-22JAN16-3/8
• 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. DF89619,00B5DA3 -19-22JAN16-4/8
• 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. Continued on next page
TM12660 (18APR18)
9001-10-130
DF89619,00B5DA3 -19-22JAN16-5/8
041818
PN=164
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. DF89619,00B5DA3 -19-22JAN16-6/8
• 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. DF89619,00B5DA3 -19-22JAN16-7/8
• 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 Solenoid Test. (Group 9015-20.) Is secondary pilot shutoff solenoid (marked PiC) (Y66) within specification?
NO: Secondary pilot shutoff solenoid (marked PiC) (Y66) malfunction. Replace solenoid. DF89619,00B5DA3 -19-22JAN16-8/8
011816.02 — OPT Solenoid 1 Feedback Abnormal
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA and below 70 mA. DF89619,00B5DA4 -19-22JAN16-1/8
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-131
DF89619,00B5DA4 -19-22JAN16-2/8
041818
PN=165
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 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector (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).
DF89619,00B5DA4 -19-22JAN16-3/8
• 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. DF89619,00B5DA4 -19-22JAN16-4/8
• 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. Continued on next page
TM12660 (18APR18)
9001-10-132
DF89619,00B5DA4 -19-22JAN16-5/8
041818
PN=166
Main Controller (MCZ) Diagnostic Trouble Codes
• 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. DF89619,00B5DA4 -19-22JAN16-6/8
• 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. DF89619,00B5DA4 -19-22JAN16-7/8
• 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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. DF89619,00B5DA4 -19-22JAN16-8/8
011816.03 — OPT Solenoid 1 Feedback Current High
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) current above 920 mA. DF89619,00B5DA5 -19-22JAN16-1/7
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-10-133
DF89619,00B5DA5 -19-22JAN16-2/7
041818
PN=167
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 31-pin connector A (X31).
• See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) - Auxiliary function lever (AFL) connector (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).
DF89619,00B5DA5 -19-22JAN16-3/7
• 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. DF89619,00B5DA5 -19-22JAN16-4/7
• 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
TM12660 (18APR18)
9001-10-134
DF89619,00B5DA5 -19-22JAN16-5/7
041818
PN=168
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. DF89619,00B5DA5 -19-22JAN16-6/7
• 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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. DF89619,00B5DA5 -19-22JAN16-7/7
011816.04 — OPT Solenoid 1 Feedback Current Low
Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61) feedback current below 56 mA. DF89619,00B5DA6 -19-22JAN16-1/7
Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure DF89619,00B5DA6 -19-22JAN16-2/7
• 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 (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
TM12660 (18APR18)
9001-10-135
DF89619,00B5DA6 -19-22JAN16-3/7
041818
PN=169
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. DF89619,00B5DA6 -19-22JAN16-4/7
• 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. DF89619,00B5DA6 -19-22JAN16-5/7
• 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
TM12660 (18APR18)
9001-10-136
DF89619,00B5DA6 -19-22JAN16-6/7
041818
PN=170
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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid A (marked 1A) (Y61) within specification?
NO: AFL solenoid A (marked 1A) (Y61) malfunction. Replace solenoid. DF89619,00B5DA6 -19-22JAN16-7/7
011817.02 — OPT Solenoid 2 Feedback Abnormal
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) current above 920 mA and below 70 mA. DF89619,00B5DA7 -19-22JAN16-1/8
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure DF89619,00B5DA7 -19-22JAN16-2/8
• 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 (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).
DF89619,00B5DA7 -19-22JAN16-3/8
• 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
TM12660 (18APR18)
9001-10-137
DF89619,00B5DA7 -19-22JAN16-4/8
041818
PN=171
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. DF89619,00B5DA7 -19-22JAN16-5/8
• 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. DF89619,00B5DA7 -19-22JAN16-6/8
• 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. DF89619,00B5DA7 -19-22JAN16-7/8
• 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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. DF89619,00B5DA7 -19-22JAN16-8/8
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
TM12660 (18APR18)
9001-10-138
DF89619,00B5DA8 -19-22JAN16-1/7
041818
PN=172
Main Controller (MCZ) Diagnostic Trouble Codes Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure DF89619,00B5DA8 -19-22JAN16-2/7
• 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 (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).
DF89619,00B5DA8 -19-22JAN16-3/7
• 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. DF89619,00B5DA8 -19-22JAN16-4/7
• 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
TM12660 (18APR18)
9001-10-139
DF89619,00B5DA8 -19-22JAN16-5/7
041818
PN=173
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. DF89619,00B5DA8 -19-22JAN16-6/7
• 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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. DF89619,00B5DA8 -19-22JAN16-7/7
011817.04 — OPT Solenoid 2 Feedback Current Low
Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62) feedback current below 56 mA. DF89619,00B5DA9 -19-22JAN16-1/7
Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure DF89619,00B5DA9 -19-22JAN16-2/7
• 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 (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
TM12660 (18APR18)
9001-10-140
DF89619,00B5DA9 -19-22JAN16-3/7
041818
PN=174
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. DF89619,00B5DA9 -19-22JAN16-4/7
• 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. DF89619,00B5DA9 -19-22JAN16-5/7
• 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
TM12660 (18APR18)
9001-10-141
DF89619,00B5DA9 -19-22JAN16-6/7
041818
PN=175
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 Proportional YES: Checks complete. Solenoid Test. (Group 9015-20.) Is AFL solenoid B (marked 1B) (Y62) within specification?
NO: AFL solenoid B (marked 1B) (Y62) malfunction. Replace solenoid. DF89619,00B5DA9 -19-22JAN16-7/7
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.
RH60123,0000CB4 -19-12AUG15-1/6
Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure RH60123,0000CB4 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Hydraulic oil temperature sensor (B40). See 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 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 E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
RH60123,0000CB4 -19-12AUG15-3/6
• 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 Temperature Sensor Test. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is hydraulic oil temperature sensor (B40) within specification?
NO: Hydraulic oil temperature sensor (B40) malfunction. Replace sensor.
Continued on next page
TM12660 (18APR18)
9001-10-142
RH60123,0000CB4 -19-12AUG15-4/6
041818
PN=176
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 E (X36). Check for continuity between:
• Pin 1 of hydraulic oil temperature sensor connector (B40) and pin 1 of cab harness-to-main controller 17-pin connector C (X33).
• Pin 2 of hydraulic oil temperature sensor connector (B40) and pin 25 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 E (X36).
RH60123,0000CB4 -19-12AUG15-5/6
• 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 connector (B40) for approximately 5 V.
YES: Checks complete.
Is correct voltage indicated?
NO: Short circuit to power. Repair or replace harness. See appropriate harness. RH60123,0000CB4 -19-12AUG15-6/6
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. RH60123,0000CB5 -19-12AUG15-1/6
Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure RH60123,0000CB5 -19-12AUG15-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Hydraulic oil temperature sensor (B40). See 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 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 E (X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9001-10-143
RH60123,0000CB5 -19-12AUG15-3/6
041818
PN=177
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 Temperature Sensor Test. (Group 9015-20.)
YES: Go to Voltage Check.
Is hydraulic oil temperature sensor (B40) within specification?
NO: Hydraulic oil temperature sensor (B40) malfunction. Replace sensor. RH60123,0000CB5 -19-12AUG15-4/6
• 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 connector (B40) for YES: Go to Short Circuit approximately 5 V. Check. Is correct voltage indicated?
NO: Open circuit. Repair or replace harness. See appropriate harness. RH60123,0000CB5 -19-12AUG15-5/6
• 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. RH60123,0000CB5 -19-12AUG15-6/6
020010.02 — Abnormal Exhaust Filter This code will set because of other codes that are present. RH60123,0000CB6 -19-29AUG16-1/3
Abnormal Exhaust Filter Diagnostic Procedure Diagnose codes 011200 and 011401 first. RH60123,0000CB6 -19-29AUG16-2/3
• 1
Code Check
Clear and check again for diagnostic trouble codes.
YES: Diagnose other codes first.
Are other codes present?
NO: Checks complete. RH60123,0000CB6 -19-29AUG16-3/3
020011.02 — Electric Lever Alarm Electric control lever system is abnormal.
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. Continued on next page
TM12660 (18APR18)
9001-10-144
DF89619,00B5D8C -19-26FEB16-1/3
041818
PN=178
Main Controller (MCZ) Diagnostic Trouble Codes Electric Control Lever Alarm Diagnostic Procedure DF89619,00B5D8C -19-26FEB16-2/3
• 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) right grip harness connector (marked R_LEVER) (X538). - Auxiliary function lever (AFL) left grip harness connector (marked L_LEVER) (X539). - Auxiliary function lever (AFL) connector (X574). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
DF89619,00B5D8C -19-26FEB16-3/3
020012.02 — Line Filter Restriction Alarm Not applicable to this machine. RH60123,0000CB7 -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 (DTCs) generated with this code. Correct all diagnostic trouble codes before continuing with procedure. DF89619,00B5D8D -19-26FEB16-1/3
Attachment Pedal or Blade and Outrigger Control Lever Alarm Diagnostic Procedure DF89619,00B5D8D -19-26FEB16-2/3
• 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: Pilot 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) right grip harness connector (marked R_LEVER) (X538). - Auxiliary function lever (AFL) left grip harness connector (marked L_LEVER) (X539). - Auxiliary function lever (AFL) connector (X574). - Auxiliary function lever (AFL) harness-to-auxiliary function lever (AFL) solenoid harness connector (X577).
DF89619,00B5D8D -19-26FEB16-3/3
TM12660 (18APR18)
9001-10-145
041818
PN=179
Main Controller (MCZ) Diagnostic Trouble Codes
TM12660 (18APR18)
9001-10-146
041818
PN=180
Group 20
Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes For additional information on the engine control unit circuit, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service ADVISOR™, or by connection with MPDr.
• See Reading Diagnostic Trouble Codes With Monitor Display. (Group 9015-20.)
• See Reading Diagnostic Trouble Codes With Service
ADVISOR™ Diagnostic Application. (Group 9015-20.)
• See MPDr Application. (Group 9015-20.) Service ADVISOR is a trademark of Deere & Company
RH60123,00009E8 -19-09JUL12-1/1
000081.00 — High Exhaust Filter Differential Pressure (P2453) Exhaust filter pressure difference is more than 60 kPa (0.6 bar) (8.7 psi).
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009E9 -19-02SEP16-1/1
000081.01 — Low Exhaust Filter Differential Pressure (P2452) Exhaust filter pressure difference is less than 0.5 kPa (0.005 bar) (0.07 psi).
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009EA -19-12AUG15-1/1
000081.02 — Zero-Point Calibration of Exhaust Filter Differential Pressure Sensor is Abnormal (P2456) Learning value is 4.5 kPa (0.045 bar) (0.65 psi) or more.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009EB -19-12AUG15-1/1
000081.03 — Exhaust Filter Differential Pressure Sensor Circuit High Input (P2455)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the exhaust filter pressure difference sensor is more than 4.89 V.
RH60123,00009EC -19-12AUG15-1/1
000081.04 — Exhaust Filter Differential Pressure Sensor Circuit Low Input (P2454)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the exhaust filter pressure difference sensor is less than 0.18 V.
RH60123,00009ED -19-12AUG15-1/1
000091.02 — Accelerator Pedal Position Sensor 1-2 Correlation (P2138) Opening amount difference between accelerator sensors 1 and 2 is 45% or more.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable • Engine Malfunction Indicator: OFF RH60123,00009EE -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-1
041818
PN=181
Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.03 — Accelerator Pedal Position Sensor 1 High Input (P2123) Voltage at accelerator sensor 1 is more than 4.9 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Machine will not operate • Engine Malfunction Indicator: OFF RH60123,00009EF -19-09JUL12-1/1
000091.03 — Accelerator Pedal Position Sensor 2 High Input (P2128) Voltage at accelerator sensor 2 is more than 4.9 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Machine will not operate • Engine Malfunction Indicator: OFF RH60123,00009F0 -19-12AUG15-1/1
000091.04 — Accelerator Pedal Position Sensor 1 Low Input (P2122) Voltage at accelerator sensor 1 is less than 0.2 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Machine will not operate • Engine Malfunction Indicator: OFF RH60123,00009F1 -19-12AUG15-1/1
000091.04 — Accelerator Pedal Position Sensor 2 Low Input (P2127) Voltage at accelerator sensor 2 is less than 0.2 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Machine will not operate • Engine Malfunction Indicator: OFF RH60123,00009F2 -19-12AUG15-1/1
000100.03 — Engine Oil Pressure Sensor Circuit High Input (P0523)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON
Voltage at the engine oil pressure sensor is more than 4.85 V.
RH60123,00009F3 -19-12AUG15-1/1
000100.04 — Engine Oil Pressure Sensor Circuit Low Input (P0522) Voltage at the engine oil pressure sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,00009F4 -19-12AUG15-1/1
000102.00 — Over Boost-Pressure (P0234) Boost pressure is more than 260 kPa (2.6 bar) (38 psi) higher than the maximum target boost pressure.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009F6 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-2
041818
PN=182
Engine Control Unit (ECU) Diagnostic Trouble Codes
000102.03 — Boost Pressure Sensor Circuit High Input (P0238) Voltage at the boost pressure sensor is more than 4.9 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009F7 -19-12AUG15-1/1
000102.04 — Boost Pressure Sensor Circuit Low Input (P0237) Voltage at the boost pressure sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,00009F8 -19-12AUG15-1/1
000105.03 — Boost Temperature Sensor Circuit High Input (P1113)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine speed will not increase • Machine Operation: Operable • Engine Malfunction Indicator: ON
Voltage at the boost temperature sensor is more than 4.94 V.
RH60123,00009F9 -19-12AUG15-1/1
000105.04 — Boost Temperature Sensor Circuit Low Input (P1112) Voltage at the boost temperature sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine speed will not increase • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,00009FA -19-12AUG15-1/1
000108.03 — Atmospheric Pressure Sensor Circuit High Input (P2229)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the atmospheric pressure sensor is more than 4.0 V.
RH60123,00009FB -19-12AUG15-1/1
000108.04 — Atmospheric Pressure Sensor Circuit Low Input (P2228)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the atmospheric pressure sensor is less than 0.5 V.
RH60123,00009FC -19-12AUG15-1/1
000110.00 — Overheat (P0217)
• Machine Symptom: None • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Coolant temperature is more than 110°C (230°F). For more information, see Isuzu engine manual 4HK1.
RH60123,00009FD -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-3
041818
PN=183
Engine Control Unit (ECU) Diagnostic Trouble Codes
000110.03 — Engine Coolant Temperature Circuit High Input (P0118)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the coolant temperature sensor is more than 4.85 V.
RH60123,00009FE -19-12AUG15-1/1
000110.04 — Engine Coolant Temperature Circuit Low Input (P0117)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the coolant temperature sensor is less than 0.1 V.
RH60123,00009FF -19-12AUG15-1/1
000132.03 — Air Flow Sensor Circuit High Input (P0103) Voltage at the air flow sensor is more than 4.9 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A00 -19-12AUG15-1/1
000132.04 — Air Flow Sensor Circuit Low Input (P0102) Voltage at the air flow sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A01 -19-12AUG15-1/1
000157.00 — Pressure Increase in Common Rail (Secondary) (P0088)
For more information, see Isuzu engine manual 4HK1.
The first stage "abnormal common rail pressure" is active and common rail pressure is 190 MPa (1.9 bar) (28 psi) or more.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
RH60123,0000A02 -19-12AUG15-1/1
000157.03 — Common Rail Pressure Sensor Circuit High Input (P0193)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss, engine may stall • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the common rail pressure sensor is more than 4.8 V.
RH60123,0000A03 -19-12AUG15-1/1
000157.04 — Common Rail Pressure Sensor Circuit Low Input (P0192)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Automatic abnormal engine speed Voltage at the common rail pressure sensor is less than 0.7 V.
increase
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A04 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-4
041818
PN=184
Engine Control Unit (ECU) Diagnostic Trouble Codes
000157.15 — Abnormal Common Rail Pressure (Over Pumping) (P0089)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low
Common rail pressure is more than 40 MPa (0.4 bar) (5.8 psi) higher than the target rail pressure.
power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A05 -19-12AUG15-1/1
000157.16 — Pressure Increase in Common Rail (Primary) (P0088)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
Common rail pressure is 185 MPa (1.85 bar) (27 psi) or more.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A06 -19-12AUG15-1/1
000158.03 — Abnormally High Battery System Voltage (P0563)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON
System voltage is more than 32 V.
RH60123,0000A07 -19-12AUG15-1/1
000172.03 — Intake Air Temperature Sensor Circuit High Input (P0113)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the intake air temperature sensor is more than 4.85 V.
RH60123,0000A08 -19-12AUG15-1/1
000172.04 — Intake Air Temperature Sensor Circuit Low Input (P0112)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the intake air temperature sensor is less than 0.1 V.
RH60123,0000A09 -19-12AUG15-1/1
000173.00 — Abnormally High Exhaust Temperature Sensor 1 (DPF Inlet) (P0426) Temperature of exhaust temperature sensor 1 is 880°C (1616°F) or more.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A0A -19-12AUG15-1/1
000173.03 — Exhaust Temperature Sensor 1 Circuit High Input (DPF Inlet) (P0428) Voltage at exhaust temperature sensor 1 is more than 4.85 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A0B -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-5
041818
PN=185
Engine Control Unit (ECU) Diagnostic Trouble Codes
000173.04 — Exhaust Temperature Sensor 1 Circuit Low Input (DPF Inlet) (P0427) Voltage at exhaust temperature sensor 1 is less than 0.2 V. Exhaust temperature is equivalent to 1000°C (1832°F).
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A0C -19-12AUG15-1/1
000174.03 — Combustion Temperature Sensor Circuit High Input (P0183) Voltage at the fuel temperature sensor is more than 4.85 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine speed will not increase • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A0D -19-12AUG15-1/1
000174.04 — Combustion Temperature Sensor Circuit Low Input (P0182) Voltage at the fuel temperature sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine speed will not increase • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A0E -19-12AUG15-1/1
000190.00 — Engine Overrun (P0219) Engine speed is more than specification (2500 rpm).
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON
For more information, see Isuzu engine manual 4HK1. RH60123,0000A0F -19-12AUG15-1/1
000628.02 — Abnormal ROM (P0601)
• Machine Symptom: Engine will not start • Machine Operation: None while operating; will not
Internal control module memory check sum error.
start/restart after shutdown
For more information, see Isuzu engine manual 4HK1.
• Engine Malfunction Indicator: ON RH60123,0000A10 -19-12AUG15-1/1
000633.07 — Common Rail Pressure Limiter Open (P0087) Common rail pressure sensor detected pattern change indicating pressure limiter open.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON RH60123,0000A11 -19-12AUG15-1/1
000636.02 — Abnormal Cam Angle Sensor (No Signal) (P0340)
• Machine Symptom: None while running; restart not possible
• Machine Operation: None while operating; will not
The signal from camshaft sensor is not present.
start/restart after shutdown
For more information, see Isuzu engine manual 4HK1.
• Engine Malfunction Indicator: ON RH60123,0000A12 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-6
041818
PN=186
Engine Control Unit (ECU) Diagnostic Trouble Codes
000636.07 — Phase Difference Between Cam and Sensor (P0016) Camshaft sensor signal and crankshaft sensor signal are out of synchronization while the engine is running.
• Machine Symptom: None while running; restart not possible
• Machine Operation: None while operating; will not start/restart after shutdown
• Engine Malfunction Indicator: ON
For more information, see Isuzu engine manual 4HK1. RH60123,0000A13 -19-12AUG15-1/1
000639.02 — Abnormal CAN Time-Out (U0101)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine speed will not increase • Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON
CAN message not received in time specified.
RH60123,0000A14 -19-12AUG15-1/1
000639.19 — Abnormal CAN Bus (U0073) CAN communication circuit malfunction.
• Machine Symptom: Engine speed will not increase • Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON
For more information, see Isuzu engine manual 4HK1. RH60123,0000A15 -19-12AUG15-1/1
000651.05 — Cylinder 1 Injector Circuit Open (P0201)
• Machine Symptom: Rough idle, engine vibration, low
No input signal of injector 1 monitor.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
power, dark smoke
For more information, see Isuzu engine manual 4HK1. RH60123,0000A16 -19-12AUG15-1/1
000652.05 — Cylinder 2 Injector Circuit Open (P0202)
• Machine Symptom: Rough idle, engine vibration, low
No input signal of injector 2 monitor.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
power, dark smoke
For more information, see Isuzu engine manual 4HK1. RH60123,0000A17 -19-12AUG15-1/1
000653.05 — Cylinder 3 Injector Circuit Open (P0203)
• Machine Symptom: Rough idle, engine vibration, low
No input signal of injector 3 monitor.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
power, dark smoke
For more information, see Isuzu engine manual 4HK1. RH60123,0000A18 -19-12AUG15-1/1
000654.05 — Cylinder 4 Injector Circuit Open (P0204)
• Machine Symptom: Rough idle, engine vibration, low
No input signal of injector 4 monitor.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
power, dark smoke
For more information, see Isuzu engine manual 4HK1. RH60123,0000A19 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-7
041818
PN=187
Engine Control Unit (ECU) Diagnostic Trouble Codes
000723.02 — Crank Position Sensor Failure (No Signal) (P0335) Even if the camshaft signal is present, the crankshaft signal is not present.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss, engine may stall • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A1A -19-12AUG15-1/1
000723.02 — Crank Position Sensor Failure (Abnormal Signal) (P0336) The pulse of crankshaft signal is not matched.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss, engine may stall • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A1B -19-12AUG15-1/1
001077.02 — Abnormal CPU (P0606)
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
CAN communication circuit malfunction. For more information, see Isuzu engine manual 4HK1.
RH60123,0000A1C -19-12AUG15-1/1
001079.02 — Abnormal 5V-Electric Power Circuit #1 (P0641)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
Voltage of 5 V power source circuits 1 or 5 is over 5.5 V or less than 4.5 V.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A1D -19-12AUG15-1/1
001080.02 — Abnormal 5V-Electric Power Circuit #2 (P0651)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
Voltage of 5 V power source circuits 2 or 6 is over 5.5 V or less than 4.5 V.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A1E -19-12AUG15-1/1
001131.03 — Manifold Temperature Sensor Circuit High Input (P041C)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON
Voltage at the manifold temperature sensor is more than 4.94 V.
RH60123,0000A1F -19-12AUG15-1/1
001131.04 — Manifold Temperature Sensor Circuit Low Input (P041D) Voltage at the manifold temperature sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A20 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-8
041818
PN=188
Engine Control Unit (ECU) Diagnostic Trouble Codes
001239.01 — Pressure Decline in Common Rail (No Pumping Pressure) (P0093) Engine speed: 900 rpm or more. Rail pressure: 15 MPa (150 bar) (2176 psi) or less.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A21 -19-12AUG15-1/1
001239.31 — Pressure Decline in Common Rail (No Pumping Pressure) (Fuel Temperature less than 5° C) (P0093) Engine speed: 900 rpm or more. Rail pressure: 15 MPa (150 bar) (2176 psi) or less. Temperature at 5°C (41°F) or less.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000B17 -19-12AUG15-1/1
001239.17 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093) Actual common rail pressure is over 50 MPa (500 bar) (7252 psi) lower than the target rail pressure.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A22 -19-12AUG15-1/1
001239.31 — Pressure Decline in Common Rail (Lack of Pumping Pressure) (Fuel Temperature less than 5° C) (P1093) Actual common rail pressure is over 50 MPa (500 bar) (7252 psi) lower than the target rail pressure. Temperature at 5°C (41°F) or less.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000B18 -19-12AUG15-1/1
001347.03 — SCV Drive Circuit + Short Circuit B (P0092)
For more information, see Isuzu engine manual 4HK1.
Suction control valve current is over 2400 mA, or difference between suction control valve current and target current is 1000 mA or more.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
RH60123,0000A23 -19-12AUG15-1/1
001347.04 — SCV Drive Circuit Open or Short Circuited to GND (P0091)
For more information, see Isuzu engine manual 4HK1.
Suction control valve current is less than 50 mA, or difference between suction control valve current and target current is 1000 mA or more.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
RH60123,0000A24 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-9
041818
PN=189
Engine Control Unit (ECU) Diagnostic Trouble Codes
001381.03 — Fuel Filter Restriction Sensor Circuit High Input (P1294) Voltage at the restriction sensor is more than 4.9 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A25 -19-12AUG15-1/1
001381.04 — Fuel Filter Restriction Sensor Circuit Low Input (P1293) Voltage at the restriction sensor is less than 0.1 V.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A26 -19-12AUG15-1/1
001485.05 — Abnormal Main Relay Circuit (Inactivation) (P0685) Voltage in the main relay system is 1.0 V or less with the main relay coil output ON.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine will not start • Machine Operation: Engine will not start/restart after shutdown
• Engine Malfunction Indicator: ON RH60123,0000A27 -19-12AUG15-1/1
001485.06 — Abnormal Main Relay Circuit (Kept Closed) (P0687) Even if the main relay coil output is turned OFF, the main relay is kept ON.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A28 -19-12AUG15-1/1
010001.02 — EGR Position Error (Brushless Type) (P0409) Output signal of EGR position sensor is not present.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A29 -19-12AUG15-1/1
010001.13 — Abnormal EGR Zero-Point Calibration (P1404) EGR opening amount change is abnormal during zero-point calibration.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A2A -19-12AUG15-1/1
010002.02 — Abnormal EGR Valve Control Circuit (P0404) Difference between the target valve lift and actual position is more than 20%.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A2B -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-10
041818
PN=190
Engine Control Unit (ECU) Diagnostic Trouble Codes
010003.02 — Abnormal Injector Common 1 Circuit (P2146)
For more information, see Isuzu engine manual 4HK1.
Injector charge voltage circuit of the common power supply 1 (injectors 1 and 4) has been opened, shorted to ground or voltage.
• Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
RH60123,0000A2C -19-12AUG15-1/1
010004.02 — Abnormal Injector Common 2 Circuit (P2149)
For more information, see Isuzu engine manual 4HK1.
Injector charge voltage circuit of the common power supply 2 (injectors 2 and 3) has been opened, shorted to ground or voltage.
• Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
RH60123,0000A2D -19-12AUG15-1/1
010005.01 — Abnormal Charge Circuit (Bank 1) (P1261) Injector charge voltage circuit of the common power supply 1 (injectors 1 and 4) has been opened.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON RH60123,0000A2E -19-12AUG15-1/1
010006.01 — Abnormal Charge Circuit (Bank 2) (P1262) Injector charge voltage circuit of the common power supply 2 (injectors 2 and 3) has been opened.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
• Machine Operation: Machine will not operate • Engine Malfunction Indicator: ON RH60123,0000A2F -19-12AUG15-1/1
010007.02 — Abnormal CPU Monitor IC (P0606) No change of RUN-SUB pulse in 20 milliseconds.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A30 -19-12AUG15-1/1
010008.02 — Abnormal A/D Converter (P060B) Analog/Digital conversion cannot be done.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A31 -19-12AUG15-1/1
010009.02 — Abnormal 5V-Electric Power Circuit #3 (P0697)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low Voltage of 5 V power source circuits 3 or 7 is over 5.5 V or less than 4.5 V.
power, dark smoke
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A32 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-11
041818
PN=191
Engine Control Unit (ECU) Diagnostic Trouble Codes
010010.02 — Abnormal 5V-Electric Power Circuit #4 (P1655)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Rough idle, engine vibration, low power, dark smoke
Voltage of 5 V power source circuits 4 or 8 is over 5.5 V or less than 4.5 V.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A33 -19-12AUG15-1/1
010012.02 — Abnormal 12V Circuit (P0560)
• Machine Symptom: Rough idle, engine vibration, low
Voltage of 12 V power source circuit is over 19 V or less than 7 V.
• Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
power, dark smoke
For more information, see Isuzu engine manual 4HK1. RH60123,0000A34 -19-12AUG15-1/1
010013.02 — Abnormal EEPROM/Abnormal HDEEPROM (P1621)
For more information, see Isuzu engine manual 4HK1.
Abnormal EEPROM is detected.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A35 -19-12AUG15-1/1
010022.02 — Abnormal Intake Throttle Control Circuit (P0638) ECU detects a difference between the actual opening angle and desired opening angle of the intake throttle.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A36 -19-12AUG15-1/1
010022.03 — Intake Throttle Position Sensor Circuit High Input (P0123)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the intake throttle position sensor is more than 4.9 V.
RH60123,0000A37 -19-12AUG15-1/1
010022.04 — Intake Throttle Position Sensor Circuit Low Input (P0122)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at the intake throttle position sensor is less than 0.3 V.
RH60123,0000A38 -19-12AUG15-1/1
010023.02 — Abnormal CAN VNT Time-out/ISO-CAN VNT Communication Error (U0110) The message from turbo controller is not received.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Low power • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000B11 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-12
041818
PN=192
Engine Control Unit (ECU) Diagnostic Trouble Codes
010023.12 — Abnormal VNT Turbo (P0045)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Low power • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
The abnormal message from turbo controller has been received.
RH60123,0000B12 -19-12AUG15-1/1
010023.19 — VNT Communication Error (U0411) The abnormal communication message from turbo controller has been received.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Low power • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000B13 -19-12AUG15-1/1
010024.03 — Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
Voltage at exhaust temperature sensor 2 is more than 4.85 V.
RH60123,0000A3C -19-12AUG15-1/1
010024.04 — Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C) Voltage at exhaust temperature sensor 2 is less than 0.2 V. Exhaust temperature is equivalent to 800°C (1472°F).
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A3D -19-12AUG15-1/1
010025.05 — Exhaust Filter Light Failure (P1669) No exhaust filter lamp monitor signal. NOTE: The exhaust filter lamp is contained within the exhaust filter parked cleaning switch (S16).
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A3E -19-28APR17-1/1
010026.00 — Exhaust Filter PM Over-Restriction 2 (P1455)
For more information, see Isuzu engine manual 4HK1.
In this case it is evaluated that PM trapping amount is out of exhaust filter regeneration level. Evaluated by the operating period.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A3F -19-12AUG15-1/1
010026.15 — Exhaust Filter PM Over-Restriction (P242F)
For more information, see Isuzu engine manual 4HK1.
In this case it is evaluated that PM trapping amount is out of exhaust filter regeneration level. Evaluated by a pressure difference.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A40 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-13
041818
PN=193
Engine Control Unit (ECU) Diagnostic Trouble Codes
010027.00 — Exhaust Filter Cleaning Decision Error (P1471)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
In this case cleaning evaluation after regeneration is invalid twice.
RH60123,0000A41 -19-12AUG15-1/1
010028.00 — Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B) Temperature of exhaust temperature sensor 2 is 870°C (1598°F) or more.
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON RH60123,0000A42 -19-12AUG15-1/1
010029.00 — Over Frequent Exhaust Filter Regeneration Time-Out (P2458)
For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
In this case regeneration time-out is continuous three times.
RH60123,0000A43 -19-12AUG15-1/1
010032.02 — QR Code Error (P0602)
For more information, see Isuzu engine manual 4HK1.
ECU detects that the injector ID code or the fuel delivery rate data is not programmed in the ECU or programmed injector ID code is incorrect.
• Machine Symptom: None • Machine Operation: Operable • Engine Malfunction Indicator: ON RH60123,0000A44 -19-12AUG15-1/1
010033.02 — Abnormal RAM (P0604) Abnormal random access memory (RAM) is detected. For more information, see Isuzu engine manual 4HK1.
• Machine Symptom: Engine will not start • Machine Operation: Engine will not start/restart after shutdown
• Engine Malfunction Indicator: ON RH60123,0000A45 -19-12AUG15-1/1
010040.19 — Abnormal ISO-CAN Bus (U0001) CAN communication circuit malfunction.
• Machine Symptom: Power loss • Machine Operation: Operable, but steering not possible • Engine Malfunction Indicator: ON
For more information, see Isuzu engine manual 4HK1. RH60123,0000A46 -19-12AUG15-1/1
TM12660 (18APR18)
9001-20-14
041818
PN=194
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
RH60123,0000AA6 -19-09JUL12-1/1
013002.02 — ECU Communication Error Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AA7 -19-12AUG15-1/1
013003.02 — Main Controller (MCZ) Communication Error 1
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AA8 -19-12AUG15-1/1
013004.02 — Main Controller (MCZ) Communication Error 2
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AA9 -19-12AUG15-1/1
013005.02 — Monitor Controller (DSZ) Communication Error 1
Check CAN 0 circuit. See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AAA -19-12AUG15-1/1
013006.02 — Monitor Controller (DSZ) Communication Error 2
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AAB -19-12AUG15-1/1
013007.02 — Machine Controller (BCZ) Communication Error
Check CAN 1 circuit. See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,0000AAC -19-12AUG15-1/1
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)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
For more information:
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
JL58967,00003ED -19-13MAY16-1/1
TM12660 (18APR18)
9001-30-1
041818
PN=195
Monitor Controller (DSZ) Diagnostic Trouble Codes
TM12660 (18APR18)
9001-30-2
041818
PN=196
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 JL58967,00003CE -19-11MAR16-1/1
013303.02 — Abnormal Monitor Internal Temperature Sensor
The monitor screen becomes dark. JL58967,0000646 -19-10OCT16-1/4
Monitor Internal Temperature Sensor Diagnostic Procedure JL58967,0000646 -19-10OCT16-2/4
• 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.) JL58967,0000646 -19-10OCT16-3/4
• 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.) JL58967,0000646 -19-10OCT16-4/4
013304.02 — Alternator Alarm Alternator output above 33.5 volts. JL58967,0000647 -19-10OCT16-1/3
Alternator Alarm Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-40-1
JL58967,0000647 -19-10OCT16-2/3
041818
PN=197
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. JL58967,0000647 -19-10OCT16-3/3
013310.03 — Shorted Circuit in Coolant Temperature Sensor
See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Diagnose the Diagnostic Trouble Codes (DTC) of the Engine Control Unit (ECU). JL58967,0000648 -19-10OCT16-1/4
Shorted Circuit in Coolant Temperature Sensor Diagnostic Procedure Coolant temperature logo turns red or gauge (pointer) disappears on monitor. JL58967,0000648 -19-10OCT16-2/4
• 1
Resistance Check at Monitor Controller
Measure resistance at pin 19 on monitor controller 28-pin connector A (X20).
YES: Go to Coolant Temperature Sensor Check.
Is resistance 50 ohms or less for longer than 60 seconds.
NO: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.) JL58967,0000648 -19-10OCT16-3/4
• 2
Coolant Temperature Sensor Check
Measure resistance at coolant temperature sensor switch (B43) ground.
YES: Open circuit. Repair or replace the harness. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) See Engine Harness (W4) Wiring Diagram. (Group 9015-10.)
Is resistance less than 50 ohms?
NO: Replace the coolant temperature sensor switch (B43). JL58967,0000648 -19-10OCT16-4/4
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.
Continued on next page
TM12660 (18APR18)
9001-40-2
JL58967,0000649 -19-10OCT16-1/5
041818
PN=198
Information Controller (ICZ) Diagnostic Trouble Codes Fuel Level Sensor Open Circuit Diagnostic Procedure JL58967,0000649 -19-10OCT16-2/5
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Fuel level sensor connector (B18) and machine harness splice connector (X97). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin YES: Go to Resistance connector A (X20). See Cab Harness (W1) Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Check. NO: Repair or replace connector. See appropriate harness. JL58967,0000649 -19-10OCT16-3/5
• 2
Resistance Check
Key switch in OFF position.
Disconnect fuel level sensor connector (B18). Check resistance between pins 1 and 2 on fuel level sensor connector (B18). Is sensor within specifications?
YES: Go to Continuity 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
NO: Fuel level sensor malfunction. Replace sensor.
JL58967,0000649 -19-10OCT16-4/5
• 3
Continuity Check
Key switch in OFF position.
Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18). Check for continuity between:
• Pin 1 on fuel level sensor connector (B18) and pin 24 on machine harness splice connector (X97).
• Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20).
YES: Monitor controller malfunction. Replace monitor controller. See Monitor Controller (DSZ) Remove and Install. (Group 9015-20.)
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. JL58967,0000649 -19-10OCT16-5/5
TM12660 (18APR18)
9001-40-3
041818
PN=199
Information Controller (ICZ) Diagnostic Trouble Codes
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. JL58967,000064A -19-10OCT16-1/6
Fuel Level Sensor Shorted Circuit Diagnostic Procedure JL58967,000064A -19-10OCT16-2/6
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Fuel level sensor connector (B18) and machine harness splice connector (X97). See Machine Harness (W2) Component Location. (Group 9015-10.)
• Cab harness-to-machine harness 100-pin connector (X3) and monitor controller 28-pin YES: Go to Resistance connector A (X20). See Cab Harness (W1) Component Location. (Group 9015-10.)
Are connectors in good condition and free of corrosion and debris?
Check. NO: Repair or replace connector. See appropriate harness. JL58967,000064A -19-10OCT16-3/6
• 2
Resistance Check
Key switch in OFF position.
Disconnect fuel level sensor connector (B18). Check resistance between pins 1 and 2 on fuel level sensor connector (B18). Is sensor within specifications?
YES: Go to Continuity 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
TM12660 (18APR18)
9001-40-4
NO: Fuel level sensor malfunction. Replace sensor.
JL58967,000064A -19-10OCT16-4/6
041818
PN=200
Information Controller (ICZ) Diagnostic Trouble Codes
• 3
Continuity Check
Key switch in OFF position.
Disconnect monitor controller 28-pin connector A (X20) and fuel level sensor connector (B18). Check for continuity between:
• Pin 1 on fuel level sensor connector (B18) and pin 24 on machine harness splice connector (X97).
• Pin 2 on fuel level sensor connector (B18) and pin 18 on monitor controller 28-pin connector A (X20).
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness. JL58967,000064A -19-10OCT16-5/6
• 4
Short Circuit Check
Key switch in OFF position.
Disconnect monitor controller 28-pin connector A (X20). Check for continuity between pin 18 on monitor controller 28-pin connector A (X20) and machine ground.
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.) JL58967,000064A -19-10OCT16-6/6
• See Controller Area Network 0 (CAN 0) Circuit
013334.02 — Radiator Coolant Error
Diagnostics. (Group 9001-10.)
Diagnose the diagnostic trouble codes (DTC) in the engine control unit (ECU), then clear codes and re-check DTCs.
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
JL58967,00003D4 -19-14MAR16-1/1
014001.02 — Flash Memory Read/Write Error JL58967,00003D5 -19-14MAR16-1/3
Flash Memory Read/Write Error Diagnostic Procedure Flash Memory Read/Write Error in monitor controller. JL58967,00003D5 -19-14MAR16-2/3
• 1
Diagnostic Trouble Code 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. JL58967,00003D5 -19-14MAR16-3/3
TM12660 (18APR18)
9001-40-5
041818
PN=201
Information Controller (ICZ) Diagnostic Trouble Codes
014002.02 — External RAM Read/Write Error JL58967,00003D6 -19-14MAR16-1/3
External RAM Read/Write Error Diagnostic Procedure External RAM Read/Write Error in monitor controller. JL58967,00003D6 -19-14MAR16-2/3
• 1
Diagnostic Trouble Code 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. JL58967,00003D6 -19-14MAR16-3/3
014003.02 — Abnormal EEPROM JL58967,00003D7 -19-14MAR16-1/3
Abnormal EEPROM Diagnostics Procedure Abnormal EEPROM in monitor controller. JL58967,00003D7 -19-14MAR16-2/3
• 1
Diagnostic Trouble Code 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. JL58967,00003D7 -19-14MAR16-3/3
014006.02 — Communication Terminal:Communication Error JL58967,00003D8 -19-14MAR16-1/5
Communication Terminal:Communication Error Diagnostic Procedure JL58967,00003D8 -19-14MAR16-2/5
• 1
Fuse Check
Key switch in OFF position.
Remove fuses (F6000—F6002). See JDLink™ Harness (W6004) Component Location. (Group 9015-10.) Check fuses (F6000—F6002) for continuity.
YES: Go to Power Check.
Is continuity indicated?
NO: Replace defective fuse(s). Continued on next page
TM12660 (18APR18)
9001-40-6
JL58967,00003D8 -19-14MAR16-3/5
041818
PN=202
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. JL58967,00003D8 -19-14MAR16-4/5
• 3
Harness Check
Key switch in OFF position.
Disconnect satellite (SAT) module control unit 48-pin connector (X6015). Disconnect modular telematics gateway (MTG) connector (X6014). Check continuity between:
• Pin A1 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A2 on modular telematics gateway (MTG) connector (X6014).
• Pin A2 on satellite (SAT) module control unit 48-pin connector (X6015) and pin A1 on YES: Go to Interface modular telematics gateway (MTG) connector (X6014).
Is continuity indicated?
Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.) NO: Repair or replace harness. See appropriate harness. JL58967,00003D8 -19-14MAR16-5/5
014008.02 — Abnormal Internal RAM JL58967,00003D9 -19-14MAR16-1/3
Abnormal Internal RAM Diagnostic Procedure Abnormal Internal RAM in monitor controller. JL58967,00003D9 -19-14MAR16-2/3
• 1
Diagnostic Trouble Code 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. JL58967,00003D9 -19-14MAR16-3/3
014021.02 — Communication Terminal Security Error
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
Security malfunction of mobile communication equipment. For more information:
• See Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.)
• See Interface Controller Area Network (N-CAN) Diagnostics. (Group 9001-10.)
JL58967,00003DA -19-14MAR16-1/1
TM12660 (18APR18)
9001-40-7
041818
PN=203
Information Controller (ICZ) Diagnostic Trouble Codes
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 JL58967,00003DB -19-09NOV17-1/1
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)
Diagnostics. (Group 9001-10.) Diagnostics. (Group 9001-10.)
For more information:
• See Controller Area Network 0 (CAN 0) Circuit Diagnostics. (Group 9001-10.)
JL58967,00003DC -19-14MAR16-1/1
020100.02 — Overheat Alarm
• See Engine Control Unit (ECU) Diagnostic Trouble
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
Codes. (Group 9001-20.)
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
For more information: JL58967,00003DD -19-14MAR16-1/1
TM12660 (18APR18)
9001-40-8
041818
PN=204
Information Controller (ICZ) Diagnostic Trouble Codes
020101.02 — Engine Warning Alarm X21 1
760
18
19
36
A4
A1 X4 WHT/YEL
WHT/YEL
1
X15-130
TX1223582 —UN—20SEP16
X21-B12
TX1223582 Engine Circuit Diagnostic A1—Engine Control Unit (ECU) A4—Monitor Controller (DSZ)
X4— Cab Harness-to-Machine X21— Monitor Controller 36-Pin Harness 32-Pin Connector Connector B X15— Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Engine Control Unit (ECU) Diagnostic Trouble
For more information:
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
Codes. (Group 9001-20.)
TX04577,000011F -19-28SEP16-1/5
Engine Warming Alarm Diagnostic Procedure TX04577,000011F -19-28SEP16-2/5
• 1
Connector Check
Key switch in OFF position.
Check the following connectors for damage, corrosion, or debris:
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group 9015-10.) - Engine control unit (ECU)-to-machine harness 94-pin connector (X15). - Machine harness-to-cab harness 32-pin connector (X4).
• Cab Harness (W1). See Cab Harness (W1) Component Location. (Group 9015-10.)
YES: Go to Continuity Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connector. See appropriate harness.
- Monitor controller (DSZ) 36 pin-connector B (X21)-to-cab harness (W1). - Cab harness-to-machine harness 32-pin connector (X4).
Continued on next page
TM12660 (18APR18)
9001-40-9
TX04577,000011F -19-28SEP16-3/5
041818
PN=205
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Continuity Check
Key switch in OFF position.
Disconnect monitor controller (DSZ)-to-machine harness 36-pin connector B (X21). See Monitor Controller (DSZ) Circuit Theory of Opearation. (Group 9015-15.) Disconnect engine control unit (ECU)-to-machine harness 94-pin connector (X15). See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Check continuity between:
• Pin B12 of monitor controller 36-pin connector B (X21) and pin 130 of engine control
YES: Go to Short Circuit Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate harness.
unit (ECU) 94-pin connector (X15).
TX04577,000011F -19-28SEP16-4/5
• 3
Short Circuit Check
Key switch in OFF position.
Engine control unit (ECU)-to-machine harness 94-pin connector (X15) disconnected. Check for continuity between:
• Pin 130 of engine control unit (ECU)-to-machine harness 94-pin connector (X15) and YES: Short to ground. machine ground.
Repair or replace harness. See appropriate harness.
Is continuity indicated?
NO: Checks complete. TX04577,000011F -19-28SEP16-5/5
020102.02 — Engine Oil Pressure Alarm
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
For more information: JL58967,00003DF -19-14MAR16-1/1
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.
JL58967,00003E0 -19-14MAR16-1/5
Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure JL58967,00003E0 -19-14MAR16-2/5
• 1
Filter Check
Replace hydraulic oil filter.
YES: Go to Hydraulic Oil Filter Restriction Switch Check.
Is DTC 020105.02 still present?
NO: Checks complete. Continued on next page
TM12660 (18APR18)
9001-40-10
JL58967,00003E0 -19-14MAR16-3/5
041818
PN=206
Information Controller (ICZ) Diagnostic Trouble Codes
• 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. JL58967,00003E0 -19-14MAR16-4/5
• 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.) JL58967,00003E0 -19-14MAR16-5/5
020106.02 — Air Cleaner Restriction Alarm Air filter restriction switch (B16) detects a restriction.
• See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
• See System Functional Schematic. (Group 9015-10.)
Additional References: JL58967,00003E1 -19-08MAR18-1/6
Air Cleaner Restriction Alarm Diagnostic Procedure JL58967,00003E1 -19-08MAR18-2/6
• 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 (X4). - Monitor controller 36-pin connector B (X21).
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group
YES: Go to Filter Check.
Are connectors in good condition and free of corrosion and debris?
NO: Repair or replace connectors. See appropriate harness.
9015-10.) - Air filter restriction switch (B16). - Cab harness-to-machine harness 100-pin connector (X4).
Continued on next page
TM12660 (18APR18)
9001-40-11
JL58967,00003E1 -19-08MAR18-3/6
041818
PN=207
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Filter Check
Key switch in OFF position.
Clean or replace air cleaner. See Replace Air Cleaner Elements. (Operator’s Manual.)
YES: Go to Component Check.
Is DTC 020106.02 still present?
NO: Checks complete. JL58967,00003E1 -19-08MAR18-4/6
• 3
Component Check
Key switch in OFF position.
Disconnect air filter restriction switch (B16).
YES: Go to Circuit Check.
Is DTC 020106.02 still present?
NO: Air filter restriction switch malfunction. Replace switch. JL58967,00003E1 -19-08MAR18-5/6
• 4
Circuit Check
Key switch in OFF position.
Air filter restriction switch (B16) disconnected. Disconnect monitor controller 36-pin connector B (X21). Check for continuity between pin 14 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: Checks complete. JL58967,00003E1 -19-08MAR18-6/6
020107.02 — Water Separator 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.
JL58967,00003E2 -19-14MAR16-1/4
Water-in-Fuel Separator Alarm The monitor controller (DSZ) monitors water-in-fuel for engine protection. When water is detected in the fuel, a signal is sent to the monitor controller (DSZ). JL58967,00003E2 -19-14MAR16-2/4
• 1
Sensor Check
Disconnect water-in-fuel sensor (B17).
See Pump Harness (W8) Component Location. (Group 9015-10.) Connect Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
YES: Go to Circuit Check.
Is display fault code 020107.02 still present?
NO: Replace water-in-fuel sensor (B17).
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9001-40-12
JL58967,00003E2 -19-14MAR16-3/4
041818
PN=208
Information Controller (ICZ) Diagnostic Trouble Codes
• 2
Circuit Check
Disconnect monitor controller (DSZ) 36-pin connector B (X21) and water-in-fuel sensor (B17). See Pump Harness (W8) Component Location. (Group 9015-10.) Check for continuity between pin 7 of monitor controller (DSZ) 36-pin connector B (X21) and machine ground.
YES: Short to ground. Repair or replace the harness. See Pump Harness (W8) Component Location. (Group 9015-10.) See Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
Is continuity present?
NO: Checks complete. JL58967,00003E2 -19-14MAR16-4/4
020109.02 — Pilot Control Shut-Off Lever Alarm JL58967,00003E3 -19-14MAR16-1/6
Pilot Control Shut-Off Lever Alarm Diagnostic Procedure JL58967,00003E3 -19-14MAR16-2/6
• 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. JL58967,00003E3 -19-14MAR16-3/6
• 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?
NO: Monitor controller is OK. JL58967,00003E3 -19-14MAR16-4/6
• 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. Continued on next page
TM12660 (18APR18)
9001-40-13
JL58967,00003E3 -19-14MAR16-5/6
041818
PN=209
Information Controller (ICZ) Diagnostic Trouble Codes
• 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. JL58967,00003E3 -19-14MAR16-6/6
020110.02 — Fuel Filter Restriction Alarm JL58967,00003E4 -19-14MAR16-1/8
Fuel Filter Restriction Alarm Diagnostic Procedure JL58967,00003E4 -19-14MAR16-2/8
• 1
Filter Check
Replace fuel filters.
• See Replace Primary Fuel Filter and Water Separator. (Operator’s Manual.) • See Replace Final Fuel Filter and Water Separator. (Operator’s Manual.) • See Replace Auxiliary Fuel Filter and Water Separator. (Operator’s Manual.) Operate machine.
YES: Go to Fuel System Check.
Does diagnostic trouble code (DTC) 020110.02 become active?
NO: Checks complete. JL58967,00003E4 -19-14MAR16-3/8
• 2
Fuel System Check
Thoroughly inspect fuel circuit for obstructions. See Engine Fuel System Component Location. (Group 9010-05.)
YES: Go to Fuel Tank.
Are all lines and hoses straight, clear of debris, and in good condition; not kinked, damaged, or collapsed?
NO: Repair or replace parts as necessary. JL58967,00003E4 -19-14MAR16-4/8
• 3
Fuel Tank
If machine is not equipped with fuel shutoff valve, go to next step in this check.
If equipped, verify fuel shutoff valve is in full open position.
YES: Go to next step in this check.
Is fuel shutoff valve in full open position?
NO: Place fuel shutoff valve in full open position.
Disconnect fuel supply hose to primary fuel filter from fuel tank outlet. Allow fuel to drain into an appropriate container.
YES: Go to next step in this check.
Does fuel run freely?
NO: Inspect fuel tank for debris.
Run wire through fuel tank outlet to possibly clear debris.
YES: Inspect fuel tank for debris.
Does fuel flow increase?
NO: Go to Fuel Transfer Pump. Continued on next page
TM12660 (18APR18)
9001-40-14
JL58967,00003E4 -19-14MAR16-5/8
041818
PN=210
Information Controller (ICZ) Diagnostic Trouble Codes
• 4
Fuel Transfer Pump
YES: Go to Fuel Feel Valve.
1
M2
TX1207003 —UN—07JAN16
Fuel Transfer Pump Screen 1— Screen M2—Fuel Transfer Pump Remove and inspect screen (1) in fuel transfer pump (M2). Is screen clear of debris?
NO: Replace screen. Inspect fuel system for source of debris. JL58967,00003E4 -19-14MAR16-6/8
• 5
Fuel Feel Valve
YES: Go to Supply Fuel System.
2
TX1207004 —UN—07JAN16
Fuel Feed Valve 2— Fuel Feed Valve Remove and inspect fuel feed valve. See Isuzu 4HK1 Interim Tier 4 Engine Manual. Is valve clear of corrosion and debris and moving freely?
NO: Replace fuel feed valve. See Isuzu 4HK1 Interim Tier 4 Engine Manual. JL58967,00003E4 -19-14MAR16-7/8
• 6
Supply Fuel System
Fill an approved container with clean prefiltered fuel. Install a clean hose to inlet of fuel transfer pump to container to bypass auxiliary (if equipped) and primary fuel filters. Operate machine.
YES: Replace fuel transfer pump.
Does DTC 020110.02 become active?
NO: Go to next step in this check.
Thoroughly inspect fuel circuit for obstructions to fuel transfer pump. See Engine Fuel System Component Location. (Group 9010-05.)
YES: Replace auxiliary (if equipped) and primary filter headers.
Are all lines and hoses straight, clear of debris, and in good condition; not kinked, damaged, or collapsed?
NO: Repair or replace parts as necessary. JL58967,00003E4 -19-14MAR16-8/8
TM12660 (18APR18)
9001-40-15
041818
PN=211
Information Controller (ICZ) Diagnostic Trouble Codes
020114.02 — Overheat 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.
JL58967,00003E5 -19-14MAR16-1/6
Overheat Alarm JL58967,00003E5 -19-14MAR16-2/6
• 1
Sensor Check
Disconnect coolant temperature sensor (B43).
See Engine Harness (W4) Component Location. (Group 9015-10.) Connect Service ADVISOR™ . See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
YES: Go to Circuit Check.
Is display fault code 020114.02 still present?
NO: Replace coolant temperature sensor (B43).
Service ADVISOR is a trademark of Deere & Company JL58967,00003E5 -19-14MAR16-3/6
• 2
Circuit Check
Disconnect monitor controller (A4) and coolant temperature sensor (B43).
See Cab Harness (W1) Component Location. (Group 9015-10.) Check for continuity between monitor controller (A4) pin A19 and ground.
YES: Short to ground. Repair or replace the harness. See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) See Machine Harness (W2) Wiring Diagram. (Group 9015-10.) See Engine Harness (W4) Wiring Diagram. (Group 9015-10.)
Is continuity present?
NO: Go to Switch Check. JL58967,00003E5 -19-14MAR16-4/6
• 3
Switch Check
Disconnect engine overheat sensor (B42).
See Engine Harness (W4) Component Location. (Group 9015-10.) Connect Service ADVISOR™ . See Service ADVISOR™ Connection Procedure. (Group 9015-20.)
YES: Go to Open Circuit Check.
Is display fault code 20114.2 still present?
NO: Replace engine overheat sensor (B42).
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9001-40-16
JL58967,00003E5 -19-14MAR16-5/6
041818
PN=212
Information Controller (ICZ) Diagnostic Trouble Codes
• 4
Open Circuit Check.
Disconnect monitor controller (DSZ) and engine overheat sensor (B42).
Check for continuity between monitor controller (DSZ) pin B15 and engine overheat sensor (B42) pin 1.
YES: Checks complete.
Is continuity present?
NO: Open circuit. Repair or replace the harness. See Cab Harness (W1) Wiring Diagram. See Engine Harness (W4) Wiring Diagram. (Group 9015-10.) JL58967,00003E5 -19-14MAR16-6/6
020137.02 — Exhaust Filter Alarm
For more information:
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
• See Isuzu 4HK1 Interim Tier 4 Engine Manual. JL58967,00003E6 -19-14MAR16-1/1
020141.02 — Exhaust Temperature Alarm Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
For more information:
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
• See Isuzu 4HK1 Interim Tier 4 Engine Manual. JL58967,00003E7 -19-14MAR16-1/1
020142.02 — Intake Air Temperature Alarm Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
For more information:
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
• See Isuzu 4HK1 Interim Tier 4 Engine Manual. JL58967,00003E8 -19-14MAR16-1/1
020145.02 — Boost Temperature Increase Alarm
For more information:
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
JL58967,00003E9 -19-14MAR16-1/1
020146.02 — Fuel Temperature Increase Alarm
For more information:
Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
JL58967,00003EA -19-14MAR16-1/1
TM12660 (18APR18)
9001-40-17
041818
PN=213
Information Controller (ICZ) Diagnostic Trouble Codes
020149.02 — EGR Gas Temperature Alarm Diagnose the diagnostic trouble codes (DTCs) in the engine control unit (ECU).
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
• See Isuzu 4HK1 Interim Tier 4 Engine Manual.
For more information: JL58967,00003EB -19-14MAR16-1/1
TM12660 (18APR18)
9001-40-18
041818
PN=214
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 RH60123,00009C1 -19-27JUN12-1/1
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 Temperature Sensor Test. (Group 9015-20.)
Additional References: RH60123,00009C2 -19-02AUG12-1/7
Open Circuit in Air Recirculation Sensor Diagnostic Procedure RH60123,00009C2 -19-02AUG12-2/7
• 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. RH60123,00009C2 -19-02AUG12-3/7
• 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 Temperature Sensor Test. (Group 9015-20.)
NO: Air recirculation sensor (B55) malfunction. Replace sensor.
Continued on next page
TM12660 (18APR18)
9001-50-1
RH60123,00009C2 -19-02AUG12-4/7
041818
PN=215
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. RH60123,00009C2 -19-02AUG12-5/7
• 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. RH60123,00009C2 -19-02AUG12-6/7
• 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 3 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. RH60123,00009C2 -19-02AUG12-7/7
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 Temperature Sensor Test. (Group 9015-20.)
(Group 9031-05.)
Additional References: RH60123,00009C3 -19-02AUG12-1/7
Short-Circuited Air Recirculation Sensor Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-50-2
RH60123,00009C3 -19-02AUG12-2/7
041818
PN=216
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. RH60123,00009C3 -19-02AUG12-3/7
• 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 Temperature Sensor Test. (Group 9015-20.)
NO: Air recirculation sensor (B55) malfunction. Replace sensor. RH60123,00009C3 -19-02AUG12-4/7
• 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. RH60123,00009C3 -19-02AUG12-5/7
• 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 3 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
TM12660 (18APR18)
9001-50-3
RH60123,00009C3 -19-02AUG12-6/7
041818
PN=217
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. RH60123,00009C3 -19-02AUG12-7/7
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 Temperature Sensor Test. (Group 9015-20.)
Ambient air temperature sensor (B22) is above normal operating voltage. Additional References:
RH60123,00009C4 -19-02AUG12-1/7
Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure RH60123,00009C4 -19-02AUG12-2/7
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Ambient air temperature sensor (B22). 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. RH60123,00009C4 -19-02AUG12-3/7
• 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 Temperature Sensor Test. (Group 9015-20.)
NO: Ambient air temperature sensor (B22) malfunction. Replace sensor.
Continued on next page
TM12660 (18APR18)
9001-50-4
RH60123,00009C4 -19-02AUG12-4/7
041818
PN=218
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. RH60123,00009C4 -19-02AUG12-5/7
• 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. RH60123,00009C4 -19-02AUG12-6/7
• 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. RH60123,00009C4 -19-02AUG12-7/7
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 Temperature Sensor Test. (Group 9015-20.)
(Group 9031-05.)
Additional References: RH60123,00009C5 -19-02AUG12-1/7
Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9001-50-5
RH60123,00009C5 -19-02AUG12-2/7
041818
PN=219
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). 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. RH60123,00009C5 -19-02AUG12-3/7
• 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 Temperature Sensor Test. (Group 9015-20.)
NO: Ambient air temperature sensor (B22) malfunction. Replace sensor. RH60123,00009C5 -19-02AUG12-4/7
• 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. RH60123,00009C5 -19-02AUG12-5/7
• 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
TM12660 (18APR18)
9001-50-6
RH60123,00009C5 -19-02AUG12-6/7
041818
PN=220
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. RH60123,00009C5 -19-02AUG12-7/7
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.) • See Temperature Sensor Test. (Group 9015-20.)
Additional References:
RH60123,00009C6 -19-02AUG12-1/6
Short-Circuited Solar Radiation Sensor Diagnostic Procedure RH60123,00009C6 -19-02AUG12-2/6
• 1
Connector Check
Turn key switch to OFF position.
Check the following connectors for damage, corrosion, or debris:
• Solar sensor (B21). 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. RH60123,00009C6 -19-02AUG12-3/6
• 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
TM12660 (18APR18)
9001-50-7
RH60123,00009C6 -19-02AUG12-4/6
041818
PN=221
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 6 of controller.
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009C6 -19-02AUG12-5/6
• 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. RH60123,00009C6 -19-02AUG12-6/6
21 — Open Circuit in Air Conditioner Freeze Control Switch
• See Air Conditioning System Cycle of Operation.
Air conditioner freeze control switch (B41) circuit is open.
• See System Functional Schematic. (Group 9015-10.) • See Temperature Sensor Test. (Group 9015-20.)
(Group 9031-05.)
Additional References: RH60123,00009C7 -19-02AUG12-1/7
Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure RH60123,00009C7 -19-02AUG12-2/7
• 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
TM12660 (18APR18)
9001-50-8
Check. NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009C7 -19-02AUG12-3/7
041818
PN=222
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.
YES: Go to Voltage Check.
Does resistance meet specification?
NO: Air conditioner freeze control switch (B41) malfunction. Replace switch. RH60123,00009C7 -19-02AUG12-4/7
• 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. RH60123,00009C7 -19-02AUG12-5/7
• 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. RH60123,00009C7 -19-02AUG12-6/7
• 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. RH60123,00009C7 -19-02AUG12-7/7
TM12660 (18APR18)
9001-50-9
041818
PN=223
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
22 — Short-Circuited Air Conditioner Freeze Control Switch
• See Air Conditioning System Cycle of Operation.
Air conditioner freeze control switch (B41) circuit is open.
• See System Functional Schematic. (Group 9015-10.) • See Temperature Sensor Test. (Group 9015-20.)
(Group 9031-05.)
Additional References: RH60123,00009C8 -19-02AUG12-1/7
Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure RH60123,00009C8 -19-02AUG12-2/7
• 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. RH60123,00009C8 -19-02AUG12-3/7
• 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.
YES: Go to Voltage Check.
Does resistance meet specification? See Temperature Sensor Test. (Group 9015-20.)
NO: Air conditioner freeze control switch (B41) malfunction. Replace switch. RH60123,00009C8 -19-02AUG12-4/7
• 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
TM12660 (18APR18)
9001-50-10
RH60123,00009C8 -19-02AUG12-5/7
041818
PN=224
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. RH60123,00009C8 -19-02AUG12-6/7
• 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. RH60123,00009C8 -19-02AUG12-7/7
43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
• See System Functional Schematic. (Group 9015-10.) • See Temperature Sensor Test. (Group 9015-20.)
Air conditioner and heater blower port change servomotor (M10) malfunction. Additional References:
RH60123,00009C9 -19-02AUG12-1/6
Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure RH60123,00009C9 -19-02AUG12-2/6
• 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
TM12660 (18APR18)
9001-50-11
NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009C9 -19-02AUG12-3/6
041818
PN=225
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. RH60123,00009C9 -19-02AUG12-4/6
• 3
Continuity Check
Turn key switch to OFF position.
Air conditioner and heater blower port change servomotor (M10) disconnected. Disconnect air conditioner and heater mixer servomotor (M11). Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 3 of servomotor and pin 25 of controller.
YES: Go to Short to Ground Check.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009C9 -19-02AUG12-5/6
• 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 servomotor 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. RH60123,00009C9 -19-02AUG12-6/6
44 — Abnormal Air Conditioner and Heater Mixer Servomotor Air conditioner and heater mixer servomotor (M11) malfunction.
• See Air Conditioning System Cycle of Operation. (Group 9031-05.)
• See System Functional Schematic. (Group 9015-10.) • See Temperature Sensor Test. (Group 9015-20.)
Additional References: Continued on next page
TM12660 (18APR18)
9001-50-12
RH60123,00009CA -19-02AUG12-1/6
041818
PN=226
Air Conditioner Controller (ACF) Diagnostic Trouble Codes Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure RH60123,00009CA -19-02AUG12-2/6
• 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?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009CA -19-02AUG12-3/6
• 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. RH60123,00009CA -19-02AUG12-4/6
• 3
Continuity Check
Turn key switch to OFF position.
Air conditioner and heater mixer servomotor (M11) disconnected. Disconnect air conditioner and heater blower port change servomotor (M10). Disconnect air conditioner controller (ACF) (A7). Check for continuity between pin 3 of servomotor and pin 7 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
TM12660 (18APR18)
9001-50-13
RH60123,00009CA -19-02AUG12-5/6
041818
PN=227
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 servomotor 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. RH60123,00009CA -19-02AUG12-6/6
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.)
RH60123,00009CB -19-02AUG12-1/6
Abnormal High/Low Refrigerant Pressure Diagnostic Procedure RH60123,00009CB -19-02AUG12-2/6
• 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). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
• Air conditioner high/low pressure switch (B20). See Heater and Air Conditioner
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.
Harness (W41) Component Location. (Group 9015-10.)
RH60123,00009CB -19-02AUG12-3/6
• 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 pressure switch.
YES: Air conditioner high/low pressure switch (B20) malfunction. Replace pressure switch.
Is continuity indicated?
NO: Go to Voltage Check. Continued on next page
TM12660 (18APR18)
9001-50-14
RH60123,00009CB -19-02AUG12-4/6
041818
PN=228
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 pressure switch (B20) for machine voltage. • Pin 2 of 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. RH60123,00009CB -19-02AUG12-5/6
• 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 pressure switch and machine ground.
YES: Checks complete.
Is continuity indicated?
NO: Repair or replace harness. See appropriate wiring diagram or schematic. RH60123,00009CB -19-02AUG12-6/6
91 — Communication Error CAN communication malfunction.
For more information, see Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,00009CC -19-27JUN12-1/1
92 — CAN Bus Off Error CAN Bus Off malfunction.
For more information, see Controller Area Network 1 (CAN 1) Circuit Diagnostics. (Group 9001-10.) RH60123,00009CD -19-27JUN12-1/1
TM12660 (18APR18)
9001-50-15
041818
PN=229
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
TM12660 (18APR18)
9001-50-16
041818
PN=230
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 ..............................9005-10-16
TM12660 (18APR18)
9005-1
041818
PN=1
Contents
TM12660 (18APR18)
9005-2
041818
PN=2
Group 10
Operational Checkout Procedure Operational Checkout
Complete necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring) prior to doing checkout. The machine must be at operating temperature for many of the checks. See Hydraulic Oil Warm-up Procedure. (Group 9025-25.)
This procedure is used to check operation of machine. It is designed so you can do a walk around inspection, check machine operation, and perform specific checks from the operator's seat. If there is a problem with machine, diagnostic information in this checkout will help pinpoint the probable cause. This information may allow you to perform a simple adjustment to correct the problem. Use the table of contents to help find adjustment procedures. A location will be required which is level and has adequate space to complete checks. No tools or equipment are needed to perform checkout.
Read each check completely before performing. If no problem is found, you will be instructed to go to the next check. If a problem is indicated, you will be referred to a procedure for adjustment, repair, or replacement. The monitor can be used to perform diagnostic and operational checks. The monitor can display engine speed, pressures, and diagnostic trouble codes (DTCs). TZ24494,0000F9A -19-10FEB14-1/57
Diagnostic Trouble Code Check TZ24494,0000F9A -19-10FEB14-2/57
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 • 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, and 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 TZ24494,0000F9A -19-10FEB14-3/57
Operational Checks—Key Switch Off, Engine Off Checks Continued on next page
TM12660 (18APR18)
9005-10-1
TZ24494,0000F9A -19-10FEB14-4/57
041818
PN=233
Operational Checkout Procedure Horn Circuit Check
1
TX1093717 —UN—29JUN11
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
TM12660 (18APR18)
9005-10-2
TZ24494,0000F9A -19-10FEB14-5/57
041818
PN=234
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
1
50.0 h
10:00 AM F
H
6
E C
TX1086583A —UN—11JAN11
Hour Meter and Fuel Gauge Screen 1— Hour Meter 2— Home Button 6— Fuel Gauge Press and hold home button (2) until default screen appears. LOOK: Does hour meter (1) display machine hours?
Continued on next page
TM12660 (18APR18)
9005-10-3
YES: Go to next check.
TZ24494,0000F9A -19-10FEB14-6/57
041818
PN=235
Operational Checkout Procedure LOOK: Does fuel gauge (6) display correct fuel level?
NO: Check power on 5 A fuse (F17) (marked POWER ON). 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 or see Monitor Harness (W3) Wiring Diagram. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in.
TZ24494,0000F9A -19-10FEB14-7/57
Operational Checks—Key Switch On, Engine Off Checks Continued on next page
TM12660 (18APR18)
9005-10-4
TZ24494,0000F9A -19-10FEB14-8/57
041818
PN=236
Operational Checkout Procedure Monitor Start—Up Check
TX1086287A —UN—28DEC10
System Starting Screen
TX1086304A —UN—28DEC10
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 about 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 controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9005-10-5
TZ24494,0000F9A -19-10FEB14-9/57
041818
PN=237
Operational Checkout Procedure Monitor, Gauges, and Battery Relay Checks
TX1087186A —UN—28JUN13
Default Screen
50.0 h ECO 10:00 AM
8
F
H
E
C
AUTO
24.0˚C
FM VOL
CH1
81.3 ST MHz
TX1089107 —UN—08MAR11
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 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. Continued on next page
TM12660 (18APR18)
9005-10-6
TZ24494,0000F9A -19-10FEB14-10/57
041818
PN=238
Operational Checkout Procedure Turn key switch to ON position. LISTEN: Does battery relay click? LOOK: Does engine coolant temperature gauge (5) display correct engine coolant temperature? LOOK: Does fuel gauge (6) display correct fuel level?
YES: Go to next check.
LOOK: Does hour meter (4) display machine hours?
NO: Monitor does not turn ON. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications. (Group 9015-10.)
LOOK: Does work mode indicator (1) display correct work mode (dig or attachment)?
NO: Check wiring. See Cab Harness (W1) Wiring Diagram or see Monitor Harness (W3) Wiring Diagram. (Group 9015-10.)
LOOK: Does travel mode indicator (7) display correct travel mode?
NO: Check key switch. See Electrical Component Checks. (Group 9015-20.) Check battery relay. See Electrical Component Checks. (Group 9015-20.) Check wiring. See Machine Harness (W2) Wiring Diagram and see Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
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 Machine Harness (W2) Wiring Diagram and see Cab Harness (W1) 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 Monitor Display or see Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic 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 wiring. See Machine Harness (W2) Wiring Diagram and see Machine Harness (W2) Component Location. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. Continued on next page
TM12660 (18APR18)
9005-10-7
TZ24494,0000F9A -19-10FEB14-11/57
041818
PN=239
Operational Checkout Procedure Rear Camera Check
TX1086305A —UN—28DEC10
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
TM12660 (18APR18)
9005-10-8
TZ24494,0000F9A -19-10FEB14-12/57
041818
PN=240
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 switch to ON position. When the default screen (5) is displayed, press monitor dial (2) on the switch panel. LOOK: Does main menu (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).
TX1087390A —UN—27JAN11
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).
YES: Go to next check.
Press home button.
NO: Menus do not display. Check monitor 5 A fuse (F14) (marked MONITOR). See Fuse and Relay Specifications. (Group 9015-10.)
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
TM12660 (18APR18)
9005-10-9
TZ24494,0000F9A -19-10FEB14-13/57
041818
PN=241
Operational Checkout Procedure Travel Lever and Pedal Neutral Checks
1
2
TX1093760 —UN—31AUG11
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
TM12660 (18APR18)
9005-10-10
TZ24494,0000F9A -19-10FEB14-14/57
041818
PN=242
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 1st position. LOOK: Is monitor panel back light and base machine work light on? LOOK: Does switch panel illuminate? Turn light switch to 2nd position. LOOK: Does base machine work light stay on and switch panel stay illuminated?
YES: Go to next check.
LOOK: Does boom work light come on and monitor back panel light change to night mode?
NO: Check work and drive lights 20 A fuse (F1) (marked LAMP) and controller 5 A fuse (F10) (marked CONTROLLER). 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
TM12660 (18APR18)
9005-10-11
See Cab Harness (W1) Wiring Diagram. (Group 9015-10.) TZ24494,0000F9A -19-10FEB14-15/57
041818
PN=243
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 1st INT position. LOOK: Does wiper operate intermittently (8 second interval)? Turn windshield wiper and washer switch to 2nd INT position. LOOK: Does wiper operate intermittently, but faster than when in first position (5 second interval)? Turn windshield wiper and washer switch to 3rd 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
TM12660 (18APR18)
9005-10-12
TZ24494,0000F9A -19-10FEB14-16/57
041818
PN=244
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
TM12660 (18APR18)
9005-10-13
TZ24494,0000F9A -19-10FEB14-17/57
041818
PN=245
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
TM12660 (18APR18)
9005-10-14
TZ24494,0000F9A -19-10FEB14-18/57
041818
PN=246
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
TM12660 (18APR18)
9005-10-15
See Windshield Wiper and Washer Circuit Theory of Operation. (Group 9015-15.) TZ24494,0000F9A -19-10FEB14-19/57
041818
PN=247
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.
TZ24494,0000F9A -19-10FEB14-20/57
Operational Checks—Key Switch On, Engine On Checks Continued on next page
TM12660 (18APR18)
9005-10-16
TZ24494,0000F9A -19-10FEB14-21/57
041818
PN=248
Operational Checkout Procedure Monitor and Gauge Circuit Checks
TX1087196A —UN—28JUN13
Operating Screen 1— Power Mode Indicator 2— Hour Meter 3— Engine Coolant Temperature Gauge 4— Fuel Gauge 5— Alarm Indicator 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.
YES: Go to next check.
Start engine.
NO: Engine oil pressure alarm displayed. Immediately stop engine and check engine oil level. See Check Engine Oil Level. (Operator’s Manual.)
LOOK: Do all alarm indicator displays remain off after engine starts?
IF OK: Check engine oil pressure. For more information, see Isuzu 4HK1 Interim Tier 4 Engine Manual.
LOOK: Does alarm indicator remain off after engine starts?
NO: Alternator alarm indicator displayed. Check alternator drive belt.
LOOK: Does engine coolant temperature gauge (3) display correct engine coolant temperature?
IF OK: Check alternator. See Alternator Test. (Group 9015-20.)
LOOK: Does fuel gauge (4) display correct fuel level?
NO: Other alarm indicators display on monitor. See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM12660 (18APR18)
9005-10-17
TZ24494,0000F9A -19-10FEB14-22/57
041818
PN=249
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
TM12660 (18APR18)
9005-10-18
TZ24494,0000F9A -19-10FEB14-23/57
041818
PN=250
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
TM12660 (18APR18)
9005-10-19
TZ24494,0000F9A -19-10FEB14-24/57
041818
PN=251
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. Turn engine speed dial (1) clockwise. LISTEN: Does engine speed increase?
YES: Go to next check.
Turn engine speed dial counterclockwise.
NO: Check controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications. (Group 9015-10.)
LISTEN: Does engine speed decrease?
IF OK: Check engine speed dial on monitor display. See Service Menu. (Group 9015-16.) See Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.) Check wiring harness. See System Functional Schematic. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9005-10-20
TZ24494,0000F9A -19-10FEB14-25/57
041818
PN=252
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 Press power mode button (4) until PWR (power) mode is displayed on monitor. Turn auto-idle switch (2) to A/I OFF position. Turn engine speed dial (1) to H (fast idle) position. Press power mode button until ECO (economy) mode is displayed on monitor. LOOK/LISTEN: Does engine speed decrease? Press power mode button until PWR (power) mode is displayed on monitor.
YES: Go to next check.
LOOK/LISTEN: Does engine speed increase?
NO: See Engine Speed Control System Operation (Group 9010-05) for additional information on engine speed and power mode.
Continued on next page
TM12660 (18APR18)
9005-10-21
TZ24494,0000F9A -19-10FEB14-26/57
041818
PN=253
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 Press power mode button (4) until PWR (power) mode is displayed on monitor. 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 controller 5 A fuse (F10) (marked CONTROLLER). See Fuse and Relay Specifications. (Group 9015-10.) See Service Menu. (Group 9015-16.) See Engine Speed Control System Operation. (Group 9010-05.)
Press power mode button until H/P (high power) mode is displayed on monitor.
NO: Check main controller (MCZ) pressure sensors. See Pressure Sensor Test. (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
TM12660 (18APR18)
9005-10-22
TZ24494,0000F9A -19-10FEB14-27/57
041818
PN=254
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 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
TM12660 (18APR18)
9005-10-23
TZ24494,0000F9A -19-10FEB14-28/57
041818
PN=255
Operational Checkout Procedure Travel Alarm Check
A
B
C TX1095497 —UN—09AUG11
Travel Alarm A—Pilot Shutoff Lever B—Travel Levers C—Travel Pedals CAUTION: Avoid possible injury. Machine will move during this check. Make sure area is clear and large enough to operate machine. Place pilot shutoff lever (A) in unlocked (DOWN) position. Push travel pedals or levers forward. LISTEN: Does travel alarm sound?
YES: Go to next check.
Push travel pedals or pull levers rearward.
NO: Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications. (Group 9015-10.)
LISTEN: Does travel alarm sound?
NO: Check wiring. See Travel Alarm Circuit Theory of Operation. (Group 9015-15.) Continued on next page
TM12660 (18APR18)
9005-10-24
TZ24494,0000F9A -19-10FEB14-29/57
041818
PN=256
Operational Checkout Procedure Travel Alarm Cancel Switch Circuit Check
TX1115267A —UN—06JUN12
Left Console 1— Seat Heater Switch 2— 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. LISTEN: Does travel alarm sound?
YES: Go to next check.
While continuing travel, push travel alarm cancel switch (2).
NO: Check travel alarm 5 A fuse (F5) (marked OPT 1). See Fuse and Relay Specifications. (Group 9015-10.)
LISTEN: Does travel alarm stop sounding?
NO: Check wiring. See Travel Alarm Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM12660 (18APR18)
9005-10-25
TZ24494,0000F9A -19-10FEB14-30/57
041818
PN=257
Operational Checkout Procedure Hydraulic Oil Tank Pressurization Check
1
2 TX1093766 —UN—28JUN13
Hydraulic Oil Tank Cover 1— Hydraulic Oil Tank Pressure Release Button 2— Hydraulic Oil Tank Cover IMPORTANT: The pressurized oil tank creates pressure at the inlet to the hydraulic pumps. If tank cover does not seal, hydraulic pumps could cavitate and be damaged. 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. TZ24494,0000F9A -19-10FEB14-31/57
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
TM12660 (18APR18)
9005-10-26
TZ24494,0000F9A -19-10FEB14-32/57
041818
PN=258
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
TM12660 (18APR18)
9005-10-27
TZ24494,0000F9A -19-10FEB14-33/57
041818
PN=259
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 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
TM12660 (18APR18)
9005-10-28
YES: Go to next check.
TZ24494,0000F9A -19-10FEB14-34/57
041818
PN=260
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
TM12660 (18APR18)
9005-10-29
NO: Check swing valve spool and spring. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) TZ24494,0000F9A -19-10FEB14-35/57
041818
PN=261
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 then put a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin. Position upperstructure with cab over travel motors, perpendicular to tracks. Turn engine speed dial to L (slow idle) position. Wait approximately 5 minutes with all functions in neutral. NOTE: Function does not need to be fully actuated to disengage the swing park brake. Slowly actuate bucket load function to disengage the swing park brake. Do not hold the function over relief for more than 10 seconds. 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 Front (6-Spool) Disassemble and Assemble. (Group 3360.) Continued on next page
TM12660 (18APR18)
9005-10-30
TZ24494,0000F9A -19-10FEB14-36/57
041818
PN=262
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 then put a block under the track. Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-to-frame pivot pin. Swing upperstructure clockwise so it is 90 degrees to the slope. Turn engine speed dial (1) to H (fast idle) position. Press power mode button (4) until H/P (high power) mode is displayed on monitor. Actuate the swing function to swing uphill. LOOK: Does upperstructure swing uphill? Swing upperstructure 180 degrees counterclockwise and repeat procedure. Turn engine speed dial to H (fast idle) position.
YES: Go to next check.
Power mode button in H/P (high power) mode.
NO: See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)
Continued on next page
TM12660 (18APR18)
9005-10-31
TZ24494,0000F9A -19-10FEB14-37/57
041818
PN=263
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 Front (6-Spool) Disassemble and Assemble. (Group 3360.) TZ24494,0000F9A -19-10FEB14-38/57
Dig Function Drift Check (loaded bucket)
TX1095487 —UN—28JUN13
Machine Position—Loaded Bucket Fill bucket with material to specification. Specification Loaded Bucket—Weight (approximate).............................................................. 1050 kg 2315 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............................................................................................ 20 mm 0.79 in. Arm Cylinder—Drift............................................................................................... 20 mm 0.79 in. Bucket Cylinder—Drift........................................................................................... 20 mm 0.79 in. Bottom of Bucket-to-Ground—Drift..................................................................... 150 mm 5.90 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
TM12660 (18APR18)
9005-10-32
TZ24494,0000F9A -19-10FEB14-39/57
041818
PN=264
Operational Checkout Procedure Dig Function Drift Check (empty bucket)
TX1109902 —UN—28JUN13
Machine Position—Empty Bucket 1— Arm Tip Position Above Ground Empty bucket of material. Extend arm cylinder, then retract about 50 mm (2 in.). Extend bucket cylinder, then retract about 50 mm (2 in.). Lower boom until arm tip is 1 m (40 in.) above ground (1). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Measure distance from arm tip to ground. Compare measurements to specifications. Dig Function Drift Specifications (empty bucket)—Specification Boom Cylinder—Drift.............................................................................................. 5 mm 0.20 in. Arm Cylinder—Drift............................................................................................... 10 mm 0.39 in. Bucket Cylinder—Drift........................................................................................... 10 mm 0.39 in. Arm Tip-to-Ground—Drift...................................................................................... 90 mm 3.54 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
TM12660 (18APR18)
9005-10-33
TZ24494,0000F9A -19-10FEB14-40/57
041818
PN=265
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: Avoid possible machine damage. Position machine as shown. Operate swing and arm in slowly a few times before attempting to perform check to ensure bucket does not contact machine or ground. Position machine as shown. Turn engine speed dial (1) to H (fast idle) position. Turn auto-idle switch (2) to A/I OFF position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Operate swing function and record time required for three complete revolutions. Specification Swing Function—Time—Three Revolutions............................................................................................. 14.3—16.3 sec. 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 power mode button (4) until PWR (power) mode is displayed on monitor. Raise boom high enough so bucket does not contact the machine or ground during arm in and swing combined operation. Operate swing function and slowly actuate arm in function when upperstructure is in line with tracks. Record time required for three complete revolutions.
Continued on next page
TM12660 (18APR18)
9005-10-34
TZ24494,0000F9A -19-10FEB14-41/57
041818
PN=266
Operational Checkout Procedure 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.) TZ24494,0000F9A -19-10FEB14-42/57
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 With Engine Running At Slow Idle. (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
TM12660 (18APR18)
9005-10-35
TZ24494,0000F9A -19-10FEB14-43/57
041818
PN=267
Operational Checkout Procedure Boom Up, Arm In, and Bucket Combined Function Operation 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 auto-idle switch (2) to A/I OFF position. Press power mode button (4) until PWR (power) mode is displayed on monitor. Actuate boom up function, arm in function, and then bucket function in combination.
YES: Go to next check.
LOOK: Does boom continue to move at approximately the same speed after bucket function is actuated?
NO: If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9005-10-36
TZ24494,0000F9A -19-10FEB14-44/57
041818
PN=268
Operational Checkout Procedure Boom Regenerative Valve Operation 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 power mode button (4) until PWR (power) mode is displayed on monitor. Raise boom and extend the arm to full extension.
YES: Go to next check.
Actuate the boom down, then arm in and boom up functions in combined operation.
NO: Check boom up pressure sensor (B30). See Pressure Sensor Test. (Group 9015-20.)
LOOK: Does the boom move smoothly through the complete cycle down and up and not hesitate when it goes past the vertical position?
NO: Check boom regenerative valve. See Boom Regenerative Valve Circuit Operation. (Group 9025-05.) See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9005-10-37
TZ24494,0000F9A -19-10FEB14-45/57
041818
PN=269
Operational Checkout Procedure Arm Regenerative Valve Operation 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 power mode button (4) until PWR (power) mode is displayed on monitor. Extend the arm to full extension and then lower boom so bucket is on the ground.
YES: Go to next check.
Actuate the boom up and arm in functions in combined operation.
NO: Check arm in pressure sensor (B31). See Pressure Sensor Test. (Group 9015-20.) Check arm regenerative solenoid valve. See Arm Regenerative Valve Circuit Operation. (Group 9025-05.)
LOOK: Does the arm move smoothly through the complete cycle and not hesitate when it goes through the vertical position?
Continued on next page
TM12660 (18APR18)
9005-10-38
IF OK: Check arm regenerative valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) TZ24494,0000F9A -19-10FEB14-46/57
041818
PN=270
Operational Checkout Procedure Bucket Regenerative Valve Operation 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 power mode button (4) until PWR (power) mode is displayed on monitor. Actuate boom up, arm out and bucket dump functions. Actuate boom down function, arm in function, and then bucket curl function.
YES: Go to next check.
LOOK: Does the bucket move smoothly through the complete cycle and not hesitate when it goes to the curl position?
NO: Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation. (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9005-10-39
TZ24494,0000F9A -19-10FEB14-47/57
041818
PN=271
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 Pressure Sensor Test. (Group 9015-20.) See Travel Motor Speed Circuit Operation. (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9005-10-40
TZ24494,0000F9A -19-10FEB14-48/57
041818
PN=272
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 power mode button (4) until PWR (power) mode is displayed on monitor.
Continued on next page
TM12660 (18APR18)
9005-10-41
TZ24494,0000F9A -19-10FEB14-49/57
041818
PN=273
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
TM12660 (18APR18)
9005-10-42
TZ24494,0000F9A -19-10FEB14-50/57
041818
PN=274
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 Combined Travel And Dig Functions Slow Or No Power. (Group 9025-15.)
LOOK: Does machine mistrack excessively when the arm is extended?
NO: Go to next check.
Continued on next page
TM12660 (18APR18)
9005-10-43
TZ24494,0000F9A -19-10FEB14-51/57
041818
PN=275
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 Machine Will Not turn? Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline. (Group 9025-15.) Continued on next page
TM12660 (18APR18)
9005-10-44
TZ24494,0000F9A -19-10FEB14-52/57
041818
PN=276
Operational Checkout Procedure 245GLC Cycle Times Check
CAUTION: Prevent possible injury from unexpected machine movement. Clear all persons from the area before operating machine. NOTE: Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-up Procedure. (Group 9025-25.) NOTE: Cycle times are calculated using 2.91 m arm and 0.8 m3 bucket. Different weight and attachments will affect cycle times.
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 power mode button (4) until PWR (power) mode is displayed on monitor. Rotate monitor dial (5) to highlight and select Dig mode from Work Mode menu. See Main Menu—Work Mode. (Operator’s Manual.)
Continued on next page
TM12660 (18APR18)
9005-10-45
TZ24494,0000F9A -19-10FEB14-53/57
041818
PN=277
Operational Checkout Procedure
TX1095475 —UN—11AUG11
Boom
TX1095499 —UN—28JUN13
Arm, Bucket, Swing Move machine to position shown for each test. Record cycle time for each function. Specification Boom Raise (cylinder extend)—Cycle Time............................................................................................................ 3.2—3.8 sec. Boom Lower (cylinder retract)—Cycle Time............................................................................................................ 2.4—3.0 sec. Arm In (cylinder extend)—Cycle Time........................................................ 3.0—3.6 sec. Arm Out (cylinder retract)—Cycle Time...................................................... 2.4—3.0 sec. Bucket Load (cylinder extend)—Cycle Time............................................................................................................ 2.7—3.3 sec. Bucket Dump (cylinder retract)—Cycle Time............................................................................................................ 1.8—2.4 sec. Swing Left or Right, three Revolutions—Cycle Time........................................................................ 14.3—16.3 sec. Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in FAST position)—Cycle Time............................................................................. 12.6—13.8 sec. Drive 20 m (65 ft.) (check in forward and reverse with travel speed switch in SLOW position)—Cycle Time................................................................. 19.4—21.4 sec. Track Raised for three Revolutions (check in forward and reverse with travel mode switch in FAST position)—Cycle Time........................................................................................................ 17.3—19.3 sec. Track Raised for three Revolutions (check in forward and reverse with travel mode switch in SLOW position)—Cycle Time........................................................................................................ 26.4—30.4 sec.
YES: Go to next check.
LOOK: Does machine perform within specifications?
NO: See All Hydraulic Functions Slow or see Some Dig Functions Slow (Not All). (Group 9025-15.)
Continued on next page
TM12660 (18APR18)
9005-10-46
TZ24494,0000F9A -19-10FEB14-54/57
041818
PN=278
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: Go to next check.
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 harness. See System Functional Schematic, 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
TM12660 (18APR18)
9005-10-47
TZ24494,0000F9A -19-10FEB14-55/57
041818
PN=279
Operational Checkout Procedure Heater and Air Conditioner Controls Check (automatic temperature control)
PUSH MENU/SET
PUSH
5
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
50.0 h ECO 10:00 AM
F
H
E
C
8
9 AUTO
10
FM
24.0˚C
VOL
CH1
81.3 ST MHz
7 TX1087006 —UN—17JAN11
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)? Continued on next page
TM12660 (18APR18)
9005-10-48
TZ24494,0000F9A -19-10FEB14-56/57
041818
PN=280
Operational Checkout Procedure Turn temperature control/mode switch (5) 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 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 wiring harness. See System Functional Schematic, 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.
TZ24494,0000F9A -19-10FEB14-57/57
TM12660 (18APR18)
9005-10-49
041818
PN=281
Operational Checkout Procedure
TM12660 (18APR18)
9005-10-50
041818
PN=282
Section 9010 Engine Contents Page
Group 05—Theory of Operation Isuzu Engine.............................................. 9010-05-1 Engine Fuel System Component Location ................................................. 9010-05-2 Engine Cooling System Component Location ............................. 9010-05-4 Cold Weather Starting Aid ......................... 9010-05-5 Engine Speed Control System Operation............................................... 9010-05-6 Group 15—Diagnostic Information Isuzu Engine.............................................. 9010-15-1 Group 20—Adjustments Isuzu Engine.............................................. 9010-20-1 Group 25—Tests Isuzu Engine.............................................. 9010-25-1
TM12660 (18APR18)
9010-1
041818
PN=1
Contents
TM12660 (18APR18)
9010-2
041818
PN=2
Group 05
Theory of Operation Isuzu Engine For more information, see Isuzu 4HK1 Interim Tier 4 Engine Manual. BD53302,0001795 -19-12NOV13-1/1
TM12660 (18APR18)
9010-05-1
041818
PN=285
Theory of Operation
Engine Fuel System Component Location
8 12
6
M2 7
5
9
4
3 2
1
TX1117188 —UN—09AUG12
12
TX1117188 Engine Fuel System Component Location (1 of 2) 1— Fuel Tank-to-Primary Fuel 4— Auxiliary Fuel Filter and Water 7— Fuel Transfer Pump-to-Final Filter and Water Separator Separator Fuel Filter and Water Hose 5— Primary Fuel Filter and Water Separator Hose 2— Final Fuel Filter and Water Separator-to-Auxiliary Fuel 8— Fuel Tank Separator-to-High Pressure Filter and Water Separator 9— Final Fuel Filter and Water Fuel Pump Hose Hose Separator 3— Primary Fuel Filter and Water 6— Auxiliary Fuel Filter and Water 12— Fuel Cooler-to-Fuel Tank Separator Separator-to-Fuel Transfer Hose Pump Hose Continued on next page
TM12660 (18APR18)
9010-05-2
M2—Fuel Transfer Pump
TZ24494,0000925 -19-09AUG12-1/2
041818
PN=286
Theory of Operation
8 17 18 16 15
14 10
19 13
M2 9
2
4 3
1 12 2 11
TX1118485 —UN—08AUG12
12 10
TX1118485 Engine Fuel System Component Location (2 of 2) 1— Fuel Tank-to-Primary Fuel Filter and Water Separator Hose 2— Final Fuel Filter and Water Separator-to-High Pressure Fuel Pump Hose 3— Primary Fuel Filter and Water Separator
4— Auxiliary Fuel Filter and Water 13— High Pressure Fuel Pump 17— High Pressure Common Separator 14— High Pressure Common Rail-to-Fuel Injector Line (4 8— Fuel Tank Rail-to-High Pressure Fuel used) 9— Final Fuel Filter and Water Pump Return Line 18— Fuel Injector Leak-Off Line Separator 15— High Pressure Fuel 19— Fuel Regulator 10— High Pressure Common Pump-to-High Pressure M2—Fuel Transfer Pump Rail-to-Fuel Cooler Hose Common Rail Line 11— Fuel Cooler 16— High Pressure Common Rail 12— Fuel Cooler-to-Fuel Tank Hose TZ24494,0000925 -19-09AUG12-2/2
TM12660 (18APR18)
9010-05-3
041818
PN=287
Theory of Operation
Engine Cooling System Component Location 5
6 12 11 7 4
3
10
9 8 2
TX1119078 —UN—16AUG12
13
1
TX1119078 Engine Cooling System Component Location 1— Radiator-to-Bypass Housing 6— Thermostat Housing-toHose Radiator Hose 2— Surge Tank Overflow Hose 7— Surge Tank 3— Radiator 8— Heater Core-to-Bypass 4— Fan Housing Hose 5— Radiator-to-Surge Tank Hose
9— Thermostat Housing-toHeater Core Hose 10— Water Pump 11— Bypass Housing-toThermostat Housing Hose
12— Bypass Housing 13— Drain Valve
TZ24494,0000921 -19-20AUG12-1/1
TM12660 (18APR18)
9010-05-4
041818
PN=288
Theory of Operation
Cold Weather Starting Aid
S1
G1
F61
K16 K13
F16
TX1115626 —UN—22JUN12
2
A1
1
B4 TX1115626 Cold Weather Starting Aid Diagram 1— Glow Plug Indicator Lamp 2— Glow Plug (4 used) A1—Engine Control Unit (ECU)
B4—Engine Coolant Temperature F61— Battery 45 A Fuse G1—Battery Sensor K13— Key Cut Relay F16— Glow Relay 5 A Fuse K16— Glow Plug Relay
The glow plug system allows easier cold weather starting and reduces white smoke and noise during start-up. The engine control unit (ECU) (A1) determines the time required for glow (pre-glow, glow, after-glow), and operates the glow plug relay (K16) and glow plug indicator lamp (1). When key switch (S1) is turned to ON position, the ECU receives signal from the engine coolant temperature sensor (B4). The ECU determines the time
S1— Key Switch
for pre-glow and glow and sends current to the glow plug relay so proper starting conditions are achieved. The ECU after-glow function assists the engine to stabilize idling immediately after starting. For more information, see starting and charging circuit theory of operation. See Starting and Charging Circuit Theory of Operation. (Group 9015-15.) TZ24494,00008E3 -19-10JUL12-1/1
TM12660 (18APR18)
9010-05-5
041818
PN=289
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
-
-
-
750—850
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
-
-
-
1950—2050
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
1950—2050
-
Fast Travel
-
Over Relief
1950—2050
PWR (power) Mode Fast Idle
Unlock
OFF
-
-
Neutral
Enabled
No Load
1650—1750
Fast Idle
Unlock
OFF
-
-
Neutral
Disabled
No Load
1750—1850
Fast Idle
Unlock
OFF
-
-
Fast Travel
-
Over Relief
1950—2050
Neutral
-
No Load
1600—1700
ECO (economy) Mode Fast Idle
Unlock
OFF
-
-
Manual Regeneration Engine Speed Slow Idle
Lock
OFF
< 70°C < 158°F
-
-
-
-
1350—1450
Slow Idle
Lock
OFF
> 70°C > 158°F
-
-
-
-
1000—1100
Slow Idle
-
OFF
Auto Regeneration Engine Speed -
-
-
1000—1100
Continued on next page
TM12660 (18APR18)
9010-05-6
JF80813,0000230 -19-23OCT17-1/3
041818
PN=290
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 • Idle speed-up control • ECO control
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
Engine Speed Dial
OFF INT
ACC N O
ON
OFF
3
START
The purpose of the engine speed dial is to control the engine speed via operator input.
TX1131978 —UN—28JUN13
L
PUSH MODE
1 2 3 4 5
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.
OFF 1 2
6 7 8 9 0
4 Switch Panel 1— Engine Speed Dial 2— Auto-Idle Switch
H/P (High Power) Mode
3— Travel Mode Switch 4— Power Mode Button
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. PWR (Power) Mode
indicate high pressure.
The function of PWR mode is to control the engine speed from slow idle to fast idle in response to the position of the engine speed dial. ECO (Economy) Mode 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.
Heater Control 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. 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
TM12660 (18APR18)
9010-05-7
JF80813,0000230 -19-23OCT17-2/3
041818
PN=291
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.) Auto-Idle Control The purpose of auto-idle control is to lower engine speed to reduce fuel consumption and noise levels while engine is running and no hydraulic functions are actuated. 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. 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 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. 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. JF80813,0000230 -19-23OCT17-3/3
TM12660 (18APR18)
9010-05-8
041818
PN=292
Group 15
Diagnostic Information Isuzu Engine For more information, see Isuzu 4HK1 Interim Tier 4 Engine Manual. BD53302,0001796 -19-12NOV13-1/1
TM12660 (18APR18)
9010-15-1
041818
PN=293
Diagnostic Information
TM12660 (18APR18)
9010-15-2
041818
PN=294
Group 20
Adjustments Isuzu Engine For more information, see Isuzu 4HK1 Interim Tier 4 Engine Manual. BD53302,0001797 -19-12NOV13-1/1
TM12660 (18APR18)
9010-20-1
041818
PN=295
Adjustments
TM12660 (18APR18)
9010-20-2
041818
PN=296
Group 25
Tests Isuzu Engine For more information, see Isuzu 4HK1 Interim Tier 4 Engine Manual. TZ24494,0000889 -19-16MAY12-1/1
TM12660 (18APR18)
9010-25-1
041818
PN=297
Tests
TM12660 (18APR18)
9010-25-2
041818
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 .................. 9015-10-2 System Functional Schematic, Component Location, and Wiring Diagram Master Legend ........................ 9015-10-6 System Functional Schematic ................. 9015-10-13 Cab Harness (W1) Component Location ............................................... 9015-10-51 Cab Harness (W1) Wiring Diagram ............................................... 9015-10-55 Machine Harness (W2) Component Location ............................................... 9015-10-73 Machine Harness (W2) Wiring Diagram ............................................... 9015-10-77 Monitor Harness (W3) Component Location ............................................... 9015-10-90 Monitor Harness (W3) Wiring Diagram ............................................... 9015-10-92 Engine Harness (W4) Component Location ............................................... 9015-10-95 Engine Harness (W4) Wiring Diagram ............................................. 9015-10-103 Side Camera Harness (W5) Component Location ......................... 9015-10-106 Side Camera Harness (W5) Wiring Diagram ............................................. 9015-10-107 Side Monitor Harness (W6) Component Location ......................... 9015-10-108 Side Monitor Harness (W6) Wiring Diagram ..............................................9015-10-111 Pump Harness (W8) Component Location ............................................. 9015-10-114 Pump Harness (W8) Wiring Diagram ............................................. 9015-10-117 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location ......................... 9015-10-119 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram ............................................. 9015-10-119 Pilot Shutoff Switch Harness (W11) Component Location ......................... 9015-10-120 Pilot Shutoff Switch Harness (W11) Wiring Diagram.................................. 9015-10-121 Auxiliary Fuse Box Harness (W13) Component Location ......................... 9015-10-124 Auxiliary Fuse Box Harness (W13) Wiring Diagram.................................. 9015-10-127
Heated Air Seat Harness (W14) Component Location ......................... 9015-10-130 Heated Air Seat Harness (W14) Wiring Diagram.................................. 9015-10-131 Multi-Function Pilot Control Lever Harness (W15) Component Location ............................................. 9015-10-132 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram.......... 9015-10-137 Travel Alarm Cancel Switch Harness (W16) Component Location ............................................. 9015-10-143 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram.......... 9015-10-143 Attachment Harness (W17) Component Location ......................... 9015-10-144 Attachment Harness (W17) Wiring Diagram ............................................. 9015-10-146 Rear Camera Harness (W19) Component Location ......................... 9015-10-148 Rear Camera Harness (W19) Wiring Diagram.................................. 9015-10-149 9-Pin Service ADVISOR™ Connector (W20) Component Location ............................................. 9015-10-149 9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram ............................................. 9015-10-150 Pilot Shutoff Valve Harness (W21) Component Location ......................... 9015-10-151 Pilot Shutoff Valve Harness (W21) Wiring Diagram.................................. 9015-10-152 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location ............................................. 9015-10-152 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram.......... 9015-10-153 Seat Heater Switch Harness (W24) Component Location ......................... 9015-10-153 Seat Heater Switch Harness (W24) Wiring Diagram.................................. 9015-10-154 Travel Alarm Harness (W26) Component Location ......................... 9015-10-155 Travel Alarm Harness (W26) Wiring Diagram ............................................. 9015-10-156 Travel Sub Harness (W27) Component Location ......................... 9015-10-156 Travel Sub Harness (W27) Wiring Diagram ............................................. 9015-10-157 Starter Switch Harness (W29) Component Location ......................... 9015-10-158 Continued on next page
TM12660 (18APR18)
9015-1
041818
PN=1
Contents
Page
Page
Starter Switch Harness (W29) Wiring Diagram.................................. 9015-10-158 Data Converter Harness (W30) Component Location ......................... 9015-10-160 Data Converter Harness (W30) Wiring Diagram.................................. 9015-10-162 Data Converter Interface Harness (W31) Component Location............... 9015-10-163 Data Converter Interface Harness (W31) Wiring Diagram ....................... 9015-10-164 2-Speed Harness (W32) Component Location ......................... 9015-10-165 2-Speed Harness (W32) Wiring Diagram ............................................. 9015-10-166 Heater and Air Conditioner Harness (W41) Component Location............... 9015-10-167 Heater and Air Conditioner Harness (W41) Wiring Diagram ....................... 9015-10-169 Spool Control Harness (W43) Component Location ......................... 9015-10-171 Spool Control Harness (W43) Wiring Diagram.................................. 9015-10-172 Auxiliary Solenoid Harness (W61) Component Location ......................... 9015-10-174 Auxiliary Solenoid Harness (W61) Wiring Diagram.................................. 9015-10-176 Auxiliary Function Lever (AFL) Harness (W75) Component Location ............................................. 9015-10-178 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram.......... 9015-10-181 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location ......................... 9015-10-183 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram ............................................. 9015-10-184 Auxiliary Function Lever (AFL) Grip Harness (W77) Component Location ............................................. 9015-10-185 Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram ............................................. 9015-10-185 Auxiliary Function Enable Switch Harness (W78) Component Location ............................................. 9015-10-185 Auxiliary Function Enable Switch Harness (W78) Wiring Diagram.......... 9015-10-186 Satellite (SAT) Harness (W6003) Component Location ......................... 9015-10-186 Satellite (SAT) Harness (W6003) Wiring Diagram.................................. 9015-10-187 JDLink™ Harness (W6004) Component Location ......................... 9015-10-188 JDLink™ Harness (W6004) Wiring Diagram ............................................. 9015-10-191
Group 15—Sub-System Diagnostics Controller Area Network (CAN) Theory of Operation............................... 9015-15-1 Starting and Charging Circuit Theory of Operation............................... 9015-15-5 Monitor Controller (DSZ) Circuit Theory of Operation............................. 9015-15-11 Engine Control Unit (ECU) Circuit Theory of Operation............................. 9015-15-19 Exhaust Aftertreatment Circuit Theory of Operation............................. 9015-15-28 Main Controller (MCZ) Circuit Theory of Operation............................. 9015-15-31 Travel Alarm Circuit Theory of Operation............................................. 9015-15-46 Machine Controller (BCZ) Circuit Theory of Operation............................. 9015-15-47 Windshield Wiper and Washer Circuit Theory of Operation ................. 9015-15-49 Lighting Circuit Theory of Operation............................................. 9015-15-53 Pilot Shutoff Circuit Theory of Operation............................................. 9015-15-57 Attachment Control Circuit Theory of Operation......................................... 9015-15-60 Group 16—Monitor Operation Service Menu............................................. 9015-16-1 Troubleshooting......................................... 9015-16-1 Monitoring.................................................. 9015-16-2 Controller Version ...................................... 9015-16-6 Issued Warning Record ............................. 9015-16-7 Operation................................................... 9015-16-7 Side Monitor Operation.............................. 9015-16-7 Machine Setting......................................... 9015-16-8 Monitor Setting ........................................ 9015-16-13 Alarm Setting ........................................... 9015-16-15 Engine Setting ......................................... 9015-16-15 Exhaust Filter No. .................................... 9015-16-15 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 Clearing Engine Diagnostic Trouble Codes .................................................... 9015-20-5 MPDr Application..................................... 9015-20-10 MPDr Connection Procedure................... 9015-20-11 Fuse Test ................................................. 9015-20-12 Relay Test................................................ 9015-20-15 Glow Plug Relay Test .............................. 9015-20-15 Continued on next page
TM12660 (18APR18)
9015-2
041818
PN=2
Contents
Page
Page
Pressure Sensor Test .............................. 9015-20-16 Solenoid Test ........................................... 9015-20-17 Proportional Solenoid Test....................... 9015-20-18 Temperature Sensor Test ........................ 9015-20-19 Alternator Test ......................................... 9015-20-20 Controller Area Network (CAN) Circuit Test........................................... 9015-20-23 Controller Area Network (CAN) Diagnostics .........................................9015-20-23 Electrical Component Checks ................. 9015-20-27 Component Checks .................................9015-20-25 Battery Remove and Install ..................... 9015-20-33 Rear Cover Remove and Install .............. 9015-20-36 Main Controller (MCZ) Remove and Install ............................................ 9015-20-37 Machine Controller (BCZ) Remove and Install ............................................ 9015-20-39 Engine Control Unit (ECU) Remove and Install ............................................ 9015-20-40 Exhaust Differential Pressure Sensor Zero Point Calibration ............. 9015-20-42 Ash Reset ................................................ 9015-20-43 No Load Max ........................................... 9015-20-44 Data Converter Remove and Install ................................................... 9015-20-45 Monitor Adjustable Relief Bleed Procedure ............................................ 9015-20-46 Monitor Controller (DSZ) Remove and Install ............................................ 9015-20-47 Air Conditioner Controller (ACF) Remove and Install.............................. 9015-20-47 Key Switch Remove and Install ............... 9015-20-49 Right Switch Console Remove and Install ................................................... 9015-20-50 Left Switch Console Remove and Install ................................................... 9015-20-52 Travel Alarm Remove and Install ............ 9015-20-53 Heater Control Disable and Enable ................................................. 9015-20-54 Disconnect Tab Retainer Connectors .......................................... 9015-20-54 Disconnecting Spring Wire Clip Connectors .......................................... 9015-20-54 Replace DEUTSCH™ Connectors .......................................... 9015-20-55 Replace DEUTSCH™ Rectangular or Triangular Connectors ..................... 9015-20-56 Install DEUTSCH™ Contact.................... 9015-20-57 Replace WEATHER PACK™ Connector ............................................ 9015-20-58 Install WEATHER PACK™ Contact ................................................ 9015-20-59 Replace (Pull Type) Metri-Pack™ Connectors .......................................... 9015-20-60 Replace (Push Type) Metri-Pack™ Connectors .......................................... 9015-20-61 Replace CINCH™ Connectors ................ 9015-20-61 Install CINCH™ Contact.......................... 9015-20-63 Repair 32 and 48 Way CINCH™ Connectors .......................................... 9015-20-64
Remove Connector Body from Blade Terminals ................................... 9015-20-66
TM12660 (18APR18)
9015-3
041818
PN=3
Contents
TM12660 (18APR18)
9015-4
041818
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
TM12660 (18APR18)
9015-05-1
DW9628,00004E9 -19-31AUG12-1/8
041818
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
TM12660 (18APR18)
G2—Battery K14— Battery Relay S1— Key Switch W5—Battery To Frame Ground W6—Engine To Frame Ground
9015-05-2
DW9628,00004E9 -19-31AUG12-2/8
041818
PN=304
System Information
TX1001167 —UN—02FEB11
Wiring Diagram
Wiring Diagram Example
Continued on next page
TM12660 (18APR18)
9015-05-3
DW9628,00004E9 -19-31AUG12-3/8
041818
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
TM12660 (18APR18)
9015-05-4
DW9628,00004E9 -19-31AUG12-4/8
041818
PN=306
System Information
T195714 —UN—30OCT03
Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-05-5
DW9628,00004E9 -19-31AUG12-5/8
041818
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
TM12660 (18APR18)
9015-05-6
DW9628,00004E9 -19-31AUG12-6/8
041818
PN=308
System Information
Electrical Schematic Symbols T143000 —UN—21JUN01
DW9628,00004E9 -19-31AUG12-7/8
Continued on next page
TM12660 (18APR18)
9015-05-7
041818
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
DW9628,00004E9 -19-31AUG12-8/8
TM12660 (18APR18)
9015-05-8
041818
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.
• 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 • VLT—Violet • WHT—White • YEL—Yellow
• BLK—Black CW08338,0000D03 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-1
041818
PN=311
System Diagrams
Fuse and Relay Specifications
3 2
TX1119368 —UN—01AUG12
1
TX1119368 Relay and Fuse Block Component Location 1— Relay Block
2— Fuse Block 1
3— Fuse Block 2 Continued on next page
TM12660 (18APR18)
9015-10-2
CW08338,0000D04 -19-28AUG12-1/4
041818
PN=312
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— Travel Alarm 5 A Fuse (marked OPT. 1 ALT) F6— 12 Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) F7— Start Position Signal 5 A Fuse (marked START) F8— Engine Control Unit (ECU) 30 A Fuse (marked ECU) F9— Radio Backup 10 A Fuse (marked BACK UP) F10— Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11— Fuel Pump 5 A Fuse (marked FUEL PUMP) F12— Radio and Dome 5 A Fuse (marked RADIO) F13— Lighter 10 A Fuse (marked LIGHTER) F14— Monitor 5 A Fuse (marked MONITOR) F15— Cab Auxiliary Power Connector One 10 A Fuse (marked AUX) F16— Glow Relay 5 A Fuse (marked GLOW RELAY) F17— Power On 5 A Fuse (marked POWER ON) F18— Idle Stop 5 A Fuse (marked IDLE STOP) F19— Horn 10 A Fuse (marked HORN) F20— Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
Continued on next page
TM12660 (18APR18)
9015-10-3
F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F20 F19 F18 F17 F16 F15 F14 F13 F12 F11
TX1086711 —UN—28JUN13
Fuse Block 1
Fuse Block 1
CW08338,0000D04 -19-28AUG12-2/4
041818
PN=313
System Diagrams
Additional fuses located near the Engine Control Unit (ECU):
F30 F29 F28 F27 F26 F25 F24 F23 F22 F21
• F6000—JDLink™ Unswitched Power 7.5 A Fuse (if equipped)
• F6001—JDLink™ Ground 7.5 A Fuse (if equipped) • F6002—JDLink™ Switched Power 7.5 A Fuse (if equipped)
Additional fuses located under cover behind cooling package door:
F40 F39 F38 F37 F36 F35 F34 F33 F32 F31
• F45—Starter In-line 30 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 One 10 A Fuse (marked CAB LAMP FRONT) F23— Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) F24— 12 Volt Power Unit 10 A Fuse (marked 12V UNIT) F25— IMOBI 5 A Fuse (marked IMOBI) F26— Quick Hitch 5 A Fuse (marked QUICK HITCH) F27— Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) F28— Not Used F29— Not Used F30— Not Used
F31— Seat Compressor 10 A Fuse (marked SEAT COMPR) F32— Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) F33— Warning Lamp 10 A Fuse (marked WARNING LAMP) F34— Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) F35— Not Used F36— Not Used F37— Not Used F38— Not Used F39— Not Used F40— Not Used
TX1086712 —UN—28JUN13
Fuse Block 2
Fuse Block 2
JDLink is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-10-4
CW08338,0000D04 -19-28AUG12-3/4
041818
PN=314
System Diagrams
TX1087683 —UN—08FEB11
Relay Block
Relay Block K1—Load Dump Relay K2—Pilot Shutoff Relay K3—Security Alarm Relay K4—Starter Cut Relay
K5—Security Relay K6—Windshield Wiper Relay K7—Work Light Relay K8—Boom Light Relay
K9—Windshield Washer Relay K10— Horn Relay K11— Idle Stop Relay K12— Accessory Cut Relay
K13— Key Cut Relay K14— ECU Power Relay
Additional relays are located by the air conditioning unit:
• K34—Starter Relay
• K17—Air Conditioner and Heater Blower Motor Relay • K18—Air Conditioner Compressor Clutch Relay
Additional relays located behind cab seat:
Additional relays located under cover behind cooling package door:
• K16—Glow Plug Relay • K19—Battery Relay
• K20—Seat Heater Relay • K30—Right Solenoid Relay B • K31—Right Solenoid Relay C • K32—Left Solenoid Relay B • K33—Left Solenoid Relay C CW08338,0000D04 -19-28AUG12-4/4
TM12660 (18APR18)
9015-10-5
041818
PN=315
System Diagrams
System Functional Schematic, Component Location, and Wiring Diagram Master Legend
• A1—Engine Control Unit (ECU) (SE11, SE12, SE13, SE14, SE15) (W2)
(W41)
• A2—Variable Geometry Turbocharger (VGT) (SE15)
• B42—Engine Overheat Sensor (SE4) (W4) • B43—Coolant Temperature Sensor (SE4) (W4) • B44—Mass Air Flow (MAF)/Intake Air Temperature
(W2)
• A3—Main Controller (MCZ) (SE7, SE8, SE9, SE10) (W1)
(IAT) Sensor (SE11) (W2)
• A4—Monitor Controller (DSZ) (SE4, SE5, SE6) (W1), (W3)
• A5—Data Converter (SE20) (W30) • A6—Radio (SE18) (W1) • A7—Air Conditioner Controller (ACF) (SE23) (W41) • A8—12-Volt Power Converter (SE25) (W13) • A10—Monitor (SE6) (W3) • A11—Machine Controller (BCZ) (SE19) (W1) • A12—Rear Camera (SE6) (W19) • A13—Side Monitor (SE6) (W6) • A14—Side Camera (SE6) (W5) • A6000—Modular Telematics Gateway (MTG) Controller (if equipped) (SE21) (W6004)
• A6001—GPS/Cellular Antenna (SE21) (W6004) • A6002—Satellite (SAT) Module Control Unit (if equipped) (SE21) (W6003)
• A6003—Satellite (SAT) Antenna (SE21) • B1—Crankshaft Position Sensor (SE11) (W4) • B2—Camshaft Position Sensor (SE13) (W4) • B3—Manifold Air Temperature Sensor (SE14) (W4) • B4—Engine Coolant Temperature Sensor (SE13) (W4) • B5—Fuel Temperature Sensor (SE12) (W4) • B6—Engine Oil Level Sensor (SE11) (W2) • B7—Turbocharger Boost Temperature Sensor (SE13) (W4)
• B11—Engine Oil Pressure Sensor (SE13) (W4) • B12—Fuel Rail Pressure Sensor (SE11) (W4) • B13—Fuel Filter Restriction Sensor (SE15) (W8) • B14—Intake Air Throttle Valve Position Sensor (SE12) (W4)
• B15—Turbocharger Boost Pressure Sensor (SE11) (W4)
• B16—Air Filter Restriction Switch (SE4) (W2) • B17—Water-in-Fuel Sensor (SE5) (W8) • B18—Fuel Level Sensor (SE4) (W2) • B20—Air Conditioner High/Low-Pressure Switch (SE23) (W2)
• B21—Solar Sensor (SE24) (W3) • B22—Ambient Air Temperature Sensor (SE24) (W2) • B23—High Note Horn (SE22) (W2) • B24—Low Note Horn (SE22) (W2) • B25—Right Speaker (SE18) (W1) • B26—Left Speaker (SE18) (W1) • B27—Hydraulic Oil Filter Restriction Switch (if equipped) (SE4) (W2)
• B30—Boom Up Pressure Sensor (SE7) (W2) • B31—Arm In Pressure Sensor (SE7) (W2) • B32—Front Attachment Pressure Sensor (SE8) (W2) • B33—Swing Pressure Sensor (SE8) (W2) • B34—Travel Pressure Sensor (SE8) (W2) • B35—Pump 1 Delivery Pressure Sensor (SE8) (W8) • B36—Pump 1 Control Pressure Sensor (SE8) (W8) • B37—Pump 2 Delivery Pressure Sensor (SE8) (W8) TM12660 (18APR18)
• B38—Pump 2 Control Pressure Sensor (SE9) (W8) • B39—Bucket In Pressure Sensor (SE9) (W2) • B40—Hydraulic Oil Temperature Sensor (SE10) (W2) • B41—Air Conditioner Freeze Control Switch (SE24)
• B45—Barometric Pressure Sensor (SE15) (W2) • B47—Exhaust Gas Recirculation (EGR) Valve Sensor (SE12) (W4)
• B48—Exhaust Differential Pressure Sensor (SE14) (W2) • B49—Exhaust Temperature Sensor 1 (DPF) (SE14) (W2)
• B50—Exhaust Temperature Sensor 2 (DOC) (SE15) (W2)
• B51—Turbocharger Position Sensor (SE15) (W4) • B55—Air Recirculation Sensor (SE24) (W41) • B56—Pump 3 Delivery Pressure Sensor (SE9) (W8) • B57—Pump 3 Control Pressure Sensor (SE9) (W8) • B60—Attachment Pressure Sensor (SE9) (W17) • B61—Arm Out Pressure Sensor (SE9) (W32) • B62—Attachment Pressure Sensor 2 (SE9) (W17) • B63—Attachment Pressure Sensor 3 (SE10) (W2) • B68—Secondary Hydraulic Oil Temperature Sensor (SE30) (W76)
• B80—Seat Temperature Switch 1 (SE26) • B81—Seat Temperature Switch 2 (SE26) • B85—Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (SE30) (W76)
• E1—Work Light (SE17) (W2) • E2—Boom Light (SE17) (W2) • E3—Cab Dome Light (SE19) (W1) • E5—Switch Panel Back Light 1 (SE5) • 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 (SE20) • E10—Switch Panel Back Light 5 (SE20) • F1—Work and Boom Lights 20 A Fuse (marked LAMP) (SE17) (W1)
• F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) (SE16) (W1)
• F3—Air Conditioner and Heater 20 A Fuse (marked HEATER) (SE22) (W1)
• F4—Solenoid 20 A Fuse (marked SOLENOID) (SE3) (W1)
• F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT) (SE10) (W1)
• F6—12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) (SE17) (W1)
• F7—Start Position Signal 5 A Fuse (marked START) (SE2) (W1)
• F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU) (SE12) (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—Fuel Pump 5 A Fuse (marked FUEL PUMP) (SE2) (W1)
Continued on next page
9015-10-6
CW08338,0000D05 -19-15SEP16-1/6
041818
PN=316
System Diagrams
• F12—Radio and Dome 5 A Fuse (marked RADIO)
(SE18) (W1) • F13—Lighter 10 A Fuse (marked LIGHTER) (SE18) (W1) • F14—Monitor 5 A Fuse (marked MONITOR) (SE4) (W1) • F15—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX) (SE18) (W1) • F16—Glow Relay 5 A Fuse (marked GLOW RELAY) (SE3) (W1) • F17—Power On 5 A Fuse (marked POWER ON) (SE4) (W1) • F18—Idle Stop 5 A Fuse (marked IDLE STOP) (SE1) (W1) • F19—Horn 10 A Fuse (marked HORN) (SE22) (W1) • F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT) (SE17) (W1) • F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER) (SE26) (W13) • F22—Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) (SE25) (W13) • F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) (SE25) (W13) • F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) (SE25) (W13) • F25—IMOBI 5 A Fuse (marked IMOBI) (SE25) (W13) • F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) (SE25) (W13) • F27—Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) (SE25) (W13) • F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) (SE26) (W13) • F32—Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2) (SE25) (W13) • F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) (SE25) (W13) • F34—Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) (SE25) (W13) • F50—Fuse Box (W1) • F51—Auxiliary Fuse Box (W13) • F60—Alternator 65 A Fuse (SE1) (W2) • F61—Battery 45 A Fuse (SE1) (W2) • F62—Wiper Motor Assembly Circuit Breaker (SE16) • F6000—JDLink™ Unswitched Power 7.5 A Fuse (if equipped) (SE21) (W6004) • F6001—JDLink™ Ground 7.5 A Fuse (if equipped) (SE21) (W6004) • F6002—JDLink™ Switched Power 7.5 A Fuse (if equipped) (SE21) (W6004) • G1—Battery (SE1) (W2) • G2—Battery (SE1) (W2) • G3—Alternator (SE3) (W2) • G5—12-Volt Power Outlet (SE25) (W13) • H2—Security Alarm (SE4) (W1) • H3—Monitor Warning Alarm (SE4) (W3) • H4—Travel Alarm (SE10) (W26) • H5—Swing Alarm (not used) (W2) • K1—Load Dump Relay (SE3) (W1) • K2—Pilot Shutoff Solenoid Relay (SE3) (W1) • K3—Security Alarm Relay (SE4) (W1) • K4—Starter Cut Relay (SE2) (W1) • K5—Security Relay (SE2) (W1) • K6—Windshield Wiper Relay (SE16) (W1)
• K7—Work Light Relay (SE17) (W1) • K8—Boom Light Relay (SE17) (W1) • K9—Windshield Washer Relay (SE16) (W1) • K10—Horn Relay (SE22) (W1) • K11—Idle Stop Relay (SE1) (W1) • K12—Accessory Cut Relay (SE1) (W1) • K13—Key Cut Relay (SE1) (W1) • K14—ECU Power Relay (SE12) (W1) • K15—Air Conditioner Compressor Off Relay (SE22) (W41)
• K16—Glow Plug Relay (SE11) (W2) • K17—Air Conditioner and Heater Blower Motor Relay (SE23) (W41)
• K19—Battery Relay (SE1) (W2) (W6004) • K20—Seat Heater Relay (SE26) (W14) • K30—Right Solenoid Relay B (SE27) (W15) • K31—Right Solenoid Relay A (SE27) (W15) • K31—Right Solenoid Relay A (marked RSW1) (SE29) (W15)
• K32—Left Solenoid Relay B (SE27) (W15) • K32—Left Solenoid Relay B (marked LSW1) (SE29) (W15)
• K33—Left Solenoid Relay A (SE27) (W15) • K33—Left Solenoid Relay A (marked LSW3) (SE29) (W15)
• K34—Starter Relay (SE2) (W2) • M1—Starter Motor (SE2) (W2) • M2—Fuel Transfer Pump (SE2) (W8) • M3—Exhaust Gas Recirculation (EGR) Valve Actuator (SE12) (W4)
• M5—Windshield Wiper Motor (SE16) • M6—Windshield Washer Motor (SE16) (W2) • M7—Air Conditioner and Heater Blower Motor (SE23) (W41)
• M8—Intake Air Throttle (SE12) (W4) • M9—Air Conditioner and Heater Internal and External Servo Motor (SE24) (W41)
• M10—Air Conditioner and Heater Blower Port Change Servo Motor (SE24) (W41)
• M11—Air Conditioner and Heater Mixer Servo Motor (SE24) (W41)
• M12—Seat Air Compressor Motor (SE26) (W14) • R1—Glow Plug 1 (SE12) (W4) • R2—Glow Plug 2 (SE12) (W4) • R3—Glow Plug 3 (SE12) (W4) • R4—Glow Plug 4 (SE12) (W4) • R8—Engine CAN Termination Resistor (SE15) (W2) • R9—Lighter Connector (SE18) (W1) • R10—Interface CAN Resistor 1 (SE20) (W30) • R11—Interface CAN Resistor 2 (SE20) (W31) • R13—Engine Control Unit (ECU) Resistor (SE12) (W2) • R15—Engine Speed Dial (SE7) (W1) • R16—Blower Motor Resistor and Thermofuse (SE23) (W41)
• R18—Seat Heater (marked SEAT HEATER) (SE26) (W14)
• S1—Key Switch (SE1) (W29) • S2—Cab Dome Light Switch (SE19) • S3—Pilot Shutoff Switch 1 (SE3) (W11) • S4—Pilot Shutoff Switch 2 (SE3) (W11) • S5—Horn Switch (SE22, SE28) (W1) S6—Engine Stop Switch (SE1) (W1) • Continued on next page CW08338,0000D05 -19-15SEP16-2/6
TM12660 (18APR18)
9015-10-7
041818
PN=317
System Diagrams
• S7—Power Dig Switch (SE10, SE28) (W1) • S8—Auto-Idle Switch (SE7) (W1) • S9—Windshield Wiper and Washer Switch (SE20) (W1) • S10—Work Light Switch (SE6) (W1) • S11—Travel Speed Switch (SE7) (W1) • S12—Power Mode Button (SE7) (W1) • S13—Travel Alarm Cancel Switch (SE10) (W16) • S14—Door Switch (SE20) (W1) • S16—Exhaust Filter Parked Cleaning Switch (SE11) (W9)
• S20—Seat Belt Switch (SE6) (W1) • S21—Blower Motor Speed Switch (SE5) (W1) • S22—Temperature Control/Mode Switch (SE5) (W1) • S23—Radio Volume and Power Switch (SE6) (W1) • S24—Radio Tuning Switch (SE5) (W1) • S25—Monitor Dial (SE5) (W1) • S26—Back Button (SE5) (W1) • S27—Home Button (SE5) (W1) • S28—Window Switch (SE16) • S29—Auxiliary Function Lever (AFL) Proportional Control Switch (SE28) (W75)
• S30—Right Pilot Control Lever Switch B (marked B) (SE27) (W15)
• S31—Right Pilot Control Lever Switch A (marked C) (SE27) (W15)
• S31—Right Pilot Control Lever Switch A (SE28) (W75) • S32—Left Pilot Control Lever Switch B (marked B) (SE27) (W15)
• S32—Left Pilot Control Lever Switch B (SE28) (W75) • S33—Left Pilot Control Lever Switch A (marked C) (SE27) (W15)
• S33—Left Pilot Control Lever Switch A (SE28) (W75) • S34—Right Enable Switch (SE27, SE29) (W22) • S35—Left Enable Switch (SE27, SE29) (W22) • S40—Hydraulic Oil Temperature Switch (if equipped) (SE4) (W2)
• V13—Work Light 1 Diode (SE19) (W1) • V14—Work Light 2 Diode (SE19) (W1) • V17—Side Monitor Diode (SE6) (W6) • V20—Pilot Shutoff Switch Diode (SE3) (W11) • V22—Pilot Shutoff Solenoid Diode (SE30) (W75) • V30—Right Solenoid Diode B (SE27) (W61) • V31—Right Solenoid Diode A (SE27) (W61) • V32—Left Solenoid Diode B (SE27) (W61) • V33—Left Solenoid Diode A (SE27) (W61) • W1—Cab Harness (W1) • W2—Machine Harness (W2) • W3—Monitor Harness (W3) • W4—Engine Harness (W4) • W5—Side Camera Harness (W5) • W6—Side Monitor Harness (W6) • W8—Pump Harness (W8) • W9—Exhaust Filter Parked Cleaning Switch Harness (W9)
• W11—Pilot Shutoff Switch Harness (W11) • W13—Auxiliary Fuse Box Harness (W13) • 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) • W20—Service ADVISOR™ Harness (W20) • W21—Pilot Shutoff Valve Harness (W21) • W22—Auxiliary 3-Button Cancel Switch Harness (W22) • W24—Seat Heater Switch Harness (W24) • W26—Travel Alarm Harness (W26) • W27—Travel Sub Harness (W27) • W29—Starter Switch Harness (W29) • W30—Data Converter Harness (W30) • W31—Data Converter Interface Harness (W31) • W32—2-Speed Harness (W32) • W35—Cab Harness Ground 1 (W1) • W36—Cab Harness Ground 2 (W1) • W37—Cab Harness Ground 3 (W1) • W38—Side Monitor Mounting Bracket Ground (W6) • W39—Cab Harness Ground 4 (W1) • W41—Heater and Air Conditioner Harness (W41) • W43—Spool Control Harness (W43) • W60—Radio Antenna (SE18) • W61—Auxiliary Solenoid Harness (W61) • W75—Auxiliary Function Lever (AFL) Harness (W75) • W76—Auxiliary Function Lever (AFL) Solenoid Harness
• S45—Auxiliary Function Enable Switch (SE29) (W78) • S50—0 Key (SE5) (W1) • S51—1 Key (SE5) (W1) • S52—2 Key (SE5) (W1) • S53—3 Key (SE5) (W1) • S54—4 Key (SE5) (W1) • S55—5 Key (SE5) (W1) • S56—6 Key (SE5) (W1) • S57—7 Key (SE5) (W1) • S58—8 Key (SE5) (W1) (W76) • S59—9 Key (SE5) (W1) • S60—Keypad (SE5, SE6) (W1) • W77—Auxiliary Function Lever (AFL) Grip Harness (W77) • S61—Seat Compressor Switch (SE26) • S62—Seat Heater Switch (SE26) (W24) • W78—Auxiliary Function Enable Switch Harness (W78) • V1—Battery Relay Diode (SE1) (W1) • W6003—Satellite (SAT) Harness (W6003) • V2—Not Used (W1) • W6004—JDLink™ Harness (W6004) • V3—Load Dump Relay Diode (SE3) (W1) • X1—Service ADVISOR™ Diagnostic Connector (SE14) (W20) • V4—Security Diode (SE2) (W1) • V5—Starter Cut Relay Diode (SE3) (W1) • X2—MPDr 6-Pin Connector (SE4) (W1) • V6—Auxiliary Power Connector Diode (SE18) (W1) • X3—Cab Harness-to-Machine Harness 100-Pin Connector (SE2, SE7, SE12, SE17) (W1), (W2) • V7—Start Relay Diode (SE2) (W1) • V8—Air Conditioner Clutch Diode (SE22) (W1) • X4—Cab Harness-to-Machine Harness 32-Pin Connector (SE4, SE6) (W1), (W2) • V9—Pilot Shutoff Diode (SE3) (W1) • V10—Starter Protection Diode (SE1) (W1) • X5—Machine Harness-to-Engine Harness 32-Pin Connector (SE4, SE11, SE12, SE13, SE14) (W2), (W4) • V11—Accessory Cut Diode (SE1) (W1) • V12—Starter Cut Diode (SE2) (W1) Continued on next page CW08338,0000D05 -19-15SEP16-3/6 TM12660 (18APR18)
9015-10-8
041818
PN=318
System Diagrams
• X6—Machine Harness-to-Engine Harness 16-Pin
Connector (SE12) (W2), (W4) • X7—Machine Harness-to-Engine Harness 14-Pin Connector (SE12, SE15) (W2), (W4) • X8—Machine Harness-to-Engine Harness 1-Pin Connector (W2), (W4) • X9—Machine Harness-to-Engine Harness 20-Pin Connector (SE13) (W2), (W4) • X10—Machine Controller 8-Pin Connector A (SE19) (W1) • X11—Machine Controller 20-Pin Connector B (SE19) (W1) • X12—Side Monitor 16-Pin Connector A (SE6) (W6) • X13—Side Monitor 20-Pin Connector B (SE6) (W6) • X14—Engine Control Unit (ECU)-to-Machine Harness 60-Pin Connector (SE11, SE12, SE13, SE14, SE15) (W2) • X15—Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector (SE11, SE12, SE13, SE14, SE15) (W2) • X17—Cab Harness-to-Monitor Harness Connector (W1), (W3) • X18—Monitor 12-Pin Connector C (SE6) (W3) • X19—Monitor 2-Pin Connector G (SE6) (W3) • X20—Monitor Controller 28-Pin Connector A (SE4, SE5, SE6) (W1) • X21—Monitor Controller 36-Pin Connector B (SE4, SE5, SE6) (W1) • X22—Monitor Controller 16-Pin Connector D (SE4, SE5, SE6) (W1) • X23—Monitor Controller 12-Pin Connector C (SE4, SE5, SE6) (W3) • X24—Monitor Controller 2-Pin Connector G (SE4, SE5, SE6) (W3) • X25—Cab Harness Auxiliary Power Connector 1 (SE18) (W1) • X26—Optional Connector (SE17, SE26, SE28, SE30) (W1), (W6), (W15), (W75) • X27—Cab Harness-to-Switch Panel Connector 1 (SE20) (W1) • X28—Cab Harness-to-Switch Panel Connector 2 (SE5) (W1) • X29A—Cab Harness-to-Switch Panel Connector 3 (SE6, SE7) (W1), (W6) • X29B—Cab Harness-to-Switch Panel Connector 5 (SE6) (W1), (W6) • 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 Connector (SE16) (W1)
• X40—Pump Harness-to-Machine Harness Connector (SE2, SE7, SE8, SE9, SE15) (W2), (W8)
• X41—Data Converter Harness Connector (W1), (W30) • X42—CAN 1 Connector (not used) (W1), (W30) • X43—Optional Fuse Connector (W1), (W13) • X44—Optional Light Connector (SE17, SE26) (W1), (W13)
• X45—Option 2 12-Pin Connector (not used) (W1) • X46—Attachment Connector (W2), (W17) • X47—Cab Harness-to-Key Switch Harness Connector (W1), (W29)
• X48—Attachment Connector 2 (SE8) (W2) • X49—Cab Harness-to-Spool Control Harness Connector (SE10) (W1), (W43)
• X50—Travel Sub Harness-to-Travel Alarm Cancel Switch Harness Connector (W1), (W16), (W27)
• X51—Air Conditioner 4-Pin Connector (W1), (W41) • X52—Air Conditioner 10-Pin Connector (SE23) (W1), (W41)
• X53—Heated Air Seat Harness-to-Heated Seat Switch
Harness 3-Pin Connector (marked SEAT HEATER) (W14), (W24) • X54—Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) (SE26) (W13), (W14) • X55—Front Cab Light 1 Connector (marked CAB LAMP FRONT) (SE26) (W13) • X56—Front Cab Light 2 Connector (marked CAB LAMP FRONT+2) (SE25) (W13) • X57—Rear Cab Light Connector (marked CAB LAMP REAR) (SE25) (W13) • X58—Warning Light Connector (marked WARNING LAMP) (SE25) (W13) • X59—Satellite Communication Connector (marked IMOBI) (SE25) (W13) • X60—12-Volt Power Supply (marked 12V UNIT) (SE25) (W13) • X61—Quick Hitch Connector (marked QUICK HITCH) (SE25) (W13) • X62—Cab Auxiliary Power Connector 2 (marked AUX_2) (SE25) (W13) • X63—Cab Auxiliary Power Connector 3 (marked AUX_3) (SE25) (W13) • X64—Machine Harness-to-Rear Camera Harness Connector (SE6) (W2) (W19) • X65—Cab Harness-to-Pilot Shutoff Switch Harness Connector (W1), (W11) • X66—Cab Harness-to-Side Monitor Harness 2-Pin Connector 1 (SE6) (W1), (W6) • X67—Machine Harness Auxiliary Power Connector (W2) • X68—Cab Harness-to-Side Monitor Harness 2-Pin Connector 2 (SE6) (W1), (W6) • X69—Side Camera Harness-to-Side Monitor Harness 4-Pin Connector (SE6) (W5), (W6) • X70—Data Converter Interface Connector (W30), (W31) • X71—Machine Harness-to-Service ADVISOR™ Harness 8-Pin Connector (SE14) (W2), (W20) • X72—Machine Harness-to-Service ADVISOR™ Harness 3-Pin Connector (SE14) (W20), (W31)
Continued on next page
TM12660 (18APR18)
9015-10-9
CW08338,0000D05 -19-15SEP16-4/6
041818
PN=319
System Diagrams
• X73—Cab Harness-to-Speakers Connector (SE18)
(W1) • X75—Cab Harness-to-Pilot Shutoff Valve Harness Connector (W1), (W21) • X76—Cab Harness Connector 1 (not used) (SE4) (W1) • X77—Radio Auxiliary Connector (SE18) (W1) • X78—Optional Switch Connector (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) • X86—Machine Harness-to-Travel Alarm Harness Connector (W2), (W26) • X87—Attachment Harness-to-2-Speed Harness Connector (W17), (W32) • X90A—Not Used (SE7) (W1) • X90B—Not Used (SE7) (W1) • X91A—Not Used (SE7) (W1) • X91B—Not Used (SE7) (W1) • X92A—Not Used (SE12) (W1) • X92B—Not Used (SE12) (W1) • X93—Not Used (SE12) (W1) • X94—Machine Harness-to-Hydraulic Oil Temperature Switch Connector (SE4) (W2) • X97—Pump Harness Splice Connector (SE7, SE8, SE9) (W8) • X98—Machine Harness Splice Connector (SE7, SE8, SE9) (W2) • X99—Cab Ground Splice (W1) • X101—Fuel Injector Harness Connector 1 (SE13) (W4) • X102—Not Used (W1) • X104—Not Used (W2) • X105—Not Used (W2) • X107A—Not Used (W1) • X107B—Not Used (W1) • X108A—Not Used (W1) • X108B—Not Used (W1) • X109—Not Used (W2) • X135—Pilot Shutoff Harness Splice 1 (W11) • X136—Pilot Shutoff Harness Splice 2 (W11) • X137—Pilot Shutoff Harness Splice 3 (W11) • X160—P01 RED Splice (W6004) • X161—G01 BLK Splice (W6004) • X162—G01 BLK Splice 2 (W6004) • X300—7 RED/BLK Splice (W41) • X301—17 RED/BLU Splice (W41) • X302—25 BRN/RED Splice (W41) • X303—26 BLK Splice (W41) • X534—Right Auxiliary Solenoid Connector (marked SR/H) (SE27, SE29) (W15), (W61) • X535—Left Auxiliary Solenoid Connector (marked SL/H) (SE27, SE29) (W15), (W61) • X536—Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) (SE28) (W77) • X537—Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP) (SE28) (W77) • X538—Auxiliary Function Lever (AFL) Right Grip Harness Connector (marked R_LEVER) (SE28) (W75), (W77)
• X539—Auxiliary Function Lever (AFL) Left Grip Harness Connector (marked L_LEVER) (SE28) (W75), (W77)
• X540—Auxiliary Function Enable Switch Harness Connector (marked EL_SW) (W75), (W78)
• X541—Auxiliary Function Lever (AFL) Right Switch Connector (marked R-SW) (SE28) (W15), (W75)
• X542—Auxiliary Function Lever (AFL) Left Switch Connector (marked L-SW) (SE29) (W15), (W75)
• X543—Auxiliary Function Lever (AFL) Horn Switch Connector (SE10, SE28) (W1), (W75)
• X544—Auxiliary Function Lever (AFL) Power Dig Switch Connector (SE22, SE29) (W1), (W75)
• X574—Auxiliary Function Lever (AFL) Connector (SE10, SE30) (W1), (W75)
• X577—Auxiliary Function Lever (AFL) Harness-to-
Auxiliary Function Lever (AFL) Solenoid Harness Connector (SE30) (W75), (W76) • X578—Not Used (W1) • X579—Not Used (W1) • X6007—JDLink™ Harness Ground 1 (SE21) (W6004) • X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector (SE21) (W6004) • X6015—Satellite (SAT) Module Control Unit 48-Pin Connector (SE21) (W6003) • X6016—JDLink™ Harness-to-Satellite (SAT) Harness Connector (SE21) (W6003) (W6004) • X6020—CAN 0 Connector (marked CAN) (SE11, SE21) (W2) (W6004) • X6021—Interface CAN Connector (marked N-CAN) (SE21) (W31) (W6004) • Y1—Electronic Injector 1 (SE13) (W4) • Y2—Electronic Injector 2 (SE13) (W4) • Y3—Electronic Injector 3 (SE13) (W4) • Y4—Electronic Injector 4 (SE13) (W4) • Y10—Pilot Shutoff Solenoid (SE2) (W21) • Y11—Air Conditioner Compressor Clutch (SE22) (W2) • Y12—Exhaust Filter Regulator Solenoid (pump 1) (marked SZ) (SE7) (W2) • Y13—Exhaust Filter Regulator Solenoid (bypass cut-off valve) (marked SJ) (SE7) (W2) • Y14—Suction Control Valve (SE14) (W4) • Y16—Turbocharger Actuator (SE15) (W4) • Y20—Pump 2 Flow Rate Limit Solenoid (marked SB) (SE7) (W8) • Y21—Torque Control Solenoid (marked ST) (SE7) (W8) • Y22—Dig Regenerative Solenoid (marked SF) (SE7) (W2) • Y23—Arm Regenerative Solenoid (marked SC) (SE8) (W2) • Y24—Power Dig Solenoid (marked SI) (SE8) (W2) • Y26—Pump 1 Flow Rate Limit Solenoid (marked SA) (SE8) • Y27—Arm 2 Flow Control Solenoid (marked SD) (SE8) (W2) • Y28—Pump 3 Torque Control Solenoid (marked SU) (SE7) (W8) • Y29—Arm 1 Flow Control Solenoid (marked SE) (SE8) (W2) • Y30—Pump 3 Flow Rate Limit Solenoid (marked SX) (SE8) • Y31—Arm 3 Spool Control Solenoid (marked A2) (SE10) (W43)
Continued on next page
TM12660 (18APR18)
9015-10-10
CW08338,0000D05 -19-15SEP16-5/6
041818
PN=320
System Diagrams
• Y32—Boom 3 Spool Control Solenoid (marked A1)
(SE10) (W43) • Y34—Right Solenoid (marked SR/H) (SE27) (W61) • Y35—Left Solenoid (marked SL/H) (SE27) (W61) • Y38—Attachment Relief Solenoid (SE9) (W17) • Y39—Attachment Relief Solenoid 2 (SE9) (W17) • Y40—Selector Valve Solenoid Valve (SE9) (W17) • Y41—Secondary Relief Solenoid Valve (SE9) (W17) • Y43—2-Speed Activation Solenoid Valve (SE9) (W32)
• Y44—Flow Rate Adjustment Solenoid Valve (SE9) (W32)
• Y61—Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (SE30) (W76)
• Y62—Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (SE30) (W76)
• Y66—Secondary Pilot Shutoff Solenoid Valve (marked PiC) (SE30) (W76)
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company CW08338,0000D05 -19-15SEP16-6/6
TM12660 (18APR18)
9015-10-11
041818
PN=321
System Diagrams
TM12660 (18APR18)
9015-10-12
041818
PN=322
System Diagrams
System Functional Schematic TX1121202 —UN—23AUG12
RED
K5 SECURITY RELAY
V7 START RELAY DIODE
E
C
K34 STARTER RELAY RED
BLK S
RED
RED
WHT
WHT
G3 ALTERNATOR
041818
PN=323
S4 PILOT SHUTOFF SWITCH 2
ORG
2
B
S3 PILOT SHUTOFF SWITCH 1
M1 STARTER MOTOR
1
2
K1 LOAD DUMP RELAY
3
5
4
RED ORG
F11 5A FUSE
WHT
3
1
System Functional Schematic (SE1—SE3) (1 of 10) Continued on next page
BLU
X3
SE2 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1121202
BLU/YEL
WHT
B12
WHT
SE1
WHT
YEL/BLK
YEL/BLK
L
3
BLU 2
YEL/GRN
BLK/WHT
RED
RED
TO SE11 A1 (PIN 152)
RED/BLU
B
V5 STARTER CUT RELAY DIODE 1
LT GRN/BLK
BLK/WHT
BLK/WHT
S
TO SE11 A1 (PIN 100)
M2 FUEL TRANSFER PUMP
BRN
9
WHT
BLK
10
VLT/GRN
1
TO SE12 A1 (PIN 121)
9015-10-13
RED
X40
1
BLK
TO SE4 A4 (PIN A17)
BLK
TM12660 (18APR18)
B
R
GRN
WHT/RED 4
2
RED
FROM SE4 F17
4
5
F7 5A FUSE
BLK
BLK
RED
F60 65A FUSE
4
F
BLK
G2 BATTERY
5
BRN
K4 STARTER CUT RELAY
3
BLK
+ A
BLK
2
RED/BLK
B
V1 BATTERY RELAY DIODE
3
WHT
S
2
GRY/RED
RED
-
WHT
E
WHT/RED
+ S6 ENGINE STOP SWITCH
2
VLT
BRN
1
BRN
G1 BATTERY
4
TO SE11 K16 (PIN 3)
3
WHT/RED
RED
K19 BATTERY RELAY
BRN
WHT/RED
F61 45A FUSE
5
1
K2 PILOT SHUTOFF SOLENOID RELAY
VLT/RED
VLT/GRN
WHT/RED
2
3
WHT
V10 STARTER PROTECTION DIODE
1
V9 PILOT SHUTOFF DIODE
V20 PILOT SHUTOFF SWITCH DIODE
WHT
TO SE10 A3 (PIN C5)
BLU
ST
RED
BLK
YEL/GRN WHT
M
WHT
4
YEL/GRN
WHT
WHT
5
RED
2
RED
4
V4 SECURITY DIODE
RED
5
K13 KEY CUT RELAY
V3 LOAD DUMP RELAY DIODE
ORG
2
TO SE18 R9
K11 IDLE STOP RELAY
F16 5A FUSE
RED
BLU
S1 KEY SWITCH
3
3
TO SE8 A3 (PIN F1,F2,F3)
RED
1
WHT
1
Y10 PILOT SHUTOFF SOLENOID
3
2
BLK
YEL/GRN
1
F4 20A FUSE
GRN/YEL
WHT/BLK
G2
RED
4
YEL/BLK
VLT
5
V11 ACCESSORY CUT DIODE
K12 ACC CUT RELAY
BLU
2
3
VLT/GRN
G1
1
VLT/WHT
TO SE18 F15
ACC BAT
F18 5A FUSE
YEL/BLK
RED
PNK/WHT
PNK/BLK
BLU
RED
V12 STARTER CUT DIODE
RED GRN WHT YEL/BLK GRN/WHT
RED
BLU
HEAT OFF ACC ON START
RED GRN WHT YEL/BLK GRN/WHT
GRN
WHT
RED
M ST
RED
ACC
VLT/RED
G2
GRN/WHT
G1
WHT
B
POSITION HEAT OFF ACC ON START
ORG
TO SE10 A3 (PIN F13)
VLT WHT
SE3 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-1/20
System Diagrams
TM12660 (18APR18)
9015-10-14
041818
PN=324
System Diagrams
F4— Solenoid 20 A Fuse (marked G2—Battery S1— Key Switch SOLENOID) G3—Alternator S3— Pilot Shutoff Switch 1 F7— Start Position Signal 5 A K1—Load Dump Relay S4— Pilot Shutoff Switch 2 Fuse (marked START) K2—Pilot Shutoff Solenoid Relay S6— Engine Stop Switch F11— Not Used K4—Starter Cut Relay V1— Battery Relay Diode F16— Glow Relay 5 A Fuse K5—Security Relay V3— Load Dump Relay Diode (marked GLOW RELAY) K11— Idle Stop Relay V4— Security Diode F18— Idle Stop 5 A Fuse (marked K12— Accessory Cut Relay V5— Starter Cut Relay Diode IDLE STOP) K13— Key Cut Relay V7— Start Relay Diode F60— Alternator 65 A Fuse K19— Battery Relay V9— Pilot Shutoff Diode F61— Battery 45 A Fuse K34— Starter Relay V10— Starter Protection Diode G1—Battery M1—Starter Motor M2—Fuel Transfer Pump Continued on next page
TM12660 (18APR18)
9015-10-15
V11— Accessory Cut Diode V12— Starter Cut Diode V20— Pilot Shutoff Switch Diode X3— Cab Harness-to-Machine Harness 100-Pin Connector X40— Pump Harness-to-Machine Harness Connector Y10— Pilot Shutoff Solenoid
CW08338,0000D06 -19-15SEP16-2/20
041818
PN=325
System Diagrams
TM12660 (18APR18)
9015-10-16
041818
PN=326
System Diagrams
TX1209766 —UN—01FEB16
RED GRN WHT RED/BLK
VLT
BLK
TO SE7 A3 (PINS F16, F17)
041818
S25
X18
8 13 9
11 10 12
14 16 15
1
2
5
S22
S24
S26
TO SE7 X97 (PIN 24)
S27
RED BLU/RED
FROM SE19 A11 (PIN B3)
4
S21
G2 G1
C = X23 G = X24
A11 B31 A12
B26
BLK
7
FROM SE17 K7 (PIN 5)
X30 CAB HARNESSTO-SWITCH PANEL CONNECTOR 4
E6 SWITCH PANEL BACK LIGHT 2
E7 SWITCH PANEL BACK LIGHT 3
A24 LT GRN BLK/PNK BLU/WHT
16
15
WHT/VLT GRN/WHT 1 3
X19
2
13 14
A23
A26
A25
TO SE19 A11
X29B PNK
16
15
1 3
13 14
2
E8 SWITCH PANEL BACK LIGHT 4
0 1 2
S23 RADIO VOLUME AND POWER SWITCH
BLK
X29A CAB HARNESSTO-SWITCH PANEL CONNECTOR 3 S10 WORK LIGHT SWITCH
TO SE10 CAN 0
BLU (CAN 1 LOW)
B25
3
6
A = X20 B = X21 D = X22
C3 C2 C6 C5 C1
GRN (CAN 1 HIGH)
A9
G2 G1
CABLE CABLE
D9 D1
GRN (CAN 0 HIGH)
A7
C3 C2 C6 C5 C1
RED/YEL YEL GRN BLK/YEL BLU
GRY
BLK/YEL
D3 D2
K
1 4
A14 SIDE CAMERA
B30 A6
5
A
A10 MONITOR
YEL BLK WHT GRY WHT GRY
WHT GRY
E1 E2 E7 E8
BLU/WHT
TO SE18
TO SE17
X69
WHT/VLT GRN/WHT
A5
4
BLU/WHT BLK/PNK LT GRN
B28 A4
3
V17
PNK
1 2
BLU BRN GRY
FROM SE2 F7
A3
WHT/YEL LT GRN/RED BLK
X66
2
B21
TO SE17
X13
BLU (CAN 0 LOW)
1 2
RED BLK/YEL WHT GRY
WHT GRY
GRY
WHT
WHT GRY 1 2
B9 B10 B11 B7
RED
2
B29 A10
System Functional Schematic (SE4—SE6) (2 of 10)
PN=327
X68
A8 A14 A5 A13
BLU/RED
A8
SE5 245GLC SYSTEM FUNCTIONAL SCHEMATIC
Continued on next page
B20
4
A1 A10
BRN/BLK PNK
B19
4
GRY
3 WHT
BLK
YEL RED
2 BLK
BLK
X28 CAB HARNESSTO-SWITCH PANEL CONNECTOR 2 X4
1 RED
WHT
1
WHT 1
TX1209766
9015-10-17
X64
RED
Q
B17 WATERIN-FUEL SENSOR
B1
BLK
2
B2
RED
Q
SE4
TM12660 (18APR18)
ORG
GRY
PNK
GRN
LT BLU B3
RED/GRN
B18 FUEL LEVEL SENSOR
B4
B27 A17
1
B27 HYDRAULIC OIL FILTER RESTRICTION SWITCH
5
A13 SIDE MONITOR X12 A3 A11
RED B5
IF EQUIPPED
YEL
P
2
GRN/RED
T
B43 1 COOLANT TEMPERATURE SENSOR
B42 ENGINE OVERHEAT SENSOR
BLK
ORG
T
B16 AIR FILTER RESTRICTION SWITCH
A12 REAR CAMERA
A4 MONITOR CONTROLLER (DSZ) B7
WHT/BLU
S40 HYDRAULIC OIL TEMPERATURE SWITCH
T
B6
YEL/RED
24
RED
BLK
P
2
C = X23 G = X24
X94
X5
X5
A = X20 B = X21 D = X22
BRN
BLK
X4
WHT/BLU
4
8
B22
A18
1
X76
B17
YEL/RED
A1 A28 A13
B14 B13
B35
BRN/BLU
B15
BLK
YEL/BLU
A22
WHT/BLU
A19
WHT/BLK
B11
BLK
ORG VLT
B36
S60 KEYPAD
RED
BLU/WHT
D15
A4 MONITOR CONTROLLER (DSZ) D8 B10
1
WHT/BLU
B18
12
WHT/YEL BRN GRN/BLU
B9
10
WHT/YEL BRN/YEL GRN/BLU
GRN/RED
D5
9
YEL/BLU BLK/RED GRY/RED
BLK/GRN
B12
8
YEL/BLU BLK/RED GRY
WHT/YEL
B16
7
YEL BLK/RED WHT
WHT/RED
D6
6
BLK
YEL/WHT
D7
BLK/RED
WHT/RED
A16
RED/GRN
RED/BLK
D16
BLK/GRN
GRN/WHT
A15
GRN/BLK
BLU/YEL
BLU/YEL
5
RED
3
4
BRN/BLU
1
3
E5 SWITCH PANEL BACK LIGHT 1
9
BRN/YEL
2
2
S59
8
GRY
4
11
S58
7
PNK
X2
BLK
TO SE12 A1 (X15 PIN 147)
4
6
GRN
5
S57
YEL GRN RED/WHT
2
S56
5
LT GRN/YEL
K3 SECURITY ALARM RELAY
3
ORG/WHT
TO SE12 A1 (X15 PIN 130)
1
RED/GRN
TO SE12 A1 (X15 PIN 145)
GRN/RED
2
TO SE12 A1 (X15 PIN 124)
S55
4
GRN/WHT
RED/BLU PNK/GRN
3
YEL
1
2
S54
YEL/GRN BLU ORG
2
H2 SECURITY ALARM
S53
RED/BLU BLU/BLK BLK/YEL
BLU/BLK WHT
RED/BLU
H3 MONITOR WARNING ALARM
1
F14 5A FUSE
S52
1
WHT/RED
RED/BLK
TO SE18 A6 (PIN 16)
0
BRN
RED/BLU
S51
RED/GRN
TO SE10 S16 (PIN 1)
TO SE10 A3 (PIN A1)
S50
F9 10A FUSE
BLU/BLK
F17 5A FUSE
YEL
RED/BLK TO SE1 S6 (PIN 2)
RED GRN WHT RED/BLK
BLU/YEL
RED GRN WHT YEL/BLK GRN/WHT
TO SE10 CAN 1
BLK
SE6 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-3/20
System Diagrams
TM12660 (18APR18)
9015-10-18
041818
PN=328
System Diagrams
A4—Monitor Controller (DSZ) A10— Monitor A12— Rear Camera A13— Side Monitor A14— Side Camera B16— Air Filter Restriction Switch B17— Water-in-Fuel Sensor B18— Fuel Level Sensor B27— Hydraulic Oil Filter Restriction Switch (if equipped) B42— Engine Overheat Sensor B43— Coolant Temperature Sensor 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)
X5— Machine Harness-to-Engine X30— Cab Harness-to-Switch H2—Security Alarm Harness 32-Pin Connector H3—Monitor Warning Alarm Panel Connector 4 X12— Side Monitor 16-Pin K3—Security Alarm Relay X64— Machine Harness-to-Rear Connector A S10— Work Light Switch Camera Harness X13— Side Monitor 20-Pin S21— Blower Motor Speed Connector Connector B Switch X66— Cab Harness-to-Side S22— Temperature Control/Mode X18— Monitor 12-Pin Connector Monitor Harness 2-Pin C Switch Connector 1 S23— Radio Volume and Power X19— Monitor 2-Pin Connector G X68— Cab Harness-to-Side X20— Monitor Controller 28-Pin Switch Monitor Harness 2-Pin Connector A S24— Radio Tuning Switch Connector 2 X21— Monitor Controller 36-Pin X69— Side Camera S25— Monitor Dial Connector B S26— Back Button Harness-to-Side Monitor X22— Monitor Controller 16-Pin S27— Home Button Harness 4-Pin Connector Connector D S40— Hydraulic Oil Temperature X76— Cab Harness Connector 1 X23— Monitor Controller 12-Pin Switch (if equipped) (not used) Connector C S50— 0 Key X94— Machine Harness-toX24— Monitor Controller 2-Pin S51— 1 Key Hydraulic Oil Temperature Connector G S52— 2 Key Switch Connector X28— Cab Harness-to-Switch S53— 3 Key Panel Connector 2 S54— 4 Key X29A— Cab Harness-to-Switch S55— 5 Key Panel Connector 3 S56— 6 Key X29B— Cab Harness-to-Switch S57— 7 Key Panel Connector 5 S58— 8 Key S59— 9 Key S60— Keypad V17— Side Monitor Diode X2— MPDr 6-Pin Connector X4— Cab Harness-to-Machine Harness 32-Pin Connector Continued on next page
TM12660 (18APR18)
9015-10-19
CW08338,0000D06 -19-15SEP16-4/20
041818
PN=329
System Diagrams
TM12660 (18APR18)
9015-10-20
041818
PN=330
System Diagrams
TX1209274 —UN—26JAN16
BLK
ORG/BLU
GRY
BLU/YEL
LT GRN/BLK
GRN/BLK
BRN
GRN/BLU
BRN/YEL
YEL/RED
B15
B22
B21
B23
B24
B12
B11
C4
C3
D14
D15
D9
C14
C8
C15
C13
D8
D28
D27
BLK/RED
BLU/RED
BLK/YEL
YEL/RED
WHT/RED
BLU/RED
2
B30 BOOM UP PRESSURE SENSOR
3
GRN/YEL
YEL/BLK
GRY/RED
WHT/GRN
BLK/PNK
2
3
3
B32 FRONT ATTACHMENT PRESSURE SENSOR P B33 SWING PRESSURE SENSOR
SE7
2
1
2
3
3
B34 TRAVEL PRESSURE SENSOR B35 PUMP 1 P DELIVERY PRESSURE SENSOR
3
2
1
System Functional Schematic (SE7—SE9) (3 of 10)
9015-10-21
041818
PN=331
D17
D18 18
X46
1
3
1
P B39 2 BUCKET IN PRESSURE SENSOR
3
D29 15
19
X46
X46
15
BLK/YEL ORG/BLU
RED/YEL
BLK/YEL BLK
P
6
X97
3 2 B57 PUMP 3 CONTROL PRESSURE B56 SENSOR P PUMP 3 DELIVERY PRESSURE SENSOR
PNK
2
1
B61 P ARM OUT 2 PRESSURE SENSOR
3
B62 ATTACHMENT PRESSURE SENSOR 2
3
B60 ATTACHMENT PRESSURE SENSOR
3
2
2
P RED
BLU
BLK
X97 BLK
1
X40
19
1 GRN/BLK
18
X97
RED 1
P
RED/YEL
YEL/BLU
RED
BLK/YEL
RED/YEL
P 2 B38 PUMP 2 CONTROL PRESSURE SENSOR
3
X98
X97
1
19
X40
23
17
YEL
X97
X97
11
X98
RED
15
2
BLK
RED
BLK
RED
BLK
3 2 B36 PUMP 1 CONTROL PRESSURE B37 SENSOR P PUMP 2 DELIVERY PRESSURE SENSOR
SE8 245GLC SYSTEM FUNCTIONAL SCHEMATIC
Continued on next page
X97
X40
RED/YEL
P
16
7
18
BLK
1
X97
14
X40
ORG
X97
P 2
1
B31 P ARM IN PRESSURE SENSOR
R15 ENGINE SPEED DIAL
P
FROM SE4 B17 (PIN 2)
RED 14
3
X97
BLK
X98 1
RED
LT GRN/BLK
P
BLK
X40
RED
22
13
X97
5
GRY
21
X98
RED 2
10
X98
17
X40
BLK
20
X98 1
YEL/RED
RED/YEL
BLU/YEL
BLK/YEL
RED/YEL
BLU/RED
9
X98
X97 RED
19
X98
24
BLK/YEL
RED/YEL
BLK/YEL
BLK/RED
8
X98
4
VLT
BLK/YEL
GRN/YEL
7
X98
1
6
RED/YEL
18
X98 RED/YEL
YEL/BLK 4
BLK/YEL
X91
TX1209274
TM12660 (18APR18)
B16
GRN/YEL
BLK/YEL
X98
L H
BLK
A21
6 2
YEL/GRN
BLU/WHT
LT BLU
ORG
WHT
0 A1
S11 TRAVEL SPEED SWITCH
A20
D7
X97 S8 AUTOIDLE SWITCH
A9
BLK/YEL RED/YEL
D2
X90
5
A8
D6
BLK
12
A28
1
D8
1
BRN/WHT
BLK/BLU
GRN/BLU
BLK/GRN
8
A29
1
X46
X3
X3
2
9
BLK/YEL
TO SE10 X574 (PIN 11)
FROM SE4 B18 (PIN 1)
WHT/GRN
RED
F16 F17
F25
TO SE10 X574 (PIN 4)
X90
A27
8
D = X34 E = X35 F = X36
RED/YEL
F26
D16
RED/YEL
F8
WHT
F7
A = X31 B = X32 C = X33
A26
4
2
BLK
A13
6
2
GRY
A12
2
2
WHT/YEL
WHT/VLT
A10
5
WHT/YEL
1
WHT/YEL
A11
1
X48
Y41 SECONDARY RELIEF SOLENOID VALVE
RED
A14
2
2
Y39 ATTACHMENT RELIEF SOLENOID 2
WHT
A15
2
2
Y38 ATTACHMENT RELIEF SOLENOID
Y43 2-SPEED ACTIVATION SOLENOID VALVE
WHT/BLU
A18
4
1
2
Y40 SELECTOR VALVE SOLENOID VALVE
Y44 FLOW RATE ADJUSTMENT SOLENOID VALVE
1
BLK/GRN
LT GRN/WHT
A19
2
1
1
GRN/BLU
YEL
A17
3
Y30 PUMP 3 FLOW RATE LIMIT SOLENOID (MARKED SX)
1
GRN/RED
GRN
A16
1
2
Y26 PUMP 1 FLOW RATE LIMIT SOLENOID (MARKED SA)
Y29 ARM 1 FLOW CONTROL SOLENOID (MARKED SE)
VLT/YEL
WHT
A5
2
Y27 ARM 2 FLOW CONTROL SOLENOID (MARKED SD)
BLU
BLK/WHT
A4
1
LT GRN/RED
ORG/RED
A6
1
RED GRN WHT RED/BLK
LT GRN
RED/YEL
2
A7
FROM SE3 F4
S12 POWER MODE BUTTON
2
A2
F9
X29
2
A3
A3 MAIN CONTROLLER (MCZ) F1 F2 F3
X40
2
WHT/GRN
7
2
RED/GRN
3
1
RED/BLK
5
1
1
GRN/RED
1
1
1
GRN/ORG
6
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
Y24 POWER DIG SOLENOID (MARKED SI)
BLU/RED
2
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
BLU/BLK
YEL
2 ORG
2 BLU
2 GRY
1
PNK
1
Y12 EXHAUST FILTER REGULATOR SOLENOID (PUMP 1) (MARKED SZ)
GRN/WHT
E5 E6
1
Y13 EXHAUST FILTER REGULATOR SOLENOID (BYPASS CUT-OFF VALVE) (MARKED SJ)
BRN/WHT
BLU
TO SE20 A5 (PIN C1,C2)
Y28 PUMP 3 TORQUE CONTROL SOLENOID (MARKED SU)
BRN
TO SE19 A11 (PIN A4)
Y20 PUMP 2 FLOW RATE LIMIT SOLENOID (MARKED SB)
BRN/BLU
Y21 TORQUE CONTROL SOLENOID (MARKED ST)
F10 5A FUSE
RED GRN WHT RED/BLK
BLK/YEL
RED GRN WHT RED/BLK
1
BLK/YEL
3
SE9 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-5/20
System Diagrams
TM12660 (18APR18)
9015-10-22
041818
PN=332
System Diagrams
A3—Main Controller (MCZ) R15— Engine Speed Dial B30— Boom Up Pressure Sensor S8— Auto-Idle Switch B31— Arm In Pressure Sensor S11— Travel Speed Switch B32— Front Attachment Pressure S12— Power Mode Button Sensor X3— Cab Harness-to-Machine B33— Swing Pressure Sensor Harness 100-Pin Connector B34— Travel Pressure Sensor X29— Cab Harness-to-Switch B35— Pump 1 Delivery Pressure Panel Connector 3 Sensor X31— Cab Harness-to-Main B36— Pump 1 Control Pressure Controller 31-Pin Sensor Connector A B37— Pump 2 Delivery Pressure X32— Cab Harness-to-Main Sensor Controller 24-Pin B38— Pump 2 Control Pressure Connector B Sensor X33— Cab Harness-to-Main B39— Bucket In Pressure Sensor Controller 17-Pin B56— Pump 3 Delivery Pressure Connector C Sensor X34— Cab Harness-to-Main B57— Pump 3 Control Pressure Controller 30-Pin Sensor Connector D B60— Attachment Pressure X35— Cab Harness-to-Main Sensor Controller 24-Pin B61— Arm Out Pressure Sensor Connector E B62— Attachment Pressure X36— Cab Harness-to-Main Sensor 2 Controller 26-Pin F10— Data Converter and Connector F Main Controller Battery X40— Pump Harness-to-Machine Power 5 A Fuse (marked Harness Connector CONTROLLER)
X46— Attachment Connector Y27— Arm 2 Flow Control X48— Attachment Connector 2 Solenoid (marked SD) X90— Not Used Y28— Pump 3 Torque Control X91— Not Used Solenoid (marked SU) X97— Pump Harness Splice Y29— Arm 1 Flow Control Connector Solenoid (marked SE) X98— Machine Harness Splice Y30— Pump 3 Flow Rate Limit Connector Solenoid (marked SX) Y12— Exhaust Filter Regulator Y38— Attachment Relief Solenoid (pump 1) (marked Solenoid SZ) Y39— Attachment Relief Y13— Exhaust Filter Regulator Solenoid 2 Solenoid (bypass cut-off Y40— Selector Valve Solenoid valve) (marked SJ) Valve Y20— Pump 2 Flow Rate Limit Y41— Secondary Relief Solenoid Solenoid (marked SB) Valve Y21— Torque Control Solenoid Y43— 2-Speed Activation (marked ST) Solenoid Valve Y22— Dig Regenerative Solenoid Y44— Flow Rate Adjustment (marked SF) Solenoid Valve Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig Solenoid (marked SI) Y26— Pump 1 Flow Rate Limit Solenoid (marked SA)
Continued on next page
TM12660 (18APR18)
9015-10-23
CW08338,0000D06 -19-15SEP16-6/20
041818
PN=333
System Diagrams
TM12660 (18APR18)
9015-10-24
041818
PN=334
System Diagrams
TX1209275 —UN—31MAR16
RED GRN
5
4
TO SE15 A2 (PIN 13)
R13 ENGINE CONTROL UNIT (ECU) RESISTOR
21
41
58
6
26
9
54
2 TO SE15 X71 (PIN 3,7)
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
1
X6020 CAN 0 CONNECTOR (MARKED CAN)
B44 MASS AIR FLOW (MAF)/ INTAKE AIR TEMPERATURE (IAT) SENSOR
B1 CRANKSHAFT POSITION SENSOR
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE11 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1209275
System Functional Schematic (SE10—SE12) (4 of 10) Continued on next page
041818
PN=335
B12 FUEL RAIL PRESSURE SENSOR
P B15 TURBOCHARGER BOOST PRESSURE SENSOR
133
14
YEL/BLU BLU/YEL BLU/RED
1 4 3 2 5
X7
49
50
124
1
13
12
8 7 6 BLK WHT
T
U V W U V W
B47 EXHAUST GAS RECIRCULATION (EGR) VALVE SENSOR
M3 EXHAUST GAS RECIRCULATION (EGR) VALVE ACTUATOR
130
145
FROM SE4 A4 (PIN B16)
147
FROM SE4 A4 (PIN B9)
FROM SE4 A4 (PIN B12)
X5
B5 FUEL TEMPERATURE SENSOR
GRN/YEL
BLU
5
WHT GRN/BLK BLK
31
WHT YEL/RED GRN/WHT VLT BLK
24 19
BLU/BLK
WHT
29
P P
TO SE21
17 10 14
BLU/BLK BLK
5
WHT
1 6 15 11
BLK RED GRY
2
BLU
YEL/WHT
35
YEL/BLU BLU/YEL BLU/RED
RED BLK/BLU 3
139
20
WHT YEL/RED GRN/WHT VLT BLK
WHT 1
WHT
BLK 5
WHT RED BLK GRY
RED/BLU 4
111 89
53 52
BLU
YEL/WHT
90
BLU
GRY
BLK
GRN
RED
67
GRN/RED
113
13
11
114
BLK/GRN
117
28
136
WHT/YEL
137
57
85
115
WHT/RED
82
86
PNK
97
81
68
YEL
65
119
121
BLU/BLK
63
66
152 A1 ENGINE CONTROL UNIT (ECU)
GRN/BLK
134
WHT
= X14 CONNECTOR
WHT RED BLK GRY
Y32 BOOM 3 SPOOL CONTROL SOLENOID (MARKED A1)
2
BLU
A20
BLU
3
BLU
A19 A21
F8 30A FUSE
1
BLK
A16
K14 ECU POWER RELAY YEL/WHT
GRY/BLU
2
A8
GRY/RED
153
BLU/BLK BLK
61
64
T
FROM SE6 A4 (PIN 23,24) (CAN 0)
9015-10-25
X3
WHT
62
BLU (CAN 0 LOW) GRN (CAN 0 HIGH)
1 BLU (CAN 0 LOW)
1
GRN (CAN 0 HIGH)
2
R4
X6
SE10
TM12660 (18APR18)
R3
BLK RED GRY
132
D3
BLK/WHT
2
FROM SE6 A4 (PIN 25,26) (CAN 1)
100
BLK GRN
X49
BLU (CAN 0 LOW)
BLU (CAN 1 LOW)
2 BLK/YEL
GRN (CAN 1 HIGH)
T
R2
GRN
BLK BLK BLK BLK BLK BLK BLK BLK BLK
2
Y31 ARM 3 SPOOL CONTROL SOLENOID (MARKED A2)
R1
BRN/YEL
122
BLU GRN
1
D2
BLU
BLU/BLK
4
E1 E2 F4 F5 F6
1
B40 HYDRAULIC OIL TEMPERATURE SENSOR
2
YEL/BLU
E4 F10
RED/BLK
ORG/BLK
WHT/BLK
BLK
FROM SE4 F17
BLK
B4
BLK
B5
GRN (CAN 0 HIGH)
FROM SE4 A4 (PIN D6)
1
B7
RED/BLU
3
RED
4
BLK/WHT
F11
154
RED/YEL
YEL/GRN
B6
1
GLOW PLUG
= X15 CONNECTOR
BLK/RED
YEL/WHT
FROM SE1 K11
D5
GRN/RED
GRN/BLK
FROM SE3 V9
D4
GRN/YEL
ORG/BLK
3
K16 GLOW PLUG RELAY
1
RED/BLU
RED/BLK
5
FROM SE2 K4 (PIN 4)
X92
ORG/BLU
1
ORG/GRN
FROM SE1 S6 (PIN 1) GRY/RED
GRN/BLK
RED/BLK
F11
9
FROM SE1 S6 (PIN 4)
RED GRN WHT RED/BLK
BLK/YEL
D = X34 E = X35 F = X36
RED/BLK
C5
BLU (CAN 1 LOW)
A1
GRN (CAN 1 HIGH)
F13
YEL/GRN
LT BLU
C1
3
B63 ATTACHMENT PRESSURE SENSOR 3
X544
2
8
RED/BLK
B6 ENGINE OIL LEVEL SENSOR
129 A = X31 B = X32 C = X33
BLK/YEL RED/YEL
2
1
S7 POWER DIG SWITCH
C2 C16 F22 C6 C7 A22 A23 A25 A24 B2
A3 MAIN CONTROLLER (MCZ)
TO SE28
RED GRN WHT RED/BLK
FROM SE3 F16
S16 EXHAUST FILTER PARKED CLEANING SWITCH
WITH AFL
0 1
TO SE7 X3 (PIN D8) C10
P
WITHOUT AFL
TO SE7 X3 (PIN D2)
WHT/YEL
D26
4
BLK
H4 TRAVEL ALARM
TO SE17 X26 (PIN 1)
WHT/YEL
11
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR
RED/YEL
BLU/YEL
8
BLK/YEL
3
ORG/BLK
7
10
YEL/BLU
2
BLU/WHT
GRY
6
WHT/BLU
5
BLK/BLU
RED/BLU
GRN/BLU
9
12
GRN/BLK
WHT/YEL
S13 TRAVEL ALARM CANCEL SWITCH
3 4 2 1 WHT/RED
GRN/BLK BLK
BLK
F5 5A FUSE
1
BLK/GRN
WHT
TO SE30 0 1
RED GRN WHT RED/BLK
VLT/GRN
RED GRN WHT RED/BLK
ORG/GRN
RED GRN WHT RED/BLK
FROM SE4 A4 (PIN D5)
M8 INTAKE AIR THROTTLE
B14 INTAKE AIR THROTTLE VALVE POSITION SENSOR
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE12 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-7/20
System Diagrams
TM12660 (18APR18)
9015-10-26
041818
PN=336
System Diagrams
A1—Engine Control Unit (ECU) F8— Engine Control Unit (ECU) A3—Main Controller (MCZ) 30 A Fuse (marked ECU) B1—Crankshaft Position Sensor H4—Travel Alarm B5—Fuel Temperature Sensor K14— ECU Power Relay B6—Engine Oil Level Sensor K16— Glow Plug Relay B12— Fuel Rail Pressure Sensor M3—Exhaust Gas Recirculation B14— Intake Air Throttle Valve (EGR) Valve Actuator Position Sensor M8—Intake Air Throttle B15— Turbocharger Boost R1—Glow Plug 1 Pressure Sensor R2—Glow Plug 2 B40— Hydraulic Oil Temperature R3—Glow Plug 3 Sensor R4—Glow Plug 4 B44— Mass Air Flow (MAF)/Intake R13— Engine Control Unit (ECU) Air Temperature (IAT) Resistor Sensor S7— Power Dig Switch B47— Exhaust Gas Recirculation S13— Travel Alarm Cancel (EGR) Valve Sensor Switch B63— Attachment Pressure S16— Exhaust Filter Parked Sensor 3 Cleaning Switch F5— Travel Alarm 5 A Fuse X3— Cab Harness-to-Machine (marked OPT. 1 ALT) Harness 100-Pin Connector X5— Machine Harness-to-Engine Harness 32-Pin Connector
X6— Machine Harness-to-Engine Harness 16-Pin Connector X7— Machine Harness-to-Engine Harness 14-Pin Connector X14— Engine Control Unit (ECU)-to-Machine Harness 60-Pin Connector X15— Engine Control Unit (ECU)-to-Machine Harness 94-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 X34— Cab Harness-to-Main Controller 30-Pin Connector D X35— Cab Harness-to-Main Controller 24-Pin Connector E
Continued on next page
TM12660 (18APR18)
9015-10-27
X36— Cab Harness-to-Main Controller 26-Pin Connector F X49— Cab Harness-to-Spool Control Harness Connector X92— Not Used X544— Auxiliary Function Lever (AFL) Power Dig Switch Connector X574— Auxiliary Function Lever (AFL) Connector X6020—CAN 0 Connector (marked CAN) Y31— Arm 3 Spool Control Solenoid (marked A2) Y32— Boom 3 Spool Control Solenoid (marked A1)
CW08338,0000D06 -19-15SEP16-8/20
041818
PN=337
System Diagrams
TM12660 (18APR18)
9015-10-28
041818
PN=338
System Diagrams
TX1213113 —UN—28MAR16
X40
8 PNK/BLU BRN/BLU BLK
12 30
WHT
110
GRN GRN
Y16 TURBOCHARGER ACTUATOR
X101
X9 MACHINE HARNESSTO-ENGINE HARNESS 20-PIN CONNECTOR
FROM SE10 (CAN 0)
BLU (CAN 0 LOW) GRN (CAN 0 HIGH)
Y14 SUCTION CONTROL VALVE X71
6
1
2
5
LT GRN/RED
8
4
7
3
2
GRN (INTERFACE CAN HIGH)
1
Y1 ELECTRONIC INJECTOR 1
Y4 ELECTRONIC INJECTOR 3
Y3 ELECTRONIC INJECTOR 2
D
C
Y2 ELECTRONIC INJECTOR 4
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE13
SE14 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1213113
System Functional Schematic (SE13—SE15) (5 of 10) Continued on next page
TM12660 (18APR18)
9015-10-29
041818
PN=339
B
J
H
X72
X1 SERVICE ADVISOR DIAGNOSTIC CONNECTOR
15 16
BLU
13
BLK
14
TO SE21 (INTERFACE CAN)
A HI
A
GRN BLU
FROM SE18 F20
BLU (INTERFACE CAN LOW)
3
FROM SE12 K14 (PIN 5)
BLU
17
GRN (ENGINE CAN HIGH) BLU (ENGINE CAN LOW)
GRN
6
69 135
LT GRN/RED
2
87
= X14 CONNECTOR
GRN
3
83
BLU
7
88
GRN
8
142
BLU
4
80
BLK
1
141
PNK
5
13
BLK/RED
2
79
= X15 CONNECTOR 72
BLK
6
112 84
45
BLU
7
RED
3
YEL
4
RED
8
BLK
5
GRN
BLU/RED
12
BLK/RED
16
WHT/BLU
1
BLK
5
1
WHT
15
BRN/GRN BRN/GRN
33
BLK/WHT
BLU
BLK/YEL
BLU
YEL
17
RED
3
48
WHT/BLK
7
16
BLU
4
46
RED/BLU
2
BLK/WHT
8
31
RED
YEL
1
60
A1 ENGINE CONTROL UNIT (ECU)
GRN/WHT
RED 70
BLU
BLK 55
ORG
WHT 8
BLK
YEL/BLK 25
WHT
BLK 40
YEL
43
23
BLU/YEL
56
PNK
YEL/GRN 10
42
WHT
WHT RED BLK GRY
BLK
22
P PNK/BLU
4 12
GRN
T
B45 BAROMETRIC PRESSURE SENSOR
BRN/BLU
7
T
B13 P FUEL FILTER RESTRICTION SENSOR
GRN/BLK
2
2
3
B50 EXHAUST TEMPERATURE SENSOR 2 (DOC)
BLK
3
B48 P EXHAUST DIFFERENTIAL PRESSURE SENSOR
B49 EXHAUST TEMPERATURE SENSOR 1 (DPF)
BLK
T
B3 MANIFOLD AIR TEMPERATURE SENSOR
BLK
20
1
WHT
25 30
B4 T ENGINE COOLANT TEMPERATURE SENSOR
YEL/BLK
BLK
13
WHT
4
B11 ENGINE OIL PRESSURE SENSOR
PNK
20 19 18 14
P
BLK
X9
T
B7 TURBOCHARGER BOOST TEMPERATURE SENSOR X5
YEL/GRN
WHT RED BLK GRY
B2 CAMSHAFT POSITION SENSOR
RED GRN WHT RED/BLK
WHT
RED GRN WHT RED/BLK
BLK
RED GRN WHT RED/BLK
+
B LO
120
-
R8 ENGINE CAN TERMINATION RESISTOR
10 11 12 5 1 2 3 8 4
LT BLU WHT BRN GRY RED WHT BLK RED/YEL BLK/YEL
A2 VARIABLE GEOMETRY TURBOCHARGER (VGT)
3 2 1 7 6 5 4 10 9
3 2 1 7 6 5 4 10 9
X7 MACHINE HARNESSTO-ENGINE HARNESS 14-PIN CONNECTOR
B51 TURBOCHARGER POSITION SENSOR
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE15 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-9/20
System Diagrams
TM12660 (18APR18)
9015-10-30
041818
PN=340
System Diagrams B49— Exhaust Temperature A1—Engine Control Unit (ECU) Sensor 1 (DPF) A2—Variable Geometry B50— Exhaust Temperature Turbocharger (VGT) Sensor 2 (DOC) B2—Camshaft Position Sensor B51— Turbocharger Position B3—Manifold Air Temperature Sensor Sensor B4—Engine Coolant Temperature R8—Engine CAN Termination Resistor Sensor X1— Service ADVISOR™ B7—Turbocharger Boost Diagnostic Connector Temperature Sensor X5— Machine Harness-to-Engine B11— Engine Oil Pressure Harness 32-Pin Connector Sensor X7— Machine Harness-to-Engine B13— Fuel Filter Restriction Harness 14-Pin Connector Sensor B45— Barometric Pressure Sensor B48— Exhaust Differential Pressure Sensor
X9— Machine Harness-to-Engine Harness 20-Pin Connector X14— Engine Control Unit (ECU)-to-Machine Harness 60-Pin Connector X15— Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector X40— Pump Harness-to-Machine Harness Connector X71— Machine Harness-toService ADVISOR™ Harness 8-Pin Connector X72— Machine Harness-toService ADVISOR™ Harness 3-Pin Connector
X101— Fuel Injector Harness Connector 1 Y1— Electronic Injector 1 Y2— Electronic Injector 2 Y3— Electronic Injector 3 Y4— Electronic Injector 4 Y14— Suction Control Valve Y16— Turbocharger Actuator
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-10-31
CW08338,0000D06 -19-15SEP16-10/20
041818
PN=341
System Diagrams
TM12660 (18APR18)
9015-10-32
041818
PN=342
System Diagrams
TX1209276 —UN—02MAR16
RED GRN WHT RED/BLK
WHT/BLK
BLU/RED
4 5 1 2
X26 OPTIONAL CONNECTOR
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE16
SE17 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1209276
System Functional Schematic (SE16—SE18) (6 of 10) Continued on next page
041818
PN=343
BLU/YEL
YEL/RED
BLK
GRN
B25 RIGHT SPEAKER
8 ACCESSORY RED/BLU
16
(B+) (+)
1 2 6 4 5
WHT BLK GRY YEL/BLU BLK
14 6 5 7
BLK
BLK
TO SE6 X13 (PIN B11)
X77 RADIO AUXILIARY CONNECTOR
(+) (-)
4
12
BLU
X25 CAB HARNESS AUXILIARY POWER CONNECTOR 1
FROM SE4 F9
(-)
GRN
GRN
A6 RADIO
BLK
E1 WORK LIGHT
X44 OPTIONAL LIGHT CONNECTOR
GRN
RED
WHT/YEL
E2 BOOM LIGHT
W60 RADIO ANTENNA
15
BLK
TO SE6 X29 (PIN 16)
LT GRN/RED
LB
RED/BLU
GRN BLK
RED/BLU
C8
X3
TO SE20 X27 (PIN 8)
9015-10-33
LT GRN/RED
TO SE6 X13 (PIN B10)
C7
X3
YEL/RED
V6 AUXILIARY POWER CONNECTOR DIODE
WHT/YEL
RED/BLU WHT/YEL RED
FROM SE19 A11 (X10 PIN A5)
TO SE6 X13 (PIN B9)
FROM SE10 F5
F12 5A FUSE
F15 10A FUSE
2
BLK
M6 WINDSHIELD WASHER MOTOR
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
TM12660 (18APR18)
LT GRN/RED
GRN
GRN
4
FROM SE19 A11 (PIN A2)
BLU/RED
VLT
BLK/BLU
5
TO SE1 S1 (PINS 5 AND 1)
F13 10A FUSE
GRN
RED WHT
2
K8 BOOM LIGHT RELAY
BLK
E
3
BLU/RED
BLK
BLK
4
FROM SE19 A11 (PIN A6)
L
BLU
5
1
BLU/RED
4
VLT
5
2
K7 WORK LIGHT RELAY
RED/BLU
2
BLK WHT
BLU RED
K9 WINDSHIELD WASHER RELAY
3
3
BLU/RED
1
M5 WINDSHIELD WIPER MOTOR
L
GRN
1
S28 WINDOW SWITCH
RED
F20 5A FUSE
3
B11
B
FROM SE1 K12
R9 1 LIGHTER CONNECTOR
RED/BLU
4
X3
F62 WIPER MOTOR ASSEMBLY CIRCUIT BREAKER
F6 20A FUSE
RED/BLK
1 2
FROM SE19 A11 (X11 PIN B9)
S
WHT
YEL/BLU BLK/RED BLK
X39 CAB HARNESSTO-WINDOW SWITCH CONNECTOR
BLK
GRY/RED
BLK/PNK
RED/BLK
4
YEL
5
K6 WINDSHIELD WIPER RELAY
F1 20A FUSE
BLK/RED
2
3
RED/BLK
1
WHT RED/BLK
F2 10A FUSE
BLK/YEL
BLK/YEL
BLK/RED
BLK/YEL
RED
YEL/BLU
RED GRN WHT RED/BLK
2 10
ORG BRN
2 4
GRN/RED WHT
1 9
GRY/BLK WHT/BLK
1 3
GRY/BLK WHT/BLK
X73 CAB HARNESSTO-SPEAKERS CONNECTOR
B26 LEFT SPEAKER
3 6 TO SE26,SE28
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE18 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-11/20
System Diagrams
TM12660 (18APR18)
9015-10-34
041818
PN=344
System Diagrams A6—Radio B25— Right Speaker B26— Left Speaker E1— Work Light E2— Boom Light F1— Work and Boom Lights 20 A Fuse (marked LAMP) F2— Windshield Wiper and Washer 10 A Fuse (marked WIPER) F6— 12-Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) F12— Radio and Dome 5 A Fuse (marked RADIO)
F13— Lighter 10 A Fuse (marked K9—Windshield Washer Relay M5—Windshield Wiper Motor LIGHTER) M6—Windshield Washer Motor F15— Cab Auxiliary Power R9—Lighter Connector Connector 1 10 A Fuse S28— Window Switch (marked AUX) V6— Auxiliary Power Connector F20— Optional Equipment 5 A Diode Fuse (marked OPT. 3 BATT) W60—Radio Antenna F62— Wiper Motor Assembly X3— Cab Harness-to-Machine Circuit Breaker Harness 100-Pin Connector K6—Windshield Wiper Relay X25— Cab Harness Auxiliary K7—Work Light Relay Power Connector 1 K8—Boom Light Relay
Continued on next page
TM12660 (18APR18)
9015-10-35
X26— Optional Connector X39— Cab Harness-to-Window Switch Connector X44— Optional Light Connector X73— Cab Harness-to-Speakers Connector X77— Radio Auxiliary Connector
CW08338,0000D06 -19-15SEP16-12/20
041818
PN=345
System Diagrams
TM12660 (18APR18)
9015-10-36
041818
PN=346
System Diagrams
TX1173196 —UN—01OCT14
RED
RED
RED
RED
WHT RED/BLK
WHT RED/BLK
WHT RED/BLK
WHT RED/BLK
V13 WORK LIGHT 1 DIODE
A11 MACHINE CONTROLLER (BCZ)
YEL/GRN YEL/RED
RED/BLK
2
GRN/BLU
BLK/WHT
3
BLK/WHT
120
-
FROM SE17 K7 B18
BLU/RED
8
BLU
E10 SWITCH PANEL BACK LIGHT 5
BLU/YEL
C1
C2
BLU
S14 DOOR SWITCH
BLK
BLU
GRN
C11 C5
TO SE1 K19
TO SE1 G2
TO SE1 G1
F6000 7.5A FUSE
C12
GRN
C6
BLU
A6003 SATELLITE (SAT) ANTENNA A
BLU/YEL
R19 BLK
X6020 CAN 0 CONNECTOR (MARKED CAN) FROM SE10
F6002 7.5A FUSE
F6001 7.5A FUSE
C14 C15
HI
+
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE19
SE20 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1173196
System Functional Schematic (SE19—SE21) (7 of 10) Continued on next page
TM12660 (18APR18)
9015-10-37
041818
PN=347
G1
1357 LT GRN
G2
R12 BLK 2
M13 LT GRN
H2
1
M12 YEL
H1
P31 RED
B LO
120
A6002 SATELLITE (SAT) MODULE CONTROL UNIT (IF EQUIPPED)
L1
-
R10 INTERFACE CAN RESISTOR 1
X6016
M1
G1001
1
A23A ORG
A23 ORG
M1
M2
P1002
2
P01A RED
P01 RED
M2
J3
J1003
3
J03 TAN
M3
A2
M1004
4
M25 PUR
A1
A1
M1005
5
M24 PUR
A2
6 = X6015
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
1356 YEL
A23B ORG P01B RED
A5 DATA CONVERTER
BLK
B1 B11
C7
R11 INTERFACE CAN RESISTOR 2
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER (IF EQUIPPED)
1356 YEL
LO
1357 LT GRN
BLU B
+ + - -
X6021 INTERFACE CAN CONNECTOR (MARKED N-CAN)
FROM SE7 F10
B17 A8
4 1
B4
B7 GRN/WHT
GRN/BLK RED
B13
A = X10 B = X11
WHT/VLT GRN/WHT
B6 B3
BLU
YEL
A6
2
TO SE6 S10
A5
BLU
YEL
1
3
B9
A2
YEL
V14 WORK LIGHT 2 DIODE
A4
2 1 0
BLK
TO SE17 K7 (PIN 2)
B19
+
BLK
B10 A7 RED/BLK
RED/BLK
TO SE17 K8 (PIN 2)
A HI
S9 WINDSHIELD WIPER AND WASHER SWITCH TO SE5 E10
GRN
WHT/YEL
BLU (INTERFACE CAN LOW)
10
GRN (INTERFACE CAN HIGH) BLU (INTERFACE CAN LOW)
E9 KEY SWITCH LIGHT
GRN (INTERFACE CAN HIGH)
FROM SE7 F10
BLK/BLU
BLK
BLK
TO SE16 K9 (PIN 2)
GRY/RED
3
E3 CAB DOME LIGHT
ORG/BLU
TO SE16 K6 (PIN 2)
YEL/RED
1
RED/BLU
ORG/BLU
2
BLU
ORG/BLU
BLK/RED
BLK
DOOR OFF ON
9
GRN
S2 CAB DOME LIGHT SWITCH
RED/BLU
YEL/RED
RED/BLU
RED/BLK
YEL/RED RED/BLU
A6001 GPS/CELLULAR ANTENNA
FROM SE14 X72 (PIN 1,3) (INTERFACE CAN)
X27 CAB HARNESSTO-SWITCH PANEL CONNECTOR 1
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
X6007 JDLINK HARNESS GROUND 1
BLK
= X6014
F3
SE21 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-13/20
System Diagrams
TM12660 (18APR18)
9015-10-38
041818
PN=348
System Diagrams
A5—Data Converter A11— Machine Controller (BCZ) A6000—Modular Telematics Gateway (MTG) Controller (if equipped) A6001—GPS/Cellular Antenna A6002—Satellite (SAT) Module Control Unit A6003—Satellite (SAT) Antenna E3— Cab Dome Light E9— Key Switch Light E10— Switch Panel Back Light 5
F6000—JDLink™ Unswitched Power 7.5 A Fuse (if equipped) F6001—JDLink™ Ground 7.5 A Fuse (if equipped) F6002—JDLink™ Switched Power 7.5 A Fuse (if equipped) R10— Interface CAN Resistor 1 R11— Interface CAN Resistor 2 S2— Cab Dome Light Switch
S9— Windshield Wiper and Washer Switch S14— Door Switch V13— Work Light 1 Diode V14— Work Light 2 Diode X10— Machine Controller 8-Pin Connector A X11— Machine Controller 20-Pin Connector B X27— Cab Harness-to-Switch Panel Connector 1 X6007—JDLink™ Harness Ground 1 X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015—Satellite (SAT) Module Control Unit 48-Pin Connector X6016—JDLink™ Harness-toSatellite (SAT) Harness X6020—CAN 0 Connector (marked CAN) X6021—Interface CAN Connector (marked N-CAN)
JDLink is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-10-39
CW08338,0000D06 -19-15SEP16-14/20
041818
PN=349
System Diagrams
TM12660 (18APR18)
9015-10-40
041818
PN=350
System Diagrams
TX1209277 —UN—15MAR16
RED
4
3 1
1
5
LT GRN
2
3
4
2
4
4
0 1
BLK
BLK
PNK/WHT
RED/GRN
GRN/WHT
1
2
M7 AIR CONDITIONER AND HEATER BLOWER MOTOR
1 2 BLK
BLK
B23 HIGH NOTE HORN
2
8
BRN/BLK
9
BLK
26
1
GRN/WHT LT GRN
30 29
GRN/BLK
21
B20 AIR CONDITIONER HIGH/LOW-PRESSURE SWITCH
16
ORG
7
15
PNK/WHT
6
M11 AIR CONDITIONER AND HEATER MIXER SERVO MOTOR
WHT/BLK
5 1
31
YEL/RED
7
32
GRN/RED
6
25
BRN/RED
3
20 7
GRN/BLK RED/BLK
5 1
M10 AIR CONDITIONER AND HEATER BLOWER PORT CHANGE SERVO MOTOR
BRN/RED 1
B21 SOLAR SENSOR
T 2
B24 LOW NOTE HORN
VLT/RED
11
VLT/WHT
10
6 3 4 5
WHT/YEL PNK/BLK RED/YEL ORG/BLK
2
BLK
T 10
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
9
X52 AIR CONDITIONER 10-PIN CONNECTOR
SE23 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1209277
System Functional Schematic (SE22—SE24) (8 of 10) Continued on next page
9015-10-41
1
2
B41 AIR CONDITIONER FREEZE CONTROL SWITCH
T 1
2
B22 AMBIENT AIR TEMPERATURE SENSOR
BRN/RED
BRN/RED
T 1
B55 AIR RECIRCULATION SENSOR BRN/RED
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
SE22
TM12660 (18APR18)
3 1
RED/GRN
PNK/WHT
TO SE28
BLK/RED WHT/RED
19 BLU/BLK
BLK
5
BLK/BLU
2
LT GRN
WHT/VLT
WHT/VLT
1
A7 AIR CONDITIONER CONTROLLER (ACF)
14 13
3
K15 AIR CONDITIONER COMPRESSOR OFF RELAY
WITH AFL
X543
17
3
WHT/GRN
RED/BLU
RED/GRN
BLK RED/BLU
PNK/WHT
WHT/VLT
5
K10 HORN RELAY
YEL
3
WITHOUT AFL
BLK
K17 AIR CONDITIONER AND HEATER BLOWER MOTOR RELAY
WHT
WHT
WHT
V8 AIR CONDITIONER CLUTCH DIODE
7
R16 BLOWER MOTOR RESISTOR AND THERMOFUSE
RED/BLU
F3 20A FUSE
WHT
1
S5 HORN SWITCH
RED/BLU
M9 AIR CONDITIONER AND HEATER INTERNAL AND EXTERNAL SERVO MOTOR
RED/BLK BRN/RED
WHT
WHT
Y11 AIR CONDITIONER COMPRESSOR CLUTCH
WHT
RED/BLU RED/BLU
F19 10A FUSE
2
WHT
RED/BLK
WHT
RED
WHT RED/BLK
041818
PN=351
SE24 CONTINUE NEXT PAGE
CW08338,0000D06 -19-15SEP16-15/20
System Diagrams
TM12660 (18APR18)
9015-10-42
041818
PN=352
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 Clutch Diode 20 A Fuse (marked HEATER) Internal and External Servo X52— Air Conditioner 10-Pin F19— Horn 10 A Fuse (marked Motor Connector HORN) M10— Air Conditioner and Heater X543— Auxiliary Function Lever K10— Horn Relay Blower Port Change Servo (AFL) Horn Switch K15— Air Conditioner Motor Connector Compressor Off Relay M11— Air Conditioner and Heater Y11— Air Conditioner K17— Air Conditioner and Heater Mixer Servo Motor Compressor Clutch Blower Motor Relay R16— Blower Motor Resistor and M7—Air Conditioner and Heater Thermofuse Blower Motor S5— Horn Switch Continued on next page
TM12660 (18APR18)
9015-10-43
CW08338,0000D06 -19-15SEP16-16/20
041818
PN=353
System Diagrams
TM12660 (18APR18)
9015-10-44
041818
PN=354
System Diagrams
TX1209278 —UN—15MAR16
0 1
X62 CAB AUXILIARY POWER CONNECTOR 2 (MARKED AUX_2)
M12 SEAT AIR COMPRESSOR MOTOR
X55 FRONT CAB LIGHT 1 (MARKED CAB LAMP FRONT)
3
BLU
2 2
T
A8 12-VOLT POWER CONVERTER BLK
2
2
1 2
4
ORG
G5 12-VOLT POWER OUTLET
R18 SEAT HEATER (MARKED SEAT HEATER) BLK
SE25
T 1 RED/BLK
SE26 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1209278
System Functional Schematic (SE25—SE27) (9 of 10) Continued on next page
TM12660 (18APR18)
9015-10-45
041818
PN=355
RED
BLU
RED 3
5
4
RED/BLU
K33 LEFT SOLENOID RELAY A
1
B80 SEAT TEMPERATURE SWITCH 1 B81 SEAT TEMPERATURE SWITCH 2
X535 LEFT AUXILIARY SOLENOID CONNECTOR (MARKED SL/H)
RED/BLU 1
RED/BLU
2
3
BLK
GRN
GRN
V33 LEFT SOLENOID DIODE A
A
V32 LEFT SOLENOID DIODE B B
Y35 LEFT SOLENOID (MARKED SL/H)
5
4
K31 RIGHT SOLENOID RELAY A
1
2
3
RED/BLU
X534 RIGHT AUXILIARY SOLENOID CONNECTOR (MARKED SR/H)
BLK
BLK
3
2
RED/YEL
RED/BLK 1
BLK
BLK
1
1
1
1 RED
YEL
2
RED/BLU
GRN YEL/RED
GRN
2
4
RED/BLU
3
5
BLK
2
2
RED/YEL
RED/WHT
RED/BLK
RED/GRN 1
BLK
4
3
BLK GRN
X56 FRONT CAB LIGHT 2 CONNECTOR (MARKED CAB LAMP FRONT+2)
BLK
1
5
K20 SEAT HEATER RELAY
2
S33 LEFT PILOT 1 CONTROL LEVER SWITCH A (MARKED C)
1
K30 RIGHT SOLENOID RELAY B
GRN
X61 X60 QUICK HITCH CONNECTOR 12-VOLT POWER (MARKED QUICK HITCH) SUPPLY CONNECTOR (MARKED 12V UNIT)
2
2
3
1
BLK
3
1
4
GRN
2
1 0
1
2
BLK
1
X58 WARNING LIGHT CONNECTOR (MARKED WARNING LAMP)
S62 SEAT HEATER SWITCH
5
GRN
1
2
X63 CAB AUXILIARY POWER CONNECTOR 3 (MARKED AUX_3)
2
RED/BLK
S61 SEAT COMPRESSOR SWITCH
K32 LEFT SOLENOID RELAY B
3
BLK
2
BLK
RED
1
1
BLK
BLK
X57 REAR CAB LIGHT CONNECTOR (MARKED CAB LAMP REAR)
2
BLK/RED
1
X59 SATELLITE COMMUNICATION CONNETOR (MARKED IMOBI)
BLK
2
BLK
BLK
BLK
BLK 1
1
BLK
BLK
BLK/RED
1
2
YEL
IF EQUIPPED
2
BLK
RED 1
RED/GRN
X44 OPTIONAL LIGHT CONNECTOR
BLK
BLK/RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
M
BLU
2
S30 RIGHT PILOT CONTROL LEVER SWITCH B (MARKED B)
RED
3
S31 RIGHT PILOT CONTROL LEVER SWITCH A (MARKED C)
BLK
WHT
1
X26
BLU/YEL 2
YEL/RED
2
X54 AUXILIARY FUSE BOX HARNESS-TO-HEATED AIR SEAT HARNESS 3-PIN CONNECTOR (MARKED SEAT HEATER)
RED/BLU
WITHOUT AFL
BLU/YEL
BLU/YEL
S32 LEFT PILOT CONTROL LEVER SWITCH B (MARKED B)
RED
F22 10A FUSE
BLU/YEL
BLU/YEL
S34 RIGHT ENABLE SWITCH BLU/YEL
BLU
BLK
F34 10A FUSE
1 2 3 4 5 6
0 1
BLU/YEL
BLU
RED/BLU
WHT
WHT
F33 10A FUSE
RED/BLK
F32 10A FUSE
RED
F27 5A FUSE
WHT
WHT
WHT
F26 5A FUSE
F21 10A FUSE RED
F25 5A FUSE
F31 10A FUSE
RED/BLU
F24 10A FUSE
WHT
WHT
WHT
WHT
F23 10A FUSE
FROM SE17 K8 (PIN 5)
FROM SE17 X26
S35 LEFT ENABLE SWITCH
LT GRN/YEL
WHT WHT
WHT
BLK
BLK
GRN
GRN
V31 RIGHT SOLENOID DIODE A
A
V30 RIGHT SOLENOID DIODE B B
Y34 RIGHT SOLENOID (MARKED SR/H)
SE27
CW08338,0000D06 -19-15SEP16-17/20
System Diagrams
TM12660 (18APR18)
9015-10-46
041818
PN=356
System Diagrams F33— Warning Lamp 10 A Fuse A8—12-Volt Power Converter (marked WARNING LAMP) B80— Seat Temperature Switch 1 F34— Cab Auxiliary Power (if equipped) Connector 2 10 A Fuse B81— Seat Temperature Switch 2 (marked AUX. 2) (if equipped) F21— Heated Air Seat 10 A Fuse G5—12-Volt Power Outlet K20— Seat Heater Relay (if (marked SEAT HEATER) equipped) F22— Front Cab Light 1 10 A Fuse (marked CAB LAMP K30— Right Solenoid Relay B K31— Right Solenoid Relay A FRONT) F23— Rear Cab Light 10 A Fuse K32— Left Solenoid Relay B (marked CAB LAMP REAR) K33— Left Solenoid Relay A M12— Seat Air Compressor F24— 12-Volt Power Unit 10 A Motor (if equipped) Fuse (marked 12V UNIT) R18— Seat Heater (marked SEAT F25— IMOBI 5 A Fuse (marked HEATER) (if equipped) IMOBI) S30— Right Pilot Control Lever F26— Quick Hitch 5 A Fuse Switch B (marked B) (marked QUICK HITCH) S31— Right Pilot Control Lever F27— Cab Auxiliary Power Switch A (marked C) Connector 3 5 A Fuse S32— Left Pilot Control Lever (marked AUX. 3) Switch B (marked B) F31— Seat Compressor 10 S33— Left Pilot Control Lever A Fuse (marked SEAT Switch A (marked C) COMPR) F32— Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
S34— Right Enable Switch X58— Warning Light Connector S35— Left Enable Switch (marked WARNING LAMP) S61— Seat Compressor Switch X59— Satellite Communication (if equipped) Connector (marked IMOBI) S62— Seat Heater Switch (if X60— 12-Volt Power Supply equipped) Connector (marked 12V V30— Right Solenoid Diode B UNIT) V31— Right Solenoid Diode A X61— Quick Hitch Connector V32— Left Solenoid Diode B (marked QUICK HITCH) V33— Left Solenoid Diode A X62— Cab Auxiliary Power X26— Optional Connector Connector 2 (marked X44— Optional Light Connector AUX_2) X54— Auxiliary Fuse Box X63— Cab Auxiliary Power Harness-to-Heated Air Connector 3 (marked Seat Harness 3-Pin AUX_3) Connector (marked SEAT X534— Right Auxiliary Solenoid HEATER) Connector (marked SR/H) X55— Front Cab Light 1 X535— Left Auxiliary Solenoid Connector (marked CAB Connector (marked SL/H) LAMP FRONT) Y34— Right Solenoid (marked X56— Front Cab Light 2 SR/H) Connector (marked CAB Y35— Left Solenoid (marked LAMP FRONT+2) SL/H) X57— Rear Cab Light Connector (marked CAB LAMP REAR)
Continued on next page
TM12660 (18APR18)
9015-10-47
CW08338,0000D06 -19-15SEP16-18/20
041818
PN=357
System Diagrams
TM12660 (18APR18)
9015-10-48
041818
PN=358
System Diagrams
TX1209279 —UN—15MAR16
FROM SE17 X26
WITH AFL
2
TO SE22 X543
1
5
X543 AUXILIARY FUNCTION LEVER (AFL) HORN SWITCH CONNECTOR
6
2
5
GRN BLK/YEL RED/YEL WHT RED/YEL
X538 AUXILIARY FUNCTION LEVER (AFL) RIGHT GRIP HARNESS CONNECTOR (MARKED R_LEVER)
4
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
BLK RED/YEL RED/WHT
BLK
BLK/YEL RED/YEL
2 1
X534 RIGHT AUXILIARY 2 1 3 SOLENOID TO CONNECTOR SE30 X534 (MARKED SR/H)
3 2 1 TO SE30 X535
X535 LEFT AUXILIARY SOLENOID CONNECTOR (MARKED SL/H)
1 9 12 11 4 5 6 2 7 3 10 8 TO SE10 X574
LT GRN/YEL BLU GRN
TO SE10 X544
GRN/BLU
X577 AUXILIARY FUNCTION LEVER (AFL) HARNESSTO-AUXILIARY FUNCTION LEVER (AFL) SOLENOID HARNESS CONNECTOR 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
BLK/BLU
BLK/BLU
K33 LEFT SOLENOID RELAY A (MARKED LSW3)
B68 SECONDARY HYDRAULIC OIL TEMPERATURE SENSOR 1
1
P 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
X542 AUXILIARY FUNCTION LEVER (AFL) LEFT SWITCH CONNECTOR (MARKED L-SW)
RED/YEL BLK/YEL
GRN/BLK
BLK
1
GRN/BLK
2
BLU GRN
Y62 AUXILIARY FUNCTION LEVER (AFL) SOLENOID B (MARKED 1B)
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR
X544 AUXILIARY FUNCTION LEVER (AFL) POWER DIG SWITCH CONNECTOR GRN/BLU
SE28
SE29 245GLC SYSTEM FUNCTIONAL SCHEMATIC
TX1209279
System Functional Schematic (SE28—SE30) (10 of 10) Continued on next page
9015-10-49
3
041818
PN=359
1 2 3 4 5 6
X26 OPTIONAL CONNECTOR
GRY
2
GRN
X536 RIGHT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR (MARKED R_GRIP)
4
1
B85 AUXILIARY FUNCTION LEVER (AFL) SOLENOID PRESSURE SENSOR (MARKED PS1)
RED/YEL
5
K32 LEFT SOLENOID RELAY B (MARKED LSW1)
V22 PILOT SHUTOFF SOLENOID DIODE
GRN/BLU
2
3
YEL WHT
6
1
GRN/BLU BLK/GRN RED/BLU BLK/YEL RED/YEL BLK/BLU GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLU/YEL
8
1
WHT/YEL
WHT/YEL
BLK
RED
BLK
9
WHT
4
1
GRN
5
K31 RIGHT SOLENOID RELAY A (MARKED RSW1)
RED/YEL
3
LT GRN/YEL BLK/YEL RED/YEL
BLK/YEL
7
GRN
BLK
1
X541
TM12660 (18APR18)
8
Y66 SECONDARY PILOT SHUTOFF SOLENOID (MARKED PiC)
2
BLU
BLU/YEL 2
BLK
BLU
3
1
1
1
BLK
X539 AUXILIARY FUNCTION LEVER (AFL) LEFT GRIP HARNESS CONNECTOR (MARKED L_LEVER)
2
GRN/BLU
BRN
3
GRN
4
GRN/BLK
5
RED
GRN/BLU
2
X537 LEFT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR (MARKED L_GRIP)
GRN
BLK
6
GRN/BLK
4
S45 AUXILIARY FUNCTION ENABLE SWITCH
WHT
BLK
BLU
7
BLU
GRN 3
GRN
PUR WHT/VLT
1
5
BLU
S29 AUXILIARY FUNCTION LEVER (AFL) PROPORTIONAL CONTROL SWITCH
S32 LEFT PILOT CONTROL LEVER SWITCH B
4
RED
WHT
S7 POWER DIG SWITCH
S33 LEFT PILOT CONTROL LEVER SWITCH A
0 1
S35 LEFT ENABLE SWITCH
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
WHT/YEL
BRN
0 1
S34 RIGHT ENABLE SWITCH
WHT/YEL
S5 HORN SWITCH
S31 RIGHT PILOT CONTROL LEVER SWITCH A
WHT
LEFT PILOT CONTROL LEVER
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
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
RED/YEL
1 2 3 4 5 6
SE30
CW08338,0000D06 -19-15SEP16-19/20
System Diagrams
TM12660 (18APR18)
9015-10-50
041818
PN=360
System Diagrams X538— Auxiliary Function Lever X574— Auxiliary Function Lever B68— Secondary Hydraulic Oil S33— Left Pilot Control Lever (AFL) Right Grip Harness (AFL) Connector Temperature Sensor Switch A Connector (marked X577— Auxiliary Function B85— Auxiliary Function Lever S34— Right Enable Switch R_LEVER) Lever (AFL) Harness-to(AFL) Solenoid Pressure S35— Left Enable Switch Auxiliary Function Lever Sensor (marked PS1) S45— Auxiliary Function Enable X539— Auxiliary Function Lever (AFL) Left Grip Harness (AFL) Solenoid Harness K31— Right Solenoid Relay A Switch Connector (marked Connector (marked RSW1) V22— Pilot Shutoff Solenoid L_LEVER) Y61— Auxiliary Function Lever K32— Left Solenoid Relay B Diode X541— Auxiliary Function Lever (AFL) Solenoid A (marked (marked LSW1) X26— Optional Connector (2 (AFL) Right Switch 1A) K33— Left Solenoid Relay A used) Connector (marked Y62— Auxiliary Function Lever (marked LSW3) X534— Right Auxiliary Solenoid R-SW) (AFL) Solenoid B (marked S5— Horn Switch Connector (marked SR/H) X542— Auxiliary Function 1B) S7— Power Dig Switch X535— Left Auxiliary Solenoid Lever (AFL) Left Switch Y66— Secondary Pilot Shutoff S29— Auxiliary Function Lever Connector (marked SL/H) Connector (marked Solenoid (marked PiC) (AFL) Proportional Control X536— Right Auxiliary Function L-SW) Switch Lever (AFL) Connector X543— Auxiliary Function Lever S31— Right Pilot Control Lever (marked R_GRIP) (AFL) Horn Switch Switch A X537— Left Auxiliary Function Connector S32— Left Pilot Control Lever Lever (AFL) Connector X544— Auxiliary Function Lever Switch B (marked L_GRIP) (AFL) Power Dig Switch Connector CW08338,0000D06 -19-15SEP16-20/20
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 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Continued on next page
TM12660 (18APR18)
9015-10-51
CW08338,0000D07 -19-02MAR16-1/3
041818
PN=361
System Diagrams
TM12660 (18APR18)
9015-10-52
041818
PN=362
System Diagrams
TX1208565 —UN—05JAN16
X2 S7 A11
F50
F51
K6
R9 S26
S27
S25
S9
X41 S1
S24 S21 R15
S12
K11 K9
X32
X43 X44 K10
K4
X33 X34
K5 X20
S7
W37
X31
V4
S23
S8
K8
K3 X35 K13
X22
X10 X11
K12
K2 K14
A3
A4
X21
S22
S60
K7
K1
V1
V7
S16
V8
S11
W9
W29
X574 X29 X30
X36
W1
V10
V2 V11 V3
V13 V14 X78
S10
S5 V12
V5 X17 V6
X4
X108 X3
V9 W36
X45 X26 X543
X92
X27 X47
S13
W16
H2 X91
X107
X90
X544
X93
X37
X51
X28
X75 X42
W39
W11
X102
X52
X49
X65
X39
S3
S4
S14 A6 X73 X77
X25
E3 X50 W27
W35 S6
TX1208565 Cab Harness (W1) Component Location Continued on next page
TM12660 (18APR18)
9015-10-53
041818
PN=363
CW08338,0000D07 -19-02MAR16-2/3
System Diagrams
TM12660 (18APR18)
9015-10-54
041818
PN=364
System Diagrams
A3—Main Controller (MCZ) S23— Radio Volume and Power X11— Machine Controller 20-Pin A4—Monitor Controller (DSZ) Switch Connector B A6—Radio S24— Radio Tuning Switch X17— Cab Harness-to-Monitor A11— Machine Controller (BCZ) S25— Monitor Dial Harness E3— Cab Dome Light S26— Back Button X20— Monitor Controller 28-Pin F50— Fuse Box S27— Home Button Connector A F51— Auxiliary Fuse Box S60— Keypad X21— Monitor Controller 36-Pin H2—Security Alarm V1— Battery Relay Diode Connector B K1—Load Dump Relay V2— Not Used X22— Monitor Controller 16-Pin K2—Pilot Shutoff Solenoid Relay V3— Load Dump Relay Diode Connector D K3—Security Alarm Relay V4— Security Diode X25— Cab Harness Auxiliary K4—Starter Cut Relay V5— Pilot Shutoff Switch Diode Power Connector 1 K5—Security Relay V6— Auxiliary Power Connector X26— Optional Connector K6—Windshield Wiper Relay Diode X27— Cab Harness-to-Switch K7—Work Light Relay V7— Start Relay Diode Panel Connector 1 K8—Boom Light Relay V8— Air Conditioner Clutch Diode X28— Cab Harness-to-Switch K9—Windshield Washer Relay V9— Pilot Shutoff Diode Panel Connector 2 K10— Horn Relay V10— Starter Protection Diode X29— Cab Harness-to-Switch K11— Idle Stop Relay V11— Accessory Cut Diode Panel Connector 3 K12— Accessory Cut Relay V12— Starter Cut Diode X30— Cab Harness-to-Switch K13— Key Cut Relay V13— Work Light 1 Diode Panel Connector 4 K14— ECU Power Relay V14— Work Light 2 Diode X31— Cab Harness-to-Main R9—Lighter W1—Cab Harness Controller 31-Pin R15— Engine Speed Dial W9—Exhaust Filter Parked Connector A S1— Key Switch Cleaning Switch Harness X32— Cab Harness-to-Main S3— Pilot Shutoff Switch 1 W11— Pilot Shutoff Switch Controller 24-Pin S4— Pilot Shutoff Switch 2 Harness Connector B S5— Horn Switch W16—Travel Alarm Cancel X33— Cab Harness-to-Main S6— Engine Stop Switch Switch Harness Controller 17-Pin S7— Power Dig Switch W27—Travel Sub Harness Connector C S8— Auto-Idle Switch W29—Starter Switch Harness X34— Cab Harness-to-Main S9— Windshield Wiper and W35—Cab Harness Ground 1 Controller 30-Pin Washer Switch W36—Cab Harness Ground 2 Connector D S10— Work Light Switch W37—Cab Harness Ground 3 X35— Cab Harness-to-Main S11— Travel Speed Switch W39—Cab Harness Ground 4 Controller 24-Pin S12— Power Mode Button X2— MPDr 6-Pin Connector Connector E S13— Travel Alarm Cancel X3— Cab Harness-to-Machine X36— Cab Harness-to-Main Switch Harness 100-Pin Connector Controller 26-Pin S14— Door Switch X4— Cab Harness-to-Machine Connector F S16— Exhaust Filter Parked Harness 32-Pin Connector X37— Cab Harness-to-Exhaust Cleaning Switch X10— Machine Controller 8-Pin Filter Switch Harness S21— Blower Motor Speed Connector A Connector Switch X39— Cab Harness-to-Window S22— Temperature Control/Mode Switch Switch X41— Data Converter Harness Connector X42— CAN 1 Connector
X43— Optional Fuse Connector X44— Optional Light Connector X45— Option 2 12-Pin Connector (not used) X47— Cab Harness-to-Key Switch Harness Connector X49— Cab Harness-to-Spool Control Harness Connector X50— Travel Sub Harnessto-Travel Alarm Cancel Switch Harness Connector X51— Air Conditioner 4-Pin Connector X52— Air Conditioner 10-Pin Connector X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector X73— Cab Harness-to-Speakers Connector X75— Cab Harness-to-Pilot Shutoff Valve Harness Connector X77— Radio Auxiliary Connector X78— Optional Switch X90— Not Used X91— Not Used X92— Not Used X93— Not Used X102— Not Used X107— Not Used X108— Not Used X543— Auxiliary Function Lever (AFL) Horn Switch Connector X544— Auxiliary Function Lever (AFL) Power Dig Switch Connector X574— Auxiliary Function Lever (AFL) Connector
CW08338,0000D07 -19-02MAR16-3/3
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.
NOTE: X578 is not incorporated on earlier cab harness designs.
Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in Continued on next page
TM12660 (18APR18)
9015-10-55
CW08338,0000D08 -19-25JAN16-1/10
041818
PN=365
System Diagrams
TM12660 (18APR18)
9015-10-56
041818
PN=366
System Diagrams
TX1208571 —UN—07JAN16
NUMBER 1 2 3 4 26 27 39 79 88 138 141 149 155 202 222 223 234 235 250 500 501 503 505 506 507 508 509 510 511 516 517 518 519 520 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 544 545 546 548 550 TX1208571
COLOR RED RED RED RED WHT/RED BLK/RED BLU BLK RED/BLK GRN/BLK WHT/YEL BLU/BLK ORG BLU/YEL WHT/BLU GRN/BLU WHT/BLK BRN WHT/BLU BLK BLK BLK WHT/BLK WHT BLK WHT BLK WHT RED GRN/YEL VLT/GRN BLK RED RED BLU RED WHT VLT VLT/GRN VLT/RED BRN VLT/WHT ORG PNK/BLK RED RED WHT/BLK BLK RED/BLU BLU/RED GRN BLK BLK PNK/GRN PNK/WHT RED/BLU WHT/VLT VLT BLK BLK
END #1 F50 X36 X36 X36 X33 X33 X35 X93 X35 X3 (610) X45 V9 X20 X21 X21 X20 X20 X21 W35 X99 X45 X3 X3 X99 V3 X99 V1 X47 X3 V4 X99 (511) (511) X47 K5 K1 K5 S6 K5 V5 K2 V5 K2 X75 K2 V7 W37 K8 K7 F50 K14 W36 H2 K10 H2 K10 K9 V1 K5
END #2 (2), (3), (4) (1) (1) (1) X3 X3 F50 W36 (764) X45 X45 X3 (530) X4 X4 X4 X4 X4 X4 X99 X3 W36 K4 F50 W39 X3 W37 (508) X3 F50 (526) W36 K1 K1 F50 (1) (508) K2 K4 V4 S6 V5 X65 X75 (1) (1) (505) V7 X3 X3 K14 W36 K3 K3 X3 (552) S5/X543 X3 W37 W36
NUMBER 551 552 560 561 562 566 568 569 570 571 572 573 589 590 591 592 593 594 595 596 598 599 600 601 602 603 604 605 606 607 609 610 611 612 615 616 617 618 632 633 660 661 662 664 665 666 667 669 745 760 761 762 763 764 766 767 768 769 771 772
COLOR WHT RED/BLU RED WHT BLK YEL/RED RED/BLU ORG BRN GRY/BLK WHT/BLK BLK BLK/PNK BLK/YEL BLK/RED BLK RED/BLK BLK RED/BLK BLK/RED GRN RED/BLK GRN GRN WHT WHT BLK BLK YEL/BLK WHT RED/GRN WHT/YEL RED LT GRN/RED BLK BLU/RED RED/BLU RED/BLU BLU/YEL BLK RED GRN BLK WHT/YEL WHT/YEL BLK GRN WHT/YEL VLT/GRN WHT/YEL GRN/RED BLK/GRN YEL/WHT RED/BLK GRY/BLU ORG/BLU GRY/RED RED/BLU BLU/BLK BLU
END #1 (508) F50 (511) X43 X43 A6 A6 A6 A6 A6 A6 W36 X39 K6 F50 X39 (764) K6 (764) K9 F50 K7 K8 K8 K10 F50 X65 S5/X543 V3 X47 F50 F50 X26 F50 W36 X26 X26 X44 F50 W37 (611) F50 X25 (610) (610) V6 (661) V2 X3 X21 X21 X22 K14 F50 X3 X3 S6 X92A X21 X10
END #2 F50 K3 F50 (506) X99 F50 (552) X73 X73 X73 X73 A6 K6 X39 X39 W36 K6 W36 K9 (591) K7 (764) (598) (598) (603) K10 W36 W36 (1312) F50 X51 X26 F50 X26 X26 (537) (536) (536) R9 R9 X3 X25 W36 X3 X3 (662) V6 (610) (526) X4 X4 X4 X3 X3 X92B X92A X3 X3 F50 (39)
NUMBER 773 800 801 810 823 824 825 845 850 851 852 853 854 855 856 870 876 877 900 910 993 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 1036 1037 1038 1039 1040 1045 1047 1054 1059 1060 1061 1062
COLOR RED/BLK GRN BLU BLU LT GRN/BLK RED/BLK VLT GRY/RED YEL GRY/RED GRN/BLK GRN/BLK RED/BLK BLK/BLU ORG BLU/RED ORG/BLK ORG/GRN WHT/RED WHT/RED BLK/BLU BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK RED/GRN RED BLK/YEL RED/YEL WHT/RED RED/GRN GRN BLK/RED ORG/BLU BLK/GRN GRN/WHT SK BLU RED BLK WHT/BLU GRN/BLK RED/YEL BLU/RED GRY/RED WHT GRY WHT/RED YEL/BLK BLU
Cab Harness (W1) Wiring Diagram (1 of 5) Continued on next page
TM12660 (18APR18)
9015-10-57
041818
PN=367
END #1 S6 X20 X20 K14 F50 X20 X21 X107A X10 X11 K3 X22 X10 X10 X22 X29 X37 X37 X47 K4 X45 (501) X21 X21 X30 (507) X35 (1015), (1016), (1017) X10 X51 X77 W37 X11 X36 X36 X36 X31 X22 X22 X3 X22 X20 X20 X20 X36 X20 X22 X33 X20 X21 X20 X36 X21 X34 X34 X68 X68 X21 X33 X35
END #2 (764) X3 X3 X3 X3 (764) X65 K6 K7 X107B X108A X108B K8 K9 K1 (616) X4 X4 K4 (900) X3 X20 W37 W37 (507) S7/X544 W36 W36 W37 X39 W36 V8 E3 (1009) (1009) (1009) X3 X4 X4 X90A X17 X2 X11 X2 X45 X2 V4 X3 X41 X41 X41 S7/X544 X41 X3 X3 X4 X4 X4 X3 (39)
NUMBER 1067 1069 1071 1074 1076 1082 1084 1085 1086 1087 1088 1089 1090 1092 1093 1094 1095 1096 1097 1098 1100 1101 1104 1105 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1124 1125 1126 1128 1132 1135 1138 1139 1140 1141 1142 1143 1145 1148 1150 1152 1153 1154 1155 1156 1157 1158 1159
COLOR BLU/BLK GRN/WHT GRN/ORG LT GRN RED/BLK GRN/RED YEL BLU BLK/WHT WHT BLK/PNK BLK WHT/RED BLU/YEL GRN/YEL BLU/GRN RED BLK GRN/BLK GRN/BLK WHT/GRN YEL/RED BRN/BLU WHT GRN/YEL ORG RED/YEL RED/GRN BRN GRN/RED WHT/YEL BLK GRY RED/YEL GRN BLK GRN GRN BLU BLU VLT/YEL LT GRN WHT 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
END #2 END #1 X31 X3 X31 X3 X31 X3 X36 X78 X17 (764) X31 X3 X31 X3 A6 (1155) X31 X3 X31 X3 X34 X3 X2 (1004) X33 X3 X34 X3 X34 X3 X34 X3 X33 X3 (1011) X4 X4 X52 X34 X3 X31 X3 X11 (566) X4 X52 X3 X52 X33 X3 X17 X52 X4 X52 X51 (609) X31 X3 X32 X3 X32 X3 X34 X3 X36 X45 X36 (1023) X34 (800) X35 (1008) A6 (1027) X52 (1027) X52 (1155) X31 X3 X31 X3 X31 X3 X22 X66 X33 X574 X31 X574 X31 X574 X574 (1023) X11 X102 X102 (611) (1003) X76 X21 (552) X21 X76 X77 A6 X3 X91B E3 (552) X20 X11 E3 (1215) X22 X31 A6 X77 X20 F50 SHEET 1 OF 5
CW08338,0000D08 -19-25JAN16-2/10
System Diagrams
TM12660 (18APR18)
9015-10-58
041818
PN=368
System Diagrams
TX1199908 —UN—21AUG15
NUMBER 1160 1161 1163 1164 1167 1168 1169 1171 1173 1175 1176 1177 1178 1179 1180 1181 1182 1183 1184 1185 1186 1187 1189 1190 1191 1192 1194 1196 1197 1198 1199 1200 1202 1203 1204 1205 1206 1207 1208 1210 1211 1212 1213 1214 1215 1216 1218 1219 1220 1221 1222 1223 1224 1225 1226 1227 1228 1229 1230 1231 TX1199908
COLOR GRN/BLU YEL/RED ORG/BLK GRY LT GRN/RED YEL/GRN BLU ORG YEL BLU/RED RED/BLK WHT BLK/YEL YEL/BLU BLU/WHT BLK/RED WHT GRY/RED WHT/YEL RED/GRN GRN/BLU BLU/WHT BLK/PNK YEL/GRN LT GRN BLK/YEL VLT/WHT BLU/WHT GRY RED/GRN BLU/YEL YEL GRN/WHT GRN/WHT LT GRN/YEL BLU GRN ORG/RED GRY BRN/YEL BRN/BLU RED RED/BLK RED/BLU ORG/BLU RED BLK/RED RED ORG/BLK BLK/GRN BLU RED GRN BLK/BLU YEL/WHT GRY BLK/YEL BLU/RED BLK/GRN WHT/GRN
END #1 X36 X21 X31 X33 X31 X20 X21 X20 X20 X21 X51 X20 X10 X20 X31 X21 X34 X20 X20 X31 X20 X20 X21 X36 X20 X574 X31 X21 A6 X21 X21 X21 X21 X34 X21 X34 X21 X31 X21 X21 X21 X28 X31 X27 X10 V2 X45 X29 X34 X36 X34 X30 X31 X36 X36 X33 X36 X31 X32 X29
END #2 X29 X30 X574 X574 X3 X30 X30 X30 X30 X30 (764) X30 X102 X30 X574 X30 X90A X30 X30 X3 X30 X29 X29 V9 X29 (1153) X3 X30 X77 X28 X28 X28 X28 (1027) X28 (801) X28 X3 X28 X28 X28 (1020) X3 (552) X27 (1095) (27) (1020) X3 X29 (1155) (1278) X3 X29 X93 X3 (1153) X3 X3 X91A
NUMBER 1234 1235 1236 1237 1238 1240 1241 1242 1243 1244 1245 1246 1248 1250 1253 1254 1255 1256 1257 1258 1261 1263 1264 1268 1269 1273 1276 1278 1280 1284 1285 1289 1293 1295 1297 1298 1300 1303 1310 1311 1312 1314 1315 1318 1319 1320 1321 1322 1323 1324 1325 1326 1327 1330 1331 1332 1333 1335 1336 1338
COLOR WHT/VLT YEL/BLU GRN/WHT YEL/RED GRN/BLK GRN/YEL BRN WHT BRN/WHT WHT RED/YEL RED/BLK BLK/WHT WHT/BLK ORG/BLU BLK BLK/YEL RED/YEL BLK/YEL PNK GRN/BLU WHT/BLU BLU/RED WHT/VLT YEL/BLK BLU/WHT RED/YEL RED LT GRN/YEL GRN YEL/RED PNK BLK/RED BRN/WHT BRN/RED GRN/RED WHT/BLK GRY BLU/YEL WHT/BLK YEL/BLK WHT/BLK BLU VLT/WHT PNK/GRN YEL/GRN BLK YEL/GRN BLU BLU YEL/GRN YEL/GRN BLU WHT/BLK RED WHT/RED BLK RED/BLK BLU BLU/YEL
END #1 X11 X34 X11 X17 X11 X11 X21 V8 X29 A6 X31 X11 X11 X11 X34 X33 X36 (1023) (1153) X21 X32 X32 X33 X32 X29 X34 X36 X11 X34 X34 X34 X34 X34 X31 X31 X36 X31 X22 X11 K12 K13 X47 (522) X35 X35 X33 W36 (1320) K12 K13 K12 K13 F50 X32 X32 (900) W37 X41 X41 X41
END #2 X29 X3 X29 X52 X27 X27 X30 (1105) X90B X77 X3 X27 X27 X27 X3 X3 (1153) X3 X3 X28 X3 X3 X3 X3 X90B X3 (1023) X27 X3 X3 X3 X3 X3 X3 X3 X78 X3 X66 S14 F50 F50 (607) K13 X45 X45 K11 K11 K11 (1327) (1327) (1320) (1320) K11 X3 X3 F50 X41 (764) (39) (202)
NUMBER 1340 1341 1342 1343 1345 1350 1352 1353 1354 1355 1356 1357 1358 1359 1360 1370 1371 1372 1373 1374 1375 1376 1377 1378 1379 1386 1387 1390 1394 1395 1396 1397 1398 1399 1550 1551 1552 1553
COLOR RED/BLU BLK/BLU BLK/GRN BLU/YEL RED/BLK BLU/YEL BLK BLK BLU/RED BLK GRN BLU WHT/BLK RED/BLK RED/BLK WHT WHT/BLK GRN YEL/BLK GRN YEL WHT/VLT YEL RED/BLK GRN/WHT VLT/GRN YEL/GRN ORG/WHT WHT/YEL RED RED/BLU BLK/BLU RED/BLK BLK/RED RED/YEL BLK WHT/BLU BLU/WHT
END #1 X36 X33 X33 X32 X35 X102 X36 X28 X27 X78 X42 X42 X36 X102 X37 K12 V11 V11 V12 V12 V13 V13 V14 V14 V14 V10 V10 X21 (610) (1095) X32 X32 X32 X32 X4 X4 X36 X22
END #2 X574 X574 X574 X574 X4 X3 X102 (507) (616) W37 (1027) (1155) X3 (764) (764) (607) (1311) F50 (1312) (1372) (850) (1234) (850) (854) (1236) (526) (1320) X4 X579 X579 X49 X49 X49 X49 (1030) (1002) X578 X578
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(1303) (1022) (1020) — (762) (1157) (1025) (856) (1135) (1553) — — — — (853) (1031)
GRY BLK/YEL RED
X66 X4 X4
BLK/GRN YEL/WHT WHT/RED ORG WHT BLU/WHT
(1178) (854) — (772) (855) (850) (1215) (1010)
BLK/YEL RED/BLK
X102 K8
BLU BLK/BLU YEL ORG/BLU BLK
(39) K9 K7 X27 W37
X11 1 1027
1278 1246
1238 1234
11 1155
1248 1250
1240 1236 1310 1101 1142 20
851 1014 10
X10
X4 X31 X17 K1 X66 X578
1
1178 854
772
4
5
855 850 1215 1010
8
X22
X76
M
GRN/BLK GRN/WHT
X108B V4
1 9
1303 1022 1020
762 1157 1025 856
1135 1553
853 1031
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)
GRN
X20
RED RED/BLK
X27 X27
GRN/BLK WHT/VLT
X27 X29
GRY/RED BLK BLU
X107B E3 X20
(1150) (1145)
YEL/BLU X21 BLK (1003)
BLK/WHT X27 WHT/BLK X27 GRN/YEL GRN/WHT BLU/YEL YEL/RED BLK/RED
X27 X29 S14 (566) X102
8 F
16
X76 F M
T MS
H
1 X20 DET
ECT
1 15
1030
1173 1177 1179 1183 1184 1168 1186 1171 1187 1191 1028 1036 14
202 824 1159 235 234
1002 801 800 1155 1027 1038 1026
28
X41
1
X21
1335 1336
X578
X578
1
2
1552
1553
1 2
(1552) (1553)
WHT/BLU BLU/WHT
X36 X22
3 1333
1338 1040 1037 1038 1036 1 19
1258 1206 1204 1202 1200 1199 1390 1208 1210 1211 1198 1037
761
825 1150 760 250 223 222 1060 771 1148
1196 1161 1169 1181 1175 1241 1189
1040 1004 1003
4
18
8
36
X41 X20 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Continued on next page
9015-10-59
1 2 3 4 5 6 7 8
X22
X21 (1030) — (1173) (1177) (1179) (1183) (1184) (1168) (1186) (1171) (1187) (1191) (1028) (1036)
BLK/GRN
X2
YEL WHT YEL/BLU GRY/RED WHT/YEL YEL/GRN GRN/BLU ORG BLU/WHT LT GRN BLK/RED RED
X30 X30 X30 X30 X30 X30 X30 X30 X29 X29 X2 X41
15 16 17 18 19 20 21 22 23 24 25 26 27 28
(202) (824) (1159) (235) (234) — — (1002) (801) (800) (1155) (1027) (1038) (1026)
BLU/YEL RED/BLK WHT/RED BRN WHT/BLK
X4 (764) F7 X4 X4
BLK BLU GRN BLU GRN WHT/BLU RED/GRN
(501) X3 X3 X11 X11 X41 X2
Cab Harness (W1) Wiring Diagram (2 of 5)
TM12660 (18APR18)
X11
X10
041818
PN=369
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
(1258) (1206) (1204) (1202) (1200) (1199) (1390) — (761) (825) (1150) (760) (250) (223) (222) (1060) (771) (1148)
PNK GRN LT GRN/YEL GRN/WHT YEL BLU/YEL ORG/WHT
X28 X28 X28 X28 X28 X28 X4
GRN/RED VLT YEL/BLU WHT/YEL WHT/BLU GRN/BLU WHT/BLU WHT/RED BLU/BLK RED/BLU
X4 X65 X76 X4 X4 X4 X4 X4 F14 (552)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
(1208) (1210) (1211) (1198) (1037) — (1196) (1161) (1169) (1181) (1175) (1241) (1189) — — (1040) (1004) (1003)
GRY BRN/YEL BRN/BLU RED/GRN BLK
X28 X28 X28 X28 X41
BLU/WHT YEL/RED BLU BLK/RED BLU/RED BRN BLK/PNK
X30 X30 X30 X30 X30 X30 X29
RED/YEL BLK BLK
X41 W37 W37
1 2 3 4 5 6 7 8
(1335) (1336) (1333) (1338) (1040) (1037) (1038) (1036)
RED/BLK BLU BLK BLU/YEL RED/YEL BLK WHT/BLU RED
(764) (39) X37 (202) X21 X21 X20 X20
SHEET 2 OF 5 CW08338,0000D08 -19-25JAN16-3/10
System Diagrams
TM12660 (18APR18)
9015-10-60
041818
PN=370
System Diagrams
1— Continued on Sheet 3 X10— Machine Controller (BCZ) 8-Pin Connector A X11— Machine Controller (BCZ) 20-Pin Connector B
X20— Monitor Controller (DSZ) 28-Pin Connector A X21— Monitor Controller (DSZ) 36-Pin Connector B
X22— Monitor Controller (DSZ) 16-Pin Connector D X41— Data Converter Harness Connector X76— Cab Harness Connector 1 (not used) Continued on next page
TM12660 (18APR18)
9015-10-61
X578— Not Used
CW08338,0000D08 -19-25JAN16-4/10
041818
PN=371
System Diagrams
TM12660 (18APR18)
9015-10-62
041818
PN=372
System Diagrams
TX1208573 —UN—07JAN16
V14
A K
(535) (534)
BLK WHT/BLK
W37 (505)
1 2 3
X78
(1377) (1379) (1378)
YEL (850) GRN/WHT (1236) RED/BLK (854)
1 2 3
X574 (1074) LT GRN (1355) BLK (1298) GRN/RED
X36 W37 X36
1 2 3 4 5 6 7 8 9 10 11 12
V4 1 2 3
(517) VLT/GRN (1031) GRN/WHT (527) VLT/RED
(526) X22 K5
V1
V13 A K
(1375) (1376)
YEL (850) WHT/VLT (1234)
V8
A K
(548) (510)
BLK WHT
W37 (508)
A K
K
BLK WHT
W37 (1105)
1 2 3 4
(1111) ORG (1237) YEL/RED (1025) WHT/RED (1076) RED/BLK
V14
X17
X78
A 1375 1376 K
1377 1379 1378
1111 1237 1025 1076
1074 1355 1298
V8
1
2
3
1
1
4
2
3
1 1138 1139 517 1031 527
V1
1
A 548 510
2
1 2 3 4 5 6 7 8 9 10
1140 1141 1341 5
6 1164 1180 1343 1342 1163 1192 1340 12
3
K
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
W37
(509) (535) (548) (633) (1003) (1004) (1010) (1013) (1333) (1355)
BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
X99 V7 V1 R9 X21 X21 X10 V8 X41 X78
1 W39 X75 1
X99 1
532 531
W39 (507) BLK (1011) BLK
X99 X51
501
509 518
X75
500
507 562
1 2
R9
2
6 632 633
1 2
1
2
1135 1303
1
1059 1054
(532) (531)
RED PNK/BLK
X66 X99 1 2 3 4 5 6
BLK BLK BLK BLK BLK BLK
X3 W37 W36 W35 W39 X43
R9 1 2
1 2
2PV (1135) WHT (1303) GRY
X22 X22
BLU/YEL BLK
F13 W37
(1054) WHT (1059) GRY
X4 X4
1 2 3 4
(1011) (609) (1113) (1176)
BLK RED/GRN RED/GRN RED/BLK
X51
W39 F3 (609) (764)
1 1011 609
2
(544) (541)
(845) — (851) —
2
845
GRY/RED K6
X107A
X107B 1 2
V9 A K
(1190) (155)
YEL/GRN X36 ORG (530)
V11 A K
(1244) (1152) — (1158) (1012) (1197)
WHT BLK
A6 A6
YEL/BLU BLK GRY
A6 W36 A6
(1373) (1374)
YEL/BLK (1312) GRN (1372)
X77 1 1244 3
(1371) (1372)
WHT/BLK (1311) GRN F50
A K
V9 W36
(662) (661)
RED/BLU PNK/GRN
K
22
23 223 250 1020 1022
27
1054 1059
32
X49
1396
4
GRY/RED X11
1112 1104 4 1124 1125 10
2
1 851
X107B
(1111) (1237) (1112) (1104) (1097) (1105) — — (1124) (1125)
ORG YEL/RED RED/YEL BRN/BLU GRN/BLK WHT
GRN BLU
X17 X17 X4 X4 X4 X3
(1027) (1155)
041818
PN=373
GRN BLK
F15 W36
1 571 569
1122 1197 1152 1158 566 8
9 572 570
1085
1244 573
568 16
X73
A 1371 1372 K
1
V10
2
571 569
V12
A 1386 1387 K
572 570 3
A 1373 1374 K
V6
V5
V5
528 530 529
1 2 3
K
1
2
3
V3
2 544 541
4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(571) (569) — (1122) (1197) (1152) (1158) (566) (572) (570) — (1085) — (1244) (573) (568)
GRY/BLK ORG
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 W36 (552)
X73 (528) (530) (529)
BRN ORG VLT/WHT
S6 X65 K2
1 2 3 4
(571) (569) (572) (570)
GRY/BLK ORG WHT/BLK BRN
A6 A6 A6 A6
V3
A 606 508
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(760) (761) (876) (222) (235) (1060) (762) (877) (234) (202) (1097) (1104) PLUG PLUG (1096) (1112)
WHT/YEL GRN/RED ORG/BLK WHT/BLU BRN WHT/RED BLK/GRN ORG/GRN WHT/BLK BLU/YEL GRN/BLK BRN/BLU
X21 X21 X37 X21 X20 X21 X22 X37 X20 X20 X52 X52
BLK RED/YEL
(1011) X52
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
(1345) (1550) (1551) PLUG PLUG PLUG (223) (250) (1020) (1022) PLUG (1390) PLUG (1054) (1059) PLUG
RED/BLK RED/YEL BLK
X35 (1030) (1002)
K
A K
(606) (508)
YEL/BLK (1312) WHT X3
V2
V2
X27 1 1278 1246
1248 1238 4
5 1250 1240
1354 1214 1215 10
A 1216 669
A K
K
X27 (1216) (669)
RED (1095) WHT/YEL (610)
X28 1 1212 1199 1200
GRN/BLU WHT/BLU RED BLK/YEL
X21 X21 X22 X22
ORG/WHT
X21
WHT GRY
X68 X68
1202 1204 5
6 1206 1258 1208 1210 1211 1198 1353 12
X29 1 1187 1191 1189
1269 1243 1231
8 1160 1221
7
1 2 3 4
X30
1
7 1223 1169 1006
1173 1177 1181 1179 1183 1175 1184 1186 1241 16
X47 (1396) (1397) (1398) (1399)
RED/BLU BLK/BLU RED/BLK BLK/RED
X32 X32 X32 X32
X42 1
X47
2
1356 1357
3
607
900
(607) — (900) (522) (1314) (511)
WHT
F50
WHT/RED BLU WHT/BLK RED
K4 F50 (607) X3
(1360) — (877) (876) — —
RED/BLK
(764)
ORG/GRN ORG/BLK
X4 X4
522 1314 511
X42 1 2
1
1 2 3 4 5 6
(1356) (1357)
GRN BLU
4
(1027) (1155)
X37
S7/X544
1
1 2
1007 1039
(1007) (1039)
BLK GRN/BLK
(507) X36
6
2
S7/X544
1 1360
2
3 877 876
6
X37 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10
X28 (1278) (1246) (1248) (1238) (1250) (1240) — (1354) (1214) (1215)
RED RED/BLK BLK/WHT GRN/BLK WHT/BLK GRN/YEL
X11 X11 X11 X11 X11 X11
BLU/RED RED/BLU ORG/BLU
(616) (552) X10
(1187) (1191) (1189) (1269) (1243) (1231) — (1160) (1221) — — (1225) (1234) (1236) (1219) (870)
BLU/WHT LT GRN BLK/PNK YEL/BLK BRN/WHT WHT/GRN
X20 X20 X21 X90B X90B X91A
GRN/BLU BLK/GRN
X36 X36
BLK/BLU WHT/VLT GRN/WHT RED BLU/RED
X36 X11 X11 (1020) (616)
1225 1234 1236 1219 870 16
1196 1161 1168 1171
X49
Continued on next page
9015-10-63
-
8
5 1097 1105
(661) (662)
A6 X AU
X4
1345 17
1 1111 1237
1 2 3 4 5 6 7 8 9 10
X25
1158 1012 1197 6
H2
(552) K3
+ -
V11
A 1190 155
A6
X25 1152 2
V12
Cab Harness (W1) Wiring Diagram (3 of 5)
TM12660 (18APR18)
1 2 3 4 5 6
2
18 1550 1551
X52
3 1113 1176 4
X107A 1 2
X77 (1386) VLT/GRN (526) (1387) YEL/GRN (1320)
X52
1
TX1208573
1 2
X68 1 2
BLK GRN
H2
15 1096 1112
2
A K
1
1397 1398 1399
X51 (632) (633)
(666) (667)
14
1
X66 (501) (509) (518) (500) (507) (562)
A K
11 1097 1104
28 1390
X68
X93 X45 X99 K14 K3 K5 A6 X39 K6 X65 S5/X543 X26 X25 X35 (1015), (1016), (1017) X77 K11 X102
A 666 667
6 1060 762 877 234 202 10
(1) K2
BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
V6
1 760 761 876 222 235 5
3
4
V10
(79) (503) (518) (539) (540) (550) (573) (592) (594) (604) (605) (615) (662) (1008) (1009) (1012) (1321) (1352)
X4 1 2
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
W37
X574
A 1013 1242 K
V4
X52 X52 X22 (764)
V13
V7 A 535 534
(1013) (1242)
X17
W36
(1138) (1139) (1140) (1141) (1341) (1164) (1180) (1343) (1342) (1163) (1192) (1340)
AU X+
V7
X29 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
(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
(1020) X21 X21 X21 X21 X21 X21 X21 X21 X21 X21 (507)
(1196) (1161) (1168) (1171) (1223) (1169) (1006) (1173) (1177) (1181) (1179) (1183) (1175) (1184) (1186) (1241)
BLU/WHT YEL/RED YEL/GRN ORG RED BLU BLK YEL WHT BLK/RED YEL/BLU GRY/RED BLU/RED WHT/YEL GRN/BLU BRN
X21 X21 X20 X20 (1278) X21 (507) X20 X20 X21 X20 X20 X21 X20 X20 X21
X30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SHEET 3 OF 5 CW08338,0000D08 -19-25JAN16-5/10
System Diagrams
TM12660 (18APR18)
9015-10-64
041818
PN=374
System Diagrams
1— Continued on Sheet 2 V12— Starter Cut Diode 2— Continued on Sheet 4 V13— Work Light 1 Diode A6—Radio V14— Work Light 2 Diode H2—Security Alarm W36—Cab Harness Ground 2 R9—Lighter W37—Cab Harness Ground 3 S7— Power Dig Switch W39—Cab Harness Ground 4 V1— Battery Relay Diode X4— Cab Harness-to-Machine V2— Not Used Harness 32-Pin Connector V3— Load Dump Relay Diode X17— Cab Harness-to-Monitor V4— Security Diode Harness Connector V5— Starter Cut Relay Diode X25— Cab Harness Auxiliary V6— Auxiliary Power Connector Power Connector 1 Diode X27— Cab Harness-to-Switch V7— Start Relay Diode Panel Connector 1 V8— Air Conditioner Clutch Diode X28— Cab Harness-to-Switch V9— Pilot Shutoff Diode Panel Connector 2 V10— Starter Protection Diode X29— Cab Harness-to-Switch V11— Accessory Cut Diode Panel Connector 3
X30— Cab Harness-to-Switch X73— Cab Harness-to-Speakers Panel Connector 4 Connector X37— Cab Harness-to-Exhaust X75— Cab Harness-to-Pilot Filter Switch Harness Shutoff Valve Harness Connector Connector X42— CAN 1 Connector (not X77— Radio Auxiliary Connector used) X78— Optional Switch Connector X47— Cab Harness-to-Key X99— Cab Ground Splice Switch Harness Connector X107A—Not Used X49— Cab Harness-to-Spool X107B—Not Used Control Harness X544— Auxiliary Function Lever Connector (AFL) Power Dig Switch X51— Air Conditioner 4-Pin Connector Connector X574— Auxiliary Function Lever X52— Air Conditioner 10-Pin (AFL) Connector Connector X66— Cab Harness-to-Side Monitor Harness 2-Pin Connector 1 X68— Cab Harness-to-Side Monitor Harness 2-Pin Connector 2 Continued on next page
TM12660 (18APR18)
9015-10-65
CW08338,0000D08 -19-25JAN16-6/10
041818
PN=375
System Diagrams
TM12660 (18APR18)
9015-10-66
041818
PN=376
System Diagrams
TX1208574 —UN—29FEB16
X33 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
X36 (1033) (1138) (1254) (1227) (1320) (1341) (1164) (1264) (1095) (26) (27) — (1061) (1090) (1110) (1342) —
SK BLU GRN/BLU BLK GRY YEL/GRN BLK/BLU GRY BLU/RED RED WHT/RED BLK/RED
X3 X574 X3 X3 K11 X574 X574 X3 X3 X3 X3
X33 1 1033 1138 1254 1227 1320 1341 6
YEL/BLK WHT/RED GRN/YEL BLK/GRN
X3 X3 X3 X574
7
1164 1264 1095 26
13
1061 1090 1110
27
12
1342
17
1 2 3 4 5 6 7 8 9 10 11 12 13
X34 (4) (3) (2) (1015) (1016) (1017) (1160) (1225) (1221) (1358) (1039) (1074) (1190)
RED RED RED BLK BLK BLK GRN/BLU BLK/BLU BLK/GRN WHT/BLK GRN/BLK LT GRN YEL/GRN
(1) (1) (1) (1009) (1009) (1009) X29 X29 X29 X3 S7/X544 X78 V9
14 15 16 17 18 19 20 21 22 23 24 25 26
(1552) — (1255) (1228) (1118) (1298) (1226) (1029) (1340) — — (1276) (1119)
WHT/BLU
X578
BLK/YEL BLK/YEL GRY GRN/RED YEL/WHT ORG/BLU RED/BLU
(1153) (1153) X45 X78 X93 X45 X574
X34
1045 1092 1182 1117 1253 1273 1280 1284 1289
11
RED/YEL RED/YEL
1094 1220
23
(1023) (1023)
10
1120 1205 1203 1222 1093 1293 1047 1285
1
22 30
1088 1235 1098
X36 1 7
4
3
2
1015
1016
1160 1225 1221 1358 1039 1074 1190 1552
18 1118 1298 1226 1029
1340
1017
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X35 — (1120) (1205) (1203) (1222) (1093) (1293) (1047) (1285) — — — — (1045) (1092)
GRN BLU GRN/WHT BLU GRN/YEL BLK/RED GRY/RED YEL/RED
(800) (801) (1027) (1155) X3 X3 X3 X3
BLU/RED BLU/YEL
X3 X3
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(1182) (1117) (1253) (1273) (1280) (1284) (1289) — — (1094) (1220) (1088) (1235) (1098) —
WHT BLK ORG/BLU BLU/WHT LT GRN/YEL GRN PNK
X90A X3 X3 X3 X3 X3 X3
BLU/GRN ORG/BLK BLK/PNK YEL/BLU GRN/BLK
X3 X3 X3 X3 X3
X35
6
1255 1228 17 1
1276 1119 26
1008
1121
7
1318 88
39
1062
1319 1345
6 16
17
24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
X45 (1008) (1121) (1318) (88) (39) (1062) — — — — (1319) (1345) — — — — — — — — — — — —
BLK BLK VLT/WHT RED/BLK BLU BLU
PNK/GRN RED/BLK
W36 (1008) X45 (764) F10 (39)
X26
X45 X4
1 2 3 4 5 6
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
1 2 3 4 5 6 7 8 9 10 11 12
F5 F6 F20 (537) (536) W36
(141) — (1318) (1118) (1029) (138) (1319) (149) — (993) (1218) (503)
WHT/YEL
(610)
VLT/WHT GRY ORG/BLU GRN/BLK PNK/GRN BLU/BLK
X35 X36 X36 X3 X35 X3
BLK/BLU BLK/RED BLK
X3 (27) W36
X45 X26 1 610 611 612 3
1 141
1318 1118 1029 5
6 138 1319 149
993 1218 503 12
4 616 617 615 6
2
3 X3
X108B
X31
2
ML
1
1
1157
1069
1295
1071
1082 1229
1067
1132 1167
9
10
1224 1087 1084 1194 1086 1207 1213 1185 1245 1100 1126 1128 21
22
1139 1180 1163 1140 1297
1018 1114
1300
1395 1
(1157) (1069) (1295) (1071) (1082) (1229) (1067) (1132) (1167) (1224) (1087) (1084) (1194) (1086) (1207) (1213)
YEL/WHT GRN/WHT BRN/WHT GRN/ORG GRN/RED BLU/RED BLU/BLK LT GRN LT GRN/RED GRN WHT YEL VLT/WHT BLK/WHT ORG/RED RED/BLK
X22 X3 X3 X3 X3 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) (1126) (1128) (1139) (1180) (1163) (1140) (1297) (1018) (1114) (1300) — —
RED/GRN RED/YEL WHT/GRN BLU VLT/YEL WHT/BLU BLU/WHT ORG/BLK YEL/BLU BRN/RED RED/GRN BRN WHT/BLK
X3 X3 X3 X3 X3 X574 X574 X574 X574 X3 X3 X3 X3
1343
1397
1396
1398
1399 7
8
1268 1116
1261 1115 16
17
1263
1230 1330 1331 24
1
1
1394 2
BLU/YEL
X574
BLK/BLU RED/BLU RED/BLK BLK/RED
X49 X49 X49 X49
WHT/VLT WHT/YEL
1090 1088 1110
1092 1047 1293
1116 1115 1230
1 1331 1254 800
1264 1235 1061 6
1 1285 1045 1093
1268 1261 1263 6
X108A
810 4
X3 X3
13 14 15 16 17 18 19 20 21 22 23 24
— — (1261) (1115) — — — — (1263) (1230) (1330) (1331)
GRN/BLU GRN/RED
X3 X3
1 2 3
(1395) — (1394)
RED
(1095)
WHT/YEL
(610)
WHT/BLU BLK/GRN WHT/BLK RED
X3 X3 X3 X3
(852) —
537 536
8
7
5
660 664
6
4
2
508 505
3
1
GRN/BLK
1350
K3
516 745 763 1 1067 1229 1094
(853) —
GRN/BLK
8
A
1033 26
27 1289
1273 1280 1284 6
X22
501 6
5 1105 1023
2 D
X108B 1 2
1153
C
15 764 768 1220 1253 767 766 769 21
X108A 1 2
511 1
7
TX1208574
506 3
15 1300 1114 1297 1018 1256 1257 138 21 1098
B
1117
665 149 993
542 546 823
1 1295 1069 1071
1082 1100 1245 6
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
(1067) BLU/BLK (1229) BLU/RED (1094) BLU/GRN (1273) BLU/WHT (1280) LT GRN/YEL (1284) GRN (516) GRN/YEL (745) VLT/GRN (763) YEL/WHT (26) WHT/RED (27) BLK/RED (1289) PNK (1350) BLU/YEL (1033) SK BLU (764) RED/BLK (768) GRY/RED (1220) ORG/BLK (1253) ORG/BLU (767) ORG/BLU (766) GRY/BLU (769) RED/BLU (1295) BRN/WHT (1069) GRN/WHT (1071) GRN/ORG (1082) GRN/RED
X31 X31 X34 X34 X34 X34 F16 (526) K14 X33 X33 X34 X102 X33 F17 S6 X34 X34 X92A X92B X92A X31 X31 X31 X31
B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 C1 C2 C3 C4 C5 C6 C7 C8
(1100) (1245) (665) (149) (993) (542) (546) (823) (1098) (1117) (1300) (1114) (1297) (1018) (1256) (1257) (138) (511) (508) (505) (810) (660) (664) (537) (536)
WHT/GRN RED/YEL WHT/YEL BLU/BLK BLK/BLU PNK/WHT VLT LT GRN/BLK GRN/BLK BLK WHT/BLK BRN BRN/RED RED/GRN RED/YEL BLK/YEL GRN/BLK RED WHT WHT/BLK BLU RED WHT/YEL BLU/RED RED/BLU
X31 X31 (610) X45 X45 K10 K9 F11 X34 X34 X31 X31 X31 X31 (1023) (1153) X45 X47 V3 K4 K14 (611) (610) K7 K8
D1 D2 D3 D4 D5 D6 D7 D8 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17
(1105) (1023) (506) PLUG PLUG (501) PLUG (1153) (1331) (1254) (800) (1264) (1235) (1061) (1330) (1227) (801) (1090) (1088) (1110) (1095) (1358) PLUG PLUG (1132)
WHT RED/YEL WHT
X52 X90A F50
BLK
X99
BLK/YEL RED BLK GRN BLU/RED YEL/BLU YEL/BLK WHT/BLK GRY BLU WHT/RED BLK/PNK GRN/YEL RED WHT/BLK
X91B X32 X33 X20 X33 X34 X33 X32 X33 X20 X33 X34 X33 X33 X36
LT GRN
X31
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
(1167) (1213) (1185) (1084) (1285) (1045) (1093) (1268) (1261) (1263) (1092) (1047) (1293) (1116) (1115) (1230) PLUG PLUG (1194) (1126) (1128) (1207) (1086) (1087) (1224)
LT GRN/RED RED/BLK RED/GRN YEL YEL/RED BLU/RED GRN/YEL WHT/VLT GRN/BLU WHT/BLU BLU/YEL GRY/RED BLK/RED WHT/YEL GRN/RED BLK/GRN
X31 X31 X31 X31 X34 X34 X34 X32 X32 X32 X34 X34 X34 X32 X32 X32
VLT/WHT BLU VLT/YEL ORG/RED BLK/WHT WHT GRN
X31 X31 X31 X31 X31 X31 X31
SHEET 4 OF 5 Cab Harness (W1) Wiring Diagram (4 of 5) Continued on next page
TM12660 (18APR18)
X3
F
1330 1227 801
2
X579 — (1343) — (1397) (1396) (1398) (1399) — — — (1268) (1116)
15 1194 1126 1128 1207 1086 1087 1224 21
1358
852
3
X32 1 2 3 4 5 6 7 8 9 10 11 12
E
1095
X579
X32
31
X31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
853
1132 1167 1213 1185 1084 21
15
9015-10-67
041818
PN=377
CW08338,0000D08 -19-25JAN16-7/10
System Diagrams
TM12660 (18APR18)
9015-10-68
041818
PN=378
System Diagrams
2— Continued on Sheet 3 3— Continued on Sheet 5 X3— Cab Harness-to-Machine Harness 100-Pin Connector X26— Optional Connector X31— Cab Harness-to-Main Controller (MCZ) 31-Pin Connector A
X32— Cab Harness-to-Main Controller (MCZ) 24-Pin Connector B X33— Cab Harness-to-Main Controller (MCZ) 17-Pin Connector C X34— Cab Harness-to-Main Controller (MCZ) 30-Pin Connector D
X108A—Not Used X35— Cab Harness-to-Main X108B—Not Used Controller (MCZ) 24-Pin X579— Not Used Connector E X36— Cab Harness-to-Main Controller (MCZ) 26-Pin Connector F X45— Option 2 12-Pin Connector (not used) Continued on next page
TM12660 (18APR18)
9015-10-69
CW08338,0000D08 -19-25JAN16-8/10
041818
PN=379
System Diagrams
TM12660 (18APR18)
9015-10-70
041818
PN=380
System Diagrams
TX1208575 —UN—29FEB16
X92A
X91B 1
X92B
1231 2 2 1153
X92A
1 2
E1
1 767 769 2
X90A
E2 1 1023 1182 2
S1
X39
X3
1 2 3 4
1
GRY/BLU
BLK/PNK BLK/RED BLK BLK/YEL
1 2
— (1231)
X29
1
2 1243 1269 1
1 2
— (1153)
(1143) (1352) (1178) (1142) (1350) (1359)
RED BLK BLK/YEL BLK/RED BLU/YEL RED/BLK
X29 X29
1310
(1310)
BLU/YEL
X11
BLK
X99
W35 1
(500)
W35
X93 F M
4
1 1143
X93 M
E3
3 1178 1142 1350 1359 6
1
2
3
E3 1 2
(1023) (1182)
1 2
S5/X543 X3
RED/YEL WHT
1 2 3
X3 X35
(1154) (1156) (1014)
RED/BLU ORG/BLU BLK
YEL/WHT BLK
X36 W36
X2
(545) (605)
WHT/VLT BLK
1 2 3 4 5 6
K10 W36
F
1154 1156 1014
BLK/YEL
(1226) (79)
S5/X543
1352 2
X90A YEL/BLK BRN/WHT
1
(611) X36 X10 X11 X3 (764)
X102
X39 WHT/GRN
1 2 3 4 5 6
K6 F2 W36 K6
X91A
X91B
X90B (1269) (1243)
— (766)
(589) (591) (592) (590)
589 591 592 590
X90B
1 2
X3 X3
S14
S14
X102 ORG/BLU RED/BLU
X92B S2
1
(767) (769)
1
2
2 766
1 2
1
ML
X91A
2
545
X65
605
(552) (1215) X11
1 2 3
X65 530 825 604 1
2
3
S6 1 768
773
3 528 526
2 6
(530) (825) (604)
ORG VLT BLK
V5 X21 W36
BLK/RED RED/GRN BLK BLK/GRN
F50
X20 X20 (1004) X20
F10
F9 552
X2
F7 1159
1 1028 1026 1089 3
(768) (773) (528) (526) — —
GRY/RED RED/BLK BRN VLT/GRN
39
F8 538
S6 1 2 3 4 5 6
(1028) (1026) (1089) (1030) — —
X3 (764) V5 K4
4 1030
F6 611 F5 610 F4
1
F3 609 F2 591 F1 598
K12 2
1325 1311 1323
1 561 2 562
X43 1 2
1
5
X44
3 1370
618
(561) (562)
WHT BLK
(506) X99
1
(618)
RED/BLU
(536)
1 2 3 4 5
K6
X44
(1323) (1325) (1370) (1311) —
BLU YEL/GRN WHT WHT/BLK
(1327) (1320) (607) F50
K9 596
I3
546
I5
F3
598 G3
600 H3
594
F5
537 G5
536 H5
850
601
854
595
855
602
G1
G2
H1
H2
I1
I2
J1
041818
(1327) (1320) (1322) — (1321)
BLU YEL/GRN YEL/GRN
F18 X33 (1320)
BLK
W36
K1 A1 A2 A3 A4 A5
603
J3
K4
542
J5
D1 D2 D3 D4 D5
545 J2
G4
H4
520 A3
531 B3
541 C3
900 D3
550 E3
524 A5
525 B5
540 C5
D5
E5
K7
523 525 527
G1 G2 G3 G4 G5
F4
I4
519
856
533
529
552
852
910 505 526
A1
A2
B1
B2
C1
C2
D1
A4
B4
K1
K2
4
1 763
5
810
3
538
C4
K3
D2
E4
K5 2
(763) (539) (538) — (810)
YEL/WHT BLK GRN
X3 W36 F8
BLU
X3
E2
D4
K14 1 2 3 4 5
E1
J4
K4
4
1
1326 1312 1324 5 3 1315
Cab Harness (W1) Wiring Diagram (5 of 5)
PN=381
1 2 3 4 5
K10
599
K14
9015-10-71
1327
F2
539
TM12660 (18APR18)
1320
593 589 845
2
Continued on next page
1
3 1322
K8
K13
10A
10A
30A
5A
5A
522
5A
1332
20A
5A
1312
612 F20 603 F19 1327 F18 764 F17 516 F16
5A 20A
607
5A
506
20A 10A 20A
10A
1311
10A
1372 551
5A 5A
661 F15 771 F14 632 F13 566 F12 823 F11
K11
2
5 1321
K7
590
F1
TX1208575
K11
K12
5A
560
6
3
X43
5A
K13 1 2 3 4 5
(1324) (1326) (1315) (1312) —
BLU YEL/GRN BLU YEL/BLK
(1327) (1320) (522) F50
K2 (519) (856) (520) — (524)
RED ORG RED
(511) X22 (511)
WHT
(508)
(910) (526) (900) (505) —
WHT/RED VLT/GRN WHT/RED WHT/BLK
(900) S6 X47 X3
(599) (850) (598) — (537)
RED/BLK YEL GRN
(764) X10 F1
BLU/RED
X3
(602) (545) (603) — (542)
WHT WHT/VLT WHT
(603) S5/X543 F19
PNK/WHT
X3
B1 B2 B3 B4 B5
K3 (533) (529) (531) — (525)
RED VLT/WHT PNK/BLK
(1) V5 X75
VLT
K5
(523) (527) (550) (525) —
RED VLT/RED BLK VLT
(1) V4 W36 K2
(601) (854) (600) — (536)
GRN RED/BLK GRN
(598) X10 (598)
RED/BLU
X3
K5 E1 E2 E3 E4 E5
(552) (852) (541) — (540)
RED/BLU GRN/BLK PNK/GRN
F9 X108A H2
BLK
W36
(593) (845) (590) (589) (594)
RED/BLK GRY/RED BLK/YEL BLK/PNK BLK
(764) X107A X39 X39 W36
(595) (855) (596) — (546)
RED/BLK BLK/BLU BLK/RED
(764) X10 (591)
VLT
X3
K6
K8 H1 H2 H3 H4 H5
C1 C2 C3 C4 C5
F1 F2 F3 F4 F5
K9 I1 I2 I3 I4 I5
K10 J1 J2 J3 J4 J5
SHEET 5 OF 5 CW08338,0000D08 -19-25JAN16-9/10
System Diagrams
TM12660 (18APR18)
9015-10-72
041818
PN=382
System Diagrams K8—Boom Light Relay 3— Continued on Sheet 4 K9—Windshield Washer Relay E3— Cab Dome Light K10— Horn Relay F50— Fuse Box K11— Idle Stop Relay K1—Load Dump Relay K2—Pilot Shutoff Solenoid Relay K12— Accessory Cut Relay K13— Key Cut Relay K3—Security Alarm Relay K14— Engine Control Unit (ECU) K4—Starter Cut Relay Power Relay K5—Security Relay S5— Horn Switch K6—Windshield Wiper Relay S6— Engine Stop Switch K7—Work Light Relay
S14— Door Switch W35—Cab Harness Ground 1 X2— MPDr 6-Pin Connector X39— Cab Harness-to-Window Switch Connector X43— Optional Fuse Connector X44— Optional Light Connector X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector
X90A— Not Used X90B— Not Used X91A— Not Used X91B— Not Used X92A— Not Used X92B— Not Used X93— Not Used X102— Not Used X543— Auxiliary Function Lever (AFL) Horn Switch Connector CW08338,0000D08 -19-25JAN16-10/10
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 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Continued on next page
TM12660 (18APR18)
9015-10-73
CW08338,0000D09 -19-15SEP16-1/3
041818
PN=383
System Diagrams
TM12660 (18APR18)
9015-10-74
041818
PN=384
System Diagrams
TX1209810 —UN—17MAR16
B27
B31
B39
Y23 S40 X67
E1
Y22
Y27 Y24 Y29
X94 B30 E2
B63 B48 B32 B23
X105 X104
B18
B34
B50
B33 B49
B16 X109
B44 X3
A2
B24
Y13
X46
Y12
X48
R8 B22
X98 X4 R13
A1
X64 W19
B40
W2 A12
G3 K16 K19
X15 X14 B45
B6
K34 F61
X71
F60
M6
H5
Y11 M1
X86
X40
X8
X6020
X7 X6 X9
B20
X5
TX1209810 Machine Harness (W2) Component Location Continued on next page
TM12660 (18APR18)
9015-10-75
041818
PN=385
CW08338,0000D09 -19-15SEP16-2/3
System Diagrams
TM12660 (18APR18)
9015-10-76
041818
PN=386
System Diagrams
A1—Engine Control Unit (ECU) B48— Exhaust Differential A2—Variable Geometry Pressure Sensor Turbocharger (VGT) B49— Exhaust Temperature A12— Rear Camera Sensor 1 (DPF) B6—Engine Oil Level Sensor B50— Exhaust Temperature B16— Air Filter Restriction Sensor 2 (DOC) Switch B63— Attachment Pressure B18— Fuel Level Sensor Sensor 3 B20— Air Conditioner E1— Work Light High/Low-Pressure Switch E2— Boom Light B22— Ambient Air Temperature F60— Alternator 65 A Fuse Sensor F61— Battery 45 A Fuse B23— High Note Horn G3—Alternator B24— Low Note Horn H5—Swing Alarm B27— Hydraulic Oil Filter K16— Glow Plug Relay Restriction Switch (if K19— Battery Relay equipped) K34— Starter Relay B30— Boom Up Pressure Sensor M1—Starter Motor B31— Arm In Pressure Sensor M6—Windshield Washer Motor B32— Front Attachment Pressure R8—Engine CAN Termination Sensor Resistor B33— Swing Pressure Sensor R13— Engine Control Unit (ECU) B34— Travel Pressure Sensor Resistor B39— Bucket In Pressure Sensor S40— Hydraulic Oil Temperature B40— Hydraulic Oil Temperature Switch (if equipped) Sensor W2—Machine Harness B44— Mass Air Flow (MAF)/Intake W19—Camera Harness Air Temperature (IAT) X3— Cab Harness-to-Machine Sensor Harness 100-Pin Connector B45— Barometric Pressure X4— Cab Harness-to-Machine Sensor Harness 32-Pin Connector X5— Machine Harness-to-Engine Harness 32-Pin Connector
X6— Machine Harness-to-Engine X94— Machine Harness-toHarness 16-Pin Connector Hydraulic Oil Temperature X7— Machine Harness-to-Engine Switch Connector Harness 14-Pin Connector X98— Machine Harness Splice X8— Machine Harness-to-Engine Connector Harness 1-Pin Connector X104— Not Used X9— Machine Harness-to-Engine X105— Not Used Harness 20-Pin Connector X109— Not Used X14— Engine Control Unit X6020—CAN 0 Connector (ECU)-to-Engine Harness (marked CAN) 60-Pin Connector Y11— Air Conditioner X15— Engine Control Unit Compressor Clutch (ECU)-to-Engine Harness Y12— Exhaust Filter Regulator 94-Pin Connector Solenoid (pump 1) (marked X40— Pump Harness-to-Machine SZ) Harness Connector Y13— Exhaust Filter Regulator X46— Attachment Connector Solenoid (bypass cut-off X48— Attachment Connector 2 valve) (marked SJ) X64— Machine Harness-to-Rear Y22— Dig Regenerative Solenoid Camera Harness (marked SF) Connector Y23— Arm Regenerative X67— Machine Harness Auxiliary Solenoid (marked SC) Power Connector Y24— Power Dig Solenoid X71— Machine Harness-to(marked SG) Service ADVISOR™ Y27— Arm 2 Flow Control Harness 8-Pin Connector Solenoid (marked SD) X86— Machine Harness-to-Travel Y29— Arm 1 Flow Control Alarm Harness Connector Solenoid (marked SE)
Service ADVISOR is a trademark of Deere & Company CW08338,0000D09 -19-15SEP16-3/3
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 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
Continued on next page
TM12660 (18APR18)
9015-10-77
CW08338,0000D0A -19-15SEP16-1/8
041818
PN=387
System Diagrams
TM12660 (18APR18)
9015-10-78
041818
PN=388
System Diagrams
TX1209868 —UN—03FEB16
NUMBER 26 27 138 140 149 202 222 223 234 235 250 501 502 504 505 506 508 511 512 513 514 515 516 521 536 537 542 543 546 547 549 595 596 597 608 613 614 619 620 664 665 668 700 701 703 707 708 709 710 711 713 714 715 716 717 718 721 722 723 724 TX1209868
COLOR WHT/RED BLK/RED GRN/BLK BLK BLU/BLK BLU/YEL WHT/BLU GRN/BLU WHT/BLK BRN WHT/BLU BLK WHT WHT BLK/WHT WHT WHT RED RED RED BLK/YEL YEL/BLU GRN/YEL BLK RED/BLU BLU/RED PNK/WHT PNK/WHT VLT BLK BLK RED/BLU BLK BLK/YEL BLK RED BLK RED WHT WHT/YEL WHT/YEL WHT/YEL PNK/BLU BRN/BLU GRN/BLK RED BLU/BLK YEL/BLK WHT GRN BLU/BLK VLT GRN/WHT YEL/RED WHT GRN GRN/YEL BLK BLU/YEL BRN/GRN
END #1 X86 H5 X86 X86 H5 G3 X5 B16 X5 B18 X94 G3 G3 G3 K34 G3 K19 F60 K16 X67 K16 X15 K16 K19 E2 E1 B24 B23 M6 M6 X67 K34 K34 X98 B16 K34 E1 F60 K19 X46 X86 X105 X15 X15 X15 X5 X5 X5 X5 X9 X5 X6 X6 X6 X5 (711) X9 X5 X6 X9
END #2 X3 X3 X3 (501) X3 X4 X4 X4 X4 X4 X4 X3 (508) F61 X3 X3 X3 X3 (511) (511) X8 K16 X3 (501) X3 X3 X3 (542) X3 (501) (501) M1 (501) B18 (501) M1 (501) K19 F61 X3 X3 (664) B45 B45 B45 X14 X14 X14 (806) X14 X14 X14 X14 X14 X14 X14 X14 (804) X14 X14
NUMBER 727 728 729 730 731 732 733 734 735 736 737 745 746 748 749 750 751 754 755 760 761 762 763 764 765 766 767 768 769 770 775 776 780 781 782 783 784 785 786 787 800 801 804 805 806 807 808 809 810 811 812 813 816 818 819 822 823 830 831 832
COLOR GRN/YEL BLK BLU/RED YEL/BLU BRN/GRN BLU RED/BLK BLK/WHT RED BLK/YEL YEL BRN/YEL GRN/WHT BRN/BLU PNK/BLU RED/BLU BLU/YEL BLK YEL WHT/YEL GRN/RED BLK/GRN YEL/WHT YEL/WHT RED/BLK YEL/WHT BLK WHT GRY/RED GRN WHT BLK BLU BLU BLK BLK BLK BLK BLK BLK/WHT GRN BLU BLK RED WHT RED GRN BLU BLU BLK GRN BLU GRN/BLK BLK WHT BLK LT GRN/BLK GRN BLU PNK
END #1 X5 X5 X6 X6 (724) X9 X9 X9 X9 X9 X9 X15 X15 (701) (700) X15 X15 (811) X15 X15 X15 X15 X15 X15 X15 X15 X15 X15 X15 X15 X5 X5 X15 X15 (811) (811) (811) (811) (811) X15 X15 X15 X5 X5 X5 X9 X6020 X6020 X3 (754)(782)(783)(784)(785)(786)(885)(886)(887)(888) X15 X15 X7 X9 X9 (501) X3 A2 A2 X7
END #2 X14 X14 X14 X14 X14 X14 X14 X14 X14 X14 X14 X3 X40 X40 X40 B44 X71 X71 X71 X4 X4 X4 X3 X3 (763) X3 X3 X3 X3 (769) X14 X14 (810) (810) X15 X15 X15 X15 X15 (505) X3 X3 X14 X14 X14 X14 (800) (801) (780)(781)(882)(883) (501) R8 R8 X14 X14 X14 X40 X40 (812) (813) X14
NUMBER 833 834 835 836 837 838 840 841 842 843 857 858 859 863 864 866 869 872 873 874 875 876 877 878 880 882 883 885 886 887 888 889 890 891 892 893 894 895 896 897 898 993 994 1000 1001 1018 1020 1022 1033 1045 1047 1049 1051 1053 1055 1056 1057 1058 1060 1061
COLOR YEL WHT BLK WHT RED BLK/BLU GRN BLU BLU BLK BLK BLK BLU GRN/YEL BLK RED BLK GRN/YEL WHT ORG BLU ORG/BLK ORG/GRN YEL BLU BLU BLU BLK BLK BLK BLK BLU/BLK WHT BRN GRN/YEL RED/YEL BLK/YEL RED WHT BLK GRN/YEL BLK/BLU BLK BLK BLK BRN/YEL RED BLK SK BLU BLU/RED GRY/RED BLK/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL BLK/YEL WHT/RED YEL/BLK
NUMBER 1067 1069 1071 1082 1084 1086 1087 1088 1090 1091 1092 1093 1094 1095 1096 1097 1098 1100 1104 1105 1110 1112 1114 1115 1116 1117 1123 1126 1127 1128 1129 1130 1131 1132 1133 1135 1136 1147 1167 1170 1185 1194 1201 1207 1209 1213 1220 1224 1227 1229 1230 1235 1245 1253 1254 1255 1256 1257 1261 1263
COLOR BLU/BLK GRN/WHT GRN/ORG GRN/RED YEL BLK/WHT WHT BLK/PNK WHT/RED BLK/YEL BLU/YEL GRN/YEL BLU/GRN RED BLK GRN/BLK GRN/BLK WHT/GRN BRN/RED WHT GRN/YEL RED/YEL GRN/BLK GRN/RED WHT/YEL BLK GRN/YEL BLU BLK VLT/YEL WHT PNK BLK BLU/GRN GRN WHT BLU BLK/YEL LT GRN/RED BLK/YEL RED/GRN LT GRN/WHT PNK ORG/RED YEL/GRN RED/BLK ORG GRN GRN/YEL BLU/RED BLK/GRN YEL/BLU RED/YEL ORG/BLU BLK BLK/YEL RED/YEL BLK/YEL GRN/BLU WHT/BLU
END #1 X40 X40 X40 X40 Y24 Y22 Y23 X40 X40 X98 B33 B30 X104 X105 B20 B20 X46 Y12 B22 Y11 X40 B22 X48 X46 X46 X46 X5 Y29 X5 Y29 X5 X5 X5 Y27 (800) X64 (801) X98 Y27 X98 Y13 Y24 X15 Y22 X5 Y13 B63 Y23 X46 X40 X46 X40 Y12 X46 X46 X98 X46 X46 X46 X46
END #2 X3 X3 X3 X3 X3 X3 X3 X3 X3 X40 X3 X3 X3 X3 X4 X4 X3 X3 X4 X3 X3 X4 X3 X3 X3 X3 X14 X3 (818) X3 X14 X14 X14 X3 X71 X4 X71 B32 X3 B40 X3 X3 X71 X3 X14 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3 X3
NUMBER 1264 1268 1270 1272 1273 1276 1277 1279 1280 1283 1284 1285 1289 1293 1295 1296 1297 1299 1300 1303 1308 1309 1316 1330 1331 1345 1349 1350 1351 1358 1390
COLOR BLU/RED WHT/VLT BLK/YEL BLK/YEL BLU/WHT RED/YEL BLK/YEL RED/YEL LT GRN/YEL RED/YEL GRN YEL/RED PNK BLK/RED BRN/WHT BLK/YEL BRN/BLU RED/YEL GRN/BLU GRY RED/YEL BLK/YEL RED/YEL WHT RED RED/BLK BLK BLU/YEL BLK WHT/BLK ORG/WHT
END #1 X40 X46 X98 X98 X104 X98 X98 X98 X104 X104 X104 B34 X104 B31 X40 X104 X48 X98 X48 X64 X98 X98 X98 X46 X46 X46 X109 X109 X46 B6 X40
END #2 X3 X3 B34 B33 X3 X3 B31 B30 X3 (1256) X3 X3 X3 X3 X3 (1257) X3 X40 X3 X4 X98 B63 B63 X3 X3 X4 (501) X3 (501) X3 X4
(SHEET 1 OF 4) Machine Harness (W2) Wiring Diagram (1 of 4) Continued on next page
TM12660 (18APR18)
END #2 END #1 X7 X14 X6 (717) X6 (728) X15 B44 X15 B44 X15 B44 (812) X71 (813) X71 A2 (810) A2 (501) B50 (700) B49 (700) R13 (810) X15 (SHIELD) (872) X15 B48 X15 B48 (804) B44 X15 X3 (SHIELD) X15 B48 B49 X15 B50 X15 X15 X4 X15 X4 X9 X14 X9 X14 X15 (810) X15 (810) (811) X15 (811) X15 (811) X15 (811) X15 A2 X7 A2 X7 A2 X7 X15 R13 A2 X7 A2 X7 A2 X7 A2 X7 A2 X7 A2 X7 H5 X3 H5 (501) B23 (501) B24 (501) X48 X3 X64 X4 X64 X4 B40 X3 B32 X3 B39 X3 X98 B30 X98 B31 B32 X98 X98 B33 X98 B34 B39 X98 X98 B39 X15 X4 X40 X3
9015-10-79
041818
PN=389
CW08338,0000D0A -19-15SEP16-2/8
System Diagrams
TX1209869 —UN—03FEB16
BLK BLK BLK BLK BLK BLK BLU BLK BRN/BLU RED
(811) (811) (811) (811) (811) (811) (810) X3 B45 B48
BLU/YEL
X71
ORG BLU RED/BLU RED GRN/WHT WHT GRY/RED GRN GRN/BLK BLU BLU YEL/WHT
BLK
BLK/WHT
B49 B50 B44 B44 X40 B48 X3 (769) B45 R8 (810) X3
(811)
(505)
A2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
GRN BLU BLK BLK/BLU YEL/WHT GRN/YEL
R8 (810) B48 B44 X3 —
WHT
B44
BLK
(811)
WHT ORG/GRN
X3 X4
WHT/RED
X4
ORG/BLK WHT/YEL
X4 X4
BLU BLU YEL/WHT PNK/BLU RED/BLK BLK
X3 (810) X3 B45 (763) (811)
GRN/YEL
R13
YEL PNK
X71 X71
BLK/GRN
X4
GRN/RED
X4
BRN/YEL YEL/BLU GRN
X3 K16 X3
A2 (895) (896) (897) (894) (898) PLUG PLUG (893)
TX1209869
RED WHT BLK BLK/YEL GRN/YEL
RED/YEL
X7 X7 X7 X7 X7
X7
9 10 11 12 13 14 15 16
PLUG (889) (890) (891) (842) (843) (830) (831)
BLU/BLK WHT BRN BLU BLK GRN BLU
X7 X7 X7 (810) (501) (812) (813)
X3 (737) (878) — — (729) (717) — (775) (708) (1209) (707) (1130) (713) (816) (731) (732) (880) — — (723) (806) (819) (1129) — (709) (728) — (727) — (724) (735) — (734) — (730) — — — — (1131) (804) (818) (721) — (718) (733) — (736) (833) (832) — (716) (715) (714) (776) (807) (805) (1123) — (711)
YEL YEL
X9 X9
BLU/RED WHT
X6 X5
WHT BLU/BLK YEL/GRN RED PNK BLU/BLK GRN/BLK BRN/GRN BLU BLU
BLU/YEL WHT WHT WHT YEL/BLK BLK
X5 X5 X5 X5 X5 X5 X7 (724) X9 X9
X6 X5 X9 X5 X5 X5
GRN/YEL
X5
BRN/GRN RED
X9 X9
BLK/WHT
X9
YEL/BLU
X6
BLK BLK BLK GRN/YEL
X5 X5 X9 X9
GRN RED/BLK
(711) X9
BLK/YEL YEL PNK
X9 X7 X7
YEL/RED GRN/WHT VLT BLK RED RED GRN/YEL GRN
X6 X6 X6 X5 X9 X5 X5
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 B14 B15 B16 B17 B18 B19 B20 B21 C1 C2 C3 C4 C5 C6 C7 C8
X3 (1067) (1229) (1094) (1273) (1280) (1284) (516) (745) (763) (26) (27) (1289) (1350) (1033) (764) (768) (1220) (1253) (767) (766) (769) (1295) (1069) (1071) (1082) (1100) (1245) (665) (149) (993) (542) (546) (823) (1098) (1117) (1300) (1114) (1297) (1018) (1256) (1257) (138) (511) (508) (505) (810) PLUG (664) (537) (536)
BLU/BLK BLU/RED BLU/GRN BLU/WHT LT GRN/YEL GRN GRN/YEL BRN/YEL YEL/WHT WHT/RED BLK/RED PNK BLU/YEL SK BLU YEL/WHT WHT ORG ORG/BLU BLK YEL/WHT GRY/RED BRN/WHT GRN/WHT GRN/ORG GRN/RED WHT/GRN RED/YEL WHT/YEL BLU/BLK BLK/BLU PNK/WHT VLT LT GRN/BLK GRN/BLK BLK GRN/BLU GRN/BLK BRN/BLU BRN/YEL RED/YEL BLK/YEL GRN/BLK RED WHT BLK/WHT BLU
X40 X40 X104 X104 X104 X104 K16 X15 X15 X86 H5 X104 X109 B40 X15 X15 B63 X46 X15 X15 X15 X40 X40 X40 X40 Y12 Y12 X86 H5 H5 B24 M6 X40 X46 X46 X48 X48 X48 X48 X46 X46 X86 F60 K19 K34 (780)(781)(882)(883)
WHT/YEL BLU/RED RED/BLU
X46 E1 E2
D1 D2 D3 D4 D5 D6 D7 D8 E1 E2 E3 E4 E5 E6 E7 E8 E9 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
X4 (1105) (1276) (506) PLUG PLUG (501) PLUG (1255) (1331) (1254) (800) (1264) (1235) (1061) (1330) (1227) (801) (1090) (1088) (1110) (1095) (1358) PLUG PLUG (1132) (1167) (1213) (1185) (1084) (1285) (1045) (1093) (1268) (1261) (1263) (1092) (1047) (1293) (1116) (1115) (1230) PLUG PLUG (1194) (1126) (1128) (1207) (1086) (1087) (1224)
WHT RED/YEL WHT
Y11 X98 G3
BLK
G3
BLK/YEL RED BLK GRN BLU/RED YEL/BLU YEL/BLK WHT GRN/YEL BLU WHT/RED BLK/PNK GRN/YEL RED WHT/BLK
X98 X46 X46 X15 X40 X40 X40 X46 X46 X15 X40 X40 X40 X105 B6
X4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(760) (761) (876) (222) (235) (1060) (762) (877) (234) (202) (1097) (1104) PLUG PLUG (1096) (1112)
WHT/YEL GRN/RED ORG/BLK WHT/BLU BRN WHT/RED BLK/GRN ORG/GRN WHT/BLK BLU/YEL GRN/BLK BRN/RED
X15 X15 X15 X5 B18 X15 X15 X15 X5 G3 B20 B22
BLK RED/YEL
X46
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B20 B22
(1345) PLUG PLUG PLUG PLUG PLUG (223) (250) (1020) (1022) PLUG (1390) PLUG (1135) (1303) PLUG
GRN/BLU WHT/BLU RED BLK
B16 X94 X64 X64
ORG/WHT
X40
WHT GRY
X64 X64
(1095) (668)
RED WHT/YEL
X105
X3 (664)
1 1095 668
RED/BLU
1 2 3 4 5 6 7 8
1296 1283
1273 8
X3
E2 BLU/GRN LT GRN/RED RED/BLK RED/GRN YEL YEL/RED BLU/RED GRN/YEL WHT/VLT GRN/BLU WHT/BLU BLU/YEL GRY/RED BLK/RED WHT/YEL GRN/RED BLK/GRN
Y27 Y27 Y13 Y13 Y24 B34 B32 B30 X46 X46 X46 B33 B39 B31 X46 X46 X46
11 12 13 14 15 16 17 18 19 20
BRN/BLU GRN/BLU BRN/YEL GRN/BLK
X3 X3 X3 X3
(1351) (1345) (1254) PLUG (1253) (1256) (664) (1117) (1098) (1257)
BLK RED/BLK BLK
(501) X4 X3
ORG/BLU RED/YEL WHT/YEL BLK GRN/BLK BLK/YEL
X3 X3 X3 X3 X3 X3
(1297) (1300) (1018) (1114)
1
(1280) (1094) (1289) (1284) (1296) (1283) PLUG (1273)
LT GRN/YEL BLU/GRN PNK GRN BLK/YEL RED/YEL
X3 X3 X3 X3 (1257) (1256)
4
1115 1230 5
1261
1263 1268
9
1227
13 1254
BLU/WHT
X3
1331
8
1351 1345
12
1253
3
X48
1116 1330 1
664 1117
154
1256 16
515
801
745 760
761
762
876
1060
877
1201 755
892
888
765
700
764
786
836
872
763
838
864
768
132 110
813
787 703
770
769
873
746
837
750
875
785
766
874
751
866
701
767
88
68
887
886
882 111 64 885
784
781
89
780
67
783
60 711
30 724
807
721
804 1131
818
776
714
715
50 832
716
44
36
29
21 727
731 15
1123 805
816
728
709
1129 819
713 1130 707 1209 708
775
806
14
35 730 20 723 5
717
833
736
733 46
734
735 31 880
729
878
X98 X3 X98
3
B32
2
B23
1018 1114 3
4
1
2 542 1001
B24
(542) (1001)
PNK/WHT BLK
X3 (501)
(543) (1000)
PNK/WHT BLK
(542) (501)
B24 1 2
B23 1 2
X3
63
782 61
62
21 12241087 1086 1207 1128 1126 1194 15 21 1084 1185 1213 11671132 1358 1293 1047 1092 1110 1088 1090 1093 1045 1285 1 6 1061 1235 1264
1230 1115 1116 6 1263 1261 1268
732 16
501 6
737 1
15
1095 801 1227 1330 800 1254 1331
8 1255
7
8 536 537 7
5
4
6 664
5
1
810 4
6 506 3
A2 X4
14
1104 1097 11
17 1345
1112 1096 15
22
18
27
1022 1020 250 223 23
32
X9
2
543 1000
2
1
895 896 897 894
4
5
898
8
9
893
1
R8
1303 1135
1390 28
2 1276 1105 1
3 505 508 2
D
C
511 1
2
812 813
889 890 891 12
13 842 843 830 831 16
X15 X15
1147
1
1297 1300
20
51
59
1045
1
65
66 883 133
112 90 812
RED/YEL BLU/RED BLK/YEL
1053
2
1098 1257
17
134 800
(1053) (1045) (1147)
T FR
X46
10 202 234 877 762 1060 6
GRN BLU
1 2 3
X15
R8 (812) (813) PLUG
B32
1
X14 Y24 Y29 Y29 Y22 Y22 Y23 Y23
X3 X3 X3 X3 X3 X3 X3 X3 X3
1
45 718
LT GRN/WHT BLU VLT/YEL ORG/RED BLK/WHT WHT GRN
GRN/RED BLK/GRN WHT/YEL WHT GRN/BLU WHT/BLU WHT/VLT RED GRN/YEL
1 2 3 4
4
5
(536)
X46 (1115) (1230) (1116) (1330) (1261) (1263) (1268) (1331) (1227) PLUG
X48
1280 1094 1289 1284
2
E2 1
1 2 3 4 5 6 7 8 9 10
X104
1
5 235 222 876 761 760 1
1 2 3
X46
X104
X105 1 2
RED/BLK
21 138 1257 1256 1018 1297 1114 1300 15 21 769 766 767 1253 1220 768 764 15 1033 1117 1350 1098 B A 763 745 516 993 149 665 1289 27 26 823 546 542 1094 12291067 1 1071 1069 1295 1 6 1284 1280 1273 6 1245 11001082
2
X14
108 — 109 — 110 (812) 111 (882) 112 (864) 113 (838) 114 (763) 115 (872) 116 — 117 (836) 118 — 119 (786) 120 — 121 (768) 122 (877) 123 — 124 (1060) 125 — 126 — 127 — 128 — 129 (876) 130 (760) 131 — 132 (801) 133 (883) 134 (764) 135 (700) 136 (765) 137 (888) 138 — 139 (892) 140 — 141 (755) 142 (1201) 143 — 144 — 145 (762) 146 — 147 (761) 148 — 149 — 150 — 151 — 152 (745) 153 (515) 154 (800)
87
1 2 3 4 5 6 7 8
X15
3
61 (782) 62 (783) 63 (784) 64 (885) 65 (886) 66 (887) 67 (780) 68 (767) 69 (701) 70 (866) 71 — 72 (751) 73 — 74 — 75 — 76 — 77 — 78 — 79 (874) 80 (875) 81 (750) 82 (837) 83 (746) 84 (873) 85 (769) 86 (770) 87 (703) 88 (813) 89 (781) 90 (766) 91 — 92 — 93 — 94 — 95 — 96 — 97 (785) 98 — 99 — 100 (787) 101 — 102 — 103 — 104 — 105 — 106 — 107 —
86
X15
X109
X109 1 2
(1349) (1350)
2
BLK BLU/YEL
(501) X3
1
1350 1349
Machine Harness (W2) Wiring Diagram (2 of 4)
(SHEET 2 OF 4) CW08338,0000D0A -19-15SEP16-3/8
Continued on next page
TM12660 (18APR18)
9015-10-80
041818
PN=390
System Diagrams
1— Continued on Sheet 3 2— Continued on Sheet 3 3— Continued on Sheet 3 A2—Variable Geometry Turbocharger (VGT) B23— High Note Horn B24— Low Note Horn
B32— Front Attachment Pressure X14— Engine Control Unit Sensor (ECU)-to-Engine Harness E2— Boom Light 60-Pin Connector R8—Engine CAN Termination X15— Engine Control Unit Resistor (ECU)-to-Engine Harness X3— Cab Harness-to-Machine 94-Pin Connector Harness 100-Pin Connector X46— Attachment Connector X4— Cab Harness-to-Machine Harness 32-Pin Connector Continued on next page
TM12660 (18APR18)
9015-10-81
X48— Attachment Connector 2 X104— Not Used X105— Not Used X109— Not Used
CW08338,0000D0A -19-15SEP16-4/8
041818
PN=391
System Diagrams
TM12660 (18APR18)
9015-10-82
041818
PN=392
System Diagrams
TX1209870 —UN—16MAR16
Y24 1
Y27 2
1084
1
1194
Y29 2
1132
Y22
1
1167
2
1126
1
1128
1207
B39
Y23 2
1
1086
B39
2
1087
1057
1047
1100
1293
1277
1
12
2
3
P
1245
1 1213
B18
1185
F M
(235) (597)
RED/BLK RED/GRN
X3 X3
2
1 2 3
(1051) (1293) (1277)
RED/YEL BLK/RED BLK/YEL
B63
BRN BLK/YEL
X4 X98
B40
1 2
(513) (549)
RED BLK
1 2
2
1033 1170
(511) (501)
X98 1 2 3 4 5 6 7 8 9 10 11 12
1
2
Y13
1 2 3
(1309) (1220) (1316)
(1033) (1170)
1285
1270
1279
1093
1049
1
2
3
1
2
3
X3 X98
1
(250)
WHT/BLU
X4
X94
3
BLK/YEL ORG RED/YEL
3
X98 X3 X98
(1084) (1194)
YEL LT GRN/WHT
X3 X3
Y27 1 2
(1132) (1167)
BLU/GRN LT GRN/RED
X3 X3
Y29 1 2
(1126) (1128)
BLU VLT/YEL
X3 X3
Y22 1 2
(1207) (1086)
ORG/RED BLK/WHT
X3 X3
B34 B34
1
X98 13
1 2 3
(1056) (1285) (1270)
B30 RED/YEL YEL/RED BLK/YEL
X98 X3 X98
B30 1 2 3
(1279) (1093) (1049)
RED/YEL GRN/YEL BLK/YEL
X98 X3 X98
Y23 1 2
(1087) (1224)
WHT GRN
1
2
1055
1092
1272
1
2
3
(1276) (1299) (1308) (1308) (1316) (1279) (1051) (1053) (1055) (1056) (1057) PLUG
RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL RED/YEL
X3 X40 X98 X98 B63 B30 B31 B32 B33 B34 B39
13 14 15 16 17 18 19 20 21 22 23 24
(1255) (1091) (597) (1309) (1170) (1049) (1277) (1147) (1272) (1270) (1058) PLUG
1276 1299 1308 1308 1316 1279 1051 1053 1055 1056 1057
12
1255 1091
24
597
1309 1170 1049 1277 1147 1272 1270 1058
1 2 3 4 5
749
BLU/RED BLK
X3 X40 B18 B63 B40 B30 B31 B32 B33 B34 B39
1229
823 822
1088 1110
1091 1235
1090
1061 1264
B6
17
20
1358
(1358)
665
26
(547) (546)
BLK VLT
2
WHT BLK/BLU RED RED/BLU BLK
E
F
F M
504 506
B16
(608) (223)
M
B33
547
1
546
2
1
B22 (1104) (1112)
BRN/RED RED/YEL
X4 X4
2
BLK GRN/BLU
838
837
750
(501) X4
M6
E S
(521) (508)
BLK WHT
(755) (1201) (1133) (840) (754) (751) (1136) (841)
YEL PNK GRN GRN BLK BLU/YEL BLU BLU
X15 X15 (800) (812) (811) X15 (801) (813)
1
1 2
2
1097 1096
4
F61 504 1
F61
755 1201 1133 840
1 2
754 751 1136 841
620
(504) (620)
WHT WHT
2
G3 K19
A
619
620
511
1
619
2
1
X6020 1 2
1 2
K19
2
A B
808 809
(620) (619)
WHT RED
F61 F60
(808) (809)
S
(800) (801)
B
E
1 (703) GRN/BLK X15 2 (700) PNK/BLU X15 3 (701) BRN/BLU X15 Machine Harness (W2) Wiring Diagram (3 of 4)
C
595 613
B45
041818
(202) (502)
BLU/YEL WHT
X4 (508)
E
(501)
BLK
X3
B
(504) (506)
WHT WHT
F61 X3
(27) (149) (994) (993)
BLK/RED BLU/BLK BLK BLK/BLU
X3 X3 (501) X3
GRN/BLK BLK
X4 X4
(511) (619)
RED RED
X3 K19
512
1
514
1
K16
515
1
516
2
1 2
(515) (516)
YEL/BLU GRN/YEL
X15 X3
1
(514)
BLK/YEL
X8
1
(512)
RED
(511)
K16
505 596
GRN BLU
1
B45
703 700 701
3
K34
K34 B C
(595) (613)
RED/BLU RED
M1 M1
E S
(596) (505)
BLK BLK/WHT
(501) X3
2
859 892
PN=393
1 2
(1097) (1096)
F60
K19
1
Continued on next page
X3
F60
8
5
1 2 3 4
4
B
X6020
TX1209870
X4 (701) X3 X3 X3 X98 X3 X3 X3 X98
B20
B20
B44
X71 1 2 3 4 5 6 7 8
ORG/WHT BRN/BLU WHT/RED GRN/YEL BLK/PNK RED/YEL BLU/RED YEL/BLK YEL/BLU BLK/YEL
H5
H5
(501) X3
B22 1
149
3
S
1104 1112
2
27
994 993
508
869
1
K19 521
5
836
1 2
(1390) (748) (1090) (1110) (1088) (1299) (1264) (1061) (1235) (1091)
501
4
X15 X15 X15 X15 (804)
E
X98 X3 X98
WHT/BLK
G3
202 502
B16
(501) X3
1
RED/YEL BLU/YEL BLK/YEL
11 12 13 14 15 16 17 18 19 20
G3 1
140 138
K19
X3 X3
9015-10-83
1
X86 2
X3 X3 X3 X15 X3 X3 X3 (700) (501) X3
B6
1
1
BLU/BLK BRN/WHT GRN/ORG GRN/WHT BLU/RED GRN/WHT GRN/RED PNK/BLU BLK LT GRN/BLK
B
X3 (501)
X71
TM12660 (18APR18)
1295 1067
1082 1069
1299
3
(836) (838) (837) (750) (869)
2
(1055) (1092) (1272)
746 1071
X40 (1067) (1295) (1071) (746) (1229) (1069) (1082) (749) (822) (823)
4 1 2
E1
1 2 3
BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL
1 2 3 4 5 6 7 8 9 10
1
748 1390
M6
B33
(537) (614)
4
X3 X3 (501) X3
1
E1 1 2
WHT/YEL WHT/RED BLK GRN/BLK
X98
Y24 1 2
(665) (26) (140) (138)
B44 S3
1056
SK BLU BLK/YEL
X94
1
250
1309 1220 1316
1 2 3 4
X40
X40
X86
X98 X3 X98
X67
B63 TR
(1213) (1185)
549
1
1
B18
SJ
SZ
X3 X3
513
X98 X3 X98
F
1
WHT/GRN RED/YEL
RED/YEL GRY/RED BLK/YEL
B40
2
PI
(1100) (1245)
B31 (1057) (1047) (1058)
X67
Y13 2
Y12
1 2
3
C
M
1 2
1051
BK
2
SC
SF
SE
SD
SI
Y12
B31
1224
1
1
1058
1 2 3
R13
R13 1 2
(859) (892)
BLU GRN/YEL
(810) X15
(SHEET 3 OF 4) CW08338,0000D0A -19-15SEP16-5/8
System Diagrams
TM12660 (18APR18)
9015-10-84
041818
PN=394
System Diagrams 1— Continued on Sheet 2 B40— Hydraulic Oil Temperature X40— Pump Harness-to-Machine Y12— Exhaust Filter Regulator Harness Connector Solenoid (pump 1) (marked 2— Continued on Sheet 2 Sensor SZ) 3— Continued on Sheet 2 B44— Mass Air Flow (MAF)/Intake X67— Machine Harness Auxiliary Power Connector Y13— Exhaust Filter Regulator 4— Continued on Sheet 4 Air Temperature (IAT) X71— Machine Harness-toSolenoid (bypass cut-off B6—Engine Oil Level Sensor Sensor Service ADVISOR™ valve) (marked SJ) B16— Air Filter Restriction B45— Barometric Pressure Harness 8-Pin Connector Y22— Dig Regenerative Solenoid Switch Sensor X86— Machine Harness-to-Travel (marked SF) B18— Fuel Level Sensor B63— Attachment Pressure Alarm Harness Connector Y23— Arm Regenerative B20— Air Conditioner Sensor 3 X94— Machine Harness-toSolenoid (SC) High/Low-Pressure Switch E1— Work Light Hydraulic Oil Temperature Y24— Power Dig Solenoid B22— Ambient Air Temperature F60— Alternator 65 A Fuse Switch Connector (marked SG) Sensor F61— Battery 45 A Fuse X98— Machine Harness Splice Y27— Arm 2 Flow Control B30— Boom Up Pressure Sensor G3—Alternator Connector Solenoid (marked SD) B31— Arm In Pressure Sensor H5—Swing Alarm X6020—CAN 0 Connector Y29— Arm 1 Flow Control B33— Swing Pressure Sensor K16— Glow Plug Relay (marked CAN) Solenoid (marked SE) B34— Travel Pressure Sensor K19— Battery Relay B39— Bucket In Pressure Sensor K34— Starter Relay M6—Windshield Washer Motor R13— Engine Control Unit (ECU) Resistor Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-10-85
CW08338,0000D0A -19-15SEP16-6/8
041818
PN=395
System Diagrams
TM12660 (18APR18)
9015-10-86
041818
PN=396
System Diagrams
TX1116212 —UN—15AUG12
X7 X8 X8 1
514 1
(514)
BLK/YEL
K16
X7
X6
3 889 890 891 1 7 898 895 896 897 4 10 893 894 14 816 833 832
4 8
8 11
716 715 714 834 730 723 729 835
X9
1 5
12
9
16
13
4
1 735 733
736
737
732
878
734 880
721
819 807
818 711
20
724
X5
17 1
806
775
709
710
5
6
805
776
234 1209 707
222
10
11
727
1127 1123 14
15
804
722
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X6 (891) (890) (889) (897) (896) (895) (898) PLUG (894) (893) PLUG (832) (833) (816)
728 1131
22
23
713 1130
27
28
717 1129 708
32
A2 A2 A2 A2 A2 A2 A2
BLK/YEL RED/YEL
A2 A2
PNK YEL GRN/BLK
X14 X14 X14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X9 (834) (714) (715) (716) (835) (729) (723) (730) PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
WHT VLT GRN/WHT YEL/RED BLK BLU/RED BLU/YEL YEL/BLU
(717) X14 X14 X14 (728) X14 X14 X14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B
17
18
BRN WHT BLU/BLK BLK WHT RED GRN/YEL
595
M1
C
M1 B C
(595) (613)
RED/BLU RED
K34 K34
(736) PLUG (733) (735) (732) PLUG (878) (737) PLUG PLUG PLUG (734) (724) (721) PLUG (880) (711) (818) (807) (819)
BLK/YEL
X14
RED/BLK RED BLU
X14 X14 X14
YEL YEL
X14 X14
BLK/WHT BRN/GRN GRN/YEL
X14 X14 X14
BLU GRN BLK RED WHT
X14 X14 X14 X14 X14
613
X64
X64
4 2 4
1022 1020
1
1303 1135
3
1 2 3 4
(1020) (1022) (1135) (1303)
RED BLK WHT GRY
1
X5
1105
Y11 Y11 1
(1105)
WHT
X3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X5 (806) (775) (709) (222) (710) (805) (776) (234) (1209) (707) (727) PLUG (1127) (1123) (804) PLUG
WHT WHT YEL/BLK WHT/BLU WHT RED BLK WHT/BLK YEL/GRN RED GRN/YEL BLK GRN/YEL BLK
X14 X14 X14 X4 (806) X14 X14 X4 X14 X14 X14 (818) X14 X14
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
864
(722) PLUG (728) (1131) PLUG PLUG PLUG (713) (1130) PLUG PLUG PLUG (717) (1129) (708) PLUG
BLK
(804)
BLK BLK
X14 X14
B48
3 873
866
B48
1 2 3
2
(864) (873) (866)
1
BLU/BLK PNK
X15 X15 X15
1 2
(874) (858)
ORG BLK
X15 (700)
(857) (875)
BLK BLU
(700) X15
X14 X14 2
1 875 857
WHT WHT BLU/BLK
BLK WHT RED
B49 B49
858 874
X14 X14 X14
B50 B50
1 2
(SHEET 4 OF 4)
TX1116212 Machine Harness (W2) Wiring Diagram (4 of 4) Continued on next page
TM12660 (18APR18)
X4 X4 X4 X4
9015-10-87
041818
PN=397
CW08338,0000D0A -19-15SEP16-7/8
System Diagrams
TM12660 (18APR18)
9015-10-88
041818
PN=398
System Diagrams
4— Continued on Sheet 3 B48— Exhaust Differential Pressure Sensor B49— Exhaust Temperature Sensor 1 (DPF) B50— Exhaust Temperature Sensor 2 (DOC)
X8— Machine Harness-to-Engine Y11— Air Conditioner M1—Starter Motor Harness 1-Pin Connector X5— Machine Harness-to-Engine Compressor Clutch X9— Machine Harness-to-Engine Harness 32-Pin Connector Harness 20-Pin Connector X6— Machine Harness-to-Engine X64— Machine Harness-to-Rear Harness 16-Pin Connector Camera Harness X7— Machine Harness-to-Engine Connector Harness 14-Pin Connector CW08338,0000D0A -19-15SEP16-8/8
TM12660 (18APR18)
9015-10-89
041818
PN=399
System Diagrams
Monitor Harness (W3) Component Location
A4
X21 X22
X23
A10 X17 X20 X24 B21 X18 W3 H3 X19
TX1119096 —UN—16AUG12
W1
TX1119096 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 X21— Monitor Controller 36-Pin Harness Connector B X18— Monitor 12-Pin Connector X22— Monitor Controller 16-Pin C Connector D X19— Monitor 2-Pin Connector G X23— Monitor Controller 12-Pin X20— Monitor Controller 28-Pin Connector C Connector A
X24— Monitor Controller 2-Pin Connector G
CW08338,0000D0B -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-90
041818
PN=400
System Diagrams
TM12660 (18APR18)
9015-10-91
041818
PN=401
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
TX1116049
1
(1109)
BLU/BLK
X17
2
(1107)
WHT
X17
TX1116049 —UN—20JUN12
1
Monitor Harness (W3) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-92
CW08338,0000D0C -19-28AUG12-1/2
041818
PN=402
System Diagrams B21— Solar Sensor H3—Monitor Warning Alarm X17— Cab Harness-to-Monitor Harness
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 CW08338,0000D0C -19-28AUG12-2/2
TM12660 (18APR18)
9015-10-93
041818
PN=403
System Diagrams
TM12660 (18APR18)
9015-10-94
041818
PN=404
System Diagrams
Engine Harness (W4) Component Location TX1110972 —UN—23MAR12
Y4 Y3
B3
Y2 Y1
B47,M3 X101 B7 B15
B14, M8 R1-R4 B12 B4,B43 B5 Y14
B42
B11
W4
X5 X9
X6
X8 X7
TX1110972 Engine Harness (W4) Component Location Continued on next page
TM12660 (18APR18)
9015-10-95
041818
PN=405
CW0833,0000BDD -19-06MAY14-1/4
System Diagrams
TM12660 (18APR18)
9015-10-96
041818
PN=406
System Diagrams B15— Turbocharger Boost B3—Manifold Air Temperature R3—Glow Plug 3 Pressure Sensor Sensor R4—Glow Plug 4 B4—Engine Coolant Temperature B42— Engine Overheat Switch W4—Engine Harness B43— Coolant Temperature Sensor X5— Machine Harness-to-Engine Sensor B5—Fuel Temperature Sensor Harness 32-Pin Connector B47— Exhaust Gas Recirculation X6— Machine Harness-to-Engine B7—Turbocharger Boost (EGR) Valve Sensor Temperature Sensor Harness 16-Pin Connector M3—Exhaust Gas Recirculation X7— Machine Harness-to-Engine B11— Engine Oil Pressure (EGR) Valve Actuator Sensor Harness 14-Pin Connector B12— Fuel Rail Pressure Sensor M8—Intake Air Throttle X8— Machine Harness-to-Engine R1—Glow Plug 1 B14— Intake Air Throttle Valve Harness 1-Pin Connector R2—Glow Plug 2 Position Sensor Continued on next page
TM12660 (18APR18)
9015-10-97
X9— Machine Harness-to-Engine Harness 20-Pin Connector X101— Fuel Injector Harness Connector 1 Y1— Electronic Injector 1 Y2— Electronic Injector 2 Y3— Electronic Injector 3 Y4— Electronic Injector 4 Y14— Suction Control Valve
CW0833,0000BDD -19-06MAY14-2/4
041818
PN=407
System Diagrams
TM12660 (18APR18)
9015-10-98
041818
PN=408
System Diagrams
TX1090466 —UN—11APR11
Y16
B2
B1
X5
X9
X6 X7
TX1090466
X8 Engine Harness (W4) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-99
041818
PN=409
CW0833,0000BDD -19-06MAY14-3/4
System Diagrams
TM12660 (18APR18)
9015-10-100
041818
PN=410
System Diagrams B1—Crankshaft Position Sensor X6— Machine Harness-to-Engine X8— Machine Harness-to-Engine Y16— Turbocharger Actuator Harness 16-Pin Connector Harness 1-Pin Connector B2—Camshaft Position Sensor X5— Machine Harness-to-Engine X7— Machine Harness-to-Engine X9— Machine Harness-to-Engine Harness 14-Pin Connector Harness 20-Pin Connector Harness 32-Pin Connector CW0833,0000BDD -19-06MAY14-4/4
TM12660 (18APR18)
9015-10-101
041818
PN=411
System Diagrams
TM12660 (18APR18)
9015-10-102
041818
PN=412
System Diagrams
Engine Harness (W4) Wiring Diagram TX1160002 —UN—23MAY14
END #1 B14 B5 B14 B4 X5 X5 R1—R4 X5 X5 X5 X5 X9 X5 X6 X6 X6 X5 X9 X5 X6 X9 X5 X5 X6 X6 X9 X9 X9 X9 X9 X9 X5 X5 X5 X5 X5 X9 X7 X9 X9 X7 X7 X6 X6 X9 X9 Y16 Y16 Y16 Y16 Y16 Y16 Y16 Y16 Y16 X5 X5 X5 X5 X5
END #2 (834) (835) (835) (1131) B42 B43 X8 B12 B5 B4 B12 Y14 B15 B47 B47 B47 B15 B2 B12 M3 Y14 B11 B15 M3 M3 X101 X101 X101 X101 X101 X101 B3 B3 B1 B1 B1 B2 B14 B2 B2 M8 B14 B47 B47 X101 X101 X7 X7 X7 X7 X7 X7 X7 X7 X7 B12 B7 B11 B11 B11
NUMBER (1209)
COLOR BLK/RED
END #1 X5
X5
END #2 B7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(834) (714) (715) (716) (835) (729) (723) (730) PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
BLU GRN/YEL GRN/WHT GRN/BLK BLU/WHT WHT/BLU WHT/BLK WHT/RED
B47 B47 B47 B47 B47 M3 M3 M3
X5 1 806 775 709 222 710
5
6 805 776 234 1209 707 10
X6 4 716 715 714 834
1
8 730 723 729 835
5
12
9
16
13
11 727
1127 1123 14
15 804
722 17
18
728 1131
22
23
713 1130
27
28
717 1129 708
32
X7 3 889 890 891 1
(806) (775) (709) (222) (710) (805) (776) (234) (1209) (707) (727) PLUG (1127) (1123) (804) PLUG (722) PLUG (728) (1131) PLUG PLUG PLUG (713) (1130) PLUG PLUG PLUG (717) (1129) (708) PLUG
PUR/WHT GRN/YEL RED/BLK GRN BLU GRY/BLK WHT/RED RED BLK/RED BLU/WHT BLK
B1 B3 B4 B42 B12 B1 B3 B43 B7 B12 B11 B7 B12 B1
BRN
B12
(1131) 1 X5 X5
B42
4 709
737 880 732 878
234
5
3
8
GRN
4
X5
Y16
894 891 890 889
1 2
898 (711) (724)
RED/BLK RED/WHT
(737) (880) (732) (878) (735) (734) (736) (733)
BLK/WHT BLU/RED BLK RED BLU BLK/RED WHT/BLU WHT/BLK
X9 X9 X9 X9 X9 X9 X9 X9
(893) (897) (896) (895) (894) (891) (890) (889)
RED BLU BRN BLU/WHT BLK BLU/RED YEL/RED GRN/RED
X7 X7 X7 X7 X7 X7 X7 X7
B3 1 2
X9 X9
5
8
1 2 3 4 5 6 7 8
(775) (776)
1 2 3 4 5 6 7 8
(834) (714) (715) (716) (835) (729) (723) (730)
B5
1
2
711 724
1
1 2 3
BLU GRN/YEL GRN/WHT GRN/BLK BLU/WHT WHT/BLU WHT/BLK WHT/RED
X6 X6 X6 X6 X6 X6 X6 X6
B3 4
B2 (805) (804) (806)
GRY/BLK WHT/BLK PUR/WHT
X5 X5 X5
1 2 3
B1
2
2 708
X5 X5
B47, M3 1
B1
GRN/YEL WHT/RED
B47, M3
Y16
1
RED/WHT WHT/BLK YEL/GRN
X101
735 734 736 733
893 897 896 895
B15 B11
B15 B11
4
1
(222)
1 2 3 4 5 6 7 8
X8
2
B42
Y14 BLU BLU/YEL
BLK/WHT
(807) (818) (819)
TAN ORG/BLK YEL
1
X9 X9 X9
835 729 723 730
B2 805 804 806
3
1
5 807 818 819
8
3
B5
B15 B11 B5
1 2
(2) (708)
BLU/WHT YEL/GRN
2
775 776
834 714 715 716
B15
(835) X5
721 1
898 895 896 897
713 728 717
3
893 894 14 816 833 832
11
(891) (890) (889) (897) (896) (895) (898) PLUG (894) (893) PLUG (832) (833) (816)
BLU/RED YEL/RED GRN/RED BLU BRN BLU/WHT BLK/WHT
Y16 Y16 Y16 Y16 Y16 Y16 Y16
BLK RED
Y16 Y16
B15
X7 1 2 3 4 5 6 7 8 9 10 11 12 13 14
GRN RED/WHT VLT/WHT
M8 M8 B14
514
X8
1
(514)
1 2 3
X9
X8 BLK/WHT
R1—R4
X9
4
1
735 733
736
737
732
878
734 880
721
819 807
724
818 711
20
17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(736) PLUG (733) (735) (732) PLUG (878) (737) PLUG PLUG PLUG (734) (724) (721) PLUG (880) (711) (818) (807) (819)
WHT/BLU
X101
WHT/BLK BLU BLK
X101 X101 X101
RED BLK/WHT
X101 X101
X101 Y14 B2
BLU/RED RED/BLK ORG/BLK TAN YEL
X101 Y14 B2 B2 B2
9015-10-103
041818
PN=413
BLU RED/BLU RED/WHT
X5 X5 X5
1
11271209
2
B14, M8 B12
B11 1
BLK/RED RED/WHT BLK/WHT
(713) (728) (717)
B7
1131 1130 1129
1
3
B7 722 707 710
1 2
3
(1127) (1209)
RED/BLU BLK/RED
X5 X5
1
—
1
3 816 833 832
6
BLU BLU/WHT VLT/WHT RED/WHT GRN
(834) (835) X7 X7 X7
B14, M8 B11 1 2 3
B12 (1131) (1130) (1129)
BLK/YEL BLU/YEL WHT/BLK
Engine Harness (W4) Wiring Diagram Continued on next page
TM12660 (18APR18)
BLK/YEL RED/BLK RED
Y14 RED/BLU BLK/YEL
(514) 1
(4) (709) (234)
1 RED/BLU BLK/WHT WHT/BLK
1
B4, B43 1 2 3
X101
R1-R4
R1-R4
B4, B43
7
COLOR BLU BLU/WHT BLU/WHT BLK/YEL GRN RED BLK/WHT BLU/WHT YEL/GRN RED/BLK BLU RED/BLK BLU GRN/YEL GRN/WHT GRN/BLK RED/WHT BLK/WHT BRN WHT/BLK RED/WHT BLK RED/BLU WHT/BLU WHT/RED BLK WHT/BLK BLK/RED BLU WHT/BLU BLK/WHT GRN/YEL WHT/RED WHT/BLK GRY/BLK PUR/WHT TAN VLT/WHT ORG/BLK YEL GRN RED/WHT BLU BLU/WHT RED BLU/RED GRN/RED YEL/RED BLU/RED RED BLK BLU/WHT BRN BLU BLK/WHT BLK/WHT RED/BLU WHT/BLK BLU/YEL BLK/YEL
72
NUMBER 1 2 3 4 222 234 514 707 708 709 710 711 713 714 715 716 717 721 722 723 724 727 728 729 730 732 733 734 735 736 737 775 776 804 805 806 807 816 818 819 832 833 834 835 878 880 889 890 891 893 894 895 896 897 898 1123 1127 1129 1130 1131 TX1160002
X5 X5 X5
1 2 3
(722) (707) (710)
BRN BLU/WHT BLU
X5 X5 X5
1 2 3 4 5 6
— (1) (3) (816) (833) (832)
CW0833,0000BDE -19-06MAY14-1/2
System Diagrams
TM12660 (18APR18)
9015-10-104
041818
PN=414
System Diagrams M8—Intake Air Throttle B1—Crankshaft Position Sensor B14— Intake Air Throttle Valve Position Sensor R1—Glow Plug 1 B2—Camshaft Position Sensor B15— Turbocharger Boost R2—Glow Plug 2 B3—Manifold Air Temperature Pressure Sensor R3—Glow Plug 3 Sensor R4—Glow Plug 4 B4—Engine Coolant Temperature B42— Engine Overheat Switch B43— Coolant Temperature X5— Machine Harness-to-Engine Sensor Sensor Harness 32-Pin Connector B5—Fuel Temperature Sensor B47— Exhaust Gas Recirculation X6— Machine Harness-to-Engine B7—Turbocharger Boost (EGR) Valve Sensor Harness 16-Pin Connector Temperature Sensor M3—Exhaust Gas Recirculation X7— Machine Harness-to-Engine B11— Engine Oil Pressure (EGR) Valve Actuator Harness 14-Pin Connector Sensor B12— Fuel Rail Pressure Sensor
X8— Machine Harness-to-Engine Harness 1-Pin Connector X9— Machine Harness-to-Engine Harness 20-Pin Connector X101— Fuel Injector Harness Connector 1 Y14— Suction Control Valve Y16— Turbocharger Actuator
CW0833,0000BDE -19-06MAY14-2/2
TM12660 (18APR18)
9015-10-105
041818
PN=415
System Diagrams
TX1178302 —UN—26NOV14
Side Camera Harness (W5) Component Location
Side Camera Harness (W5) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-106
MB00333,000023E -19-13JAN15-1/2
041818
PN=416
System Diagrams A14— Side Camera W5—Side Camera Harness
X69— Side Camera Harness-to-Side Monitor Harness 4-Pin Connector MB00333,000023E -19-13JAN15-2/2
Side Camera Harness (W5) Wiring Diagram COLOR YEL BLK WHT GRY
NUMBER 10 11 12 13
END #1 A14 A14 A14 A14
END #2 X69 X69 X69 X69
A14 X69 3 2
5
1
11 12 1
13 4
4
10
11
10
13
12
3
2
1 2 3 4 5
(12) (10) — (13) (11)
WHT YEL
X69 X69
GRY BLK
X69 X69
1 2 3 4
TX1175093
(10) (11) (12) (13)
YEL BLK WHT GRY
A14 A14 A14 A14
TX1175093 —UN—23OCT14
X69
A14
Side Camera Harness (W5) Wiring Diagram A14— Side Camera (if equipped) X69— Side Camera Harness-to-Side Monitor Harness 4-Pin Connector MB00333,000023F -19-13JAN15-1/1
TM12660 (18APR18)
9015-10-107
041818
PN=417
System Diagrams
TX1178305 —UN—01DEC14
Side Monitor Harness (W6) Component Location
Side Monitor Harness (W6) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-108
MB00333,0000240 -19-13JAN15-1/2
041818
PN=418
System Diagrams A13— Side Monitor W6—Side Monitor Harness X12— Side Monitor 16-Pin Connector A X13— Side Monitor 20-Pin Connector B
X26— Optional Connector X29A— Cab Harness-to-Switch Panel Connector 3 X29B— Cab Harness-to-Switch Panel Connector 5
X66— Cab Harness-to-Side Monitor Harness 2-Pin Connector 1 X68— Cab Harness-to-Side Monitor Harness 2-Pin Connector 2
X69— Side Camera Harness-to-Side Monitor Harness 4-Pin Connector
MB00333,0000240 -19-13JAN15-2/2
TM12660 (18APR18)
9015-10-109
041818
PN=419
System Diagrams
TM12660 (18APR18)
9015-10-110
041818
PN=420
System Diagrams
Side Monitor Harness (W6) Wiring Diagram TX1175094 —UN—17NOV14
NUMBER 1 3 4 5 6 7 8 11 12 13 15 16 17 36 111 610 611 612 615 616 617 870 1135 1160 1187 1189 1191 1219 1221 1225 1231 1234 1236 1243 1269 1303
COLOR GRY BLK/YEL WHT RED LTGRN/RED WHT/YEL BLU BLU BLU/WHT PNK YEL/RED GRN/WHT RED/GRN WHT GRY WHT/YEL RED LTGRN/RED BLU BLU/RED RED/BLU BLU/RED WHT ORG BLU/WHT BLU/PNK LTGRN RED BLK/GRN BLK/BLU WHT/GRN WHT/VLT GRN/WHT BRN/WHT YEL/BLU GRY
END #1 X12 X12 X12 X12 (612) (610) X13 (8) V17 (1236) X29B X29A X29A X68 X68 X26 X26 X26 X26 X26 X26 X29A X12 X29B X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X66
END #2 X69 X69 X69 X69 X13 X13 (615) W38 X13 V17 X29A X29B X29B X12 X12 X26 X26 X26 X26 X26 X26 X29B X66 X29A X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X12
X12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X29B (1135) — (36) — (4) — — (5) — (1303) (111) — (1) (3) — —
WHT
X66
WHT
X68
WHT
X69
RED
X69
GRY GRY
X66 X68
GRY BLK/YEL
X26 1
610
611
612
3
4
616
617
615
6
X26
X69 X69
3
612
611
610
1
6
615
617
616
4
W38 1
(11)
BLU
X26
(8)
1 2 3 4 5 6
X12 W38 1 1135
36
4
5
8 MB
9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1303 111
1
3
16
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LTGRN/RED BLU/RED RED/BLU BLU
X26 X26 X26 X26 X26 X26
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
— — — — — — (12) — (7) (6) (8) — — — — — — — — —
1
15
7
16
870 1219 1236 1234 1225
17
1221 1160 8
X29A
1187 1191 1189 1160 1221 17
7
1269 1243 1231
15
16 1225 1234 1236 1219 870
8 11
20 A
12
13
K
V17 BLU/WHT
V17
WHT/YEL LTGRN/RED BLU
(610) (612) (615)
V17 A K
1
2
36
111
2
BLU/WHT PNK
X13 (1236)
1 2
Side Monitor Harness (W6) Wiring Diagram Continued on next page
9015-10-111
041818
PN=421
5
3
2
3
4
1
4
X69 (36) (111)
WHT GRY
X12 X12
(1135) (1303)
WHT GRY
X12 X12
1 2 3 4
(5) (3) (4) (1)
RED BLK/YEL WHT GRY
16
X29A
X69
X66 1 2
1
X66
X68 (12) (13)
8
1
1303 1135
X68
TX1175094
TM12660 (18APR18)
1
16
10
6
X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A X29A
1189 1191 1187
1231 1243 1269
1 12
BLU/WHT LT GRN BLU/PNK YEL/BLU BRN/WHT WHT/GRN YEL/RED ORG BLU/GRN RED/GRN GRN/WHT BLK/BLU WHT/VLT GRN/WHT RED BLU/RED
X29B
7
X13 X13
(1187) (1191) (1189) (1269) (1243) (1231) (15) (1160) (1221) (17) (16) (1225) (1234) (1236) (1219) (870)
X12 X12 X12 X12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(1187) (1191) (1189) (1269) (1243) (1231) (15) (1160) (1221) (17) (16) (1225) (1234) (1236) (1219) (870)
BLU/WHT LT GRN BLU/PNK YEL/BLU BRN/WHT WHT/GRN YEL/RED ORG BLU/GRN RED/GRN GRN/WHT BLK/BLU WHT/VLT GRN/WHT RED BLU/RED
X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B X29B
MB00333,0000241 -19-13JAN15-1/2
System Diagrams
TM12660 (18APR18)
9015-10-112
041818
PN=422
System Diagrams
V17— Side Monitor Diode W38—Side Monitor Mounting Bracket Ground X12— Side Monitor 16-Pin Connector A X13— Side Monitor 20-Pin Connector B
X26— Optional Connector X29A— Cab Harness-to-Switch Panel Connector 3 X29B— Cab Harness-to-Switch Panel Connector 5
X66— Cab Harness-to-Side Monitor Harness 2-Pin Connector 1 X68— Cab Harness-to-Side Monitor Harness 2-Pin Connector 2
X69— Side Camera Harness-to-Side Monitor Harness 4-Pin Connector
MB00333,0000241 -19-13JAN15-2/2
TM12660 (18APR18)
9015-10-113
041818
PN=423
System Diagrams
Pump Harness (W8) Component Location
B13 M2 B17 B36
Y28 Y20 Y21
B57
B38
W8 X97
TX1118854 —UN—22AUG12
X40
TX1118854 Pump Harness (W8) Component Location (front) B13— Fuel Filter Restriction Sensor B17— Water-in-Fuel Sensor B36— Pump 1 Control Pressure Sensor B38— Pump 2 Control Pressure Sensor
B57— Pump 3 Control Pressure X97— Pump Harness Splice Sensor Connector M2—Fuel Transfer Pump Y20— Pump 2 Flow Rate Limit W8—Pump Harness Solenoid (marked SB) X40— Pump Harness-to-Machine Y21— Torque Control Solenoid Harness Connector (marked ST) Continued on next page
TM12660 (18APR18)
9015-10-114
Y28— Pump 3 Torque Control Solenoid (marked SU)
CW08338,0000D0F -19-23APR14-1/2
041818
PN=424
System Diagrams
B35
B56
B37
X97
W8
TX1121008
TX1121008 —UN—23AUG12
X40
Pump Harness (W8) Component Location (right side) B35— Pump 1 Delivery Pressure B56— Pump 3 Delivery Pressure X40— Pump Harness-to-Machine Sensor Sensor Harness Connector B37— Pump 2 Delivery Pressure W8—Pump Harness X97— Pump Harness Splice Sensor Connector CW08338,0000D0F -19-23APR14-2/2
TM12660 (18APR18)
9015-10-115
041818
PN=425
System Diagrams
TM12660 (18APR18)
9015-10-116
041818
PN=426
System Diagrams
Pump Harness (W8) Wiring Diagram TX1115154 —UN—07JUN12
END #2 X40 X40 X40 X40 X40 X40 X97 X97 X97 X97 X40 X97 X40 X40 X40 X40 X40 X97 X40 X40 X40 X97 X40 X97 X97 X97 X97 X40 X97 X97 X97 X97 X97 X97 X97 X40 X97
B13 B13 B
748 749
A B C
A
746 C
(749) (748) (746)
BLK WHT GRN
X40 X40 X40
M2 M2 822 823 1
2
1 2
(822) (823)
BLK GRN
X40 X40
1
3
1301 1061 1066 2
1
B17
B38
(1390) (1391)
VLT BLK
X40 X97
1271 1235 1252
1
3
1
1065 1110 1302
B37
PP2
SU
1
2
1
2
1067 1229
1071 1082
Y21
Y20
Y28
B37 1 2 3
(1065) (1110) (1302)
BLK ORG RED
X97 X40 X97
3
B36
1 2 3
X40 1
X40 5 9
4
1067 1295 1229
8 12
1110 1088
1264 1061 17
749
1390 748
1069 1082
822 823
13 1090
1071 746
1299 16
1235 1091 20
1 2 3 4 5 6 7 8 9 10
X40 (1067) (1295) (1071) (746) (1229) (1069) (1082) (749) (822) (823)
GRY BRN ORG GRN BLU PNK YEL BLK BLK GRN
Y20 Y21 Y28 B13 Y20 Y21 Y28 B13 M2 M2
11 12 13 14 15 16 17 18 19 20
(1390) (748) (1090) (1110) (1088) (1299) (1264) (1061) (1235) (1091)
VLT WHT VLT ORG PNK RED GRY YEL BLU BLK
Pump Harness (W8) Wiring Diagram
9015-10-117
041818
PN=427
(1290) (1264) (1064)
RED GRY BLK
X97 X40 X97
(1295) (1069)
BRN PNK
X40 X40
(1067) (1229)
GRY BLU
X40 X40
(1071) (1082)
ORG YEL
X40 X40
Y21 1 2
1 2
3
1282 1088 1068
B56 Y28
B17 B13 B35 B37 B56 X97 B36 B38 B57 X97
(1282) (1088) (1068)
1 PP
X40 B35 B37 B36 B38 B56 B57 X97 X97 X97 X97 B17
1 2 3
Y20 1
PP3
Continued on next page
TM12660 (18APR18)
X97 X40 X97
2
1295 1069
X97
TX1115154
RED BLU BLK
B36
B56
BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK
(1271) (1235) (1252)
1290 1264 1064
24
(1091) (1063) (1065) (1064) (1066) (1282) (1252) (1306) (1306) (1307) (1307) (1391)
B57
PC1
1091 1063 1065 1064 1066 1282 1252 1306 1306 1307 1307 1391
13 14 15 16 17 18 19 20 21 22 23 14
3
1
13
X40 B35 B37 B36 B38 B56 B57 X97 X97 X97 X97
1
X97 X40 X97
PC3 1 2 3
12
RED RED RED RED RED RED RED RED RED RED RED
RED YEL BLK
B57
1299 1281 1302 1290 1301 1068 1271 1304 1304 1305 1305
(1299) (1281) (1302) (1290) (1301) (1068) (1271) (1304) (1304) (1305) (1305) PLUG
(1301) (1061) (1066)
PC 1 2
1
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3
B17
X97
X97
B38
2
1391 1390
SB
END #1 B13 B13 B13 M2 M2 B38 B35 B36 B37 B38 Y20 B56 Y21 Y28 Y28 B56 B35 X40 B37 Y20 B57 B57 B36 B57 B35 B56 B36 Y21 X40 B38 B37 X97 X97 X97 X97 B17 B17
ST
COLOR GRN WHT BLK BLK GRN YEL BLK BLK BLK BLK GRY RED PNK ORG YEL PNK VLT BLK ORG BLU BLU BLK GRY RED RED BLK RED BRN RED RED RED RED RED BLK BLK VLT BLK
NUMBER 746 748 749 822 823 1061 1063 1064 1065 1066 1067 1068 1069 1071 1082 1088 1090 1091 1110 1229 1235 1252 1264 1271 1281 1282 1290 1295 1299 1301 1302 1304 1305 1306 1307 1390 1391
1
BLK PNK RED
X97 X40 X97
1 2
3
1063 1090 1281
B35
B35 1 2 3
(1063) (1090) (1281)
BLK VLT RED
X97 X40 X97
CW08338,0000D10 -19-28AUG12-1/2
System Diagrams
TM12660 (18APR18)
9015-10-118
041818
PN=428
System Diagrams B13— Fuel Filter Restriction Sensor B17— Water-In-Fuel Sensor B35— Pump 1 Delivery Pressure Sensor B36— Pump 1 Control Pressure Sensor
B37— Pump 2 Delivery Pressure Sensor B38— Pump 2 Control Pressure Sensor B56— Pump 3 Delivery Pressure Sensor B57— Pump 3 Control Pressure Sensor
M2—Fuel Transfer Pump Y21— Torque Control Solenoid X40— Pump Harness-to-Machine (marked ST) Harness Connector Y28— Pump 3 Torque Control X97— Pump Harness Splice Solenoid (marked SU) Connector Y20— Pump 2 Flow Rate Limit Solenoid (marked SB) CW08338,0000D10 -19-28AUG12-2/2
Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location See Cab Harness (W1) Component Location. (Group 9015-10.) CW08338,0000D11 -19-01APR13-1/1
NUMBER 876 877 1360 1361 1362 1363 1364 1365
COLOR ORG/BLK ORG/GRN RED/BLK RED/BLK RED/BLK BLK GRN/WHT GRN
X37 1 (1360) 2 (1363) (877) 3 (876) 4 5 (1365) 6 (1364)
END #1 END #2 X37 S16 X37 S16 X37 S16 (1360) S16 (1360) S16 X37 S16 X37 S16 X37 S16
RED/BLK BLK ORG/GRN ORG/BLK GRN GRN/WHT 2
S16 1 (1362) 2 (877) 3 — 4 (876) 5 (1365) 6 (1364) 7 (1360) 8 (1363) — 9 10 (1361)
S16 S16 S16 S16 S16 S16
1360
X37 1364 1365 876 877 6
(1360) X37
ORG/BLK GRN GRN/WHT RED/BLK BLK
X37 X37 X37 X37 X37
RED/BLK
(1360)
1
1
1363
RED/BLK ORG/GRN
3
876
1365 1364 1360 1363
1361
5
TX1115469
4
1362 877
10
S16
TX1115469 —UN—28AUG12
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 CW08338,0000D12 -19-01APR13-1/1
TM12660 (18APR18)
9015-10-119
041818
PN=429
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 CW08338,0000D13 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-120
041818
PN=430
System Diagrams
Pilot Shutoff Switch Harness (W11) Wiring Diagram TX1087210 —UN—22FEB11
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 D LU
B
BLU S3
2 1 3
S4 1 2 3
(20) (19) (17)
BLK S3 RED X135 BLU X136
TX1087210 Pilot Shutoff Switch Harness (W11) Wiring Diagram Continued on next page
TM12660 (18APR18)
9015-10-121
041818
PN=431
CW08338,0000D14 -19-29MAY13-1/2
System Diagrams
TM12660 (18APR18)
9015-10-122
041818
PN=432
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 Harness Splice 1
X136— Pilot Shutoff Harness Splice 2 X137— Pilot Shutoff Harness Splice 3 CW08338,0000D14 -19-29MAY13-2/2
TM12660 (18APR18)
9015-10-123
041818
PN=433
System Diagrams
Auxiliary Fuse Box Harness (W13) Component Location
A8
F51
G5 X44 X58 X57 X59
X43 X56 X54 X55 X63
X60
X62
TX1121166 —UN—23AUG12
X61
TX1121166 Auxiliary Fuse Box Harness (W13) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-124
CW08338,0000D15 -19-28AUG12-1/2
041818
PN=434
System Diagrams A8—12 Volt Power Converter F51— Auxiliary Fuse Box G5—12 Volt Power Outlet X43— Optional Fuse Connector X44— Optional Light Connector X54— Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER)
X55— Front Cab Light 1 X59— Satellite Communication X63— Cab Auxiliary Power Connector (marked CAB Connector (marked IMOBI) Connector 3 (marked LAMP FRONT) X60— 12 Volt Power Supply AUX_3) X56— Front Cab Light 2 (marked 12V UNIT) Connector (marked CAB X61— Quick Hitch Connector LAMP FRONT+2) (marked QUICK HITCH) X57— Rear Cab Light Connector X62— Cab Auxiliary Power (marked CAB LAMP REAR) Connector 2 (marked X58— Warning Light (marked AUX_2) WARNING LAMP) CW08338,0000D15 -19-28AUG12-2/2
TM12660 (18APR18)
9015-10-125
041818
PN=435
System Diagrams
TM12660 (18APR18)
9015-10-126
041818
PN=436
System Diagrams
Auxiliary Fuse Box Harness (W13) Wiring Diagram Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. —XXXXXX) TX1143570 —UN—09SEP13
END #2 (561) (561) (561) (561) (561) X54 X55 X57 X60 X59 X61 X63 X54 X56 X58 X62 (562) (562) (562) (562) (562) (562) (562) (562) (562) (562) X55 X56 (1)(2)(3)(4)(5) (17)(18)(19)(20)(21) (22)(23)(24)(25)(26)
X43 X59
X59 1 2
1 2
(10) (22)
RED BLK
F25 (562)
(561) (562)
WHT BLK
(1)(2)(3)(4)(5) (17)(18)(19)(20)(21) (22)(23)(24)(25)(26)
10
RED BLK
F24 (562)
1 2 3
X60 9
X61 11 24
1 2
1 2 3
QU HIT ICK CH
(16) RED (25) BLK
F34 (562)
16
1 2 3
A
F27 (562)
X55
X44 (562) F22
27 1 2 18 7 3
CA FR B_L ON AM T P
BLK/RED BLK RED
(27) (562) F32
X56 28 1 2 19 14 3
30
40
29
39
28
38 12
1 2
(8) RED (20) BLK
F23 (562)
CAB LA MP FRONT+ 2 P AM BL CA R REA
8 20
12 26
X58
X58 1 2
(15) RED (21) BLK
F33 (562)
5A
F27
37 11
5A
3
F26
X57
X57
X63 (12) RED (26) BLK
(28) (19) (14)
X55
X44
36 10
5A 35
F25
25
UX
1 2
BLK/RED BLK RED
AUX_2
_3
X63
(27) (18) (7)
X56
X62
X62
BLK/RED
F51
13 1 2 17 6 3
AT ER SE AT HE
F26 (562)
(27)
562
X54
F31 (562) F21
IT
(11) RED (24) BLK
RED BLK RED
X55
UN
1 2
BI
23
X61
(13) (17) (6)
W LA AR M NIN P G
(9) (23)
1
X43 561
X54 X60 1 2
X44
27
22
IMO
END #1 F21,F22 F23,F24 F25,F26,F27 F31,F32 F33,F34 F21 F22 F23 F24 F25 F26 F27 F31 F32 F33 F34 X54 X55 X56 X57 X58 X59 X60 X61 X62 X63 X44 (27) X43 X43
V
COLOR WHT WHT WHT WHT WHT RED RED RED RED RED RED RED RED RED RED RED BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK/RED BLK/RED WHT BLK
12
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 25 26 27 28 561 562
10A F24
10A
9
16 2
F23
8
7
10A
10A
10A
10A
15
14
F22 1
15 21
6 F21
10A
F34
5 F33
F32
4 10A
13 F31
TX1143570 Auxiliary Fuse Box Harness (W13) Wiring Diagram Continued on next page
TM12660 (18APR18)
9015-10-127
041818
PN=437
CW08338,0000D16 -19-09JUN15-1/2
System Diagrams
TM12660 (18APR18)
9015-10-128
041818
PN=438
System Diagrams
F21— Heated Air Seat 10 A Fuse F31— Seat Compressor 10 (marked SEAT HEATER) A Fuse (marked SEAT F22— Front Cab Light One 10 A COMPR) Fuse (marked CAB LAMP F32— Front Cab Light Two 10 A FRONT) Fuse (marked CAB LAMP F23— Rear Cab Light 10 A Fuse FRONT +2) (marked CAB LAMP REAR) F33— Warning Lamp 10 A Fuse F24— 12 Volt Power Unit 10 A (marked WARNING LAMP) Fuse (marked 12V UNIT) F34— Cab Auxiliary Power F25— IMOBI 5 A Fuse (marked Connector Two 10 A Fuse IMOBI) (marked AUX. 2) F26— Quick Hitch 5 A Fuse F51— Auxiliary Fuse Box (marked QUICK HITCH) X43— Optional Fuse Connector F27— Cab Auxiliary Power X44— Optional Light Connector Connector Three 5 A Fuse (marked AUX. 3)
X54— Auxiliary Fuse Box X60— 12 Volt Power Supply Harness-to-Heated Air (marked 12V UNIT) Sear Harness 3-Pin X61— Quick Hitch Connector Connector (marked SEAT (marked QUICK HITCH) HEATER) X62— Cab Auxiliary Power X55— Front Cab Light 1 Connector 2 (marked Connector (marked CAB AUX_2) LAMP FRONT) X63— Cab Auxiliary Power X56— Front Cab Light 2 Connector 3 (marked Connector (marked CAB AUX_3) LAMP FRONT+2) X57— Rear Cab Light Connector (marked CAB LAMP REAR) X58— Warning Light (marked WARNING LAMP) X59— Satellite Communication Connector (marked IMOBI)
Auxiliary Fuse Box Harness (W13) Wiring Diagram (S.N. XXXXXX— ) See Cab Harness (W1) Wiring Diagram. (Group 9015-15.) CW08338,0000D16 -19-09JUN15-2/2
TM12660 (18APR18)
9015-10-129
041818
PN=439
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
TM12660 (18APR18)
9015-10-130
CW08338,0000D17 -19-28AUG12-1/2
041818
PN=440
System Diagrams K20— Seat Heater Relay W14—Heated Air Seat Harness M12— Seat Air Compressor W24—Seat Heater Switch R18— Seat Heater (marked SEAT Harness HEATER) X53— Heated Air Seat S62— Seat Heater Switch Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER)
X54— Auxiliary Fuse Box Harness-to-Heated Air Sear Harness 3-Pin Connector (marked SEAT HEATER)
CW08338,0000D17 -19-28AUG12-2/2
Heated Air Seat Harness (W14) Wiring Diagram COLOR
END #1
X53
END #2
R18 (6)
RED/BLK
X54
K20
(4)
RED/GRN
X54
M12
2
—
(5)
RED/BLK
K20
R18
3
(9)
(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)
7
6 5
5
2
3
RED/BLK
K20
(8)
BLK
X54
(2)
2
R18
SEAT HEATER
M12
X54
K20 (6)
(5)
2
SE A HE T AT ER
1
BLU
1
AT R SE ATE HE
2
K20
X53
K20
1
WHT/RED
(2)
1
WHT/RED
2
(7)
BLK
(8)
3
(2)
RED/BLK
X54
4
—
5
(5)
RED/BLK
TX1085426
R18
3
2
8
RED/GRN
M12
(8)
BLK
R18
(2)
RED/BLK
K20
(4)
2 3
5
2
1
10
4
M12
2
X54 1
8
1
4
X53
1
1
(4)
RED/GRN
X54
2
(10)
BLK
(8)
TX1085426 —UN—22FEB11
NUMBER
Seat Heater Switch Harness (W14) Wiring Diagram K20— Seat Heater Relay X53— Heated Air Seat M12— Seat Air Compressor Motor Harness-to-Heated Seat R18— Seat Heater (marked SEAT Switch Harness 3-Pin HEATER) Connector (marked SEAT HEATER)
X54— Auxiliary Fuse Box Harness-to-Heated Air Seat Harness 3-Pin Connector (marked SEAT HEATER) CW08338,0000D18 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-131
041818
PN=441
System Diagrams
Multi-Function Pilot Control Lever Harness (W15) Component Location
X535 X534 W15 S31
S30
S34
W22 X81 W15 S32
S33 K30 K31 X26 K32 W22 X82 K33
TX1209297 —UN—09MAR16
S35
TX1209297 Multi-Function Pilot Control Lever Harness (W15) Component Location (auxiliary function lever [AFL] not equipped) 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 (2 used)
X26— Optional Connector (2 used) 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
Continued on next page
TM12660 (18APR18)
9015-10-132
X534— Right Auxiliary Solenoid Connector (marked SR/H) X535— Left Auxiliary Solenoid Connector (marked SL/H)
MB00333,0000262 -19-02MAR16-1/4
041818
PN=442
System Diagrams NOTE: Right and left auxiliary solenoid connectors (X534 and X535) may be located inside right rear corner of cab. Continued on next page
TM12660 (18APR18)
9015-10-133
MB00333,0000262 -19-02MAR16-2/4
041818
PN=443
System Diagrams
X535 X534 W15 S34
X541 X542 W15 W22 X81 K31 S35
K33 K32 X26
X82
TX1209298 —UN—21JAN16
W22
TX1209298 Multi-Function Pilot Control Lever Harness (W15) Component Location (auxiliary function lever [AFL] equipped) 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 S35— Left Enable Switch W15—Multi-Function Pilot Control Lever Harness
W22—Auxiliary 3-Button Cancel Switch Harness (2 used) X26— Optional Connector (2 used) 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
X534— Right Auxiliary Solenoid Connector (marked SR/H) X535— Left Auxiliary Solenoid Connector (marked SL/H) X541— Auxiliary Function Lever (AFL) Right Switch Connector (marked R-SW) X542— Auxiliary Function Lever (AFL) Left Switch Connector (marked L-SW)
Continued on next page
TM12660 (18APR18)
9015-10-134
MB00333,0000262 -19-02MAR16-3/4
041818
PN=444
System Diagrams NOTE: Right and left auxiliary solenoid connectors (X534 and X535) may be located inside right rear corner of cab. MB00333,0000262 -19-02MAR16-4/4
TM12660 (18APR18)
9015-10-135
041818
PN=445
System Diagrams
TM12660 (18APR18)
9015-10-136
041818
PN=446
System Diagrams
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram TX1208989 —UN—15JAN16
1 2
RED RED
X26
END #1 END #2 (611) (8)
(610)
BLU/YEL
2
(611)
RED
3
(612)
LT GRN/RED
4
(616)
BLK
5
(617)
RED
6
(615)
RED/BLU
3
3
610
611
612
612
611
616 4
617
615 6
615 6
617
X82
3
RED
(1)
X81
4
BLU
X82
S33
5
BLU
S32
(4)
6
WHT
S33
K33
7
YEL
S32
K32
8
RED
(1)
K33
9
RED/WHT
K33
Y35
10
RED/YEL
K32
Y35
11
BLK
K31
(615) Y34
1
X26
K30
1
K31
12
GRN
K30
13
BLK
K32
(11)
14
BLK
K33
(11)
15
RED
(1)
K30
16
RED
(8)
K32
17
BLK
K30
(11)
18
BLK
(11)
Y34
19
BLK
(11)
Y35
20
BLU/YEL
X81
S31
21
BLU/YEL
(20)
S30
22
LT GRN/YEL
S30
K30
23
YEL/RED
S31
K31
24
RED/BLU
K31
Y34
610
BLU/YEL
X26
X26
611
RED
X26
X26
612
LT GRN/RED
X26
X26
S32 5 7 2 1 S32
615
BLK
X26
X26
1
(7)
YEL
K32
616
RED
X26
X26
2
(5)
BLU
(4)
617
RED/BLU
X26
X26
1
K31 (22)
LT GRN/YEL
S30
(23)
YEL/RED
(11)
BLK
(615) 2
3
(1)
RED
(611) 3
4
—
5
(24)
(17)
BLK
3
(15)
RED
(1)
4
—
5
(12)
2
GRN
Y34
K33
K32
1
(11) 2
RED/BLU
S31
Y34
1
YEL
S32 1
(6)
WHT
S33
(13)
BLK
(11) 2
(14)
BLK
(11)
(16)
RED
(8) 3
(8)
RED
(1)
4
—
Y35 5
(9)
RED/WHT
Y35
(7)
4
—
5
(10)
RED/YEL
1 610 616 4
2 4 1 6 5 9 3 8
2 4 1 7 5 10 3 16
2 4 1 K31 11 23 5 24 3 1
2 4 1 K30 17 22 5 12 3 15
K33 14
K32 13
X82 1
(4)
BLU
S33
2
(2)
RED
(8)
2 1 2 4 X82
S31 1
(23)
YEL/RED
K31
2
(20)
BLU/YEL
X81
C
20 23 S31 2 1
B B
/H
C
SR
NUMBER COLOR
S33 4 6
X81
SL
/H
1 2
1
(6)
WHT
K33
2
(4)
BLU
X82
(20) (3)
BLU/YEL RED
S31
1
(22)
LT GRN/YEL
K30
(1)
2
(21)
BLU/YEL
(20)
9 1019 X535 1 2 3
X534 24 1218 1 2 3
X534
S30
X81
2 1
S33
21 22 S30 2 1
2 1 3 20
X535
1
(24)
RED/BLU
K31
1
(9)
RED/WHT
K33
2
(12)
GRN
K30
2
(10)
RED/YEL
K32
3
(18)
BLK
(11)
3
(19)
BLK
(11)
TX1208989 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram (auxiliary function lever [AFL] not equipped) Continued on next page
TM12660 (18APR18)
9015-10-137
041818
PN=447
DF89619,00B5DAA -19-26FEB16-1/4
System Diagrams
TM12660 (18APR18)
9015-10-138
041818
PN=448
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) X26— Optional Connector (2 used) 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 X534— Right Auxiliary Solenoid Connector (marked SR/H) X535— Left Auxiliary Solenoid Connector (marked SL/H)
Continued on next page
TM12660 (18APR18)
9015-10-139
DF89619,00B5DAA -19-26FEB16-2/4
041818
PN=449
System Diagrams
TM12660 (18APR18)
9015-10-140
041818
PN=450
System Diagrams
TX1207858 —UN—15DEC15
END #1 X82 X81 K31 X541 K31 K33 K33 X542 K33 K32 K32 X542 K32 (615) X534 X81 X26 X26 X26 X26 X26 X26
END #2 (611) K31 (611) K31 X534 X82 (611) K33 X535 (65) (611) K32 X535 X535 (615) (611) X26 X26 X26 X26 X26 X26
X541
R-SW
63
W
1
1 2
(63) —
LT GRN/YEL
K31
K33 K32 (615)
X535 68 1
72
71
67
2
1
3
X542 (67) (71)
WHT YEL
K33 K32
5
64
3
62 2
GRN BLK
K31 (615)
54 1
2
/H
X534
SR
PLUG (64) (74)
1 W LS
1 2 3
2 75
61
1
2
X81 1 2
4
611
610
1
615
617
616
4
RED BLU/YEL
(611) K31
X81
68
3
66
GRN
X26
X81 X541 (611)
1
1 2 3 4 5
1
610
611
612
3
4
616
617
615
6
X534
X26
K33 65
5
BLU/YEL LT GRN/YEL RED
(65) (67) (66) — (68)
GRY WHT RED
X82 X542 (611)
RED/WHT
X535
1 2 3 4 5 6
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLK/RED RED/YEL BLK
(60) (65)
RED GRY
K32 1 69
71
(75) (61)
612
6
K32
74 3
4
67
LSW3
X534
(61) (63) (62) — (64)
K33
R
/H
SL
1 2
1 61
63
73
2
4
1
RED/WHT RED/YEL BLK
2
SW
(68) (72) (73)
1 2 3 4 5
K31
X542
X535 1 2 3
2
3
K31 X541
L-S
NUMBER COLOR 60 RED 61 BLU/YEL 62 RED 63 LT GRN/YEL 64 GRN 65 GRY 66 RED 67 WHT 68 RED/WHT 69 BLU/YEL 70 RED 71 YEL 72 RED/YEL 73 BLK 74 BLK 75 RED 610 WHT/YEL 611 RED 612 LT GRN/RED 615 BLK 616 BLK/RED 617 RED/YEL
5
72
3
70
1 2 3 4 5
(69) (71) (70) — (72)
BLU/YEL YEL RED
(65) X542 (611)
RED/YEL
X535
X82 60
65
1
2
1 2
(611) K33
X82
TX1207858 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram (auxiliary function lever [AFL] equipped) Continued on next page
TM12660 (18APR18)
9015-10-141
041818
PN=451
DF89619,00B5DAA -19-26FEB16-3/4
System Diagrams
TM12660 (18APR18)
9015-10-142
041818
PN=452
System Diagrams
K31— Right Solenoid Relay A (marked RSW1) K32— Left Solenoid Relay B (marked LSW1) K33— Left Solenoid Relay A (marked LSW3) X26— Optional Connector (2 used)
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
X534— Right Auxiliary Solenoid X542— Auxiliary Function Lever (AFL) Left Switch Connector (marked SR/H) Connector (marked X535— Left Auxiliary Solenoid L-SW) Connector (marked SL/H) X541— Auxiliary Function Lever (AFL) Right Switch Connector (marked R-SW)
DF89619,00B5DAA -19-26FEB16-4/4
Travel Alarm Cancel Switch Harness (W16) Component Location See Cab Harness (W1) Component Location. (Group 9015-10.) CW08338,0000D1B -19-28AUG12-1/1
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram COLOR GRN/BLK BLK
END #1 END #2 X50 S13 X50 S13
X50
X50 1
1 2
2
S13 S13
S13
1 5
GRN/BLK BLK
2
TRAVEL
1
(1) (2)
4 2
1
S13
10
1 2 3 4 5 6 7 8 9 10
— — — — — — — (2) (1) —
TX1116042
BLK GRN/BLK
X50 X50
TX1116042 —UN—21AUG12
NUMBER 1 2
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram S13— Travel Alarm Cancel Switch
X50— Travel Sub Harnessto-Travel Alarm Cancel Switch Harness Connector CW08338,0000D1C -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-143
041818
PN=453
System Diagrams
Attachment Harness (W17) Component Location
X46 Y41
Y40
B62
Y39
W17
B60
X87
TX1121345 —UN—24AUG12
Y38
TX1121345 Attachment Harness (W17) Component Location B60— Attachment Pressure Sensor B62— Attachment Pressure Sensor 2 W17—Attachment Harness
X46— Attachment Connector X87— Attachment Harnessto-Two Speed Harness Connector
Y38— Attachment Relief Solenoid Y39— Attachment Relief Solenoid 2 Y40— Selector Valve Solenoid Valve
Y41— Secondary Relief Solenoid Valve
CW08338,0000D1D -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-144
041818
PN=454
System Diagrams
TM12660 (18APR18)
9015-10-145
041818
PN=455
System Diagrams
Attachment Harness (W17) Wiring Diagram NUMBER 1 3 6 7 8 9 664 1098 1115 1116 1117 1227 1230 1253 1254 1256 1257 1261 1263 1268 1330 1331
COLOR WHT/YEL WHT/YEL RED/YEL RED/YEL BLK/YEL BLK/YEL WHT/YEL GRN/RED YEL/RED RED WHT/VLT GRN/WHT ORG/BLU WHT/BLU PNK/GRN RED/YEL BLK/YEL BRN GRY YEL/GRN BLU/YEL LT GRN/BLK
END #2 Y40 X87 (1256) (1256) (1257) (1257) X46 X46 X46 X87 X46 X46 X46 X87 X87 X87 X87 X46 X46 X87 X46 X46
END #1 (664) (664) B60 B62 B60 B62 (1) (3) B62 Y38 X46 B60 Y40 Y39 X46 X46 X46 X46 Y38 Y39 X46 Y41 Y41
X46 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(1115) (1230) (1116) (1330) (1261) (1263) (1268) (1331) (1227) PLUG PLUG PLUG (1254) PLUG (1253) (1256) (664) (1117) (1098) (1257)
YEL/RED ORG/BLU RED BLU/YEL BRN GRY YEL/GRN LT GRN/BLK GRN/WHT
Y38 Y39 X87 Y41 Y38 Y39 X87 Y41 Y40
PNK/GRN
X87
WHT/BLU RED/YEL WHT/YEL WHT/VLT GRN/RED BLK/YEL
X87 X87 (1) (3) B60 B62 X87
Y41 Y40
Y40 1331
1330
1 2
1
(1) (1227)
WHT/YEL GRN/WHT
(664) X46
2 1
1227
X46
Y41 1 2
1
(1330) (1331)
BLU/YEL LT GRN/BLK
Y39 1 2
X46 X46
(1230) (1263)
ORG/BLU GRY
Y39
1331 1268 1263 1261
REL2
1227 1256 1253
1254
20 1257 1098 1117
664
1
1263
2SOKU
1 2
2P 7
3 1098
9
B62 RED/YEL GRN/RED BLK/YEL
(1256) X46 (1257)
3
1116 1268
8
X87 1 2 3 4 5 6 7 8
(1253) (1256) (1257) (1254) (3) (1116) (1268) PLUG
1261
WHT/BLU RED/YEL BLK/YEL PNK/GRN WHT/YEL RED YEL/GRN
X46 X46 X46 X46 (664) X46 X46
TX1115970
(1115) (1261)
YEL/RED BRN
X46 X46
B60
PI
X87 5
2
1115
T AT
1
(7) (1098) (9)
2
1230
Y38
1 1253 1256 1257 1254 4
B62
1
Y38
17
REL1
1 2 3
X46 X46
6
1117
8
1
2
3
B60 1 2 3
(6) (1117) (8)
RED/YEL WHT/VLT BLK/YEL
(1256) X46 (1257)
TX1115970 —UN—17AUG12
4 1330 1116 1230 1115
SE
HSB
L
2
1
Attachment Harness (W17) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-146
CW08338,0000D1E -19-28AUG12-1/2
041818
PN=456
System Diagrams B60— Attachment Pressure Sensor B62— Attachment Pressure Sensor 2 X46— Attachment Connector
X87— Attachment Harnessto-Two Speed Harness Connector Y38— Attachment Relief Solenoid
Y39— Attachment Relief Solenoid 2 Y40— Selector Valve Solenoid Valve Y41— Secondary Relief Solenoid Valve CW08338,0000D1E -19-28AUG12-2/2
TM12660 (18APR18)
9015-10-147
041818
PN=457
System Diagrams
Rear Camera Harness (W19) Component Location
A12
W19
TX1119097 —UN—07AUG12
X64
TX1119097 Rear Camera Harness (W19) Component Location A12— Rear Camera W19—Camera Harness
X64— Machine Harness-to-Rear Camera Harness Connector CW08338,0000D1F -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-148
041818
PN=458
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
X6 X6
1 2 3 4
TX1116037
(1149) (1166) (1146) (1019)
YEL BLK WHT GRY
A12 A12 A12 A12
TX1116037 —UN—20JUN12
A12 1 2 3 4 5
2
Rear Camera Harness (W19) Wiring Diagram A12— Rear Camera (if equipped) X64— Machine Harness-to-Rear Camera Harness Connector CW08338,0000D20 -19-26NOV14-1/1
9-Pin Service ADVISOR™ Connector (W20) Component Location See JDLink™ Harness (W6004) Component Location. (Group 9015-10.) CW08338,0000D21 -19-29AUG12-1/1
TM12660 (18APR18)
9015-10-149
041818
PN=459
System Diagrams
9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram NUMBER COLOR END #1 END #2 754 BLK X1 X71 797 GRN X1 X71 798 BLU X1 X71 1380 LT GRN/RED X1 X72 1381 GRN X1 X72 1382 BLU X1 X72
X72 1 2 3
(1381) GRN (1380) LT GRN/RED (1382) BLU
X1 X1 X1
X71 1 2 3 4 5 6 7 8
X72
2 1 3 1382 1380 1381
X1
(PLUG) (PLUG) (797) (PLUG) (754) (PLUG) (798) (PLUG)
GRN
X1
BLK
X1
BLU
X1
X1 (754) (1380) (797) (798) — — — (1381) (1382)
BLK LT GRN/RED GRN BLU
X1 X1 X1 X1
798 D E
X71
797 C
4
1 797
F
754 A
1380 B
798 G
GRN BLU
X1 X1
1382 J
1381 H
TX1116035
8
754 5
TX1116035 —UN—20JUN12
A B C D E F G H J
9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram X1— Service ADVISOR™ Diagnostic Connector X71— Machine Harness-toService ADVISOR™ Harness 8-Pin Connector
X72— Machine Harness-toService ADVISOR™ Harness 3-Pin Connector
Service ADVISOR is a trademark of Deere & Company CW08338,0000D22 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-150
041818
PN=460
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
CW08338,0000D23 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-151
041818
PN=461
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 TX1086706 —UN—22FEB11
(1) (2)
TX1086706 Pilot Shutoff Valve Harness (W21) Wiring Diagram X75— Cab Harness-to-Pilot Shutoff Valve Harness Connector
Y10— Pilot Shutoff Solenoid
CW08338,0000D24 -19-28AUG12-1/1
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location See Multi-Function Pilot Control Lever Harness (W15) Component Location. (Group 9015-10.) CW08338,0000D25 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-152
041818
PN=462
System Diagrams
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram NUMBER 2 3 4
COLOR RED WHT YEL
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 RED
X81/X82
WHT YEL WHT
X81/X82 X81/X82 X81/X82
1 2
(4) (2)
YEL RED
S34/S35 S34/S35
TX1116031 —UN—22AUG12
1 2 3 4 5 6 7 8 9 10
TX1116031 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
X82— Multi-Function Pilot Control Lever Harness-to-Auxiliary 3-Button Cancel Switch Harness
CW08338,0000D26 -19-29AUG12-1/1
Seat Heater Switch Harness (W24) Component Location See Heated Air Seat Harness (W14) Component Location. (Group 9015-10.) CW08338,0000D27 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-153
041818
PN=463
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) —
TX1103547
BLU WHT/RED
X53 X53
TX1103547 —UN—15DEC11
S62
Seat Heater Switch Harness (W24) Wiring Diagram S62— Seat Heater Switch X53— Heated Air Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector (marked SEAT HEATER) CW08338,0000D28 -19-01APR13-1/1
TM12660 (18APR18)
9015-10-154
041818
PN=464
System Diagrams
Travel Alarm Harness (W26) Component Location
X86 W26
TX1119101 —UN—31JUL12
H4
TX1119101 Travel Alarm Harness (W26) Component Location H4—Travel Alarm W26—Travel Alarm Harness
X86— Machine Harness-to-Travel Alarm Harness CW08338,0000D29 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-155
041818
PN=465
System Diagrams
Travel Alarm Harness (W26) Wiring Diagram COLOR RED/YEL GRN/BLK BLK WHT/YEL
END #1 X86 X86 X86 X86
END #2 H4 H4 H4 H4
GRN/BLK WHT/YEL RED/YEL BLK
X86 X86 X86 X86
X86
H4 A B C D
(138) (141) (26) (140)
1 2 3 4
H4
WHT/YEL RED/YEL BLK GRN/BLK
H4 H4 H4 H4
X86 B
A
D
(141) (26) (140) (138)
1
2
138
141
26
141
140
26
138
140
C
4
TX1115428
3
TX1115428 —UN—19JUL12
NUMBER 26 138 140 141
Travel Alarm Harness (W26) Wiring Diagram H4—Travel Alarm
X86— Machine Harness-to-Travel Alarm Harness CW08338,0000D2A -19-28AUG12-1/1
Travel Sub Harness (W27) Component Location See Cab Harness (W1) Component Location. (Group 9015-10.) CW08338,0000D2B -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-156
041818
PN=466
System Diagrams
Travel Sub Harness (W27) Wiring Diagram COLOR GRN/BLK BLK BLK YEL BLK GRN/RED WHT/GRN BLU BLK/RED GRN/BLK BLU/BLK BLK WHT/YEL GRN/RED
END #1 (138) (503) (503) X45B X45B X45B X45B X45B X45B X45B X45B X45B X45B X45B
END #2 X50 X50 X45A X45A X45A X45A X45A X45A X45A X45A X45A X45A X45A X45A
X45A 1 2 3 4 5 6 7 8 9 10 11 12
X45B
(665) (44) (45) (47) (65) (138) (43) (149) (103) (993) (105) (503)
WHT/YEL YEL BLK GRN/RED WHT/GRN GRN/BLK BLK BLU/BLK BLU GRN/RED BLK/RED BLK
X45A
1 2 3 4 5 6 7 8 9 10 11 12
1
1
45
44
665
665
503 105 993 103 149
43
138
138
65
12
47
TRAVEL
5
X45B X45B X45B X45B X45B X45B (503) X45B X45B X45B X45B X45B
6
6
1
2
1
2
(1) (2)
WHT/YEL YEL BLK GRN/RED WHT/GRN GRN/BLK
X45A X45A X45A X45A X45A X45A
(149) (103) (993) (105) (503)
BLU/BLK BLU GRN/RED BLK/RED BLK
X45A X45A X45A X45A X45A
5 44
45 149 103 993
47
65
105 503
X45B
12
X50
X50 1 2
(665) (44) (45) (47) (65) (138)
GRN/BLK (138) BLK (503)
TX1120500
TX1120500 —UN—21AUG12
NUMBER 1 2 43 44 45 47 65 103 105 138 149 503 665 993
Travel Sub Harness (W27) Wiring Diagram X45A— Option 2 12-Pin Connector X45B— Option 2 12-Pin Connector
X50— Travel Sub Harnessto-Travel Alarm Cancel Switch Harness Connector CW08338,0000D2C -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-157
041818
PN=467
System Diagrams
Starter Switch Harness (W29) Component Location See Cab Harness (W1) Component Location. (Group 9015.) CW08338,0000D2D -19-28AUG12-1/1
Starter Switch Harness (W29) Wiring Diagram NUMBER COLOR 1 WHT 3 WHT/RED 4 BLU 5 WHT/GRN 6 RED
1
S1
1 5
END #1 X47 X47 X47 X47 X47
END #2 S1 S1 S1 S1 S1
3
3
3
3
1 1
5
4
6
6
4
6
6
4
(1) — (3) (4) (5) (6)
WHT
X47
WHT
S1
WHT/RED BLU WHT/GRN RED
X47 X47 X47 X47
(1) — (3) (4) (5) (6)
WHT/RED BLU WHT/GRN RED
S1 S1 S1 S1
4
X47 1 2 3 4 5 6
TX1115492
TX1115492 —UN—14JUN12
S1 1 2 3 4 5 6
X47
Starter Switch Harness (W29) Wiring Diagram S1— Key Switch X47— Cab Harness-to-Key Switch Harness Connector CW08338,0000D2E -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-158
041818
PN=468
System Diagrams
TM12660 (18APR18)
9015-10-159
041818
PN=469
System Diagrams
Data Converter Harness (W30) Component Location
A5
X41
W30
R10
X70
TX1120547 —UN—22AUG12
X42
TX1120547 Data Converter Harness (W30) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-160
CW08338,0000D2F -19-30AUG12-1/2
041818
PN=470
System Diagrams A5—Data Converter R10— Interface CAN Resistor 1
W30—Data Converter Harness X41— Data Converter Harness Connector
X42— CAN 1 Connector X70— Data Converter Interface Connector CW08338,0000D2F -19-30AUG12-2/2
TM12660 (18APR18)
9015-10-161
041818
PN=471
System Diagrams
Data Converter Harness (W30) Wiring Diagram NUMBER 301 302 303 304 305 306 307 1251 1252 1356 1357 1380
COLOR BLU BLU RED/BLK BLK BLK GRN BLU GRN BLU GRN BLU LT GRN/RED
END #1 A5 A5 A5 A5 A5 (1251) (1252) A5 A5 A5 A5 (301)
END #2 X41 (301) X41 X41 (304) R10 R10 X70 X70 X42 X42 X70
X70
X70 1 2 3
(1251) (1252) (1380)
GRN BLU LT GRN/RED
2 1 3 1380 1252 1251
A5 A5 (301)
R10 1 2 3
(306) (307) —
GRN BLU
(1251) (1252)
R10 1
2
306 307
3
A5 X42 1
301
7
303
13
1356 1252
302
1357 1251
2
1 1357 1356
6 12 17
304 305
X42 1 2
(1356) (1357)
GRN BLU
A5 A5
A5 (301) (302) — — (1356) (1252) (303) — — — (1357) (1251) — (304) (305)
BLU BLU
X41 (301)
GRN BLU RED/BLK
X42 X70 X41
3
X41
1
304
301 303
8 BLU GRN
X42 X70
BLK BLK
X41 (304)
4
X41 1 2 3 4 5 6 7 8
(303) (301) (304) — — — — —
RED/BLK BLU BLK
TX1112364
A5 A5 A5
TX1112364 —UN—09MAY12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Data Converter Harness (W30)
Continued on next page
TM12660 (18APR18)
9015-10-162
CW08338,0000D30 -19-28AUG12-1/2
041818
PN=472
System Diagrams A5—Data Converter R10— Interface CAN Resistor 1
X41— Data Converter Harness Connector
X42— CAN 1 Connector X70— Data Converter Interface Connector CW08338,0000D30 -19-28AUG12-2/2
Data Converter Interface Harness (W31) Component Location See JDLink™ Harness (W6004) Component Location. (Group 9015-10.) CW08338,0000D31 -19-30AUG12-1/1
TM12660 (18APR18)
9015-10-163
041818
PN=473
System Diagrams
Data Converter Interface Harness (W31) Wiring Diagram NUMBER 1251 1252 1341 1342 1380 1381 1382
COLOR GRN BLU GRN BLU LT GRN/RED GRN BLU
END #1 X6021 X6021 (1251) (1252) X72 X72 X72
2 1
X70
1251
3 1252
1380
END #2 X70 X70 R11 R11 X70 (1251) (1252)
X70 1 2 3
(1251) (1252) (1380)
GRN BLU LT GRN/RED
X6021 X6021 X72
1
2
1341
1342
R11
R11 1 2 3
(1341) (1342) PLUG
GRN BLU
(1251) (1252)
3
X72 X72
1381
1380
1382
1
2
3
1 2 3
(1381) (1380) (1382)
GRN LT GRN/RED BLU
(1251) X70 (1252)
TX1116016
X6021
1251
1252
1
2
1 2 3
(1251) (1252) PLUG
GRN BLU
X70 X70
TX1116016 —UN—20JUN12
X6021
Data Converter Interface Harness (W31) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-164
CW08338,0000D32 -19-30AUG12-1/2
041818
PN=474
System Diagrams R11— Interface CAN Resistor 2 W31—Data Converter Interface Harness
X70— Data Converter Interface Connector X72— Machine Harness-toService ADVISOR™ Harness 3-Pin Connector
X6021—Interface CAN Connector (marked N-CAN)
CW08338,0000D32 -19-30AUG12-2/2
2-Speed Harness (W32) Component Location See Attachment Harness (W17) Component Location. (Group 9015-10.) CW08338,0000D47 -19-04MAR13-1/1
TM12660 (18APR18)
9015-10-165
041818
PN=475
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 Y43 1
2
Y43 (652) (5)
1 2
652 5
BLU/BLK BLU
X87 X87
Y44 1
2 17 18
Y44 (17) (18)
1 2
RED YEL/GRN
X87 X87
V43 K 9
8 A
A K
V43
(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)
B61
3
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
X87
5
TX1116634
X87 1 2 3 4 5 6 7 8
B61 B61 B61 Y43 Y43 Y44 Y44
TX1116634 —UN—19JUL12
B61 1 2 3
68
2-Speed Harness (W32) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-166
CW08338,0000D48 -19-04MAR13-1/2
041818
PN=476
System Diagrams B61— Arm Out Pressure Sensor V43— 2-Speed Activation Solenoid Valve Diode (if equipped)
X87— Attachment Harnessto-Two Speed Harness Connector Y43— 2-Speed Activation Solenoid Valve (if equipped)
Y44— Flow Rate Adjustment Solenoid Valve (not used)
CW08338,0000D48 -19-04MAR13-2/2
Heater and Air Conditioner Harness (W41) Component Location X51
A7
X52
K15
W41
M10
M9 K17
R16 B41 TX1120610 —UN—22AUG12
B55
M11
M7
TX1120610
Heater and Air Conditioner Harness (W41) Component Location A7—Air Conditioner Controller (ACF) B41— Air Conditioner Freeze Control Switch B55— Air Recirculation Sensor K15— Air Conditioner Compressor Off Relay
K17— Air Conditioner and Heater M10— Air Conditioner and Heater W41—Heater and Air Conditioner Blower Motor Relay Blower Port Change Harness M7—Air Conditioner and Heater Servomotor X51— Air Conditioner 4-Pin Blower Motor M11— Air Conditioner and Heater Connector M9—Air Conditioner and Heater Mixer Servomotor X52— Air Conditioner 10-Pin Internal and External R16— Blower Motor Resistor and Connector Servomotor Thermofuse CW08338,0000D33 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-167
041818
PN=477
System Diagrams
TM12660 (18APR18)
9015-10-168
041818
PN=478
System Diagrams
Heater and Air Conditioner Harness (W41) Wiring Diagram TX1135727 —UN—30APR13
NUMBER 3 4 5 6 7A 7B 7C 7D 8 9 10 11 13 14 15 16 17A 17B 17C 17D 17E 19 20 21 25A 25B 25C 25D 25E 25H 26A 26B 26C 29 30 31 32 41 42 43 44 48
COLOR YEL/WHT RED/WHT ORG/BLK PNK/BLK RED/BLK RED/BLK RED/BLK RED/BLK BLU/BLK BRN/BLK VLT/WHT VLT/RED WHT/RED BLK/RED PNK/WHT ORG RED/BLU RED/BLU RED/BLU RED/BLU RED/BLU WHT/BLK GRY/BLK GRN/BLK BRN/RED BRN/RED BRN/RED BRN/RED BRN/RED BRN/RED BLK BLK BLK LT GRN GRN/WHT YEL/RED GRN/RED RED/GRN WHT WHT/GRN BLK/BLU YEL
END #1 A7 A7 A7 A7 A7 X52 X300 X300 A7 A7 A7 A7 A7 A7 A7 A7 A7 X51 X301 X301 X301 A7 A7 A7 A7 X52 B41 X302 X302 X302 A7 X303 X303 A7 A7 A7 A7 X51 X52 K17 M7 X51
END #2 X52 X52 B41 B55 X300 X300 M10 M11 R16 R16 X52 X52 M9 M9 M11 M11 X301 X301 M9 K15 K17 M11 M10 X52 X302 X302 X302 M10 M11 B55 X303 X51 R16 K15 K17 M10 M10 K17 K15 M7 R16 K15
A7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A7 1
16
17A
3
4
5
19
20
21
6
7A
8
9
10
11
25A 26A
13
14
15
16
29
30
31
32
17
32
YEL/WHT RED/WHT ORG/BLK PNK/BLK RED/BLK BLU/BLK BRN/BLK VLT/WHT VLT/RED
X52 X52 B41 B55 X300 R16 R16 X52 X52
WHT/RED BLK/RED PNK/WHT ORG
M9 M9 M11 M11
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
(17A) — (19) (20) (21) — — — (25A) (26A) — — (29) (30) (31) (32)
RED/BLU
X301
WHT/BLK GRY/BLK GRN/BLK
M11 M10 X52
M10 M10
X302 X303
LT GRN GRN/WHT YEL/RED GRN/RED
K15 K17 M10 M10
20
32
1 2 3 4 5 6 7
31 7
(7B) (3) (4) (25B) (21) (42) — — (10) (11)
RED/BLU YEL/WHT RED/WHT BRN/RED GRN/BLK WHT
VLT/WHT VLT/RED
X300 A7 A7 X302 A7 K15
5
21
42
10
11
10
1
7B
3
4
25B
4
1 2 3 4 5
2
1
30
17E
(17E) (30) (43) — (41)
RED/BLU GRN/WHT WHT/GRN
X301 A7 M7
RED/GRN
X51
X301
X302
X303
SIDE A
SIDE A
SIDE A
SIDE A
(7A) (7B)
(17A) (17B)
B41
X51 1
48
17B
26B
41
1 2
4
(25C) (5)
(17C) (17D) (17E)
25C
5
1
2
K17
BRN/RED ORG/BLK
X303 K17 K15 X301
SIDE B
1 17D
41
29
3
43
5
48
3
42
R16 1
2
(26A)
26C
9
(26B) (26C)
44
8
3
4
K15 1 2 3 4 5
(17D) (29) (42) — (48)
BLK BRN/BLK BLK/BLU BLU/BLK
X303 A7 M7 A7
RED/BLU LT GRN WHT
X301 A7 X52
YEL
X51
R16 1 2 3 4
(26C) (9) (44) (8)
M9 14
17C 7
M9
X302 A7
1 2 3 4 5 6 7 Heater and Air Conditioner Harness (W41) Wiring Diagram
041818
A7 A7 A7
(25D) (25E) (25H)
7D
19
15
16
M7
7
M11
TX1135727
PN=479
GRY/BLK GRN/RED YEL/RED
2
5
2
Continued on next page
X302
K15
SIDE B
1 BLK RED/GRN YEL RED/BLU
BRN/RED
1
X51 (26B) (41) (48) (17B)
X300
13
M11 25E 1 2 3 4
(25A) (25B) (25C)
SIDE B (7C) (7D)
RED/BLK
4
K17
X300 A7 A7
3
(7C) — (25D) — (20) (32) (31)
4
SIDE B
9015-10-169
25D
1
BRN/RED BLK/RED
B41
TM12660 (18APR18)
7C
X52
X52 1 2 3 4 5 6 7 8 9 10
— — (3) (4) (5) (6) (7A) (8) (9) (10) (11) — (13) (14) (15) (16)
44
43
1
2
B55 1 2
M7 (25E) — (7D) — (19) (15) (16)
BRN/RED
X302
RED/BLK
X300
WHT/BLK PNK/WHT ORG
A7 A7 A7
1 2
(43) (44)
WHT/GRN BLK/BLU
(25H) (6)
25H
6
1
2
1 2 3 4 5 6 7
B55
BRN/RED PNK/BLK
(13) — (14) — — — (17C)
WHT/RED
A7
BLK/RED
A7
RED/BLU
X301
X302 A7
K17 R16
DF89619,00B5DB9 -19-28JAN16-1/2
System Diagrams
TM12660 (18APR18)
9015-10-170
041818
PN=480
System Diagrams
A7—Air Conditioner Controller M7—Air Conditioner and Heater M11— Air Conditioner and Heater X300— 7 RED/BLK Splice (ACF) Blower Motor Mixer Servo Motor X301— 17 RED/BLU Splice B41— Air Conditioner Freeze M9—Air Conditioner and Heater R16— Blower Motor Resistor and X302— 25 BRN/RED Splice Control Switch Internal and External Servo Thermofuse X303— 26 BLK Splice B55— Air Recirculation Sensor Motor X51— Air Conditioner 4-Pin K15— Air Conditioner M10— Air Conditioner and Heater Connector Compressor Off Relay Blower Port Change Servo X52— Air Conditioner 10-Pin K17— Air Conditioner and Heater Motor Connector Blower Motor Relay DF89619,00B5DB9 -19-28JAN16-2/2
Spool Control Harness (W43) Component Location
Y31
Y32 W43
TX1121331 —UN—27AUG12
X49
TX1121331 Spool Control Harness (W43) Component Location W43—Spool Control Harness X49— Cab Harness-to-Spool Control Harness Connector
Y31— Arm 3 Spool Control Solenoid (marked A2)
Y32— Boom 3 Spool Control Solenoid (marked A1)
CW08338,0000D35 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-171
041818
PN=481
System Diagrams
Spool Control Harness (W43) Wiring Diagram COLOR RED/YEL BLK/WHT RED/BLK GRN/RED
END #2 X49 X49 X49 X49
END #1 Y32 Y32 Y31 Y31
Y31 1
2
1398
1399
X49 2
X49 1 2 3 4
1396 1397 1398 1399
RED/YEL BLK/WHT RED/BLK GRN/RED
Y32 Y32 Y31 Y31
Y31 1 2
1398 1399
RED/BLK GRN/RED
X49 X49
1396 1397
RED/YEL BLK/WHT
X49 X49
1
1397 1396 1399 1398 4
Y32
3 1
1396
2 1397
TX1120694
Y32 1 2
TX1120694 —UN—28AUG12
NUMBER 1396 1397 1398 1399
Spool Control Harness (W43) Wiring Diagram X49— Cab Harness-to-Spool Control Harness Connector
Y31— Arm 3 Spool Control Solenoid (marked A2)
Y32— Boom 3 Spool Control Solenoid (marked A1) CW08338,0000D36 -19-01APR13-1/1
TM12660 (18APR18)
9015-10-172
041818
PN=482
System Diagrams
TM12660 (18APR18)
9015-10-173
041818
PN=483
System Diagrams
Auxiliary Solenoid Harness (W61) Component Location
Y34B,Y35B
V30,V32
Y34A,Y35A
V31,V33 W61
X535
W61 X534
X534 W15
W15
TX1208979
W61
TX1208979 —UN—28JAN16
X535
Auxiliary Solenoid Harness (W61) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-174
DF89619,00B5DB7 -19-08MAR16-1/2
041818
PN=484
System Diagrams V30— Right Solenoid Diode B V31— Right Solenoid Diode A V32— Left Solenoid Diode B V33— Left Solenoid Diode A
W15—Multi-Function Pilot X535— Left Auxiliary Solenoid Y35A— Left Solenoid Connector Control Lever Harness Connector (marked SL/H) A W61—Auxiliary Solenoid Y34A— Right Solenoid Y35B— Left Solenoid Connector Harness Connector A B X534— Right Auxiliary Solenoid Y34B— Right Solenoid Connector (marked SR/H) Connector B
NOTE: Right and left auxiliary solenoid connectors (X534 and X535) on multi-function pilot control lever harness (W15) may be located inside right
rear corner of cab prior to auxiliary solenoid harness (W61) installation. DF89619,00B5DB7 -19-08MAR16-2/2
TM12660 (18APR18)
9015-10-175
041818
PN=485
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 X534,X535 X534,X535
COLOR BLK BLK BLK BLK BLK GRN GRN GRN GRN GRN GRN
END #2 X450 Y34A,Y35A Y34B,Y35B V30,V32 V31,V33 X451 Y34A,Y35A V30,V32 X452 Y34B,Y35B V31,V33
X534,X535 1 2 3
1
G05 H01 H02
2 3
X534,X535
V31,V33 M F M
V30,V32 M F
H02B G05D F
V31, V33
H01B G05C M
V30,V32
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
TX1144334 —UN—20SEP13
Y34B,Y35B Y34A,Y35A A
B
Y34A,Y35A
A B
H01A G05A
TX1144334 Auxiliary Solenoid Harness (W61) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-176
TZ24494,000115D -19-14FEB18-1/2
041818
PN=486
System Diagrams V30— Right Solenoid Diode B V31— Right Solenoid Diode A V32— Left Solenoid Diode B V33— Left Solenoid Diode A
X450— GO5 BLK Splice X535— Left Auxiliary Solenoid Y35A— Left Solenoid Connector X451— HO1 GRN Splice Connector (marked SL/H) A X452— HO2 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 TZ24494,000115D -19-14FEB18-2/2
TM12660 (18APR18)
9015-10-177
041818
PN=487
System Diagrams
Auxiliary Function Lever (AFL) Harness (W75) Component Location
X577
W75 S31 S7 S29
X536
W77
X538
X574 W75
S33
X544 S32 S5 X542
X541 V22
S45
X540 W78
W77
X539 TX1208728 —UN—04MAR16
X537
X26 X543
TX1208728 Auxiliary Function Lever (AFL) Harness (W75) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-178
DF89619,00B5DAB -19-28JAN16-1/2
041818
PN=488
System Diagrams W77—Auxiliary Function Lever X539— Auxiliary Function Lever X544— Auxiliary Function Lever S5— Horn Switch (AFL) Grip Harness (2 (AFL) Left Grip Harness (AFL) Power Dig Switch S7— Power Dig Switch used) Connector (marked Connector S29— Auxiliary Function Lever L_LEVER) X574— Auxiliary Function Lever (AFL) Proportional Control W78—Auxiliary Function Enable Switch Harness X540— Auxiliary Function (AFL) Connector Switch Enable Switch Harness X577— Auxiliary Function S31— Right Pilot Control Lever X26— Optional Connector (2 used) Connector (marked Lever (AFL) Harness-toSwitch A X536— Right Auxiliary Function EL_SW) Auxiliary Function Lever S32— Left Pilot Control Lever Lever (AFL) Connector X541— Auxiliary Function Lever (AFL) Solenoid Harness Switch B (marked R_GRIP) (AFL) Right Switch Connector S33— Left Pilot Control Lever X537— Left Auxiliary Function Connector (marked Switch A Lever (AFL) Connector R-SW) S45— Auxiliary Function Enable (marked L_GRIP) X542— Auxiliary Function Switch X538— Auxiliary Function Lever Lever (AFL) Left Switch V22— Pilot Shutoff Solenoid (AFL) Right Grip Harness Connector (marked Diode Connector (marked L-SW) W75—Auxiliary Function Lever R_LEVER) X543— Auxiliary Function Lever (AFL) Harness (AFL) Horn Switch Connector DF89619,00B5DAB -19-28JAN16-2/2
TM12660 (18APR18)
9015-10-179
041818
PN=489
System Diagrams
TM12660 (18APR18)
9015-10-180
041818
PN=490
System Diagrams
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram TX1207859 —UN—15DEC15
X577 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X577
13
22
10
13
20
18
11
12
23
24
4
GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLK/YEL
X574 X574 X574 X574 X574 (27)
BLK/BLU WHT/YEL RED/YEL BLU/YEL
X574 (610) (25) X574
16
X574 5
1
23
25
12
45
27
13
44
19
12
(29) (10) (12) (25) (23) (22) (11) (19) (44) (13) (27) (45)
V22 A K
10
29
11
22 1
6
GRN/BLU WHT/BLU YEL/BLU RED/YEL BLK/BLU GRY BLU/WHT BLU/YEL BLK/GRN ORG/BLK BLK/YEL RED/BLU
A
58
57
(57) (58)
BLK/BLU WHT/YEL
X541
1
38
2
37
1 2
37
38
2
31
32 1
X542 1 2
(35) (36)
(37) (38)
GRN BLU
610
611
612
3
4
616
617
615
6
GRN BLU
X539 X539
(610) (611) (612) (616) (617) (615)
WHT/YEL RED LT GRN/RED BLU/RED RED/BLU BLK
(46) (47) (45) (44)
WHT/YEL BLK RED/BLU BLK/GRN
X543 605 2
X538 X538
38
1 2
3 37 25
29
27 8
X538
545
EL_SW
1
(31) (32) (37) (38) — (25) (29) (27)
GRN/BLK BLK GRN BLU
X544 X544 X541 X541
RED/YEL GRN/BLU BLK/YEL
X574 X574 X574
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram Continued on next page
041818
PN=491
WHT/VLT BLK
X539 X539
3
1
X538 1 2 3 4 5 6 7 8
(545) (605)
(610) (615) X574 X574
X540
X543
32
4
9015-10-181
1
X538 X538
R_LEVER
BLK GRN/BLK
1 2 3 4 5 6
1 2 3 4
31
TM12660 (18APR18)
4
X540
1
TX1207859
1
616
X541
X544 (32) (31)
610
617
X26
X542
X538 X577 X577 X538 X577 X577 X577 X577 X540 X577 X538 X540
2
(23) (24)
K
X544
1 2
611
615
X26 V22
1 2 3 4 5 6 7 8 9 10 11 12
612
6
AFL
19
X574
3
1
46
2
47
45
44
4
L_LEVER
1
(22) (10) (11) (12) (13) (20) PLUG PLUG PLUG PLUG (23) (24) (18) (19) PLUG PLUG
SW
END #2 X574 X574 X574 X574 X577 X574 (27) X577 X577 (610) X574 X574 X574 X544 X544 X542 X542 X541 X541 X540 X540 (610) (615) (23) (24) X543 X539 X26 X26 X26 X26 X26 X26
L-
END #1 X577 X577 X577 X577 (25) X577 X577 x574 X574 X577 X538 X538 X538 X538 X538 X539 X539 X538 X538 X574 X574 X540 X540 V22 V22 X539 X543 X26 X26 X26 X26 X26 X26
W
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 GRN BLU GRN BLU BLK/GRN RED/BLU WHT/YEL BLK BLK/BLU WHT/YEL WHT/VLT BLK WHT/YEL RED LT GRN/RED BLK BLU/RED RED/BLU
R-S
NUMBER 10 11 12 13 18 19 20 22 23 24 25 27 29 31 32 35 36 37 38 44 45 46 47 57 58 545 605 610 611 612 615 616 617
545
605
35
36 4
8
X539
X539 1 2 3 4 5 6 7 8
(545) (605) (35) (36) — — — —
WHT/VLT BLK GRN BLU
X543 X543 X542 X542
DF89619,00B5DAC -19-25JAN16-1/2
System Diagrams
TM12660 (18APR18)
9015-10-182
041818
PN=492
System Diagrams X540— Auxiliary Function V22— Pilot Shutoff Solenoid Enable Switch Harness Diode Connector (marked X26— Optional Connector (2 EL_SW) used) X538— Auxiliary Function Lever X541— Auxiliary Function Lever (AFL) Right Switch (AFL) Right Grip Harness Connector (marked Connector (marked R-SW) R_LEVER) X539— Auxiliary Function Lever X542— Auxiliary Function Lever (AFL) Left Switch (AFL) Left Grip Harness Connector (marked Connector (marked L-SW) L_LEVER)
X543— Auxiliary Function Lever (AFL) Horn Switch Connector X544— Auxiliary Function Lever (AFL) Power Dig Switch Connector X574— Auxiliary Function Lever (AFL) Connector X577— Auxiliary Function Lever (AFL) Harness-toAuxiliary Function Lever (AFL) Solenoid Harness Connector DF89619,00B5DAC -19-25JAN16-2/2
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location
X577 W76
W76
Y62 Y66 Y61 B85 TX1208926 —UN—03MAR16
B68
TX1208926 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location 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 DF89619,00B5DB3 -19-28JAN16-1/1
TM12660 (18APR18)
9015-10-183
041818
PN=493
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
TX1207862
TX1207862 —UN—15DEC15
4
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram
Continued on next page
TM12660 (18APR18)
9015-10-184
DF89619,00B5DAE -19-25JAN16-1/2
041818
PN=494
System Diagrams 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)
B68— Secondary Hydraulic Oil Temperature Sensor B85— Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1)
DF89619,00B5DAE -19-25JAN16-2/2
Auxiliary Function Lever (AFL) Grip Harness (W77) Component Location See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) DF89619,00B5DAF -19-25JAN16-1/1
Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram COLOR GRN BLU PNK BLK RED YEL/RED YEL/WHT
NUMBER 1 2 3 4 6 7 8
END #2 END #1 X536/X537 X538/X539 X536/X537 X538/X539 X536/X537 X538/X539 X536/X537 X538/X539 X536/X537 X538/X539 X536/X537 X538/X539 X536/X537 X538/X539
X536/X537 1
6
8
2
7
2
7
3
8
4
6
X538/X539
3
4
3
1
1
4 8
7
6
1 3 2
8
4
PNK BLK GRN BLU
X536/X537 X536/X537 X536/X537 X536/X537
RED YEL/WHT YEL/RED
X536/X537 X536/X537 X536/X537
5
1 2 3 4 5 6 7 8
(6) (7) (8) (3) (1) (4) (2) —
RED YEL/RED YEL/WHT PNK GRN BLK BLU
1 2 3 4 5 6 7 8
X538/X539 X538/X539 X538/X539 X538/X539 X538/X539 X538/X539 X538/X539
(3) (4) (1) (2) — (6) (8) (7)
TX1207856
TX1207856 —UN—15DEC15
X538/X539 X536/X537
Auxiliary Function Lever (AFL) Grip Harness (W77) Wiring Diagram X536— Right Auxiliary Function Lever (AFL) Connector (marked R_GRIP) X537— Left Auxiliary Function Lever (AFL) Connector (marked L_GRIP)
X538— Auxiliary Function Lever X539— Auxiliary Function Lever (AFL) Right Grip Harness (AFL) Left Grip Harness Connector (marked Connector (marked R_LEVER) L_LEVER)
DF89619,00B5DB0 -19-25JAN16-1/1
Auxiliary Function Enable Switch Harness (W78) Component Location See Auxiliary Function Lever (AFL) Harness (W75) Component Location. (Group 9015-10.) DF89619,00B5DB1 -19-25JAN16-1/1
TM12660 (18APR18)
9015-10-185
041818
PN=495
System Diagrams
Auxiliary Function Enable Switch Harness (W78) Wiring Diagram NUMBER COLOR 12 RED/BLU 16 BLK/GRN 17 BLK/GRN 18 WHT/YEL
END #1 X540 X540 X540 X540
END #2 S45 S45 S45 S45
X540 EL_SW
17
16
17
12
2
4
10
5
X540 1 2 3 4
(18) (17) (12) (16)
WHT/YEL BLK/GRN RED/BLU BLK/GRN
S45
S45 S45 S45 S45
1 2 3 4 5 6 7 8 9 10
TX1207857
(18) — — — (16) — — (17) (12) —
WHT/YEL
X540
BLK/GRN
X540
BLK/GRN RED/BLU
X540 X540
TX1207857 —UN—26JAN16
12
4
18
18 16
S45
1
1
Auxiliary Function Enable Switch Harness (W78) Wiring Diagram S45— Auxiliary Function Enable Switch
X540— Auxiliary Function Enable Switch Harness Connector (marked EL_SW) DF89619,00B5DB2 -19-25JAN16-1/1
Satellite (SAT) Harness (W6003) Component Location See JDLink™ Harness (W6004) Component Location. (Group 9015-10.) CW08338,0000D37 -19-29AUG12-1/1
TM12660 (18APR18)
9015-10-186
041818
PN=496
System Diagrams
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
X6015 ABCDE FGH J K L M 4 3 2 1
X6015
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
M01 M02 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
PLUG PLUG M03 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG G01 P01 PLUG PLUG
6
1
5
2
4
3
X6016 1 2 3 4 5 6
TX1118635
M01 M02 M03 G01 P01 PLUG
TX1118635 —UN—23JUL12
X6016
Satellite (SAT) Harness (W6003) Wiring Diagram X6015—Satellite (SAT) Module Control Unit 48-Pin Connector
X6016—JDLink™ Harness-toSatellite (SAT) Harness
JDLink is a trademark of Deere & Company CW08338,0000D38 -19-28AUG12-1/1
TM12660 (18APR18)
9015-10-187
041818
PN=497
System Diagrams
JDLink™ Harness (W6004) Component Location R11 W31
X72
X70 W20
A6002 X6014 A6000 X6016 X1
W6003 X6015 A6001
X6021 X6007 X71 X6020
F6000 K19 F6002 F6001
TX1120577 —UN—22AUG12
W6004
TX1120577 JDLink™ Harness (W6004) Component Location
Continued on next page
TM12660 (18APR18)
9015-10-188
CW08338,0000D39 -19-30AUG12-1/2
041818
PN=498
System Diagrams A6000—Modular Telematics K19— Battery Relay Gateway (MTG) R11— Interface CAN Resistor 2 Controller—If Equipped W20—Service ADVISOR™ A6001—GPS/Cellular Antenna Harness A6002—Satellite (SAT) Module W31—Data Converter Interface Control Unit—If Equipped Harness F6000—JDLink™ Unswitched W6003—Satellite (SAT) Harness Power 7.5 A Fuse—If W6004— JDLink™ Harness Equipped X1— Service ADVISOR™ F6001—JDLink™ Ground 7.5 A Diagnostic Connector Fuse—If Equipped F6002—JDLink™ Switched Power 7.5 A Fuse—If Equipped
X70— Data Converter Interface Connector X71— Machine Harness-toService ADVISOR™ Harness 8-Pin Connector X72— Machine Harness-toService ADVISOR™ Harness 3-Pin Connector X6007— JDLink™ Harness Ground 1 X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015—Satellite (SAT) Module Control Unit 48-Pin Connector X6016—JDLink™ Harness-toSatellite (SAT) Harness X6020—CAN 0 Connector (marked CAN) X6021—Interface CAN Connector (marked N-CAN)
JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company CW08338,0000D39 -19-30AUG12-2/2
TM12660 (18APR18)
9015-10-189
041818
PN=499
System Diagrams
TM12660 (18APR18)
9015-10-190
041818
PN=500
System Diagrams
JDLink™ Harness (W6004) Wiring Diagram TX1120088 —UN—28AUG12
NUMBER 1356 1357 G01 G01A G01B G01E G02 M01 M02 M03 M12 M13 P01 P01A P01B P01C P02 P02A
COLOR LT GRN YEL BLK BLK BLK BLK BLK PUR PUR PUR YEL LT GRN RED RED RED RED RED RED
END #2 X6014 X6014 F6001 X6014 X160 F6001 X6014 X6016 X6016 X6016 X6014 X6014 F6000 F6000 X161 X161 F6002 F6002
X6014
A B C D E F G H J K L
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4
M
1
X6014
3 2 4
M01 M02 PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG
E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4
PLUG PLUG PLUG PLUG PLUG PLUG G01D PLUG (1357) (1356) PLUG PLUG M12 M13 PLUG PLUG
J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4
PLUG PLUG PLUG PLUG PLUG PLUG PLUG PLUG P02A PLUG PLUG PLUG G01A P01C M03 PLUG
X6007
X6021 1 2
X162 SIDE A G01C G01D SIDE B G01E
X162
1356 1357
1
X6021
2
G01
END #1 X6021 X6021 X6011 X160 X6016 X160 W6007 X6014 X6014 X6014 X6020 X6020 K19 X161 X6016 X6014 K19 X6014
1
X6016 1 2 3 4 5 6
M01 M02 M03 G01B P01B PLUG
6
1
5 4
2 3
X160
X161
SIDE A G01A G01B SIDE B G01C
SIDE A P01B P01C SIDE B P01A
2
X6020 X6020 1 2
M12 M13
X6016
F6000 B
A
F6002
F6000
A B
A B
P02 P02A
F6001
B
A B
G01 G01E
F6001
A
F6002
P01 P01A
A B
B
A
B
A
B
A
K19 P0
2
P01
TX1120088 JDLink™ Harness (W6004) Wiring Diagram JDLink is a trademark of Deere & Company
CW08338,0000D3A -19-28AUG12-1/2
Continued on next page
TM12660 (18APR18)
9015-10-191
041818
PN=501
System Diagrams
TM12660 (18APR18)
9015-10-192
041818
PN=502
System Diagrams F6000—JDLink™ Unswitched Power 7.5 A Fuse—If Equipped F6001—JDLink™ Ground 7.5 A Fuse—If Equipped F6002—JDLink™ Switched Power 7.5 A Fuse—If Equipped
K19— Battery Relay X160— P01 RED Splice X161— G01 BLK Splice X162— G01 BLK Splice 2 X6007— JDLink™ Harness Ground X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6016—JDLink™ Harness-toSatellite (SAT) Harness X6020—CAN 0 Connector (marked CAN) X6021—Interface CAN Connector (marked N-CAN)
CW08338,0000D3A -19-28AUG12-2/2
TM12660 (18APR18)
9015-10-193
041818
PN=503
System Diagrams
TM12660 (18APR18)
9015-10-194
041818
PN=504
Group 15
Sub-System Diagnostics Controller Area Network (CAN) Theory of Operation TX1249917 —UN—26MAR18
W41 HEATER AND AIR CONDITIONER HARNESS
W1 CAB HARNESS
A = X20
9
E9
BLU
GRN
CAN 1 GRN
GRN
4
-
GRN
CAN 0 A24
BLU
132
A1 ENGINE CONTROL UNIT (ECU)
A2 VARIABLE GEOMETRY TURBOCHARGER (VGT)
GRN
A6 RADIO
15
16
GRN
110
BLU
88
A3 D2 D5 MAIN CONTROLLER D4 (MCZ)
BLU CAN 1 GRN
X42
BLU
= X15
BLU
D3
GRN
-
W30 DATA CONVERTER HARNESS
E3
120
12
GRN BLU
154
+
BLU CAN 1
+
+
A7 AIR CONDITIONER CONTROLLER (ACF)
A26
A23
GRN CAN 0
-
VLT/WHT
VLT/WHT
BLU
120
10
A25
CAN 1
120
CAN 1
BLU
CAN 0
BLU
-
10
120
VLT/RED
VLT/RED
X3 +
X52 11
W2 MACHINE HARNESS
A4 MONITOR CONTROLLER (DSZ)
CAN 0 GRN
BLU
GRN
B1
INTERFACE CAN GRN
C12
+
BLU
C6
120
B11
BLU CAN 1
R8 ENGINE CAN TERMINATION RESISTOR
B = X11
A5 DATA CONVERTER
W31 DATA CONVERTER INTERFACE HARNESS
W20 SERVICE ADVISOR™ HARNESS
BLU
D
BLU
7
BLU
GRN
3
GRN
4
GRN
8
BLU
CAN 0 GRN
C J
BLU
ENGINE CAN
INTERFACE CAN
+ 120
2
BLU
GRN
1
GRN
INTERFACE CAN
120
B
-
BLU
GRN
YEL
YEL
H1
LT GRN
H2
CAN 0 2
BLU 3
1
LT GRN
R11 INTERFACE CAN RESISTOR 2
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
X6021
+
R10 INTERFACE CAN RESISTOR 1
A
1
GRN CAN 0
X72
INTERFACE CAN
GRN
W6004 JDLINK™ HARNESS
X6020
X71 BLU
BLK
-
GRN
A
GRN
BLU INTERFACE CAN
A
GRN
BLU
BLU
H
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
X70 B
BLU
ENGINE CAN
ENGINE CAN
- 120
2
BLU
GRN
A
BLU
C11
A11 MACHINE CONTROLLER (BCZ)
CAN 0
D = X34
CAN 0
GRN
-
1
GRN CAN 1
B
+
GRN
C5
GRN
1
YEL
YEL
G1
LT GRN
G2
INTERFACE CAN BLU
2
LT GRN
= X6014
TX1249917 Controller Area Network (CAN) Circuit Theory of Operation Schematic
DW9628,00005F5 -19-14MAR18-1/3
Continued on next page
TM12660 (18APR18)
9015-15-1
041818
PN=505
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-2
041818
PN=506
Sub-System Diagnostics
A1—Engine Control Unit (ECU) A2—Variable Geometry Turbocharger (VGT) A3—Main Controller (MCZ) A4—Monitor Controller (DSZ) A5—Data Converter A6—Radio A7—Air Conditioner Controller (ACF) A11— Machine Controller (BCZ) A6000—Modular Telematics Gateway (MTG) Controller R8—Engine CAN Termination Resistor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X3— Cab Harness-to-Machine W1—Cab Harness Harness 100-Pin Connector W2—Machine Harness X11— Machine Controller 20-Pin W20—Service ADVISOR™ Connector B Harness X15— Engine Control Unit W30—Data Converter Harness (ECU)-to-Machine Harness W31—Data Converter Interface 94-Pin Connector Harness X20— Monitor Controller 28-Pin W41—Heater and Air Conditioner Connector A Harness X34— Cab Harness-to-Main W6004—JDLink™ Harness Controller 30-Pin X1— Service ADVISOR™ Connector D Diagnostic Connector X42— CAN 1 Connector X52— Air Conditioner 10-Pin Connector X70— Data Converter Interface Connector
• Modular Telematics Gateway (MTG) (if equipped)
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.
(A6000)
Operations and functions of the individual devices on CAN 0 are covered separately.
The CAN consists of two buses (wires): CAN high and CAN low. These two wires carry signals opposite to each other to overcome noise interference and minimize communication errors. The high and low wires, and sometimes a ground wire, are woven together, which provides an additional method of reducing interference and thus helps the devices communicate with minimal errors. When woven together with a ground wire, the three wires are commonly referred to as a twisted triple.
• For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)
• For the MCZ, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
• For the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.)
CAN 0 also includes the following components:
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 that 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. The first device on the bus is able to transmit its signal. When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the lowest ID has higher priority to access the bus. The device that loses arbitration immediately retransmits its signal when the device with the higher priority has completed its transmission. This machine contains four CAN circuits: CAN 0, CAN 1, interface CAN, and engine CAN. CAN 0—The CAN 0 circuit provides the communication link for the following devices:
• Engine Control Unit (ECU) (A1) • Main Controller (MCZ) (A3) • Monitor Controller (DSZ) (A4)
• One terminating resistor located inside monitor controller (DSZ) (A4)
• One terminating resistor located inside engine control unit (ECU) (A1)
• Machine Harness-to-Service ADVISOR™ Harness 8-Pin Connector (X71)
CAN 0 utilizes two terminating resistors: one is located inside monitor controller (DSZ) (A4), and one is located inside engine control unit (ECU) (A1). These resistors are not accessible.
• Service ADVISOR™ Diagnostic Connector (X1) • Machine Harness-to-Service ADVISOR™ Harness 8-Pin Connector (X71)
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
TM12660 (18APR18)
X71— Machine Harness-toService ADVISOR™ Harness 8-Pin Connector X72— Data Converter Interface Harness-to-Service ADVISOR™ Harness 3-Pin Connector X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector X6020—CAN 0 Connector (marked CAN) X6021—Interface CAN Connector (marked N-CAN)
9015-15-3
DW9628,00005F5 -19-14MAR18-2/3
041818
PN=507
Sub-System Diagnostics
• For the DSZ, see Monitor Controller (DSZ) Circuit
Theory of Operation. (Group 9015-15.) • For the BCZ, see Machine Controller (BCZ) Circuit Theory of Operation. (Group 9015-15.) CAN 1 also includes the following components:
• One terminating resistor located inside monitor controller (DSZ) (A4)
• One terminating resistor located inside machine controller (BCZ) (A11)
CAN 1 utilizes two terminating resistors: one is located inside monitor controller (DSZ) (A4), and one is located inside machine controller (BCZ) (A11). These resistors are not accessible.
• Interface CAN Resistor 1 (R10) • Interface CAN Resistor 2 (R11) • Machine Harness-to-Service ADVISOR™ Harness 3-Pin Connector (X72)
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 devices:
• Engine Control Unit (ECU) (A1) • Variable Geometry Turbocharger (VGT) (A2)
Interface CAN—The interface CAN circuit provides the communication link for the following devices:
The variable geometry turbocharger (VGT) (A2) communicates on this bus with only one controller, the ECU.
• Data Converter (A5) • Modular Telematics Gateway (MTG) (if equipped)
Engine CAN also includes the following components:
(A6000)
• Service ADVISOR™ Diagnostic Connector (X1) The interface CAN provides a means of accessing CAN 1 through the Service ADVISOR™ diagnostic connector (X1).
• Engine CAN Termination Resistor (R8) • Machine Harness-to-Service ADVISOR™ Harness 8-Pin Connector (X71)
The engine CAN bus has two terminating resistors; one of them is located inside the ECU and is not accessible.
Interface CAN also includes the following components: Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company DW9628,00005F5 -19-14MAR18-3/3
TM12660 (18APR18)
9015-15-4
041818
PN=508
Sub-System Diagnostics
Starting and Charging Circuit Theory of Operation TX1240194 —UN—14JUN17
BLU
BLU
RED/BLK
B
POSITION HEAT OFF ACC ON START
G1
G2
ACC
M ST
RED
RED
10
LT GRN/BLK
ORG
WHT
VLT/GRN BLK/WHT WHT
ORG
Starting and Charging Circuit Theory of Operation Schematic Continued on next page
041818
PN=509
1
2
3
3
X65
X65 VLT VLT/GRN BLK/WHT WHT
K1 LOAD DUMP RELAY
WHT 4
GRN/YEL
RED
GLOW PLUG R1
R2
R3
R4
67
89
111
BLK/YEL 133
GRN 139
= X15
136
114
GRN/YEL
100
A1 153 ENGINE CONTROL UNIT (ECU)
BRN/YEL
5
1
R13 ENGINE CONTROL UNIT (ECU) RESISTOR
WHT A8
X3
K14 ECU POWER RELAY
YEL/WHT
BLK
YEL
BLU
RED
RED
ORG VLT
BLU
RED
BLU
ORG
V20 PILOT SHUTOFF SWITCH DIODE
TX1240194
9015-15-5
1
152
3
2
2
RED
134
BLK/WHT
GRN
1
WHT
BLK
S3 PILOT SHUTOFF SWITCH 1 X65
ORG
121
ORG
2
S4 PILOT SHUTOFF SWITCH 2
RED
F14 5A FUSE
X8
1
4
BLK/WHT
D8
2
BLU
B10
3
2
3
BLK
RED
YEL/GRN
1
M2 FUEL TRANSFER PUMP X40
V11 ACCESSORY CUT DIODE
ORG
F11 5A FUSE
B17
BLK
WHT
V9 PILOT SHUTOFF DIODE
3
WHT
B
2
GRN
C = X33 E = X35 F = X36
BLU/BLK
1
YEL/BLU
B18
4
GRY/RED
A15 A16 A17
A4 MONITOR CONTROLLER (DSZ)
A = X20 B = X21 D = X22
V5 STARTER CUT RELAY DIODE 1
BLK
M1 STARTER MOTOR
YEL/BLK
YEL/GRN
A3 MAIN CONTROLLER (MCZ)
F13
RED
RED
WHT
C5
GRN
C
K34 STARTER RELAY
E4
GRN BLU/BLK
B
S
F60 65A FUSE
E6
WHT
E
E5
V12 STARTER CUT DIODE
D16
RED/BLK
BRN
E
GRN/WHT
RED/BLK
YEL/BLK
S6 ENGINE STOP SWITCH
R
G3 ALTERNATOR
VLT/GRN
4
VLT/GRN
K12 ACCESSORY CUT RELAY
5
K16 GLOW PLUG RELAY
RED
2
RED/BLK
4
BLU/YEL
K11 IDLE STOP RELAY
5
L
BLK
2
B
YEL/BLK
4
YEL/GRN
5
WHT/BLK
2
YEL/BLK BRN
K13 KEY CUT RELAY
3
GRN/WHT
RED
V3 LOAD DUMP RELAY DIODE
WHT
RED/BLK
RED/BLK
WHT
BRN
F7 5A FUSE
F8 30A FUSE
F16 5A FUSE
BLU
BLU
WHT
BLU
A4
RED/BLU
VLT/GRN
WHT
A
G2 BATTERY
BLK/WHT
B
BLU
BLK/WHT
RED S
BLU
V7 START RELAY DIODE
S
WHT
TM12660 (18APR18)
3
F9 10A FUSE
WHT
G1 BATTERY
BLK
1
3
A = X10 BLU
2
YEL/BLK
RED/BLU
WHT/RED
1
3
VLT/GRN
RED
BLK
4
1
YEL/GRN
BLU
5
F17 5A FUSE
V4 SECURITY DIODE 1
BLU
YEL/GRN
2 K4 STARTER CUT RELAY
V10 STARTER PROTECTION DIODE
BLU
A11 MACHINE CONTROLLER (BCZ)
YEL/GRN
3
YEL/BLK
WHT/RED
F61 45A FUSE
W37 CAB HARNESS GROUND 3
BLU
BLK/WHT
RED
M
ST
BLK
C2
BLU
WHT
1
G2
V1 BATTERY RELAY DIODE
BLU
WHT/RED
G1
E
C1
ACC BAT
K19 BATTERY RELAY
C7
F18 5A FUSE
YEL/GRN
WHT/RED WHT
S1 KEY SWITCH
BLU
HEAT OFF ACC ON START
A5 DATA CONVERTER
F10 5A FUSE RED/BLK
WHT
BRN
RED
WHT
RED/BLK WHT/RED
RED
WHT/RED RED WHT
WHT RED/BLK WHT/RED RED WHT
WHT
1
2
3
5
4
BLU
DW9628,000051E -19-16JUN17-1/4
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-6
041818
PN=510
Sub-System Diagnostics
A1—Engine Control Unit (ECU) A3—Main Controller (MCZ) A4—Monitor Controller (DSZ) A5—Data Converter A11— Machine Controller (BCZ) F7— Start Position Signal 5 A Fuse (marked START) F8— Engine Control Unit (ECU) 30 A Fuse (marked ECU) F9— Radio Backup 10 A Fuse (marked BACK UP) F10— Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) F11— Fuel Pump 5 A Fuse (marked FUEL PUMP) F14— Monitor 5 A Fuse (marked MONITOR) F16— Glow Relay 5 A Fuse (marked GLOW RELAY) F17— Power On 5 A Fuse (marked POWER ON)
F18— Idle Stop 5 A Fuse (marked S4— Pilot Shutoff Switch 2 IDLE STOP) S6— Engine Stop Switch F60— Alternator 65 A Fuse V1— Battery Relay Diode F61— Battery 45 A Fuse V3— Load Dump Relay Diode G1—Battery V4— Security Diode G2—Battery V5— Starter Cut Relay Diode G3—Alternator V7— Start Relay Diode K1—Load Dump Relay V9— Pilot Shutoff Diode K4—Starter Cut Relay V10— Starter Protection Diode K11— Idle Stop Relay V11— Accessory Cut Diode K12— Accessory Cut Relay V12— Starter Cut Diode K13— Key Cut Relay V20— Pilot Shutoff Switch Diode K14— ECU Power Relay W37—Cab Harness Ground 3 K16— Glow Plug Relay X3— Cab Harness-to-Machine K19— Battery Relay Harness 100-Pin Connector K34— Starter Relay X8— Machine Harness-to-Engine M1—Starter Motor Harness 1-Pin Connector M2—Fuel Transfer Pump X10— Machine Controller 8-Pin R1—Glow Plug 1 Connector A R2—Glow Plug 2 X15— Engine Control Unit R3—Glow Plug 3 (ECU)-to-Machine Harness R4—Glow Plug 4 94-Pin Connector R13— Engine Control Unit (ECU) Resistor S1— Key Switch S3— Pilot Shutoff Switch 1
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)] • Monitor Controller (DSZ) (A4) [from radio backup 10 A fuse (marked BACK UP) (F9)] • Data Converter (A5) [from data converter and main controller battery power 5 A fuse (marked CONTROLLER) (F10)] • ECU Power Relay (K14) [from engine control unit (ECU) 30 A fuse (marked ECU) (F8)] • Glow Plug Relay (K16) • Load Dump Relay (K1) Ignition ON When key switch (S1) is placed in the ON position, current is applied from key switch pin ACC to pin 3 of accessory cut relay (K12). Utilizing the normally closed contacts of accessory cut relay, power is supplied through accessory cut diode (V11), next through monitor 5 A fuse (F14) to pin 17 of the monitor controller (DSZ) (A4), powering up the DSZ. Key switch pin M also receives power, supplying idle stop relay (K11), accessory cut relay (K12), and key cut relay (K13) through idle stop 5 A fuse (F18). Utilizing the normally closed contacts of key cut relay, power is passed through pin 3 of key cut relay, next through load dump
relay diode (V3), then to pin S of battery relay (K19), energizing the battery relay. Ground is provided to pin E of battery relay from cab harness ground 3 (W37). When energized, the battery relay allows current to pass through to pin B of starter motor (M1) and pin B 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). Current from load dump relay diode (V3) is also provided to pin R of alternator for excitation, and to fuel pump 5 A fuse (F11), providing power to fuel transfer pump (M2). Power through pin 3 of key cut relay is also provided to glow plug relay (K16) through glow relay 5 A fuse (F16) and through power on 5 A fuse (F17) to pin 2 of engine stop switch (S6), pin 7 of data converter (A5) 17-pin connector, pin 134 of engine control unit (ECU)-to-machine harness 94-pin connector (X15), pin 4 of cab harness-to-main controller 24-pin connector E (X35), and pin 16 of monitor controller 28-pin connector A (X20), indicating the key switch is in the ON position. When the ECU receives indication of the key switch in the ON position, pins 136 and 114 of engine control unit (ECU)-to-machine harness 94-pin connector (X15) are connected to power, energizing ECU power relay (K14). With ECU power relay energized, battery power is passed to pins 67, 89, 111, and 133 of engine control unit (ECU)-to-machine harness 94-pin connector. Power from ECU power relay is also passed through engine control unit (ECU) resistor (R13) to pin 139 of engine control unit (ECU)-to-machine harness 94-pin connector. Engine Start
Continued on next page
TM12660 (18APR18)
X20— Monitor Controller 28-Pin Connector A X21— Monitor Controller 36-Pin Connector B X22— Monitor Controller 16-Pin Connector D X33— Cab Harness-to-Main Controller 17-Pin Connector C X35— Cab Harness-to-Main Controller 24-Pin Connector E X36— Cab Harness-to-Main Controller 26-Pin Connector F X40— Pump Harness-to-Machine Harness Connector X65— Cab Harness-to-Pilot Shutoff Switch Harness Connector
9015-15-7
DW9628,000051E -19-16JUN17-2/4
041818
PN=511
Sub-System Diagnostics
When key switch (S1) is moved to the START position, power is applied from key switch pin ST to pins 1 and 3 of starter cut relay (K4) and through start position signal 5 A fuse (F7) to pin 17 of monitor controller 28-pin connector A (X20), indicating the key switch is in the START position. Utilizing the normally closed contacts of starter cut relay, power is passed to pin S of starter relay (K34) and pin 100 of engine control unit (ECU)-to-machine harness 94-pin connector (X15), indicating the key switch is in the START position. With battery relay (K19) energized from the ignition ON position, power from key switch pin M is supplied to pin B of starter motor (M1) and pin 3 of starter relay (K34). Starter relay (K34) is a normally open relay which closes when power is present on relay pin S and ground is present on relay pin E. 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. Starter cut relay (K4) utilizes the normally closed contacts of the relay to continue the start signal to pin S 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, thus preventing the start motor from cranking the engine. The ground on pin 2 can come from the monitor controller (DSZ) (A4), from pilot shutoff switches (S3 and S4), from the 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. When a warning alarm or security code error is detected, pin 16 of monitor controller 16-pin connector D (X22) is connected to ground. When a fault in the pilot shutoff circuit is detected, pin 10 of monitor controller 36-pin connector B (X21) is connected to ground. With either pin 16 or pin 10 of the monitor controller connected to ground, the starter cut relay (K4) is energized through security diode (V4) and engine stop switch (S6), removing the start signal from starter relay (K34). With no start signal at the 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 control lever is in down (unlocked) position, pin 2 of starter cut relay is connected to ground through starter cut relay diode (V5) and engine stop switch, 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. This prevents the activation of starter motor when pilot control lever is in the down (unlocked) position. For more
information on the pilot shutoff circuit, see Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) When the engine is running, engine control unit (ECU) (A1) provides ground to pin 2 of starter cut relay (K4). This opens the normally closed contacts of the starter cut relay, removing the start signal from starter relay (K34). The engine control unit prevents the starter from engaging while the engine is running. When the engine stop switch is in the STOP position, power from power on 5 A fuse (F17) is passed through engine stop switch to pin 121 of engine control unit (ECU)-to-machine harness 94-pin connector (X15), preventing the engine from starting, however still allowing the starter motor to crank. When the engine stop switch is in the RUN position, a path for ground is available to starter cut relay from security diode (V4) and starter cut relay diode (V5) allowing the monitor security and pilot shutoff circuit to disable the starter motor from cranking. When ground is present at starter cut relay (K4), ground is also available through starter protection diode (V10) to main controller (MCZ) (A3), idle stop relay (K11), accessory cut relay (K12), and key cut relay (K13), energizing all three relays. Ground at pin 5 of cab harness-to-main controller 17-pin connector C indicates to the main controller the engine is cranking. With idle stop relay, accessory cut relay, and key cut relay energized, power is removed from the ignition ON circuits which allows starter motor (M1) to use all available battery power to start the engine. Once the key switch (S1) is released from the START position, idle stop relay, accessory cut relay, and key cut relay are de-energized supplying ignition ON circuits with power. 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. Glow Plugs (Cold Start) Circuit If the engine control unit (ECU) determines the glow plugs need to be activated, the ECU grounds pin 153 of engine control unit (ECU)-to-machine harness 94-pin connector (X15), providing ground to pin 4 of glow plug relay (K16), energizing the relay. With the relay energized, battery power is passed to the glow plugs which start to heat the air in the combustion chamber for a set duration. The operator may start the engine at anytime 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.) Charging Circuit Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running. Pin B of the alternator is connected to battery positive (+) through alternator 65 A fuse (F60) when the battery relay (K19) is energized.
Continued on next page
TM12660 (18APR18)
9015-15-8
DW9628,000051E -19-16JUN17-3/4
041818
PN=512
Sub-System Diagnostics
Alternator pin L provides output voltage to pin 15 of monitor controller 28-pin connector A (X20), turning off the alternator indicator light and the monitor warning alarm. If voltage at pin 15 of X20 drops below operating voltage, alternator voltage indicator will illuminate and monitor warning alarm will sound. 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:
• 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 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 sent to pin 15 of monitor controller 28-pin connector A (X20). This causes the monitor controller (DSZ) (A4) to ground pin 8 of monitor controller 16-pin connector D (X22), 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 pin 8 of monitor controller 16-pin connector D (X22) retains a ground path for load dump relay until alternator stops producing output voltage, keeping the battery relay energized, thus providing a path to the batteries (G1 and G2) for any power produced by the alternator as the engine slows to a stop. Then the ground path is removed from load dump relay, and battery relay is de-energized. Load dump relay diode (V3) isolates battery power at pin 5 of load dump relay (K1) from key switch ON power circuits. DW9628,000051E -19-16JUN17-4/4
TM12660 (18APR18)
9015-15-9
041818
PN=513
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-10
041818
PN=514
Sub-System Diagnostics
Monitor Controller (DSZ) Circuit Theory of Operation TX1223588 —UN—20SEP16
E
WHT/BLK
YEL/GRN
2
BLU
3
5
K4 STARTER CUT RELAY
4
RED/BLU RED/BLU PNK/GRN
V11 ACCESSORY CUT DIODE
1
2
YEL/GRN
1
4
BLU/BLK
B17
GRN/BLK
D15
WHT/RED
WHT/RED
A17
BLU/YEL
BLU/YEL
A15
B11
GRN (CAN 1 HIGH)
A26
B36
BLU (CAN 1 LOW)
A25
F60 65A FUSE
E
BLK
BLK
C
S
BLK
RED
BLK
G2 BATTERY
B
K34 STARTER RELAY B
B1
B11
A11 MACHINE CONTROLLER (BCZ) B=X11
M1 STARTER MOTOR
BLU
S
11
4
A5 DATA CONVERTER
A6 RADIO
5
GRN
A
K19 BATTERY RELAY
WHT
WHT
E
B
V7 START RELAY DIODE
BLK/WHT
G1 BATTERY
D4
D5
12
YEL/BLU
RED
B35
BLU
X52
S
W37 CAB HARNESS GROUND 3
GRN
BLU
GRN
BLU
GRN
BLU
GRN
BLU
GRN
V10 STARTER PROTECTION DIODE
D7 A16 B18
A4 MONITOR CONTROLLER (DSZ)
GRN/BLK
RED
RED
WHT
V1 BATTERY RELAY DIODE
2
K3 SECURITY ALARM RELAY
3
5
H2 SECURITY ALARM
1
VLT/GRN
WHT/RED BLK/WHT
RED
F61 45A FUSE
S1 KEY SWITCH
WHT/RED RED/BLK RED/BLU
V3 LOAD DUMP RELAY DIODE
WHT
4
2
H3 MONITOR WARNING ALARM
10
VLT/RED
11
9
VLT/WHT
10
A=X20
A7 AIR CONDITIONER CONTROLLER (ACF)
A22
B=X21 D=X22
1
GRN (CAN 0 HIGH)
A24
BLU (CAN 0 LOW)
A23
3
2
5
4
K1 LOAD DUMP RELAY
X4 A3 MAIN CONTROLLER (MCZ)
WHT
D2
D3
A=X31 D=X34
154 132 A1 ENGINE CONTROL UNIT (ECU)
= X15
A1
124
WHT/RED
6
WHT/RED
B16
130
WHT/YEL
1
WHT/YEL
B12
145
BLK/GRN
7
BLK/GRN
D5
147
GRN/RED
2
GRN/RED
B9
YEL/WHT
D6
YEL/WHT
RED WHT
D8
WHT
5
X24
1
WHT
2
BLU/BLK WHT
RED
4
4 3
BLU/BLK
5
K12 ACCESSORY CUT RELAY
3
BLK
2
1
WHT/RED
ST
F17 5A FUSE
ORG
GRN
WHT
K13 KEY CUT RELAY
3
WHT/RED
1
BAT
M
F14 5A FUSE
L
ACC
G2
F9 10A FUSE
B
HEAT OFF ACC ON START
G1
G3 ALTERNATOR
BLU/YEL
WHT
RED
F7 5A FUSE
YEL/BLU
WHT
YEL/BLU
RED
WHT/RED YEL/BLU
RED
RED
WHT
WHT/RED BLU
F18 5A FUSE
RED
RED/BLK WHT/RED
RED WHT WHT
WHT
RED WHT WHT
M ST
YEL/BLU
ACC
BLU
G2
WHT
G1
BLU WHT/RED
B
POSITION HEAT OFF ACC ON START
WHT
TX1223588 Monitor Controller (DSZ) Circuit Schematic (1 of 2) Continued on next page
TM12660 (18APR18)
9015-15-11
041818
PN=515
JB3888,0000681 -19-15SEP16-1/6
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-12
041818
PN=516
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) F7— Start Position Signal 5 A Fuse (marked START) F9— Radio Backup 10 A Fuse (marked BACK UP) F14— Monitor 5 A Fuse (marked MONITOR) F17— Power On 5 A Fuse (marked POWER ON)
F18— Idle Stop 5 A Fuse (marked S1— Key Switch IDLE STOP) V1— Battery Relay Diode F60— Alternator 65 A Fuse V3— Load Dump Relay Diode F61— Battery 45 A Fuse V7— Start Relay Diode G1—Battery V10— Starter Protection Diode G2—Battery V11— Accessory Cut Diode G3—Alternator W37—Cab Harness Ground 3 H2—Security Alarm X4— Cab Harness-to-Machine H3—Monitor Warning Alarm Harness 32-Pin Connector K1—Load Dump Relay X11— Machine Controller 20-Pin K3—Security Alarm Relay Connector B K4—Starter Cut Relay X15— Engine Control Unit K12— Accessory Cut Relay (ECU)-to-Machine Harness K13— Key Cut Relay 94-Pin Connector K19— Battery Relay X20— Monitor Controller 28-Pin K34— Starter Relay Connector A M1—Starter Motor
Monitor Controller (DSZ) (A4)—The monitor controller (DSZ) contains the monitor software and interprets inputs from various sensors, buttons, and switches. Information sent over the controller area network (CAN) from other controllers is sent to the DSZ, where it is then displayed on the monitor. The DSZ uses the CAN 1 to communicate with the data converter (A5), radio (A6), air conditioner controller (ACF) (A7), and machine controller (BCZ) (A11) through pins 25 and 26 of DSZ connector (X20). The DSZ also communicates on CAN 0 with the engine control unit (ECU) (A1) and the main controller (MCZ) (A3) through pins 23 and 24 of DSZ connector (X20). 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 18 of DSZ connector (X21). 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 11, 22, 35, and 36 of DSZ connector (X21). 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 17 of DSZ connector (X21). Accessory power enables the radio, 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 directly to pin 3 of key cut relay (K13) and through idle stop 5 A fuse (F18) to pin 1 of key cut relay and pin 1 of accessory cut relay. Utilizing the normally closed contacts of key cut relay, current flows through load dump relay diode (V3) to pin 5 of load dump relay (K1) 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 16 of 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 17 of DSZ connector (X20), 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 15 of DSZ connector (X22), 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 (H3)—The monitor warning alarm (H3) sounds when certain diagnostic trouble codes (DTCs) or machine conditions exist that could damage the machine. The monitor warning alarm receives switched power from power on 5 A fuse (F17). Ground is provided from pin 7 of DSZ connector (X22), activating the alarm. Alternator Voltage Indicator—The alternator alarm indicator is monitored at pin 15 of DSZ connector (X20). When the alternator excitation field voltage is below charging level, the DSZ illuminates the alternator warning indicator. Pin 15 of DSZ connector (X20) is also used to activate the load dump circuit. When voltage decreases on pin 15 of DSZ connector (X22) and the key switch is in the OFF position, pin 8 of DSZ connector (X22) is placed to ground, energizing load dump relay (K1). With the load dump relay energized and the key switch in the OFF position, voltage from the alternator (G3) is allowed to return to the batteries (G1 and G2) as the engine slows to a stop. For more information on the load dump circuit, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.) Check Engine Indicator—The check engine indicator will come on if there is an engine problem.
Continued on next page
TM12660 (18APR18)
X21— Monitor Controller 36-Pin Connector B X22— Monitor Controller 16-Pin Connector D X24— Monitor Controller 2-Pin Connector G X31— Cab Harness-to-Main Controller 31-Pin Connector A X34— Cab Harness-to-Main Controller 30-Pin Connector D X52— Air Conditioner 10-Pin Connector
9015-15-13
JB3888,0000681 -19-15SEP16-2/6
041818
PN=517
Sub-System Diagnostics
The engine may run at reduced power to protect the engine but still allows 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.)
Engine Oil Pressure Indicator—The engine oil pressure indicator comes on when the engine control unit (ECU) indicates engine oil pressure is low. A signal is sent from pin 124 of ECU connector (X15) to pin 16 of DSZ connector (X21), turning on the engine oil pressure indicator.
For more information on ECU diagnostic trouble codes, see Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
Fuel Filter Restriction Indicator—The fuel filter restriction indicator comes on when the engine control unit (ECU) indicates a clogged or restricted fuel filter. A signal is sent from pin 147 of ECU connector (X15) to pin 9 of DSZ connector (X21), turning on the fuel filter restriction indicator.
Preheat Indicator—The preheat indicator comes on when the engine control unit (ECU) activates the glow plugs for cold starting. A signal is sent from pin 145 of ECU connector (X15) to pin 5 of DSZ connector, turning on the preheat indicator. For more information, see Cold Weather Starting Aid. (Group 9010-05.)
Continued on next page
TM12660 (18APR18)
9015-15-14
JB3888,0000681 -19-15SEP16-3/6
041818
PN=518
Sub-System Diagnostics
TX1209817 —UN—01FEB16
GRN
PNK
GRY
BRN/YEL
B2
B1
B19
B20
RED
B25
8 13 9
11 10 12
14 16 15
1
2
7
BLK
C3 C2 C6 C5 C1
C3 C2 C6 C5 C1
G2 G1
G = X24 A12 LT GRN BLK/PNK BLU/WHT
BLK
15
1 3
2
13 14
1
3
T
B43 COOLANT TEMPERATURE SENSOR
BLK
S25
S21
S22
S24
S26
T B42 ENGINE OVERHEAT SWITCH
S27
E6 SWITCH PANEL BACK LIGHT 2
E8 SWITCH PANEL BACK LIGHT 4
WHT/VLT GRN/WHT
B16 AIR FILTER RESTRICTION SWITCH
BLU/WHT BLK/PNK LT GRN
P 1
15
1 3
13 14
S23 RADIO VOLUME AND POWER SWITCH
2
BLU BRN GRY
X5
YEL
X5
B18 FUEL LEVEL SENSOR
X30 CAB HARNESSTO-SWITCH PANEL CONNECTOR 4
RED
4
6
RED
8
Q
BLK
S40 T HYDRAULIC OIL TEMPERATURE SWITCH
X4
X19
X29B PNK
4
X4
G2 G1
C = X23 D = X22
RED
4
X18
1 4
D9 D1
A11 B31
3
5
A = X20 B = X21
B26
YEL/RED
A9
YEL/RED
B30
BLU/WHT
A7
WHT/BLU
A6
WHT/YEL BRN GRN/BLU
B28
WHT/YEL BRN/YEL GRN/BLU
A5
YEL/BLU BLU/RED GRY/RED
A4
YEL/BLU BLK/RED BLK/WHT
B29
YEL BLK/RED WHT
A3
A10 MONITOR
2 9
B27 HYDRAULIC P OIL FILTER RESTRICTION SWITCH
A10
YEL GRN RED/WHT
RED
IF EQUIPPED
B27
YEL/GRN BLU ORG
A8
RED/BLU BLU/BLK BLK/YEL
B14 BRN/BLU
X94
A18 BRN
WHT/BLU
B15 WHT/BLU
24
A19 WHT/BLK
G = X24
4
A14 SIDE CAMERA
D3 D2
C = X23 D = X22
3
K
31
A4 MONITOR CONTROLLER (DSZ)
B13
X4
B21
A = X20 B = X21
A4 MONITOR CONTROLLER (DSZ)
WHT/BLU
B6
1 2
2
RED B22
X69
A
PNK
LT GRN/YEL
A1 A28 A13
30
X66
CABLE CABLE
GRN/WHT
B3
25 26
BRN/BLU
YEL
BLU/YEL
RED/GRN
BLK
BLK/RED
RED/GRN
BLK/GRN
B4
X4
1 2
BLU/WHT
RED/YEL YEL GRN BLK/YEL BLU
3
X28 CAB HARNESSTO-SWITCH PANEL CONNECTOR 2
1 2
X13 V17
RED BLK/YEL WHT GRY
1
X68
B9 B10 B11 B7
YEL BLK WHT GRY
12
4
A8 A14 A5 A13
WHT GRY
10
3
A1 A10
WHT GRY
9
2
WHT GRY
8
1
WHT GRY
RED
7
X64
GRY
BLK
6
X12 A3 A11
GRY
WHT
5
A13 SIDE MONITOR
4
BLK
ORG
4
1
WHT
GRY
3
5
BLK
PNK
2
2
WHT
GRN
11
B5
A12 REAR CAMERA
E5 SWITCH PANEL BACK LIGHT 1
9
LT BLU
8
GRN/RED
7
S60 KEYPAD
S59
YEL
6
S58
BRN
5
S57
GRY
1
4
S56
WHT
2
3
S55
BLK/YEL
4
2
S54
RED
X2
1
S53
RED/GRN
0
S52
YEL
S51
RED
S50
X29A CAB HARNESSTO-SWITCH PANEL CONNECTOR 3
BLK
TX1209817 Monitor Controller (DSZ) Circuit Schematic (2 of 2) Continued on next page
TM12660 (18APR18)
9015-15-15
041818
PN=519
JB3888,0000681 -19-15SEP16-4/6
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-16
041818
PN=520
Sub-System Diagnostics
A4—Monitor Controller (DSZ) S23— Radio Volume and Power A10— Monitor Switch A12— Rear Camera S24— Radio Tuning Switch A13— Side Monitor S25— Monitor Dial A14— Side Camera S26— Back Button B16— Air Filter Restriction S27— Home Button Switch S40— Hydraulic Oil Temperature B18— Fuel Level Sensor Switch (if equipped) B27— Hydraulic Oil Filter S50— 0 Key Restriction Switch (if S51— 1 Key equipped) S52— 2 Key B42— Engine Overheat Switch S53— 3 Key B43— Coolant Temperature S54— 4 Key Sensor S55— 5 Key E5— Switch Panel Back Light 1 S56— 6 Key E6— Switch Panel Back Light 2 S57— 7 Key E8— Switch Panel Back Light 4 S58— 8 Key S21— Blower Motor Speed S59— 9 Key Switch S60— Keypad S22— Temperature Control/Mode V17— Side Monitor Diode Switch X2— MPDr 6-Pin Connector X4— Cab Harness-to-Machine Harness 32-Pin Connector X5— Machine Harness-to-Engine Harness 32-Pin Connector
X12— Side Monitor 16-Pin X29B— Cab Harness-to-Switch Connector A Panel Connector 5 X13— Side Monitor 20-Pin X30— Cab Harness-to-Switch Connector B Panel Connector 4 X18— Monitor 12-Pin Connector X64— Machine Harness-to-Rear C Camera Harness X19— Monitor 2-Pin Connector G Connector X20— Monitor Controller 28-Pin X66— Cab Harness-to-Side Connector A Monitor Harness 2-Pin X21— Monitor Controller 36-Pin Connector 1 Connector B X68— Cab Harness-to-Side X22— Monitor Controller 16-Pin Monitor Harness 2-Pin Connector D Connector 2 X23— Monitor Controller 12-Pin X69— Side Camera Connector C Harness-to-Side Monitor X24— Monitor Controller 2-Pin Harness 4-Pin Connector Connector G X94— Machine Harness-toX28— Cab Harness-to-Switch Hydraulic Oil Temperature Panel Connector 2 Switch Connector X29A— Cab Harness-to-Switch Panel Connector 3
Monitor (A10)—The monitor (A10) communicates directly with the monitor controller (DSZ). The monitor receives power from pin 3 and ground from pin 5 of DSZ connector (X23). Voltage is sent from pin 2 of DSZ connector (X23) to the monitor, indicating how dark or bright the backlight will be on the monitor depending on operator setting. The monitor has a built-in temperature sensor, which is not accessible. The monitor temperature sensor provides an indication to pin 6 of DSZ connector (X23) if the monitor temperature is too high. Pin 1 of DSZ connector (X23) illuminates the alert light when an alert or diagnostic trouble code (DTC) is present.
A (X12). Video from the side camera is displayed on the side monitor.
The DSZ outputs video signal from the rear camera (A12) on pins 1 and 2 of DSZ connector (X24) to the monitor when the rear camera is active. Side Monitor (A13)—The side monitor receives battery power from pin 3, switched power from pin 1, and ground from pin 6 of optional connector (X26). The side monitor receives video signals from both the side camera (A14) and rear camera. Video from the side camera displays on the side monitor. Video from the rear camera can be displayed on the side monitor or passed to the monitor controller (DSZ) (A4) to be displayed on the main monitor (A10). Rear Camera (A12)—The rear camera communicates directly with the DSZ. Power is provided to the rear camera from pin 2 and ground is provided from pin 3 of the DSZ connector (X22). The rear camera sends the video signal to pins 3 and 11 of the side monitor 16-pin connector A (X12). The signal can be used to display the video on the side monitor or passed to pins 1 and 9 of DSZ connector (X22), in which case the DSZ outputs the video signal to the main monitor (A10). Side Camera (A14)—The side camera receives power from pin 8 and ground from pin 14 of the side monitor 16-pin connector A (X12). The side camera sends the video signal to 5 and 13 of side monitor 16-pin connector
MPDr Application—The MPDr application communicates directly with the monitor controller (DSZ). The DSZ communicates via the controller area network (CAN) with the other electronic controllers to provide information to MPDr. The DSZ provides MPDr with 5 V power from pin 1 of DSZ connector (X20) and serial communication from pins 13 and 28 of DSZ connector (X20). For more information on MPDr, see MPDr Application. (Group 9015-20.) Coolant Temperature Gauge—The coolant temperature sensor (B43) provides a variable resistance to the monitor controller (DSZ) as the engine temperature changes. The coolant temperature is then displayed on the monitor as the coolant temperature gauge. Coolant temperature sensor and engine coolant temperature sensor (B4) are both housed within the same sensor. For more information on engine coolant temperature sensor, see Engine Harness (W4) Wiring Diagram. (Group 9015-10.) Engine Overheat Indicator—The engine overheat switch (B42) passes ground to pin 15 of DSZ connector (X21) when engine temperature is too high. With ground at pin 15 of DSZ connector (X21), the engine overheat indicator is activated. 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.
Continued on next page
TM12660 (18APR18)
9015-15-17
JB3888,0000681 -19-15SEP16-5/6
041818
PN=521
Sub-System Diagnostics
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 18 of DSZ connector (X20), the fuel level indicator notification will activate, indicating a low level of fuel. Specification Fuel Level Indicator Light—Resistance................................. Illuminates Above 82—88 ohms
Air Filter Restriction Indicator—When a plugged air filter is sensed with engine running, the air filter restriction switch (B16) passes ground to pin 14 of DSZ connector (X21), causing the air filter restriction indicator to illuminate. Blower Motor Speed Switch (S21)—The blower motor speed switch (S21) is a hall-effect sensor, which offers infinite 360-degree rotation. Pressing the blower motor speed switch grounds pin 29 of DSZ connector (X21), 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 3 and 4 of DSZ connector (X20). The monitor controller communicates these inputs to the air conditioner controller (ACF) via the controller area network (CAN). For more information, see Cab Heater and Air Conditioner. (Operator’s Manual.) Temperature Control/Mode Switch (S22)—The temperature control/mode switch (S22) is a hall-effect sensor, which offers infinite 360-degree rotation. Pressing the temperature control/mode switch grounds pin 28 of DSZ connector (X21), 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 5 and 6 of DSZ connector (X20). 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 31 of DSZ connector (X21), 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 11 and 12 of DSZ connector (X20).
The DSZ communicates these inputs to the radio (A6) via the controller area network (CAN). For more information, see Operating the AM/FM Radio. (Operator’s Manual.) Radio Tuning Switch (S24)—The radio tuning switch (S24) is a hall-effect sensor, which offers infinite 360-degree rotation. Pressing the radio tuning switch grounds pin 30 of DSZ connector (X21), 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 7 and 9 of DSZ connector (X20). 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 27 of DSZ connector (X21), 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 8 and 10 of DSZ connector (X20). For more information, see Switch Panel Functions. (Operator’s Manual.) Back Button (S26)—The back button (S26) grounds pin 25 of DSZ connector (X21), returning the monitor to the previous menu. For more information, see Switch Panel Functions. (Operator’s Manual.) Home Button (S27)—The home button (S27) grounds pin 26 of DSZ connector (X21), 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 DSZ. For more information, see Switch Panel Functions. (Operator’s Manual.) JB3888,0000681 -19-15SEP16-6/6
TM12660 (18APR18)
9015-15-18
041818
PN=522
Sub-System Diagnostics
Engine Control Unit (ECU) Circuit Theory of Operation TX1213114 —UN—31MAR16
+
V7 START RELAY DIODE
BLK
RED
BLK
V1 BATTERY RELAY DIODE
GRY/RED
110
4
YEL/WHT
BLU
136
114
67
BLU 111 89
139 133
= X15 61
64 63
66 65
119 97
137
BLK BLK BLK BLK BLK BLK BLK BLK BLK
BLU
E
C
K34 STARTER RELAY RED
S
B
M1 STARTER MOTOR
A8
A16
GRN (ENGINE CAN HIGH) BLU (ENGINE CAN LOW)
GRN
B
RED/BLK
S
X3
GRY/RED
RED/BLU RED
BLK
RED RED/BLK
WHT
WHT BLK/WHT VLT/GRN GRY/RED
TX1213114
Engine Control Unit (ECU) Circuit Schematic (1 of 2) Continued on next page
041818
PN=523
GRN BLU
15 16
BLU
13
BLK
14
10 11 12 5 1 2 3 8 4
LT BLU WHT BRN GRY RED WHT BLK RED/YEL BLK/YEL
R8 ENGINE CAN TERMINATION RESISTOR
HI
+
B LO
120
-
A2 VARIABLE GEOMETRY TURBOCHARGER (VGT)
3 2 1 7 6 5 4 10 9
X7 MACHINE HARNESSTO-ENGINE HARNESS 14-PIN CONNECTOR
3 2 1 7 6 5 4 10 9
B51 TURBOCHARGER POSITION SENSOR
DW9628,0000520 -19-29MAR17-1/6
BLU
YEL/WHT
153
R13 ENGINE CONTROL UNIT (ECU) RESISTOR GRN/YEL
YEL/BLU
134
BLU
RED/BLK
R4
122
A RED
9015-15-19
R3
129
BLK
TM12660 (18APR18)
R2
5
ORG/GRN
R1
2
BLU
BLK/YEL
GLOW PLUG
BLU
3
VLT/GRN
1
WHT
G2 BATTERY
A
88
GRN
1
Y16 TURBOCHARGER ACTUATOR
RED
E
A15
K14 ECU POWER RELAY
BLK
+
4
BLK/WHT
S
2
4
5
BLK
WHT
K19 BATTERY RELAY
B
3
GRY/RED
-
WHT
2
S6 ENGINE STOP SWITCH RED/BLK
RED
G1 BATTERY
121
2
GRN
F8 ECU 30A FUSE
GRN/YEL
K4 STARTER CUT RELAY
3
152
BRN/YEL
1
100
4
K16 GLOW PLUG RELAY
5
A1 ENGINE CONTROL UNIT (ECU)
WHT/RED
RED
F61 BATTERY 45A FUSE
1
S16 EXHAUST FILTER PARKED CLEANING SWITCH
WHT/RED VLT/GRN
WHT/RED
1
X3
62
BLK/WHT
ST
9
3
ORG/BLK
V10 STARTER PROTECTION DIODE
BLU
WHT/RED
M
VLT/GRN
RED
G2
RED/BLK
VLT/GRN
4
RED
G1
5
RED/BLK
BLK/WHT
2
8
RED/BLK
RED/BLK
ACC
F17 POWER ON 5A FUSE
GRN/YEL
K13 KEY CUT RELAY
3
V3 LOAD DUMP RELAY DIODE
GRN/YEL
1
F16 GLOW RELAY 5A FUSE
YEL/BLK
BLU
S1 KEY SWITCH
RED/BLK
YEL/BLK
F18 IDLE STOP 5A FUSE
HEAT OFF ACC ON START
BAT
YEL/BLK YEL/BLK
YEL/BLK
WHT
BLU
RED
GRN/YEL
RED
WHT
RED
BLU
RED
BLU
RED
M ST
BLK
ACC
YEL/WHT
G2
RED
G1
BLU
B
POSITION HEAT OFF ACC ON START
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-20
041818
PN=524
Sub-System Diagnostics F61— Battery 45 A Fuse A1—Engine Control Unit (ECU) G1—Battery A2—Variable Geometry G2—Battery Turbocharger (VGT) K4—Starter Cut Relay B51— Turbocharger Position K13— Key Cut Relay Sensor K14— ECU Power Relay F8— Engine Control Unit (ECU) K16— Glow Plug Relay 30 A Fuse (marked ECU) K19— Battery Relay F16— Glow Relay 5 A Fuse K34— Starter Relay (marked GLOW RELAY) M1—Starter Motor F17— Power On 5 A Fuse R1—Glow Plug 1 (marked POWER ON) F18— Idle Stop 5 A Fuse (marked R2—Glow Plug 2 R3—Glow Plug 3 IDLE STOP) R4—Glow Plug 4
R8—Engine CAN Termination Resistor R13— Engine Control Unit (ECU) Resistor S1— Key Switch S6— Engine Stop Switch S16— Exhaust Filter Parked Cleaning Switch V1— Battery Relay Diode V3— Load Dump Relay Diode V7— Start Relay Diode V10— Starter Protection Diode
Continued on next page
TM12660 (18APR18)
9015-15-21
X3— Cab Harness-to-Machine Harness 100-Pin Connector X7— Machine Harness-to-Engine Harness 14-Pin Connector X15— Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector Y16— Turbocharger Actuator
DW9628,0000520 -19-29MAR17-2/6
041818
PN=525
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-22
041818
PN=526
Sub-System Diagnostics
TX1223575 —UN—20SEP16
A3 MAIN CONTROLLER (MCZ) = X34
113
21
13
11
41
53
58
6
26
9
BLU/BLK
117
28
BLU/BLK BLK
81
57
WHT
82
52
80
= X14
54
35
5
14
B1 CRANKSHAFT POSITION SENSOR
B12 FUEL RAIL PRESSURE SENSOR
49
B15 TURBOCHARGER BOOST PRESSURE SENSOR
31
2
46
16
48
M3 EXHAUST GAS RECIRCULATION (EGR) VALVE ACTUATOR
BLK/WHT BLK/RED
5
4
8
3
7
2
6
1
8
4
7
3
6
2
BLU
BLU BLU/RED
1 5
RED
BLK/YEL WHT/BLU
M8 INTAKE AIR THROTTLE
YEL
BLU
12
BLK
16
RED
RED/BLK
1
WHT/BLK
5
BLK
YEL
3
RED
7
WHT
RED 4
BLU
8
GRN
YEL
12
BLK/WHT
PNK
33
YEL
17
13
U V W U V W
B47 EXHAUST GAS RECIRCULATION (EGR) VALVE SENSOR
15
132
Y3 ELECTRONIC INJECTOR 3
BLU
23
Y2 ELECTRONIC INJECTOR 2
60 45
13
17
X9 MACHINE HARNESSTO-ENGINE HARNESS 20-PIN CONNECTOR
124
130
145
147
24
= X20
A4 MONITOR CONTROLLER (DSZ) 9
= X21
5
12
16
2
7
1
6
X4
= X22
X101
B14 INTAKE AIR THROTTLE VALVE POSITION SENSOR Y1 ELECTRONIC INJECTOR 1
GRN
BRN/BLU
PNK/BLU
GRN/BLK
BLK
1
GRN/BLK
YEL/BLU BLU/YEL BLU/RED BLK WHT
T B5 FUEL TEMPERATURE SENSOR
WHT
50
14
X5
154
135
WHT
P
X7
WHT GRN/BLK BLK
31
8 7 6
YEL/BLU BLU/YEL BLU/RED
WHT
24 19
P P
B44 MASS AIR FLOW (MAF)/ INTAKE AIR TEMPERATURE (IAT) SENSOR
29
69
30
1 4 3 2 5
WHT YEL/RED GRN/WHT VLT BLK
T
17 10 14
BLU/BLK
5
BLU/BLK BLK
1 6 15 11
WHT
2
RED GRY
3
BLK
1
WHT RED BLK GRY
5
87
20
WHT YEL/RED GRN/WHT VLT BLK
BLK
WHT
WHT RED BLK GRY
RED BLK/BLU
WHT
BLK
RED/BLU 4
83
= X15
BLK
X6
GRN
BLK
84
A1 ENGINE CONTROL UNIT (ECU)
WHT/RED
12
79
GRN GRN
43
RED GRY
56
112
WHT/YEL
70
BLK/GRN
55
GRN/RED
8
GRN/RED
RED
25
BLU (CAN 0 LOW)
PNK/BLU BRN/BLU BLK
BLK/GRN
BLK
40
GRN (CAN 0 HIGH)
WHT/YEL
WHT
23
8
3
WHT/RED
YEL/BLK
10
42
4 12
BLU
BLK
22
X40
GRN
PNK WHT
7
YEL/GRN
2
WHT RED BLK GRY
BLK
3
BLK/RED
20
BRN/GRN BRN/GRN
25 30
T
2
P
BLK
13
ORG
9
BLK
20 19 18 14
X5
T B49 EXHAUST TEMPERATURE SENSOR 1 (DPF)
2
3
B13 P FUEL FILTER RESTRICTION SENSOR
B45 BAROMETRIC PRESSURE SENSOR
GRN/WHT
P
B48 EXHAUST DIFFERENTIAL PRESSURE SENSOR
B50 EXHAUST TEMPERATURE SENSOR 2 (DOC)
BLK
1
BLU
B3 MANIFOLD AIR TEMPERATURE SENSOR
BLK
B4 ENGINE COOLANT TEMPERATURE SENSOR
WHT
BLK
PNK WHT
BLK
B11 ENGINE OIL PRESSURE SENSOR
T
WHT
X9
B7 TURBOCHARGER BOOST TEMPERATURE SENSOR
YEL/GRN
WHT RED BLK GRY
B2 CAMSHAFT POSITION SENSOR
T
P
YEL/BLK
T
Y14 SUCTION CONTROL VALVE
Y4 ELECTRONIC INJECTOR 4
TX1223575 Engine Control Unit (ECU) Circuit Schematic (2 of 2) Continued on next page
TM12660 (18APR18)
9015-15-23
041818
PN=527
DW9628,0000520 -19-29MAR17-3/6
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-24
041818
PN=528
Sub-System Diagnostics B15— Turbocharger Boost X5— Machine Harness-to-Engine A1—Engine Control Unit (ECU) Pressure Sensor Harness 32-Pin Connector A3—Main Controller (MCZ) B44— Mass Air Flow (MAF)/Intake X6— Machine Harness-to-Engine A4—Monitor Controller (DSZ) Air Temperature (IAT) Harness 16-Pin Connector B1—Crankshaft Position Sensor Sensor X7— Machine Harness-to-Engine B2—Camshaft Position Sensor B45— Barometric Pressure Harness 14-Pin Connector B3—Manifold Air Temperature Sensor X9— Machine Harness-to-Engine Sensor Harness 20-Pin Connector B4—Engine Coolant Temperature B47— Exhaust Gas Recirculation (EGR) Valve Sensor X14— Engine Control Unit Sensor B48— Exhaust Differential (ECU)-to-Machine Harness B5—Fuel Temperature Sensor Pressure Sensor 60-Pin Connector B7—Turbocharger Boost B49— Exhaust Temperature X15— Engine Control Unit Temperature Sensor Sensor 1 (DPF) (ECU)-to-Machine Harness B11— Engine Oil Pressure B50— Exhaust Temperature 94-Pin Connector Sensor Sensor 2 (DOC) X20— Monitor Controller 28-Pin B12— Fuel Rail Pressure Sensor M3—Exhaust Gas Recirculation Connector A B13— Fuel Filter Restriction (EGR) Valve Actuator X21— Monitor Controller 36-Pin Sensor M8—Intake Air Throttle Connector B B14— Intake Air Throttle Valve X4— Cab Harness-to-Machine Position Sensor Harness 32-Pin Connector
Engine Control Unit (ECU) (A1)—The engine control unit (ECU) (A1) uses information received from various sensors to determine the correct amount of fuel and injection timing based on load, temperatures, and operator input. Information from the ECU is transmitted across the controller area network (CAN) to the main controller (MCZ) (A3) and monitor controller (DSZ) (A4). The DSZ sends information across the CAN data line to the monitor, where it is displayed on the appropriate screen. For more information, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) The ECU detects malfunctions in sensors and sensor circuits, or abnormal operating conditions. When a malfunction or abnormal operating condition is detected, 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.) When the ECU receives indication of the key switch in the ON position, pins 114 and 136 of engine control unit (ECU)-to-machine harness 94-pin connector (X15) are connected to power, energizing ECU power relay (K14). With ECU power relay energized, battery power is sent to pins 67, 89, 111, and 133 of engine control unit (ECU)-to-machine harness 94-pin connector. Power from ECU power relay is also sent through engine control unit (ECU) resistor (R13) to pin 139 of engine control unit (ECU)-to-machine harness 94-pin connector. Ground is provided at pins 61—66, 97, 119, and 137 on engine control unit (ECU)-to-machine harness 94-pin connector. 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 152 of engine control unit (ECU)-to-machine harness 94-pin connector is grounded, providing ground to starter
cut relay and 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. For more information, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.) The ECU receives signals from the following components: • Variable Geometry Turbocharger (VGT) (A2) • Main Controller (MCZ) (A3) • Crankshaft Position Sensor (B1) • Camshaft Position Sensor (B2) • Manifold Air Temperature Sensor (B3) • Engine Coolant Temperature Sensor (B4) • Fuel Temperature Sensor (B5) • Turbocharger Boost Temperature Sensor (B7) • Engine Oil Pressure Sensor (B11) • Fuel Rail Pressure Sensor (B12) • Fuel Filter Restriction Sensor (B13) • Intake Air Throttle Valve Position Sensor (B14) • Turbocharger Boost Pressure Sensor (B15) • Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (B44) • Barometric Pressure Sensor (B45) • Exhaust Gas Recirculation (EGR) Valve Sensor (B47) • Exhaust Differential Pressure Sensor (B48) • Exhaust Temperature Sensor 1 (DPF) (B49) • Exhaust Temperature Sensor 2 (DOC) (B50) • Key Switch (S1) • Engine Stop Switch (S6) • Exhaust Filter Parked Cleaning Switch (S16) After processing the received signals, the ECU sends signals to various components to control the following functions:
• Fuel Injection • Exhaust Gas Recirculation (EGR) • Preheat • Engine Stop • Exhaust Filter Parked Cleaning
Continued on next page
TM12660 (18APR18)
X22— Monitor Controller 16-Pin Connector D X34— Cab Harness-to-Main Controller 30-Pin Connector D X40— Pump Harness-to-Machine Harness Connector X101— Fuel Injector Harness Connector 1 Y1— Electronic Injector 1 Y2— Electronic Injector 2 Y3— Electronic Injector 3 Y4— Electronic Injector 4 Y14— Suction Control Valve
9015-15-25
DW9628,0000520 -19-29MAR17-4/6
041818
PN=529
Sub-System Diagnostics
Crankshaft Position Sensor (B1)—Crankshaft position sensor (B1) detects engine speed and crankshaft angle. The crankshaft position sensor is installed on the flywheel housing and sends a signal to the engine control unit (ECU) (A1) as the flywheel passes the sensor. The crankshaft position sensor reads the difference between the flywheel surface and holes drilled into the outside edge of the flywheel. The holes are on the edge of the flywheel next to the ring gear and parallel with the ring gear. The crankshaft position sensor receives supply voltage from pin 21, pin 41 for ground, pin 28 for shield, and pin 57 for signal on engine control unit (ECU)-to-machine harness 60-pin connector (X14).
chamber to the required pressure for injection. When the fuel pressure exceeds the delivery valve opening pressure, the fuel is routed to the common rail and distributes fuel to electronic injectors 1—4 (Y1—Y4).
Camshaft Position Sensor (B2)—Camshaft position sensor (B2) detects the position of each cylinder, top dead center (TDC) of cylinder 1, and provides backup for the crankshaft position sensor (B1) should it malfunction. The camshaft position sensor is installed on the high pressure fuel pump and sends a signal to the ECU when the cam portion of the camshaft passes the sensor. The camshaft position sensor receives supply voltage from pin 22, pin 42 for ground, pin 43 for shield, and pin 56 for signal on engine control unit (ECU)-to-machine harness 60-pin connector.
For more information, see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
Fuel Injection Control—The engine control unit (ECU) (A1) controls fuel injection pressure, amount, and timing by sending the appropriate signals to the electronic injectors (Y1—Y4) and suction control valve (Y14). Electronic Injectors (Y1—Y4)—When the key switch is in the ON or START position, the ECU provides power to electronic injector 1 (Y1) at pin 1, electronic injector 2 (Y2) at pin 16, electronic injector 3 (Y3) at pin 2, and to electronic injector 4 (Y4) at pin 17.
Fuel Injection Amount—The engine control unit (ECU) (A1) controls the fuel injection amount based on inputs from the sensors on the engine and from messages sent over the controller area network (CAN). Main controller (MCZ) (A3) determines target engine speed using signals received from engine speed dial as well as various pressure sensors and switches on the machine. The main controller uses the CAN network to send an engine speed request to the ECU based on the target engine speed.
After receiving the requested engine speed information from the main controller, the ECU compares the requested speed with the actual engine speed. The ECU varies the fuel injection amount by controlling how long electronic injectors 1—4 (Y1—Y4) are activated and deactivated. Fuel Injection Timing—The engine control unit (ECU) (A1) controls fuel injection timing based on inputs from the sensors on the engine and from messages sent over the controller area network (CAN). The camshaft position sensor and crankshaft position sensor allow the ECU to precisely determine piston position in relation to top dead center (TDC), so that the ECU activates the correct electronic injector at the correct time. Fuel Injection Rate—To improve combustion in the cylinders, the engine control unit (ECU) (A1) may inject a small amount of fuel (pilot injection) into the cylinder prior to the main injection event. After this pilot injection ignites, the ECU injects the main supply of fuel.
The ECU activates the electronic injectors by connecting the corresponding pin of each injector to ground:
Fuel Injection Amount Correction—The engine control unit (ECU) (A1) adjusts the fuel injection amount based on starting engine speed and barometric conditions. The ECU adjusts the fuel injection amount during starting until the engine speed reaches a predetermined threshold.
• Electronic injector 1 (pin 31) • Electronic injector 2 (pin 48) • Electronic injector 3 (pin 46) • Electronic injector 4 (pin 33) Suction Control Valve (Y14)—The engine control unit (ECU) (A1) controls the amount of fuel supplied to the common fuel rail with the suction control valve (Y14). ECU pins 15 and 30 provide ground to the suction control valve and pins 45 and 60 provide power to the suction control valve. Fuel Injection Pressure—The engine control unit (ECU) (A1) determines the appropriate fuel injection pressure based on engine speed, fuel injection amount, and common rail pressure. The ECU controls fuel injection pressure by activating and deactivating suction control valve (Y14). When the suction control valve is deactivated, fuel is allowed to flow into the pumping chambers. When the ECU activates the suction control valve, the valve to the pumping chamber is closed. This prevents any fuel from flowing into the pumping chambers. The high pressure fuel pump raises the pressure of the fuel in the
The ECU also adjusts the fuel injection amount based on inputs from the barometric pressure sensor (B45). The ECU automatically corrects the fuel injection amount as the barometric pressure changes. Fuel Rail Pressure Sensor (B12)—Fuel rail pressure sensor (B12) detects fuel pressure in the common rail. The fuel rail pressure sensor is installed on the common rail and sends a varying signal to the engine control unit (ECU) (A1). The varying signal represents the varying resistance of the fuel rail pressure sensor corresponding to the common rail pressure. High resistance of the sensor indicates a low pressure. The fuel rail pressure sensor receives supply voltage from pin 21, pin 41 for ground, pin 58 for shield, and pin 11 for signal on engine control unit (ECU)-to-machine harness 60-pin connector.
Continued on next page
TM12660 (18APR18)
9015-15-26
DW9628,0000520 -19-29MAR17-5/6
041818
PN=530
Sub-System Diagnostics
Barometric Pressure Sensor (B45)—Barometric pressure sensor (B45) detects barometric pressure and sends a varying signal to the engine control unit (ECU) (A1). The varying signal represents the varying resistance of the barometric pressure sensor corresponding to the barometric pressure. The barometric pressure sensor receives supply voltage from pin 69, pin 135 for ground, and pin 87 for signal on engine control unit (ECU)-to-machine harness 94-pin connector (X15). Preheat Control—The engine control unit (ECU) (A1) controls the use of preheat from the engine coolant temperature sensor (B4) and mass air flow (MAF)/intake air temperature (IAT) sensor (B44) signals. Glow plugs 1—4 (R1—R4) heat the air in each of the engine's combustion chambers. After the engine has started, the ECU maintains preheat to allow the engine to stabilize idling. For additional information on the preheat circuit, see Cold Weather Starting Aid. (Group 9010-05.) Exhaust Gas Recirculation (EGR) Control—Exhaust gas recirculation (EGR) is the recirculation of engine exhaust gas into the intake manifold to mix with intake air. The recirculation of exhaust gas helps lower the combustion temperature and limits emissions of nitrogen oxides. The engine control unit (ECU) (A1) determines the amount based on inputs from the sensors on the engine. The EGR consists of exhaust gas recirculation (EGR) valve actuator (M3) and exhaust gas recirculation (EGR) valve sensor (B47). Exhaust Gas Recirculation (EGR) Valve Actuator (M3)—The engine control unit (ECU) (A1) calculates the opening and closing of the EGR valve according to engine speed, fuel flow rate, engine coolant temperature, barometric pressure, and intake air temperature. The ECU sends a signal to pins 5, 20, and 35 to control EGR valve actuator. Exhaust Gas Recirculation (EGR) Valve Sensor (B47)—The EGR valve sensor receives supply voltage from pin 6 and pin 26 for ground on engine control unit (ECU)-to-machine harness 60-pin connector (X14). The engine control unit (ECU) (A1) calculates the position of the EGR valve using signals received from EGR valve sensor at pins 52, 53, and 54 on engine control unit (ECU)-to-machine harness 60-pin connector. Engine Stop Control—If the engine will not stop when key switch (S1) is turned to the OFF position, moving the engine stop switch (S6) to the STOP position will force the engine control unit (ECU) (A1) to stop the engine.
the activated key cut relay (K13) to pin 121. With current at pin 121 on engine control unit (ECU)-to-machine harness 94-pin connector (X15), the ECU removes power to the electronic injectors (Y1—Y4) and suction control valve (Y14), causing the engine to stop. The ECU then de-energizes ECU power relay (K14), removing main power from the ECU. Exhaust Filter Parked Cleaning—The exhaust filter parked cleaning switch (S16) allows the operator to perform a parked exhaust filter cleaning. 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 sent through power on 5 A fuse (F17) to pin 1 of exhaust filter parked cleaning switch. When the engine control unit (ECU) (A1) has determined a parked exhaust filter cleaning is required, ground is provided to pin 5 of the exhaust filter parked cleaning switch from pin 40 of engine control unit (ECU)-to-machine harness 60-pin connector (X14), completing the circuit and activating the light emitting diode (LED). When exhaust filter parked cleaning switch is held for 3 seconds, pin 26 of engine control unit (ECU)-to-machine harness 60-pin connector is grounded, initiating the parked exhaust filter cleaning, if all requirements are met. For more information on exhaust filter parked cleaning, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) For more information, see Isuzu engine manual 4HK1. Exhaust Differential Pressure Sensor (B48)— The exhaust differential pressure sensor (B48) measures differential pressure before and after the exhaust filter detects the amount of particulate matter trapped on the exhaust filter. For more information on the exhaust differential pressure sensor, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) Exhaust Temperature Sensor 1 (DPF) (B49)— Exhaust temperature sensor 1 measures the exhaust temperature before the diesel oxidation catalyst (DOC). For more information on the exhaust filter, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.) Exhaust Temperature Sensor 2 (DOC) (B50)— Exhaust temperature sensor 2 measures the exhaust temperature after the diesel oxidation catalyst (DOC). For more information on the exhaust filter, see Exhaust Aftertreatment Circuit Theory of Operation. (Group 9015-15.)
The ECU determines the engine stop switch is in the STOP position when power flows from fuse (F17) through DW9628,0000520 -19-29MAR17-6/6
TM12660 (18APR18)
9015-15-27
041818
PN=531
Sub-System Diagnostics
Exhaust Aftertreatment Circuit Theory of Operation B50 EXHAUST TEMPERATURE SENSOR 2 (DOC)
T
T
BLU
ORG
BLK
BLK
B49 EXHAUST TEMPERATURE SENSOR 1 (DPF)
135 84
TX1148302
GRN
BLU
24
23
112
P
X20
B48 EXHAUST DIFFERENTIAL PRESSURE SENSOR
A4 MONITOR CONTROLLER (DSZ)
TX1148302 —UN—26NOV13
70
BLK
132
BLK
= X15
WHT
154
80
A1 ENGINE CONTROL UNIT (ECU)
RED/WHT
79
Exhaust Aftertreatment Circuit Theory of Operation A1—Engine Control Unit (ECU) A4—Monitor Controller (DSZ) B48— Exhaust Differential Pressure Sensor
B49— Exhaust Temperature Sensor 1 (DPF) B50— Exhaust Temperature Sensor 2 (DOC)
X15— Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector X20— Monitor Controller 28-Pin Connector A
The exhaust aftertreatment system involves two primary controllers: engine control unit (ECU) (A1) and monitor controller (DSZ) (A4). 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 CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Passive Cleaning—Passive cleaning takes place when the exhaust temperature at the diesel particulate filter (DPF) rises to 350°C (662°F). At this temperature, the
catalyst in the DPF is activated and begins burning off particulate matter. Active Cleaning—There are two types of active cleaning settings: automatic and manual. An automatic cleaning occurs every 8 hours or when the exhaust differential pressure sensor (B48) indicates to the engine control unit (ECU) that particulate matter has reached the predetermined value. To perform an active cleaning, exhaust temperature at the diesel particulate filter (DPF) must be at least 350°C (662°F). If exhaust temperature is low, hydraulic load is increased to raise temperature. For more information, see Diesel Particulate Filter (DPF) Burn Solenoid Valves. (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9015-15-28
DW9628,0000521 -19-03DEC13-1/2
041818
PN=532
Sub-System Diagnostics
Once exhaust temperature has reached 350°C (662°F), the ECU will signal the electronic injectors (Y1—Y4) to inject diesel fuel into the combustion chamber during the exhaust stroke. Unburned fuel at the diesel oxidation catalyst (DOC) raises exhaust temperatures to over 600°C (1110°F), burning off the particulate matter in the DPF. For more information on the electronic injectors, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) A manual cleaning will be requested to the operator by the engine control unit (ECU) when the exhaust differential pressure sensor (B48) indicates particulate matter in the diesel particulate filter (DPF) has exceeded the automatic cleaning threshold. A manual cleaning may be requested when long periods of light engine load have occurred or multiple automatic cleanings have been skipped. To perform a manual cleaning, the pilot shutoff lever must be in the locked (UP) position and engine speed must be set to the slow idle position. The following are conditions to cause manual or parked cleaning cancellations:
• Removal of safe state conditions.
- Throttle movement. - Pilot shutoff lever movement. • Machine malfunction detected. • CAN communication lost from DSZ to ECU. • ECU is unable to maintain exhaust filter cleaning temperature. • Manual or parked cleaning takes longer than the allotted time. • Exhaust temperatures too high. Exhaust Differential Pressure Sensor (B48)—The exhaust differential pressure sensor (B48) measures the approximate differential pressure of the areas before and after the diesel particulate filter (DPF). The engine control unit (ECU) uses this differential pressure to calculate the amount of particulate matter collected in the DPF. The ECU communicates the particulate matter level to the
monitor controller (DSZ) (A4) over the controller area network (CAN), where it is then displayed on the monitor. For more information on the DSZ, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.) The exhaust differential pressure sensor uses pin 84 for supply voltage, pin 112 for ground, and pin 70 for signal on engine control unit (ECU)-to-machine interface harness 94-pin connector (X15). Exhaust Temperature Sensor 1 (DPF) (B49)—The exhaust temperature sensor 1 (DPF) (B49) measures exhaust temperature after exhaust gas has passed through the diesel oxidation catalyst (DOC). The engine control unit (ECU) uses this signal to determine if exhaust temperatures are too high. If exhaust temperature is too high, a diagnostic trouble code (DTC) will be set. Exhaust temperature sensor 1 (DPF) and exhaust temperature sensor 2 (DOC) are used together by the ECU to ensure effective exhaust aftertreatment has occurred. The exhaust temperature sensor 1 (DPF) uses pin 79 for supply voltage and pin 135 for ground on engine control unit (ECU)-to-machine harness 94-pin connector (X15). Exhaust Temperature Sensor 2 (DOC) (B50)—The exhaust temperature sensor 1 (DOC) (B50) measures exhaust temperature before exhaust gas has entered the diesel oxidation catalyst (DOC). The engine control unit (ECU) uses this signal to determine if exhaust temperatures have reached a predetermined point to perform a exhaust filter cleaning. Exhaust temperature sensor 1 (DPF) and exhaust temperature sensor 2 (DOC) are used together by the ECU to ensure effective exhaust aftertreatment has occurred. The exhaust temperature sensor 2 (DOC) uses pin 80 for supply voltage and pin 135 for ground on engine control unit (ECU)-to-machine harness 94-pin connector (X15). For more information, see Isuzu engine manual 4HK1. DW9628,0000521 -19-03DEC13-2/2
TM12660 (18APR18)
9015-15-29
041818
PN=533
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-30
041818
PN=534
Sub-System Diagnostics
Main Controller (MCZ) Circuit Theory of Operation TX1198692 —UN—29JUL15
RED
YEL/BLK WHT
YEL/BLK
F4 20A FUSE
BAT
5
4
E
BLK
2
G3 ALTERNATOR
YEL/BLK
S1 KEY SWITCH
A3 MAIN CONTROLLER (MCZ)
BLU RED/BLK
YEL/GRN
RED
G1
WHT/RED 1
G2
RED
K13 KEY CUT RELAY
3
F10 5A FUSE
M
2
BLU
3
5
YEL/GRN
ACC
BLU
HEAT OFF ACC ON START
WHT
1
RED
B
RED
F17 5A FUSE
K4 STARTER CUT RELAY
4
YEL/GRN
BLU BLU RED RED RED
E5 E6 E4 F1 F2 F3
V10 STARTER PROTECTION DIODE
BLK/WHT
WHT/RED
F61 45A FUSE
RED
V3 LOAD DUMP RELAY DIODE
C5
VLT/GRN ST
YEL/BLK
F18 5A FUSE
RED
WHT
RED WHT BLU
M ST
RED
ACC
RED/BLK
G2
WHT
G1
BLU
B
POSITION HEAT OFF ACC ON START
E1 E2
BLK BLK
F4 F5
BLK BLK
F6
BLK
C = X33 D = X34
A
K19 BATTERY RELAY
S
E
BLK
G2 BATTERY
C
S
K34 STARTER RELAY
GRN (CAN 0 HIGH)
D2
BLU (CAN 0 LOW)
D3
1
2
WHT
3
5
4
K1 LOAD DUMP RELAY WHT
B
M1 STARTER MOTOR
= X20 = X22
24 A4 MONITOR CONTROLLER (DSZ)
23
154
132
= X15 8
A1 ENGINE CONTROL UNIT (ECU)
BLK
BLK
W37 CAB HARNESS GROUND 3
B
ORG
BLK
F60 65A FUSE
RED
RED/BLU
G1 BATTERY
RED
E
RED
WHT
B
WHT
S
F = X36
WHT
WHT
E = X35 RED
BLK/WHT
RED
V1 BATTERY RELAY DIODE
V7 START RELAY DIODE
WHT RED
ORG
WHT
WHT
TX1198692 Main Controller (MCZ) Circuit Schematic (1 of 2) Continued on next page
TM12660 (18APR18)
9015-15-31
041818
PN=535
DW9628,0000522 -19-08JUN17-1/10
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-32
041818
PN=536
Sub-System Diagnostics F60— Alternator 65 A Fuse A1—Engine Control Unit (ECU) F61— Battery 45 A Fuse A3—Main Controller (MCZ) G1—Battery A4—Monitor Controller (DSZ) F4— Solenoid 20 A Fuse (marked G2—Battery G3—Alternator SOLENOID) F10— Data Converter and Main K1—Load Dump Relay K4—Starter Cut Relay Controller (MCZ) Battery K13— Key Cut Relay Power 5 A Fuse (marked K19— Battery Relay CONTROLLER) K34— Starter Relay F17— Power On 5 A Fuse M1—Starter Motor (marked POWER ON) F18— Idle Stop 5 A Fuse (marked S1— Key Switch V1— Battery Relay Diode IDLE STOP) V3— Load Dump Relay Diode
V7— Start Relay Diode X34— Cab Harness-to-Main V10— Starter Protection Diode Controller (MCZ) 30-Pin W37—Cab Harness Ground 3 Connector D X15— Engine Control Unit X35— Cab Harness-to-Main (ECU)-to-Machine Harness Controller (MCZ) 24-Pin 94-Pin Connector Connector E X20— Monitor Controller (DSZ) X36— Cab Harness-to-Main 28-Pin Connector A Controller (MCZ) 26-Pin X22— Monitor Controller (DSZ) Connector F 16-Pin Connector D X33— Cab Harness-to-Main Controller (MCZ) 17-Pin Connector C Continued on next page
TM12660 (18APR18)
9015-15-33
DW9628,0000522 -19-08JUN17-2/10
041818
PN=537
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-34
041818
PN=538
Sub-System Diagnostics
TX1209901 —UN—03FEB16
3
7
1
2
2
0 1
1
2
3
4
1
2
BLU/RED
GRN/ORG
GRN/RED
RED/BLK
RED/GRN
WHT/GRN
RED/YEL
ORG/RED
BLK/WHT
WHT
GRN
YEL
LT GRN/WHT
LT GRN
LT GRN/RED
BLU
VLT/YEL
RED/BLK
GRN/RED
RED/YEL
BLK/WHT
WHT/BLK
A3
A2
A7
A6
A4
A5
A16
A17
A19
A18
A15
A14
A11
A10
A12
A13
A8
A9
A20
A21
D4
D5
E16
E15
F10
F11
C10
D6
D7
D14
D15
D9
C14
C8
C15
C13
D8
D28
D27
BLK/YEL
TEL/RED
WHT/RED
BLU/RED
GRN/YEL
YEL/BLK
GRY/RED
WHT/GRN
BLK/PNK
FROM SE4 B18 (PIN 1)
BLU/RED
F16 F17
BLK/RED
F25
A = X31 B = X32 C = X33
GRN/YEL
F26
3 4 2 1
S13 TRAVEL ALARM CANCEL SWITCH
A3 MAIN CONTROLLER (MCZ)
BLK/YEL
D16
RED/YEL
F8
GRN/BLK BLK
D = X34 E = X35 F = X36
RED/YEL
F7
WHT
F9
A = X31 B = X32 C = X33
BLK/YEL
A3 MAIN CONTROLLER (MCZ)
0 1
S7 POWER DIG SWITCH
X49
BLU/BLK
2
B6 ENGINE OIL LEVEL SENSOR
GRN/WHT
2
1
BRN/WHT
2
Y32 BOOM 3 SPOOL CONTROL SOLENOID (MARKED A1) H4 TRAVEL ALARM
D = X34 E = X35 F = X36 C33
LT BLU
YEL
5
2
1
1
Y31 ARM 3 SPOOL CONTROL SOLENOID (MARKED A2)
Y29 ARM 1 FLOW CONTROL SOLENOID (MARKED SE)
WHT/RED
ORG
1
1
Y27 ARM 2 FLOW CONTROL SOLENOID (MARKED SD)
BLK
BLU
6
Y24 POWER DIG SOLENOID (MARKED SI)
GRN/BLK
GRY
2
X40
1
2
2
Y23 ARM REGENERATIVE SOLENOID (MARKED SC)
BLK
2
PNK
2
1
1
BRN
2
1
Y22 DIG REGENERATIVE SOLENOID (MARKED SF)
BLK/WHT
1
Y12 EXHAUST FILTER REGULATOR SOLENOID (PUMP 1) (MARKED SZ)
RED/YEL
1
Y13 EXHAUST FILTER REGULATOR SOLENOID (BYPASS CUT-OFF VALVE) (MARKED SJ)
Y28 PUMP 3 TORQUE CONTROL SOLENOID (MARKED SU)
GRN/RED
Y20 PUMP 2 FLOW RATE LIMIT SOLENOID (MARKED SB)
RED/BLK
Y21 TORQUE CONTROL SOLENOID (MARKED ST)
X3 X3
D8
0 A1
BLK
B30 BOOM UP PRESSURE SENSOR
1
B31 P ARM IN PRESSURE SENSOR
2
3
3
B32 FRONT ATTACHMENT PRESSURE SENSOR P B33 SWING PRESSURE SENSOR
2
3
3
B35 2 PUMP 1 DELIVERY PRESSURE SENSOR
B36 PUMP 1 CONTROL PRESSURE SENSOR 1
3
P
1
3
P B39 2 BUCKET IN PRESSURE SENSOR
3
BLK/YEL 15
X40
19
6
X97
P 3
3
B56 P 2 PUMP 3 DELIVERY PRESSURE SENSOR
1
TX1209901 Main Controller (MCZ) Circuit Schematic (2 of 2) Continued on next page
TM12660 (18APR18)
9015-15-35
041818
PN=539
1
T
PNK
RED
BLK
B40 HYDRAULIC OIL TEMPERATURE SENSOR
BLK/YEL
X97 BLK
1
2 B57 PUMP 3 CONTROL PRESSURE SENSOR
1
YEL/BLU
RED
BLK/YEL
RED/YEL YEL
BLK
ORG
X98
18
X97
RED
RED
17
P B38 PUMP 2 CONTROL PRESSURE SENSOR
X40
23
X97
19
X97
11
X98
1
2
3
B37 2 PUMP 2 DELIVERY PRESSURE SENSOR
BLK
RED
BLK
RED
15
X97
7
18
X40
RED/YEL
P 2
3
16
X97
BLK
1
X97
14
X40
RED
X97
P
2
BLK
RED 14
B34 TRAVEL PRESSURE SENSOR
1
BLK
RED
YEL/RED
BLK/YEL
X98
X97 GRY
1
X40
3
BLK
X98
5
X40 RED
X98
22
X97
P 2
3
RED/YEL
21
P 2
10
X98
VLT
20 1
BLU/YEL
9
X98
17
X97
13
BLK
X98
BLK/YEL
RED/YEL
BLU/RED
BLK/YEL
RED/YEL
BLK/YEL
BLK/RED
RED/YEL
19
P
R15 ENGINE SPEED DIAL
8
X98
4 2
RED
BLK/YEL
RED/YEL
6
LT GRN/BLK
7
X98
1
L H
BLK
18
X98 WHT/GRN
YEL/BLK 4 YEL/GRN
BRN/WHT
BLK/BLU
S11 TRAVEL SPEED SWITCH
5
X98
X91
X90
BLU/WHT
S8 AUTOIDLE SWITCH
12 LT BLU
8 ORG
S12 POWER MODE BUTTON
9 WHT
X29
GRN/BLU
BLK/GRN
X90
6 2
1
GRN/YEL
2
BLU
D2
DW9628,0000522 -19-08JUN17-3/10
2
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-36
041818
PN=540
Sub-System Diagnostics H4—Travel Alarm A3—Main Controller (MCZ) R15— Engine Speed Dial B6—Engine Oil Level Sensor B30— Boom Up Pressure Sensor S7— Power Dig Switch S8— Auto-Idle Switch B31— Arm In Pressure Sensor B32— Front Attachment Pressure S11— Travel Speed Switch S12— Power Mode Button Sensor S13— Travel Alarm Cancel B33— Swing Pressure Sensor Switch B34— Travel Pressure Sensor B35— Pump 1 Delivery Pressure X3— Cab Harness-to-Machine Harness 100-Pin Connector Sensor B36— Pump 1 Control Pressure X29— Cab Harness-to-Switch Panel Connector 3 Sensor B37— Pump 2 Delivery Pressure X31— Cab Harness-to-Main Controller (MCZ) 31-Pin Sensor Connector A B38— Pump 2 Control Pressure X32— Cab Harness-to-Main Sensor Controller (MCZ) 24-Pin B39— Bucket In Pressure Sensor Connector B B40— Hydraulic Oil Temperature X33— Cab Harness-to-Main Sensor Controller (MCZ) 17-Pin B56— Pump 3 Delivery Pressure Connector C Sensor B57— Pump 3 Control Pressure X34— Cab Harness-to-Main Controller (MCZ) 30-Pin Sensor Connector D
Main Controller (MCZ) (A3)—The main controller (MCZ) uses inputs from the following sensors on the machine:
• Engine Oil Level Sensor (B6) • Boom Up Pressure Sensor (B30) • Arm In Pressure Sensor (B31) • Front Attachment Pressure Sensor (B32) • Swing Pressure Sensor (B33) • Travel Pressure Sensor (B34) • Bucket In Pressure Sensor (B39) • Pump 1 Delivery Pressure Sensor (B35) • Pump 1 Control Pressure Sensor (B36) • Pump 2 Delivery Pressure Sensor (B37) • Pump 2 Control Pressure Sensor (B38) • Pump 3 Delivery Pressure Sensor (B56) • Pump 3 Control Pressure Senor (B57) • Hydraulic Oil Temperature Sensor (B40) • Engine Speed Dial (R15) • Auto-Idle Switch (S8) • Travel Speed Switch (S11) • Power Mode Button (S12) • Pilot Shutoff Switch 1 • Pilot Shutoff Switch 2
X35— Cab Harness-to-Main Y21— Torque Control Solenoid Controller (MCZ) 24-Pin (marked ST) Connector E Y22— Dig Regenerative Solenoid X36— Cab Harness-to-Main (marked SF) Controller (MCZ) 26-Pin Y23— Arm Regenerative Connector F Solenoid (marked SC) X40— Pump Harness-to-Machine Y24— Power Dig Solenoid Harness Connector (marked SI) X49— Cab Harness-to-Spool Y27— Arm 2 Flow Control Control Harness Solenoid (marked SD) Connector Y28— Pump 3 Torque Control X90— Not Used Solenoid (marked SU) X91— Not Used Y29— Arm 1 Flow Control X97— Pump Harness Splice Solenoid (marked SE) Connector Y31— Arm 3 Spool Control X98— Machine Harness Splice Solenoid (marked A2) Connector Y32— Boom 3 Spool Control Y12— Exhaust Filter Regulator Solenoid (marked A1) Solenoid (pump 1) (marked SZ) Y13— Exhaust Filter Regulator Solenoid (bypass cut-off valve) (marked SJ) Y20— Pump 2 Flow Rate Limit Solenoid (marked SB)
Main Controller (MCZ) Power Up (power and ground)—Unswitched battery power is available at pins 5 and 6 of the main controller (MCZ) connector E (X35) through data converter and main controller (MCZ) battery power 5 A fuse (F10). Ground is provided to pins 1 and 2 of MCZ connector F (X36). 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 4 of MCZ connector E (X35) through power on 5 A fuse (F17), causing the MCZ to power up. With the battery relay (K19) energized, current flows through alternator 65 A fuse (F60) to pin B of alternator (G3). From pin B of alternator, current flows through solenoid 20 A fuse (F4) to pins 1, 2, and 3 of the MCZ connector (X36). Engine Speed Dial (R15)—The engine speed dial (R15) controls the engine speed according to the rotation angle of the dial. The main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) (A1) via the controller area network (CAN).
The MCZ controls the following solenoids:
• Exhaust Filter Regulator Solenoid (pump 1) (marked SZ) (Y12)
• Exhaust Filter Regulator Solenoid (bypass cut-off valve)
(marked SJ) (Y13) • Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20) • Torque Control Solenoid (marked ST) (Y21) • Dig Regenerative Solenoid (marked SF) (Y22) • Arm Regenerative Solenoid (marked SC) (Y23) • Power Dig Solenoid (marked SG) (Y24) • Arm 2 Flow Control Solenoid (marked SD) (Y27) • Pump 3 Torque Control Solenoid (marked SU) (Y28) • Arm 1 Flow Control Solenoid (marked SE) (Y29) • Arm 3 Spool Control Solenoid (marked A2) (Y31) • Boom 3 Spool Control Solenoid (marked A1) (Y32)
• For more information on CAN communication, see
Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) • For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) • For more information on engine speed control, see Engine Speed Control System Operation. (Group 9010-05.)
Power Mode Button (S12)—The power mode button (S12) allows the operator to cycle through three power modes: ECO (economy), PWR (power), and HP (high power). Continued on next page
TM12660 (18APR18)
9015-15-37
DW9628,0000522 -19-08JUN17-4/10
041818
PN=541
Sub-System Diagnostics
ECO power mode reduces engine speed to 1630 rpm to reduce fuel consumption in comparison to PWR mode. HP mode delivers more power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller (MCZ) sends an engine speed request to the engine control unit (ECU) via the controller area network (CAN). The engine control unit monitors several sensors in the engine and makes adjustments to maintain the engine speed requested by the MCZ.
• For more information on CAN communication, see
Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) • For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Travel Mode (HP)—When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller (MCZ) at pin 8 of MCZ connector C (X33). The MCZ then activates the power dig solenoid (Y24), depending on the status of the travel pressure sensor (B34), the front attachment pressure sensor (B32), the pump control pressure sensors (B36 and B38), and the pump delivery pressure sensors (B35 and B37).
speed, the engine speed will not increase or decrease after 4 seconds. The MCZ receives the pressure signal from the front attachment pressure sensor (B32), located in the swing park brake circuit, or the travel pressure sensor (B34) to sense if a hydraulic function has been operated. For more information on CAN communication, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Hydraulic Oil Warm-Up Circuit—When hydraulic oil temperature is below 0°C (32°F), the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the hydraulic oil. The MCZ receives oil temperature from the hydraulic oil temperature sensor (B40) located in the hydraulic oil tank. The MCZ will activate the warm-up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F). Engine Coolant Warm-Up Circuit—When engine coolant temperature is below a predefined point, the main controller (MCZ) activates a warm-up circuit, which raises the engine speed slightly above slow idle to help warm up the engine coolant. The MCZ receives coolant temperature via the controller area network (CAN) from the engine control unit (ECU). The MCZ will activate the warm-up circuit for 12 minutes or until the coolant temperature rises to 25°C (77°F).
Fast travel speed can be activated when the following conditions have been met:
• Engine speed dial (R15) is in the fast idle position • Travel pressure sensor (B34) is sensing pressure (travel function actuated)
• Front attachment pressure sensor (B32) not sensing pressure (no swing or dig functions actuated)
• Either pump 1 or pump 2 delivery pressure low • Either pump 1 or pump 2 control pressure high Activation of the power dig solenoid sends pilot pressure to the travel speed change valve in the travel motors. Pressure at the travel speed change valve changes the displacement of the travel motors, allowing for fast travel speed. Since either delivery pressure may be low and either control pressure may be high, the travel motor will shift speeds when one track is raised off the ground. If the machine is travelling in fast travel speed and a dig or swing function is operated, the machine will remain in fast travel speed, but will travel at slow travel speed as hydraulic oil is routed to other functions. For more information, see Travel Motor Speed Circuit Operation. (Group 9025-05.) A/I (auto-idle) Mode—A/I (auto-idle) is a feature that reduces engine speed when hydraulic functions are not operated for more than 4 seconds. When the auto-idle switch (S8) is turned to A/I (auto-idle), the switch sends a ground to the main controller (MCZ) to pin 7 of MCZ connector C (X33). The MCZ communicates the selected mode through the controller area network (CAN) to the monitor controller (MCZ), 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
Idle Speed-Up Circuit—The idle speed-up circuit prevents the engine from varying when travel or front attachment operation is performed while the engine is running at a speed between slow idle and idle speed-up speed. When the travel or front attachment operation is performed while the engine is between slow idle and idle speed-up speed, the main controller (MCZ) sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN). The ECU then increases the engine speed to the idle speed-up speed. Pilot Shutoff Idle Speed-Up Circuit—When engine speed dial (R15) is in the slow idle position and the pilot shutoff lever is in the UNLOCK position, the main controller (MCZ) activates the pilot shutoff idle speed-up circuit. The MCZ sends the equivalent to target engine speed to the engine control unit (ECU) via the controller area network (CAN), which increases the engine speed by 100 rpm from the slow idle speed in order to prevent engine stall during a control lever operation. Engine Starting Idle Speed-Up Circuit—The engine starting idle speed-up circuit increases the engine speed and increases the engine oil pressure when the engine starts. The engine starting idle speed-up circuit will not activate if the engine speed dial (R15) is set above 1150 rpm. When active, the engine starting idle speed-up circuit sends the signals equivalent to the target engine speed to the engine control unit (ECU) via the controller area network (CAN). The idle speed-up circuit will remain active for 15 seconds. Engine speed will then return to the engine speed set by the engine speed dial. For more information on engine speed control, see Engine Speed Control System Operation. (Group 9010-05.)
Continued on next page
TM12660 (18APR18)
9015-15-38
DW9628,0000522 -19-08JUN17-5/10
041818
PN=542
Sub-System Diagnostics
Travel Torque Up—The torque control solenoid valve may be activated during a travel function. At slow engine speeds, the torque control solenoid valve is activated and both pumps are moved to maximum displacement. 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 (Y21) is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 2 and 3 of MCZ connector A (X31). Auto-Shutdown Control—For more information on auto-shutdown control, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.) Work Modes—Work modes are selected in the monitor controller and communicated by the controller area network (CAN) to the main controller (MCZ). The MCZ can adjust pump delivery and engine speed depending on the work mode or attachment selected. Pump flow and engine speeds can be adjusted with the monitor controller or by using MPDr. Hydraulic Oil Overheat Alarm Circuit—The hydraulic oil overheat alarm circuit sounds the monitor alarm when the hydraulic oil temperature increases beyond the specified value. The main controller (MCZ) monitors hydraulic oil temperature utilizing hydraulic oil temperature sensor (B40). When hydraulic oil temperature increases and remains past a predefined point, the MCZ sends the signal to the monitor controller (DSZ) (A4) via the controller area network (CAN). The monitor controller sounds the alarm and displays the hydraulic oil overheat alarm on the monitor. For more information, see Monitor Controller (DSZ) Circuit Theory of Operation. (Group 9015-15.) Travel Alarm Circuit—The travel alarm sounds during travel operation. When the main controller (MCZ) receives the signal from travel pressure sensor (B34), MCZ sends power to travel alarm (H4), activating the alarm. After traveling continuously for more than 13 seconds, the alarm can be deactivated using travel alarm cancel switch (S13). Exhaust Filter Regulator Solenoid (pump 1) (marked SZ) (Y12)—The exhaust filter regulator solenoid (Y12) is used to increase exhaust temperature when regeneration is requested. The ECU indicates an exhaust filter cleaning is required over CAN to the MCZ.
When solenoid SZ is activated, torque control solenoid (Y21) is also energized. Solenoid SZ and torque control solenoid valves deliver pilot pressure to pump 1 regulator, increasing pump 1 control pressure. Exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) is also energized, shifting the bypass cut-off valve. The MCZ will increase target engine speed. The increased engine speed and hydraulic load will increase exhaust filter temperature. Exhaust Filter Regulator Solenoid (bypass cut-off valve) (marked SJ) (Y13)—The exhaust filter regulator solenoid (bypass cut-off valve) (Y13) is used to increase exhaust temperature when regeneration is requested. The ECU indicates an exhaust filter cleaning is required over CAN to the MCZ. The MCZ energizes solenoid SJ when the following conditions are met:
• Engine speed dial (R15) in the slow idle position • Pilot shutoff switch in the locked (UP) position • Regeneration is requested (auto, parked, service) Solenoid SJ is a pulse-width modulation solenoid valve. Solenoid SJ regulates pilot pressure to the bypass cut-off valve to maintain pump 1 delivery pressure at approximately 7—10 MPa. Solenoid SJ is activated when the neutral passage of the 4-spool side of the control valve is blocked, increasing pump 1 delivery pressure. Utilizing feedback from pump 1 delivery pressure sensor (B35), the MCZ will regulate signal to solenoid SJ, controlling pump 1 delivery pressure. When engine speed is less than 1000 rpm, the MCZ, via the CAN signal, will increase engine speed to 1000 rpm. Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20)—The pump 2 flow rate limit solenoid valve (Y20) limits the pump 2 displacement when an auxiliary (attachment) function is used. The pump 2 flow rate limit solenoid (Y20) is a proportional solenoid and is controlled by a pulse-width modulated signal from pin 8 of MCZ connector A (X31) and pin 15 of MCZ connector B (X32). The MCZ activates the pump 2 flow rate limit solenoid valve when pilot pressure is present at the attachment pressure sensor (optional) and a work mode other than dig mode is selected in the monitor. The flow rate for each attachment mode can be adjusted using MPDr. Fine adjustments to the pump 2 flow rate can be made through the monitor.
The MCZ energizes solenoid SZ when the following conditions are met:
NOTE: Flow rates and adjustments in MPDr and the monitor are approximate. Actual flow rates may vary.
• Engine speed dial (R15) in the slow idle position • Pilot shutoff switch in the locked (UP) position • Regeneration is requested (auto, parked, service)
The auxiliary flow combiner may greatly affect MPDr flow adjustments if activated.
Continued on next page
TM12660 (18APR18)
9015-15-39
DW9628,0000522 -19-08JUN17-6/10
041818
PN=543
Sub-System Diagnostics
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 preventing engine stall. As engine load decreases, the torque control solenoid is activated, increasing pump displacement and therefore increasing the efficiency of the machine. The main controller (MCZ) monitors the difference between target engine speed as set by the MCZ and the actual engine speed as read by the engine control unit (ECU) and communicated to the MCZ over controller area network (CAN). As engine speed varies above or below target speed, the MCZ adjusts the signal to the torque control solenoid 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 2 and 3 of MCZ connector A (X31). Under most conditions, the torque control solenoid is activated to some degree. For more information, see Engine Speed Sensing Control Circuit Operation. (Group 9025-05.) Dig Regenerative Solenoid (marked SF) (Y22)—The dig regenerative solenoid (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 14 and 15 of MCZ connector A (X31). The MCZ activates the dig regenerative solenoid when the following conditions have been met:
• Pump 1 and pump 2 delivery pressure high • Arm in and boom up valves are actuated at the same
The MCZ activates the arm regenerative solenoid when the following conditions have been met:
• Either pump 1 or pump 2 delivery pressure low • Arm in pressure sensor sensing high pressure (arm in function fully actuated)
• Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated)
When the arm regenerative solenoid is activated, pilot oil from the arm regenerative solenoid valve shifts the arm regenerative valve in the control valve. This shift blocks the return oil from the arm cylinder rod end from returning to the hydraulic oil tank and combines oil from rod end with the oil to the arm cylinder head end. Pilot oil from the arm regenerative solenoid also shifts the arm flow control valve, limiting the oil to the second arm spool to preserve oil flow to other functions in the control valve. For more information, see Arm Regenerative Valve Circuit Operation. (Group 9025-05.) Power Dig Solenoid (marked SI) (Y24)—The power dig solenoid (Y24) increases digging force by temporarily increasing the main hydraulic system relief pressure. The power dig switch (S7) grounds pin 11 of MCZ connector F (X36). The MCZ then energizes dig solenoid for a maximum of 8 seconds. The power dig solenoid is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 12 and 13 of MCZ connector A (X31). When the power dig solenoid valve is activated, pilot oil from the power dig 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 higher operating pressure. For more information, see Main Relief Valve Circuit Operation. (Group 9025-05.) Arm 2 Flow Control Solenoid (marked SD) (Y27)—The arm 2 flow control solenoid (Y27) reduces pressure oil through arm 2 and delivers more pressure oil to other actuators during combined operation of front attachment, so that the operating speed of actuators except arm 2 increases. The arm 2 flow control solenoid is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 8 and 9 of MCZ connector A (X31).
time
• Gravity can pull the arm in faster than the pump can supply oil to the arm cylinder head end
When the dig regenerative solenoid is activated, pilot oil from the dig regenerative solenoid shifts the dig regenerative in the control valve. This shift allows oil from the boom cylinder rod end to combine with oil in the arm cylinder head end. For more information, see Dig Regenerative Valve Circuit Operation. (Group 9025-05.)
The MCZ activates arm 2 flow control solenoid (Y27) when the following condition has been met:
Arm Regenerative Solenoid (marked SC) (Y23)—The arm regenerative solenoid (marked SC) (Y23) combines the return oil from the arm cylinder rod end with the 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 10 and 11 of MCZ connector A (X31).
• Pump 1 and 2 delivery pressure low during combined
operation of arm roll in and bucket roll in or operation of attachment and arm roll out
The arm 2 flow control solenoid delivers pilot oil that shifts arm 2 flow rate control valve. Pressure oil, which flows to the arm 2 spool from pump 1, is reduced. Therefore, as pressure oil to arm 2 spool is reduced, operating speed of other actuators increases.
Continued on next page
TM12660 (18APR18)
9015-15-40
DW9628,0000522 -19-08JUN17-7/10
041818
PN=544
Sub-System Diagnostics
Pump 3 Torque Control Solenoid (marked SU) (Y28)—The pump 3 torque control solenoid (Y28) 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 preventing engine stall. As engine load decreases, the torque control solenoid is activated, increasing pump displacement and therefore increasing the efficiency of the machine. The main controller (MCZ) monitors the difference between target engine speed as set by the MCZ and the actual engine speed as read by the engine control unit (ECU) and communicated to the MCZ over controller area network (CAN). As engine speed varies above or below target speed, the MCZ adjusts the signal to the torque control solenoid to change the pump displacement to utilize the maximum efficiency of the engine without allowing the engine to stall.
• Combined operation of attachment and arm The arm 1 flow control solenoid delivers pilot oil that shifts arm 1 flow rate control valve. Pressure oil, which flows to the arm 1 spool from pump 2, is reduced. Therefore, as pressure oil to arm 1 spool is reduced, operating speed of other actuators increases. Arm 3 Spool Control Solenoid (marked A2) (Y31) and Boom 3 Spool Control Solenoid (marked A1) (Y32)—The arm 3 spool control solenoid (Y31) and boom 3 spool control solenoid (Y32) cuts off pilot oil pressure to arm 3 spool or boom 3 spool and reduces the load of pump 3 when digging pressure increases. The arm 3 spool control solenoid is a proportional solenoid and is controlled by pulse-width modulated signal from pins 4 and 5 of MCZ connector D (X34). The boom 3 spool control solenoid is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 15 and 16 of MCZ connector E (X35).
The torque control solenoid is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 4 and 5 of MCZ connector A (X31). 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 MCZ activates arm 3 spool control solenoid (Y31) and boom 3 spool control solenoid (Y32) when the following conditions have been met:
Arm 1 Flow Control Solenoid (marked SE) (Y29)—The arm 1 flow control solenoid (Y29) reduces pressure oil through arm 1 and delivers more pressure oil to other actuators during combined operation of front attachment so that the operating speed of actuators except arm 1 increases. The arm 1 flow control solenoid is a proportional solenoid and is controlled by a pulse-width modulated signal from pins 20 and 21 of MCZ connector A (X31).
The arm 3 spool control solenoid or boom 3 spool control solenoid increases digging force by blocking pilot oil to the arm 3 spool or boom 3 spool. Therefore, as the load of pump 3 is reduced, flow rate of pump 1 and 2 increases, providing better machine control.
• Pump 1 and 2 delivery pressure is reduced • Boom up pressure sensor sensing low pressure • Arm in pressure sensor sensing low pressure
The MCZ activates arm 1 flow control solenoid (Y29) when the following condition has been met: Continued on next page
TM12660 (18APR18)
9015-15-41
DW9628,0000522 -19-08JUN17-8/10
041818
PN=545
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-42
041818
PN=546
Sub-System Diagnostics
Auxiliary Function Lever (AFL) Theory of Operation TX1209535 —UN—17MAR16
BLK/GRN
3
GRN
BLK
4
WHT
BLU
5
RED
1
6
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
BLK/YEL RED/YEL
BLK
P 2
1
T 2
3
BLK/YEL GRY 1 1
2
1 9 12 11 4 5 6 2 7 3 10 8
GRN/BLU
X544 AUXILIARY FUNCTION LEVER (AFL) POWER DIG SWITCH CONNECTOR BLK
1
BLK
GRN/BLK
2
GRN/BLK
X574 AUXILIARY FUNCTION LEVER (AFL) CONNECTOR
Y62 AUXILIARY FUNCTION LEVER (AFL) SOLENOID B (MARKED 1B)
Y61 AUXILIARY FUNCTION LEVER (AFL) SOLENOID A (MARKED 1A)
GRN/BLU BLK/GRN RED/BLU BLK/YEL BLK/YEL RED/YEL RED/YEL BLK/BLU GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLU/YEL
1
2
X538 AUXILIARY FUNCTION LEVER (AFL) RIGHT GRIP HARNESS CONNECTOR (MARKED R_LEVER) RED/YEL BLK/YEL
X541 LT GRN/YEL
6
WHT/YEL BLK/BLU BLU/YEL BLK/YEL RED/YEL GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK
1
2
GRN/BLU BLK/GRN RED/BLU BLK/YEL RED/YEL BLK/BLU GRY WHT/BLU BLU/WHT YEL/BLU ORG/BLK BLU/YEL
8
X536 RIGHT AUXILIARY FUNCTION LEVER (AFL) CONNECTOR
BLK/YEL RED/YEL GRN/BLU
7
BLK
1
BLK/YEL
GRN/BLU
GRN/BLK
3
GRN/BLU
GRN
K31 RIGHT SOLENOID RELAY A (MARKED RSW1)
2
12 11 14 6 13 1 2 3 4 5
B68 SECONDARY HYDRAULIC OIL TEMPERATURE SENSOR
GRY
5
B85 AUXILIARY FUNCTION LEVER (AFL) SOLENOID PRESSURE SENSOR (MARKED PS1)
RED/YEL
1
RED/BLU
BLK
9
4
GRN/BLK
5
BRN
3
GRN
1
LT GRN/YEL
8
X577 AUXILIARY FUNCTION LEVER (AFL) HARNESSTO-AUXILIARY FUNCTION LEVER (AFL) SOLENOID HARNESS CONNECTOR
BLK/BLU
S29 AUXILIARY FUNCTION LEVER (AFL) PROPORTIONAL CONTROL SWITCH
V22 PILOT SHUTOFF SOLENOID DIODE
WHT/YEL
WHT
WHT/YEL
S45 AUXILIARY FUNCTION ENABLE SWITCH
WHT/YEL
S34 RIGHT ENABLE SWITCH
2
WHT/YEL
WHT
RED/YEL
0 1
1
S7 POWER DIG SWITCH
BLU/YEL
RED
BRN
Y66 SECONDARY PILOT SHUTOFF SOLENOID (MARKED PiC)
2
BLK/BLU
F6 20A FUSE
F5 5A FUSE
S31 RIGHT PILOT CONTROL LEVER SWITCH A
WHT/YEL
RIGHT PILOT CONTROL LEVER
C2 C16
F11
F22 F17 F26 C7 A23 A24 F16 F25 C6 A22 A25 B2
A3 MAIN CONTROLLER (MCZ)
A = X31 B = X32
C = X33 F = X36
TX1209535 Auxiliary Function Lever (AFL) Theory of Operation Circuit Schematic Continued on next page
TM12660 (18APR18)
9015-15-43
041818
PN=547
DW9628,0000522 -19-08JUN17-9/10
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-44
041818
PN=548
Sub-System Diagnostics
A3—Main Controller (MCZ) S31— Right Pilot Control Lever B68— Secondary Hydraulic Oil Switch A Temperature Sensor S34— Right Enable Switch B85— Auxiliary Function Lever S45— Auxiliary Function Enable (AFL) Solenoid Pressure Switch Sensor (marked PS1) V22— Pilot Shutoff Solenoid F5— Travel Alarm 5 A Fuse Diode (marked OPT. 1 ALT) X31— Cab Harness-to-Main F6— 12-Volt Power Outlet 20 A Controller (MCZ) 31-Pin Fuse (marked OPT. 2 ALT) Connector A K31— Right Solenoid Relay A X32— Cab Harness-to-Main (marked RSW1) Controller (MCZ) 24-Pin S7— Power Dig Switch Connector B S29— Auxiliary Function Lever X33— Cab Harness-to-Main (AFL) Proportional Control Controller (MCZ) 17-Pin Switch Connector C X36— Cab Harness-to-Main Controller (MCZ) 26-Pin Connector F
X536— Right Auxiliary Function Y61— Auxiliary Function Lever Lever (AFL) Connector (AFL) Solenoid A (marked (marked R_GRIP) 1A) X538— Auxiliary Function Lever Y62— Auxiliary Function Lever (AFL) Right Grip Harness (AFL) Solenoid B (marked Connector (marked 1B) R_LEVER) Y66— Secondary Pilot Shutoff X541— Auxiliary Function Lever Solenoid (marked PiC) (AFL) Right Switch Connector (marked R-SW) X544— Auxiliary Function Lever (AFL) Power Dig Switch Connector X574— Auxiliary Function Lever (AFL) Connector X577— Auxiliary Function Lever (AFL) Harness-toAuxiliary Function Lever (AFL) Solenoid Harness Connector
Auxiliary Function Lever (AFL)—The MCZ provides control for AFL control.
cycle of the pilot control shutoff lever is done, AFL will need to be activated again.
Auxiliary hydraulic functions are controlled by the MCZ with inputs from the following components:
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 (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.
• Secondary hydraulic oil temperature sensor (B68) • Auxiliary function lever (AFL) solenoid pressure sensor (marked PS1) (B85)
• Auxiliary function lever (AFL) proportional control switch (S29)
• Auxiliary function enable switch (S45) After the MCZ processes received input signals, output signals are sent to the solenoids to control hydraulic speed and volume with the following components:
• Auxiliary function lever (AFL) solenoid A (marked 1A) (Y61)
• Auxiliary function lever (AFL) solenoid B (marked 1B) (Y62)
• Secondary pilot shutoff solenoid (marked PiC) (Y66) NOTE: AFL will work only when pilot control shutoff lever is in the unlocked (DOWN) position. If a
The MCZ monitors secondary hydraulic oil temperature utilizing secondary hydraulic oil temperature sensor (B68) through pin C7 of the MCZ. When hydraulic oil temperature increases or decreases and remains past a predefined point, the MCZ sends the signal to the DSZ via the CAN. The MCZ monitors hydraulic oil pressure utilizing AFL solenoid pressure sensor (B85) through pin B2 of the MCZ. When hydraulic oil pressure increases and remains past a predefined point, the MCZ sends the signal to the DSZ via the CAN. DW9628,0000522 -19-08JUN17-10/10
TM12660 (18APR18)
9015-15-45
041818
PN=549
Sub-System Diagnostics
Travel Alarm Circuit Theory of Operation WHT
WHT
TO BATTERY RELAY (KI9) (PIN A)
BLK
WHT/RED
WHT/YEL
F5 TRAVEL ALARM 5A FUSE
1
2
2
1
4
3
B34 TRAVEL PRESSURE SENSOR
YEL/RED
BLK/YEL
0 1
C10
E7
D21
E7
A3 MAIN CONTROLLER (MCZ) TX1105103
TX1105103 —UN—14FEB12
BLK
S13 TRAVEL ALARM CANCEL SWITCH
RED/YEL
H4 TRAVEL ALARM
WHT/RED
GRN/BLK
3
Travel Alarm Circuit Schematic
Continued on next page
TM12660 (18APR18)
9015-15-46
DW9628,0000523 -19-08NOV12-1/2
041818
PN=550
Sub-System Diagnostics A3—Main Controller (MCZ) B34— Travel Pressure Sensor
F5— Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
The travel alarm circuit consists of a travel pressure sensor (B34), main controller (MCZ) (A3), travel alarm (H4), and a travel alarm cancel switch (S13). The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the travel levers are moved. When the travel levers are moved, travel pressure sensor (B34) senses pilot pressure and sends a signal to the MCZ. When signal is received from travel pressure
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. DW9628,0000523 -19-08NOV12-2/2
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.) DW9628,0000524 -19-26JUL12-1/1
TM12660 (18APR18)
9015-15-47
041818
PN=551
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-48
041818
PN=552
Sub-System Diagnostics
Windshield Wiper and Washer Circuit Theory of Operation B
G1
G2
ACC
M
ST
WHT
WHT
WHT
RED/BLK
RED/BLK
RED/BLK
RED/BLK
BLK/RED BLK/YEL
M
2
GRN/BLU
13 A11 MACHINE CONTROLLER (BCZ)
BLK/WHT
3
BLK/WHT
2
= X11
BLU
2
8
BLU
BLK
E10 SWITCH PANEL BACK LIGHT 5
4
BLK/RED 3
5
4
1
2
4
3
2
F60 ALTERNATOR 65A FUSE
GRY/RED
5
BLK/BLU
GRY/RED
25
RED/YEL
A10 MONITOR
F62 WIPER MOTOR ASSEMBLY CIRCUIT BREAKER
= X23
BLK/BLU
TX1117600
Windshield Wiper and Washer Circuit Theory of Operation Continued on next page
9015-15-49
4
041818
PN=553
LB
M VLT
BLK
BLK/BLU
WHT
BLK
S
= X20
26
RED
BLU C3
BLK/BLU
X18
WHT
TM12660 (18APR18)
5
K9 WINDSHIELD WASHER RELAY
M6 WINDSHIELD WASHER MOTOR
M5 WINDSHIELD WIPER MOTOR
A4 MONITOR CONTROLLER (DSZ) 3
WHT
9
BLK WHT
G2 BATTERY
WHT
A
K19 BATTERY RELAY
WHT
BLK
E
B
BLK
S
3
L
S28 WINDOW SWITCH
8
GRN (CAN 1 HIGH) BLU (CAN 1 LOW)
RED
RED WHT
1
1 11
V3 LOAD DUMP RELAY DIODE
X39
K6 WINDSHIELD WIPER RELAY
ST
G1 BATTERY
F2 WINDSHIELD WIPER AND WASHER 10A FUSE
BLK/RED
RED/BLK
= X10
YEL/BLK
1
4
5 G2
F61 BATTERY 45A FUSE
YEL/RED
WHT
4
1
BLK
RED
3
RED
RED
BLU
G1
3
BLU
BAT
BLU
ACC
YEL/GRN
BLK
GRY/RED
K13 KEY CUT RELAY
4
1
YEL/BLK
S1 KEY SWITCH
F10 CONTROLLER 5A FUSE
GRN/BLK
S9 WINDSHIELD WIPER AND WASHER SWITCH
BLK
F17 POWER ON 5A FUSE
6
BLK/PNK
RED/BLK
RED
HEAT OFF ACC ON START
2 1 0
X27
BLK
POSITION HEAT OFF ACC ON START
YEL/BLU
TX1117600 —UN—03AUG12
M
B L E
BLK/BLU
DW9628,0000526 -19-06AUG12-1/2
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-50
041818
PN=554
Sub-System Diagnostics
A4—Monitor Controller (DSZ) A10— Monitor A11— Machine Controller (BCZ) E10— Switch Panel Back Light 5 F2— Windshield Wiper and Washer 10 A Fuse (marked WIPER) F10— Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) F17— Power On 5 A Fuse (marked POWER ON)
F60— Alternator 65 A Fuse F61— Battery 45 A Fuse F62— Wiper Motor Assembly Circuit Breaker G1—Battery G2—Battery K6—Windshield Wiper Relay 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 20-pin connector A (X10) from information controller and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin B19 of the BCZ through key switch 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 20-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 amp fuse (F2). When windshield wiper relay is energized, pin L of the windshield wiper motor is grounded, and the windshield wiper motor operates. The windshield wiper motor drives a pitman arm assembly which moves the windshield wiper blade back and forth across the windshield. When the windshield wiper is operating, the BCZ and monitor controller (DSZ) (A4) communicate through the 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 position, BCZ intermittently grounds pin B9. The monitor controller (DSZ) (A4) controls windshield wiper delay time.
S1— Key Switch S9— Windshield Wiper and Washer Switch S28— Window Switch V3— Load Dump Relay Diode 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
NOTE: Window switch (S28) must be connected for windshield wiper to operate. Power to windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When windshield wiper relay is energized, pin L of the windshield wiper motor is grounded and the windshield wiper motor operates. The windshield wiper motor drives a pitman arm assembly, which moves the windshield wiper blade back and forth across the windshield. When the windshield wiper is operating, the BCZ and DSZ communicate through the 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 8. When pin 8 is grounded the windshield washer relay (K9) is energized. Power is supplied to windshield washer motor (M6) from windshield wiper and washer 10 amp fuse (F2) through pins 3 and 1 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 8 of BCZ, and the washer motor stops.
DW9628,0000526 -19-06AUG12-2/2
TM12660 (18APR18)
9015-15-51
041818
PN=555
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-52
041818
PN=556
Sub-System Diagnostics
Lighting Circuit Theory of Operation TX1117690 —UN—07AUG12
2
5
4
2
5
4
3
2
5
4
RED/BLU
K8 BOOM LIGHT RELAY
ORG/BLU
A10 MONITOR
BLK
YEL/BLK
10 YEL
YEL/BLK
1
3
WHT/YEL
19
4
18
S14 DOOR SWITCH
C3
X18
7
RED RED/BLK
YEL
RED/YEL RED/BLU
= X20
= X10
= X23
= X11
WHT/VLT
WHT/VLT
7
GRN/WHT
GRN/WHT
17
E2 BOOM LIGHT
0 1 2
X29 CAB HARNESSTO-SWITCH PANEL CONNECTOR 3
8
BLK
WHT
WHT
25
26
1
BLU
13 14
BRN/BLK PNK
E1 WORK LIGHT
V13 WORK LIGHT 1 DIODE
11
X3 RED/BLU
BLK
BLK
F60 ALTERNATOR 65A FUSE
C8
C7
X3
G2 BATTERY
2
6
GRN
+
BLU/RED
A
K19 BATTERY RELAY
1
3
A11 MACHINE CONTROLLER (BCZ)
BLK
B
WHT
S
WHT
WHT
WHT
BLU/RED
RED
G1 BATTERY
YEL
V14 WORK LIGHT 2 DIODE
A4 MONITOR CONTROLLER (DSZ)
3
2
YEL
+
-
E
RED/BLK
BLK
F61 BATTERY 45A FUSE
GRN (CAN 1 HIGH)
ST
1
3
E3 CAB DOME LIGHT
10
BLU (CAN 1 LOW)
K13 KEY CUT RELAY
3
RED/BLU
ORG/BLU
E9 KEY SWITCH LIGHT
RED/YEL
1
K7 WORK LIGHT RELAY
2 1
BLK/RED
BLK
BLU
DOOR OFF ON
9
BLU/YEL
M
RED/BLU
GRN
WHT/BLK
S2 CAB DOME LIGHT SWITCH
X27 CAB HARNESSTO-SWITCH PANEL CONNECTOR 1
RED/BLU
BLU
RED
G2
YEL/RED RED/BLU
YEL/RED
4
F12 RADIO 5A FUSE
ORG/BLU
5
F10 CONTROLLER 5A FUSE
BLK
2
K12 ACC CUT RELAY
F1 LAMP 20A FUSE
RED/BLK
G1
3
YEL/BLK
1
YEL/BLU
YEL/BLK
WHT
BAT
V3 LOAD DUMP RELAY DIODE
F9 BACKUP 10A FUSE
GRN
S1 KEY SWITCH
ACC
V12 STARTER CUT DIODE
V11 ACCESSORY CUT DIODE
F17 POWER ON 5A FUSE
GRN
HEAT OFF ACC ON START
WHT
RED
RED
GRN
RED GRN WHT YEL/BLK
RED GRN WHT YEL/BLK
GRN
GRN
RED
M ST
GRN
ACC
RED/BLK
G2
GRN
G1
WHT
B
POSITION HEAT OFF ACC ON START
S10 WORK LIGHT SWITCH
BLU (CAN 1 LOW) GRN (CAN 1 HIGH)
TX1117690 Lighting Circuit Theory of Operation Continued on next page
TM12660 (18APR18)
9015-15-53
041818
PN=557
DW9628,0000527 -19-09AUG12-1/2
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-54
041818
PN=558
Sub-System Diagnostics
A4—Monitor Controller (DSZ) A10— Monitor A11— Machine Controller (BCZ) E1— Work Light E2— Boom Light E3— Cab Dome Light E9— Key Switch Light F1— Work and Boom Lights 20 A Fuse (marked LAMP) F9— Radio Backup 10 A Fuse (marked BACK UP) F10— Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F12— Radio and Dome 5 A Fuse (marked RADIO) F17— Power On 5 A Fuse (marked POWER ON) F60— Alternator 65 A Fuse F61— Battery 45 A Fuse G1—Battery G2—Battery K7—Work Light Relay K8—Boom Light Relay K12— Accessory Cut Relay K13— Key Cut Relay K19— Battery Relay S1— Key Switch S2— Cab Dome Light Switch
The machine controller (BCZ) (A11), receives unswitched power at pin 4 of BCZ connector A (X10) from data converter and main controller battery power 5 A fuse (F10). Switched battery power is supplied to pin 19 of BCZ connector B (X11) through key cut switch relay (K13) with the key switch (S1) in the ON position. The BCZ is grounded at pin 8 of BCZ connector A (X10). 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 6 of BCZ connector A (X10) through work light 1 diode (V13) and to pin 7 of BCZ connector A (X10), energizing work light relay, illuminating the work light. The BCZ communicates the work light switch position to the monitor controller (DSZ) (A4) via the controller area network (CAN). The DSZ then updates the monitor (A10) with the current work light operation. For more information on CAN theory of operation, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) Boom Light Operation—Turning the work light switch (S10) to position 2 will activate the work light and boom light (E2). When key switch (S1) is in the ON position, current from pin M of the key switch is passed to pin 3 of key cut relay (K13). Utilizing the normally closed contacts of key cut relay, power is passed through power on 5 A fuse (F17) to pin 1 of work light relay (K7) and boom light relay (K8). When work light switch is in position 2, ground is supplied to pins 2 and 6 of BCZ connector A (X10) through work
S10— Work Light Switch S14— Door Switch V3— Load Dump Relay Diode V11— Accessory Cut Diode V12— Starter Cut Diode V13— Work Light 1 Diode V14— Work Light 2 Diode X3— Cab Harness-to-Machine Harness 100-Pin Connector X10— Machine Controller 8-Pin Connector A X11— Machine Controller 20-Pin Connector B
X18— Monitor 12-Pin Connector C X20— Monitor Controller 28-Pin Connector A X23— Monitor Controller 12-Pin Connector C X27— Cab Harness-to-Switch Panel Connector 1 X29— Cab Harness-to-Switch Panel Connector 3
light 2 diode (V14) and to pin 17 of BCZ connector B (X11), energizing work light relay and boom light relay, illuminating the work light. The BCZ communicates the work light switch position to the DSZ via the 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.) Cab Dome Light Continuous Operation—The cab dome light (E3) receives unswitched power through backup 10 A fuse (F9). While cab dome light switch (S2) is in the ON position, ground from pin 10 of BCZ connector B (X11) 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 backup 10 A fuse (F9). While cab dome light switch (S2) is in the DOOR position, ground from pin 7 of the machine controller (BCZ), controls cab dome light and key switch light illumination. Door switch (S14) provides ground to pin 18 of the BCZ connector B (X11) while the cab door closed. While the BCZ detects ground at pin 18 of BCZ connector B (X11), no ground is provided to pin 7 of BCZ connector A (X10), 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 18 of BCZ connector B (X11), the BCZ provides ground to pin 7 of BCZ connector A (X10), illuminating the cab dome light and key switch light for 30 seconds. After 30 seconds, the BCZ removes ground from pin 7 of BCZ connector (X10) and the cab dome light and key switch light turn OFF. DW9628,0000527 -19-09AUG12-2/2
TM12660 (18APR18)
9015-15-55
041818
PN=559
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-56
041818
PN=560
Sub-System Diagnostics
Pilot Shutoff Circuit Theory of Operation TX1117856 —UN—31JUL12
BLU
BLU WHT
WHT BRN
M ST 1
3
V4 SECURITY DIODE
2
5
2
5
4
GRN/WHT
WHT
YEL/BLU
BLU
K13 KEY CUT RELAY
3
5
13
RED
3
3
WHT
1 2
3
RED
ORG
V9 PILOT SHUTOFF DIODE
WHT
S3 2 PILOT SHUTOFF SWITCH 1
ORG
RED WHT
YEL 1
V20 PILOT SHUTOFF SWITCH DIODE WHT
2
3
WHT
M1 STARTER MOTOR
2
S4 PILOT SHUTOFF SWITCH 2
1
RED
B
1
10
RED
V5 STARTER CUT RELAY DIODE
= X33 = X36
= X22
VLT
A3 MAIN CONTROLLER (MCZ)
RED
BLK
K34 STARTER RELAY
16
= X21
WHT
C
S
BLK
A4 MONITOR CONTROLLER (DSZ)
YEL/GRN
BLK
RED
BLK
B
F60 ALTERNATOR 65A FUSE
A
V10 STARTER PROTECTION DIODE
YEL/GRN
E
G2 BATTERY
BLK
4
1
WHT
S
B
WHT
5
RED/BLU
RED
E
2
K5 SECURITY RELAY
VLT
V7 START RELAY DIODE
BLK/WHT S
3
VLT/WHT
WHT RED
G1 BATTERY
WHT
4
1
VLT/GRN
RED
V1 BATTERY RELAY DIODE
4
WHT/RED
F61 BATTERY 45A FUSE
K19 BATTERY RELAY
1
4
S6 ENGINE STOP SWITCH
VLT/WHT
ST
5
3
K2 PILOT SHUTOFF SOLENOID RELAY
3
VLT/GRN
K4 STARTER CUT RELAY
M
2
2
3
BLK/WHT
RED
1
BLK
YEL/GRN
WHT/RED
G2
VLT/RED
BRN
BAT
BLU
RED PNK/WHT
1
V3 LOAD DUMP RELAY DIODE
BRN
Y10 PILOT SHUTOFF SOLENOID
ACC
S1 KEY SWITCH
F18 IDLE STOP 5A FUSE
RED
G3 ALTERNATOR
BLU
HEAT OFF ACC ON START
F4 SOLENOID 20A FUSE
VLT/RED
B
WHT
2
BRN
G1
GRN/WHT
GRN/WHT
RED
ACC
ORG
G2
BRN
G1
YEL/GRN
B
POSITION HEAT OFF ACC ON START
VLT WHT
TX1117856 Pilot Shutoff Circuit Theory of Operation Schematic Continued on next page
TM12660 (18APR18)
9015-15-57
041818
PN=561
DW9628,0000529 -19-30AUG12-1/2
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-58
041818
PN=562
Sub-System Diagnostics A3—Main Controller (MCZ) K2—Pilot Shutoff Solenoid Relay V1— Battery Relay Diode V3— Load Dump Relay Diode A4—Monitor Controller (DSZ) K4—Starter Cut Relay V4— Security Diode F4— Solenoid 20 A Fuse (marked K5—Security Relay V5— Starter Cut Relay Diode SOLENOID) K13— Key Cut Relay V7— Start Relay Diode F18— Idle Stop 5 A Fuse (marked K19— Battery Relay V9— Pilot Shutoff Diode IDLE STOP) K34— Starter Relay V10— Starter Protection Diode F60— Alternator 65 A Fuse M1—Starter Motor V20— Pilot Shutoff Switch Diode F61— Battery 45 A Fuse S1— Key Switch X21— Monitor Controller 36-Pin G1—Battery S3— Pilot Shutoff Switch 1 Connector B G2—Battery S4— Pilot Shutoff Switch 2 G3—Alternator S6— Engine Stop Switch
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: pilot shutoff switches 1 and 2 (S3 and S4), pilot shutoff switch diode (V20), pilot shutoff solenoid (Y10), pilot shutoff solenoid relay (K2), security relay (K5), monitor controller (DSZ) (A4), security diode (V4), engine stop switch (S6), and start relay diode (V7). With key switch (S1) in the ON position, current is applied from key switch pin M supplying key cut relay (K13) through idle stop 5 A fuse (F18). Utilizing the normally closed contacts of key cut relay, power is passed through pin 3 of key cut relay, through the 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 alternator 65 A fuse (F60), providing power to pin B of alternator (G3). Power from pin B of alternator passes through solenoid 20 A fuse (F4) to pilot shutoff solenoid relay (K2), security relay (K5), and pilot shutoff solenoid (Y10). When the pilot shutoff lever is moved to the unlocked (DOWN) position, pin 10 of DSZ connector B (X21) detects ground through pilot shutoff switch diode (V20), indicating that both pilot shutoff switches are in the same position. This allows the monitor to diagnose if there is a malfunction with one of the switches. When pilot shutoff solenoid relay is excited, the ground circuit in the pilot shutoff solenoid is connected to ground through pilot shutoff solenoid relay and security relay, thus energizing the solenoid allowing pressure oil from the pilot pump to be supplied to the pilot valve.
X22— Monitor Controller 16-Pin Connector D X33— Cab Harness-to-Main Controller 17-Pin Connector C X36— Cab Harness-to-Main Controller 26-Pin Connector E Y10— Pilot Shutoff Solenoid
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) and engine stop switch (S6), 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 13 of cab harness-to-main controller 26-pin connector F (X36) 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 16 of DSZ connector D (X22) is grounded, energizing the starter cut relay (K4) and security relay (K5) through security diode (V4) and engine stop switch (S6). Energized security relay removes ground to pilot shutoff solenoid relay. If pilot shutoff lever is in the unlocked (DOWN) position (pilot shutoff solenoid relay energized), the ground path to the pilot shutoff solenoid (Y10) is broken, preventing the pilot hydraulics from being enabled (unlocked). This keeps the machine from being operated when the security system is active.
DW9628,0000529 -19-30AUG12-2/2
TM12660 (18APR18)
9015-15-59
041818
PN=563
Sub-System Diagnostics
Attachment Control Circuit Theory of Operation TO F60 ALTERNATOR 65A FUSE
RED/YEL
2
B60 ATTACHMENT PRESSURE SENSOR
3
B61 ARM OUT PRESSURE SENSOR
2 3
BLK/YEL
RED/YEL
BLU/RED
3
1
RED/YEL
BLK/YEL
WHT
2
1
B32 FRONT ATTACHMENT PRESSURE SENSOR
Y44 FLOW RATE ADJUSTMENT SOLENOID VALVE (NOT USED)
BLK/YEL
1
F5 TRAVEL ALARM 5A FUSE
1
BLK/YEL
WHT/YEL
WHT/VLT
F25 D17 F16
D18
B12
B11
WHT/YEL
ORG/BLU
D14
BLK
BLK/YEL
D=X34 F=X36
RED/YEL
A=X31 B=X32 C=X33
BLU/RED
2
Y38 ATTACHMENT RELIEF SOLENOID
2 1
Y39 ATTACHMENT RELIEF SOLENOID 2
2 1
1
1
2
2
X46
WHT/YEL
Y41 SECONDARY RELIEF SOLENOID VALVE
Y40 SELECTOR VALVE SOLENOID VALVE
TX1117847
WHT/YEL
Y43 2-SPEED ACTIVATION SOLENOID VALVE
TX1117847 —UN—16JUL12
GRY
1
8
C3 BLK
ORG/BLU
2
4
C4 GRY
6
RED
2
B24
LT GRN/BLK
WHT/BLU
5
B23
BLU/YEL
BLK/GRN
1 YEL/RED
GRN/BLU
B21
BRN
B22
GRN/RED
B15
WHT
A3 MAIN CONTROLLER (MCZ)
B16
Attachment Control Circuit Schematic
Continued on next page
TM12660 (18APR18)
9015-15-60
DW9628,000052A -19-04NOV13-1/8
041818
PN=564
Sub-System Diagnostics A3—Main Controller (MCZ) X31— Cab Harness-to-Main B32— Front Attachment Pressure Controller 31-Pin Sensor Connector A B60— Attachment Pressure X32— Cab Harness-to-Main Sensor Controller 24-Pin B61— Arm Out Pressure Sensor Connector B F5— Travel Alarm 5 A Fuse X33— Cab Harness-to-Main (marked OPT. 1 ALT) Controller 17-Pin F60— Alternator 65 A Fuse Connector C X34— Cab Harness-to-Main Controller 30-Pin Connector D
The main controller (MCZ) (A3) and monitor allow for the selection of up to 11 attachments plus the standard dig mode. Only one attachment mode may be selected at one time. The machine will return-to-dig mode when the machine is powered down and restarted; however, this can be changed with MPDr, Service ADVISOR™, and the monitor to return the machine to the attachment that was last selected when the machine was powered down. Each attachment selection (1—11) can be customized using MPDr, Service ADVISOR™ , and the monitor. To customize options in the monitor, see Service Menu. (Group 9015-16.) MPDr and Service ADVISOR™ can adjust:
• Attachment name • Attachment number • Pump flow • Engine speed • Secondary relief selection
X36— Cab Harness-to-Main Controller 26-Pin Connector F X46— Attachment Connector Y38— Attachment Relief Solenoid Y39— Attachment Relief Solenoid 2 Y40— Selector Valve Solenoid Valve
Y41— Secondary Relief Solenoid Valve Y43— 2-Speed Activation Solenoid Valve Y44— Flow Rate Adjustment Solenoid Valve (not used)
• Return oil flow selection • 2-Speed selection • Accumulator selection The monitor can slightly adjust pump 2 flow rate or boom up, arm in, swing and travel priority over attachment flow depending on the options selected. To view the attachment specifications on the monitor, select an attachment from the work mode menu. The monitor will display:
• Attachment name (Breaker, Crusher, Pulverizer, Vibrating Hammer, other)
• Attachment number (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11) • Pump flow • Engine speed • Secondary relief selection (ON or OFF) • Return oil flow selection (O/T or C/V) • 2-Speed selection (ON or OFF) • Accumulator selection (ON or OFF)
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-15-61
DW9628,000052A -19-04NOV13-2/8
041818
PN=565
Sub-System Diagnostics
Attachment Name—The available attachment names are as follows:
• Breaker 1—Hydraulic Breaker 1 (BR) • Breaker 2—Hydraulic Breaker 2 (BR) • Crusher 1—Primary Crusher 1 (CR) • Pulverizer 1—Secondary Crusher 1 (PU) • Vibratory Hammer 1—Vibrating Hammer 1 (VI) • Other 1—Other Equipment (UN) • [Removal from monitor screen—(Non)] Crusher 1—Primary Crusher 1 (CR) is considered a heavier crusher than Pulverizer 1—Secondary Crusher 1 (PU). When Crusher 1—Primary Crusher is selected, more priority is given to boom, arm, swing and travel functions over the attachment function in a combined arm out, arm out boom up, swing or travel function and attachment function. 5— ATT4 (attachment 4) 6— Attachment Name 7— Attachment Number
TX1088890A —UN—01MAR11
1— Dig Mode 2— ATT1 (attachment 1) 3— ATT2 (attachment 2) 4— ATT3 (attachment 3)
Work Mode Screen Continued on next page
TM12660 (18APR18)
9015-15-62
DW9628,000052A -19-04NOV13-3/8
041818
PN=566
Sub-System Diagnostics
Attachment Number—Each attachment can be assigned a number from 1—5. Each attachment also has a dynamic number that is user defined to help differentiate attachments with the same name. For example, ATT1 (attachment 1) and ATT2 (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. ATT2 (attachment 2) breaker 1 could be changed to ATT2 (attachment 2) breaker 2 (3, 4, or 5) to distinguish between the beakers for ATT1 (attachment 1) and ATT2 (attachment 2).
TX1088891A —UN—01MAR11
8— ATT1 Type (attachment 1)
Attachment Type Continued on next page
TM12660 (18APR18)
9015-15-63
DW9628,000052A -19-04NOV13-4/8
041818
PN=567
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, pump 2, and pump 3 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
Attachment Adjustment—Pump Flow Rate 9— ATT 1 Pump 1 Maximum Flow Rate
measured using a flowmeter to accurately set pump flow. See Pump Flow Test (Group 9025-25) and See Service Menu. (Group 9015-16.)
Continued on next page
TM12660 (18APR18)
9015-15-64
DW9628,000052A -19-04NOV13-5/8
041818
PN=568
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
TM12660 (18APR18)
9015-15-65
DW9628,000052A -19-04NOV13-6/8
041818
PN=569
Sub-System Diagnostics
NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.
2-Speed Selector and Auxiliary Flow Combiner Valve—If Equipped—The 2-speed selector icon on the monitor controls the 2-speed activation solenoid valve (Y43). The 2-speed activation solenoid valve is powered by travel alarm 5 A fuse (F5) and grounded by the main controller (MCZ) pin 3. The flow rate adjustment solenoid valve is powered by MCZ pin 7 and grounded by pin 23. When activated, the 2-speed activation solenoid valve sends pilot oil to the bypass shutoff valve blocking hydraulic oil from pump 1 from returning to the hydraulic oil tank. The activated 2-speed activation solenoid valve also sends pilot oil to the auxiliary flow combiner valve to combine oil flow from pump 1 with that of pump 2. This allows for combined oil flow from pump 1 and pump 2 to operate the attachment. When 2-speed is activated, the flow rate adjustment solenoid valve can also be activated. When an arm out, boom up, swing or travel function is actuated in combination with the attachment function, the flow rate adjustment solenoid valve is activated. When the flow rate adjustment solenoid valve is activated, pilot oil is routed to the auxiliary flow rate control valve. This adjusts the auxiliary flow rate control valve to provide more or less priority to the arm out, boom up, swing and travel functions over the attachment function. The main controller (MCZ) can vary the signal to the flow rate adjustment solenoid
TX1088898A —UN—01MAR11
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 travel alarm 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 dig mode (no attachment selected).
ATT 1 Selector Valve 12— ATT 1 Selector Valve Setting
valve to vary the pilot oil pressure at the auxiliary flow rate control valve. This allows for adjustment of the priority of the attachment function over arm out, boom up, swing and travel. The 2-speed selector status can be adjusted for each attachment using MPDr, Service ADVISOR™, and the monitor. Adjustments to the priority level can be made in the monitor in the attachment adjustment menu. See Service Menu. (Group 9015-16.)
Continued on next page
TM12660 (18APR18)
9015-15-66
DW9628,000052A -19-04NOV13-7/8
041818
PN=570
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 travel alarm 5 A fuse (F5) and is grounded by the main controller (MCZ) pin 16. 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.
TX1088896A —UN—01MAR11
11— ATT 1 Relief Valve Setting
ATT 1 Relief Valve DW9628,000052A -19-04NOV13-8/8
TM12660 (18APR18)
9015-15-67
041818
PN=571
Sub-System Diagnostics
TM12660 (18APR18)
9015-15-68
041818
PN=572
Group 16
Monitor Operation Service Menu How to Display Service Menu 1. Turn key switch (2) to 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). NOTE: The service menu option will now be displayed at the bottom of the main menu.
1. 2. 3. 4. 5. 6. 7. 8. 9.
TX1086439A —UN—03JAN11
3. Rotate monitor dial and highlight service menu. Press monitor dial to access the following systems: Troubleshooting Monitoring Controller Version Issued Warning Record Operation Machine Setting Monitor Setting Engine Setting Exhaust Filter No.
Right Console Panel
4. 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
JB3888,0000670 -19-12APR13-1/1
• 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
RH60123,000098C -19-20JUN12-1/1
TM12660 (18APR18)
9015-16-1
041818
PN=573
Monitor Operation
Monitoring
• Engine • Main • Wiper/Light • Air Conditioner • Start • Clear (Hold)
NOTE: Items listed in the monitoring section may not be in the same order as the monitor on the machine. 1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight monitoring. Press monitor dial to enter the monitoring menu.
4. Press the monitor dial to select the monitoring item to be viewed in the “Start” monitoring system.
3. Rotate monitor dial to highlight a system in the following monitoring selections: NOTE: * Optional List of Engine Monitoring Items Item
Unit
Data
Coolant Temp (Meter)
°C
Input signal from coolant temperature sensor (coolant temperature gauge)
Target Engine Speed
min-1
Target engine speed signal to ECU
Engine Torque
%
Input signal from ECU
Actual Engine Speed
min-1
Input signal from crank speed sensor and cam angle sensor
Boost Pressure
kPa
Input signal from boost pressure signal
3
Target Fuel Injection Qty
mm /st
Input signal from ECU
Starter Switch
OFF/ON
Key switch ON/OFF status
Air Cleaner Restriction Switch
OFF/ON
Clogged air filter status
Muf/Fltr Switch
OFF/ON
Exhaust filter regeneration switch OFF/ON status
Engine Stop Switch
OFF/ON
Engine stop switch OFF/ON status
Common Rail Fuel Pressure
MPa
Input signal from common rail pressure sensor
Directed Engine Speed
min-1
Input signal from engine speed dial
Starter Cutoff Relay Signal
OFF/ON
Starter cutoff relay OFF/ON status
Common Rail Pressure DP
MPa
Input signal from common rail pressure sensor
Coolant Temperature
°C
Input signal from coolant temperature sensor
Fuel Temperature
°C
Input signal from fuel temperature sensor
Supply Pump Inlet Pressure
kPa
Input signal from suction control valve
Engine Oil Pressure
kPa
Input signal from oil pressure sensor
Atmospheric Pressure
kPa
Input signal from atmospheric pressure sensor
Intake Air Temperature
°C
Input signal from intake-air temperature sensor
Muf/Fltr EGP PD
kPa
Input signal from exhaust filter differential pressure sensor
Boost Temperature
°C
Input signal from boost temperature sensor
IAT in Manifold
°C
Input signal from intake air sensor
Muf/Fltr Inlet EGT
°C
Input signal from exhaust temperature sensor (DOC)
Muf/Fltr Catalyst Inlet EGT
°C
Input signal from exhaust temperature sensor (DPF)
EGR Gas Temperature
°C
Input signal from exhaust gas recirculation (EGR) valve sensor
Battery Voltage Muf/Fltr Inlet EGT Level
V -
Exhaust temperature level of exhaust filter inlet
EGR Opening Amount 1
%
Input signal from ECU
ITH Opening Amount
%
Input signal from ECU
EGR Opening Amount 2
%
Input signal from ECU
Actual Turbo Opening Amt
%
Input signal from ECU
Input signal from ECU
NOTE: * Optional Continued on next page
TM12660 (18APR18)
9015-16-2
RH60123,000098D -19-25NOV13-1/5
041818
PN=574
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
Regen Enable Signal
OFF/ON
Regen enable signal ON/OFF status
Demand Engine Speed
min-1
Input signal from engine control dial
Actual Engine Speed
min-1
Input signal from ECU
Engine Speed Deviation
min-1
Difference between actual engine speed and requested engine speed
EC Dial
V
Input signal from engine control dial
Hydraulic Oil Temperature
°C
Input signal from hydraulic oil temperature sensor
Electric Lever Signal 1*
V
Input signal from electric lever 1 (right) (assist)
Hydraulic Oil Temperature (Pilot)*
°C
Input signal from hydraulic oil temperature sensor (for electric lever)
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 3 Flow Rate
L
Command signal to maximum pump 3 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
Tgt Pump 3 Displacement
cm3
Calculation signal from engine speed and input signal from pump 3 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 3 Load Factor
%
Calculation signal from engine speed and input signal from pump 3 delivery pressure sensor
Pump 1 Delivery Pressure
MPa
Input signal from pump 1 delivery pressure sensor
Pump 2 Delivery Pressure
MPa
Input signal from pump 2 delivery pressure sensor
Pump 3 Delivery Pressure
MPa
Input signal from pump 3 delivery pressure sensor
ADD Pump Delivery Pressure*
MPa
Input signal from ADD pump delivery pressure sensor
Pump 1 Control Pressure
MPa
Input signal from pump 1 control pressure sensor
Pump 2 Control Pressure
MPa
Input signal from pump 2 control pressure sensor
Pump 3 Control Pressure
MPa
Input signal from pump 3 control pressure sensor
Boom Cyl Bottom Pressure*
MPa
Input signal from boom bottom pressure sensor
Boom Cyl Rod Pressure*
MPa
Input signal from boom rod pressure sensor
Boom Raise Pilot Pressure
MPa
Input signal from pressure sensor (boom raise)
Bucket Roll-In Pilot Press
MPa
Input signal from pressure sensor (bucket roll-in)
Arm Roll-In Pilot Pressure
MPa
Input signal from pressure sensor (arm 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) (assist)
ATT 1 Pilot Pressure*
MPa
Input from pressure sensor (auxiliary 1)
ATT 2 Pilot Pressure*
MPa
Input from pressure sensor (auxiliary 2)
Arm Roll-Out Pilot Pressure*
MPa
Input from pressure sensor (arm roll-out) Continued on next page
TM12660 (18APR18)
9015-16-3
RH60123,000098D -19-25NOV13-2/5
041818
PN=575
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
Pump 1&2 Torque P/S O/P
MPa
Control signal tp pump 1 and 2 torque control solenoid valve
Pump 3 Torque P/S Output
MPa
Control signal to pump 3 torque control solenoid valve
Pump 2 Flw Limit P/S O/P
MPa
Control signal to maximum pump 2 flow rate limit control solenoid valve
Arm 2 Flw Cont P/S Output
MPa
Control signal to 5-spool solenoid valve unit (SD)
Arm Regen P/S Output
MPa
Control signal to 5-spool solenoid valve unit (SC)
Pressure Boost P/S Output
MPa
Control signal to 5-spool solenoid valve unit (SI)
Digging Regen P/S O/P
MPa
Control signal to 5-spool solenoid valve unit (SF)
Muf/Fltr Regen P/S O/P (SJ)
MPa
Control signal to 2-spool solenoid valve unit (SJ)
Muf/Fltr Regen P/S O/P (SZ)
MPa
Control signal to 2-spool solenoid valve unit (SZ)
Arm 1 Flw Cont P/S Output
MPa
Control signal to 5-spool solenoid valve unit (SE)
OPT Cont 1 P/S (E/L) O/P*
MPa
Control signal to solenoid valve for electrical lever
OPT Cont 2 P/S (E/L) O/P*
MPa
Control signal to solenoid valve for electrical lever
Pump 1 Flw Limit P/S Output
MPa
Control signal to maximum pump 1 flow rate limit control solenoid valve
Pump 3 Flw Limit P/S Output
MPa
Analog Output 14
MPa
Control signal to maximum pump 3 flow rate limit control solenoid valve -
Analog Output 15
MPa
-
Analog Output 16
MPa
-
Auxil Flw Cont P/S Output
MPa
Control signal to auxiliary flow rate control signal valve
ATT Relief 1 P/S Output*
MPa
Control signal to auxiliary flow rate control solenoid valve
ATT Relief 2 P/S Output*
MPa
Control signal to auxiliary flow rate control solenoid valve
Breaker Relief PS Output*
MPa
Control signal to breaker relief solenoid valve
Pump 1&2 Torque P/S O/P FB
mA
Feedback from pump 1 and 2 torque control solenoid valve output
Pump 3 Torque P/S Output FB
mA
Feedback from pump 3 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 2 Flw Cont P/S O/P FB
mA
Feedback from 5-spool solenoid valve unit (SD) output
Arm Regen P/S Output FB
mA
Feedback from 5-spool solenoid valve unit (SC) output
Pressure Boost P/S Output FB
mA
Feedback from 5-spool solenoid valve unit (SI) output
Digging Regen P/S O/P FB
mA
Feedback from 5-spool solenoid valve unit (SF) output
Muf/Filtr Regen P/S O/P (SJ) FB
mA
Feedback from 2-spool solenoid valve unit (SJ) output
Muf/Filtr Regen P/S O/P (SZ) FB
mA
Feedback from 2-spool solenoid valve unit (SZ) output
Arm 1 Flw Cont P/S O/P FB
mA
Feedback from 5-spool solenoid valve unit (SE) output
OPT Cont 1 P/S (E/L) O/P FB*
mA
Feedback from solenoid valve for electrical lever output
OPT Cont 2 P/S (E/L) O/P FB*
mA
Feedback from solenoid valve for electrical lever output
Pump 1 Flw Limit P/S O/P FB
mA
Feedback from maximum pump 1 flow rate limit control solenoid valve output Continued on next page
TM12660 (18APR18)
9015-16-4
RH60123,000098D -19-25NOV13-3/5
041818
PN=576
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
Pump 3 Flw Limit P/S O/P FB
mA
Analog Output FB 14
mA
Feedback from maximum pump 3 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
Brk 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 button 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
-
O/L Warning Buzzer SW*
OFF/ON
Overload alarm switch ON/OFF status
Crane Initializing Switch*
OFF/ON
Digital Input 8
OFF/ON
ML initializing switch ON/OFF status -
Digital Input 23
OFF/ON
-
Digital Input 22
OFF/ON
-
Digital Input 21
OFF/ON
-
Digital Input 20
OFF/ON
-
Digital Input 19
OFF/ON
-
Digital Input 18
OFF/ON
-
Digital Input 17
OFF/ON
-
Line Filter Restriction SW*
OFF/ON
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
Overload alarm ON/OFF status
Swing Alarm
OFF/ON
Swing alarm ON/OFF status
Travel Alarm
OFF/ON
Travel alarm ON/OFF status
Bucket Lock Valve
OFF/ON
Bucket roll-out pilot shut off solenoid valve ON/OFF status
Auto Shut-Down Relay
OFF/ON
ON/OFF Valve Output 11
OFF/ON
Auto shut-down relay ON/OFF statue -
ON/OFF Valve Output 10
OFF/ON
-
ON/OFF Valve Output 9
OFF/ON
-
Regeneration Inhibit Light
OFF/ON
Continued on next page
TM12660 (18APR18)
9015-16-5
RH60123,000098D -19-25NOV13-4/5
041818
PN=577
Monitor Operation List of Main Controller Monitoring Items Item
Unit
Data
Selector Valve Connection
0: Unset 1: Connection 2: Uncoupled Connection
Selector valve control solenoid valve connection status
Auxil Flw Combiner Valve Connection
0: Unset 1: Connection 2: Uncoupled Connection
Auxiliary flow combiner control solenoid valve connection status
Boom Angle*
V
Input signal from boom angle sensor
Arm Angle*
V
Input signal from arm angle sensor
NOTE: * Optional 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
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
List of Air Conditioner Unit Monitoring Items
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. RH60123,000098D -19-25NOV13-5/5
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. RH60123,000098E -19-20JUN12-1/1
TM12660 (18APR18)
9015-16-6
041818
PN=578
Monitor Operation
Issued Warning Record 1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight Issued Warning Record. Press monitor dial to enter the issued warning record menu.
3. The logo and trouble of 10 alarms that were issued recently will be displayed. See Main Menu—Alarm List. (Operator’s Manual.) 4. Highlight alarm and press monitor dial to view the time of when the alarm occurred and was solved. 5. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.) JB3888,000067F -19-12APR13-1/1
Operation 1. Access service menu. See Service Menu. (Group 9015-16.)
2. Rotate monitor dial to highlight Operation. Press monitor dial to enter operation menu. 3. The hour meters will be displayed.
Hour Meters Hour 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.) RH60123,0000990 -19-20JUN12-1/1
Side Monitor Operation
1. Press power button to turn side monitor on.
IMPORTANT: Side monitor and camera lens surfaces are a resin product. Lightly wipe the surface with a wet, clean cloth to avoid abrasions. Never use an organic solvent.
2. Press screen changeover button to display an image or images as follows:
NOTE: For a clear image, clean camera lens and monitor display before operating machine.
• Image from rear camera only. • Image from side camera only. • Image from rear camera and side camera (displayed side by side).
MB00333,000024A -19-04APR16-1/1
TM12660 (18APR18)
9015-16-7
041818
PN=579
Monitor Operation
Machine Setting
3. Rotate monitor dial to highlight a setting in the machine setting selections. Press monitor dial to change machine setting.
1. Access service menu. See Service Menu. (Group 9015-16.) 2. Rotate monitor dial to highlight Machine Setting. Press monitor dial to enter machine setting menu.
List of Machine Setting Items (Constant Change) Item
Unit
Data
ECO Control Suspend
0, 1
Setting of ECO control (casual deactivation). 0: Enable Casual Deactivation
WU Control Suspend
0, 1
Setting of auto warming-up (casual deactivation). 0: Hydraulic oil/coolant temperature auto warming-up control enable 1: Hydraulic oil/coolant temperature auto warming-up control casual deactivation
Li Speed
min-1
Adjustment of slow idle speed.
WU Speed
min-1
Adjustment of auto warming-up engine speed.
Al Speed
min-1
Adjustment of auto-idle engine speed.
PWR Mode Speed
min-1
Adjustment of PWR mode fast idle engine speed.
ECO Control Selection
0, 1
ON/OFF of ECO Control. 0: OFF 1: ON
Power Mode Memory Selection
0, 1
Setting of power mode with key switch on. 0: OFF (In case power mode is ECO mode with the key switch ON.) 1: On (The power mode when turning the key switch OFF is kept.)
Heater Control Selection
0, 1
ON/OFF of heater control. 0: OFF 1: ON
Work Mode Memory Selection
0, 1
Setting of attachment mode with key switch ON. 0: OFF (Attachment mode is bucket (digging) mode when turning the key switch ON.) 1: ON (Attachment mode when turning the key switch OFF is kept.)
Power Mode Selection
0—2
Setting of power mode selection. 0: ECO, PWR mode: Selected 1: ECO mode: Fixed 2: PWR mode: Fixed
Auto Shut-Down Control
0—2
Setting of auto shut-down control with the key switch ON. 0: OFF when starting 1: ON when starting 2: Previous setting is held
Auto Shut-Down Set Time Holding
0, 1
The time until starting shut-down control is held. 0: Settable 1: Unsettable
Continued on next page
TM12660 (18APR18)
9015-16-8
RH60123,0000991 -19-23APR13-1/4
041818
PN=580
Monitor Operation List of Machine Setting Items (Constant Change) Item
Unit
Data
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 (75US class) (with an air conditioner) 6: US Cab (75US class) (without an air conditioner) 7: US Cab (135US class) (with an air conditioner) 8: US Cab (135US class) (without an air conditioner) 9: US Cab (225US class) (with an air conditioner) 10: US Cab (225US class) (without an air conditioner)
Selector Valve Open Circuit Detection
0, 1
ON/OFF of malfunction evaluation. 0: OFF 1: ON
ATT Speed Deceleration Waiting Time
ms
The time when the increased engine speed is held at attachment operation speed increase control.
List of Adjustment (Constant Change) Item
Unit
Initial Value
0, 1
Minimum Adjustment -
Adjustable Range
ECO Control Suspend
0, 1
0
WU Control Suspend
0, 1
-
0, 1
0
Li Speed
min-1
10
0—400
0
WU Speed
-1
min
10
-600—200
0
Al Speed
min-1
10
-250—400
0
PWR Mode Speed
min-1
-200—0
0
ECO Control Selection
0, 1
10 -
0, 1
1
Power Mode Memory Selection
0, 1
-
0, 1
0
Heater Control Selection
0, 1
-
0, 1
1
Work Mode Memory Selection
0, 1
-
0, 1
1
Power Mode Selection
0—2
-
0—2
0
Auto Shut-Down Control
0—2
-
0—2
0
Auto Shut-Down Set Timing 0, 1 Holding
-
0, 1
0
-
0—10
1
-
0,1
0
40
0—300
0
Air Conditioner Control Mode
0—10
Selector Valve Open Circuit 0,1 Detection ms ATT Speed Deceleration Waiting Time
Continued on next page
TM12660 (18APR18)
9015-16-9
RH60123,0000991 -19-23APR13-2/4
041818
PN=581
Monitor Operation List of Setting Item (Attachment Constant Change) Item
Unit
Data
ATT 1 Type
0—7
Kinds of attachments: 0: Unset 1: Breaker 2: Pulverizer 3: Crusher 4: Vibrating Hammer 5: Others 6: Grapple 7: Clamshell
ATT1 No.
1—5
Selection of attachments setting No. 1: 1 2: 2 3: 3 4: 4 5: 5
ATT1 Pump 1 Maximum Flow Rate
L/min
Adjustment of maximum pump 1 flow rate when using attachment.
ATT1 Pump 2 Maximum Flow Rate
L/min
Adjustment of maximum pump 2 flow rate when using attachment.
ATT1 Pump 3 Maximum Flow Rate
L/min
Adjustment of maximum pump 3 flow rate when using attachment.
ATT1 Engine Speed
min-1
Adjustment of engine speed when using attachment.
ATT1 Relief Valve
0—2
Selection of breaker relief solenoid valve, auxiliary overload relief solenoid valve. 0: Both are disabled 1: ATT relief is enabled 2: Breaker relief is enabled
ATT1 Selector Valve*
0, 1
Selection of return circuit connection of selector valve. 0: C/V 1: O/T
ATT1 Auxiliary Flow Combiner Valve*
0, 1
Setting of auxilliary flow combiner valve selection. 0: OFF 1: ON
List of Adjustment (Attachment Constant Change) ATT1 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT1 Type
0—7
1
ATT1 No.
1—5
-
1—5
1
ATT1 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
ATT1 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT1 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT1 Engine Speed
min-1
0
0—2
10 -
-500—200
ATT1 Relief Valve
0—2
0
ATT1 Selector Valve*
0, 1
-
0, 1
1
ATT1 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
0
List of Adjustment (Attachment Constant Change) ATT2 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT2 Type
0—7
1
ATT2 No.
1—5
-
1—5
2
ATT2 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
Continued on next page
TM12660 (18APR18)
9015-16-10
RH60123,0000991 -19-23APR13-3/4
041818
PN=582
Monitor Operation List of Adjustment (Attachment Constant Change) ATT2 Item
Unit
Minimum Adjustment
Adjustable Range
Initial Value
ATT2 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT2 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT2 Engine Speed
min-1
0
0—2
10 -
-500—200
ATT2 Relief Valve
0—2
0
ATT2 Selector Valve*
0, 1
-
0, 1
1
ATT2 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
0
List of Adjustment (Attachment Constant Change) ATT3 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT3 Type
0—7
2
ATT3 No.
1—5
-
1—5
1
ATT3 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
ATT3 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT3 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT3 Engine Speed
min-1
0
0—2
10 -
-500—200
ATT3 Relief Valve
0—2
1
ATT3 Selector Valve*
0, 1
-
0, 1
0
ATT3 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
1
List of Adjustment (Attachment Constant Change) ATT4 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT4 Type
0—7
3
ATT4 No.
1—5
-
1—5
1
ATT4 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
ATT4 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT4 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT4 Engine Speed
min-1
0
0—2
10 -
-500—200
ATT4 Relief Valve
0—2
1
ATT4 Selector Valve*
0, 1
-
0, 1
0
ATT4 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
1
List of Adjustment (Attachment Constant Change) ATT5 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT5 Type
0—7
6
ATT5 No.
1—5
-
1—5
1
ATT5 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
ATT5 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT5 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT5 Engine Speed
min-1
0
0—2
10 -
-500—200
ATT5 Relief Valve
0—2
1 RH60123,0000991 -19-23APR13-4/4
TM12660 (18APR18)
9015-16-11
041818
PN=583
Monitor Operation List of Adjustment (Attachment Constant Change) ATT5 Item
Unit
Initial Value
0, 1
Minimum Adjustment -
Adjustable Range
ATT5 Selector Valve*
0, 1
0
ATT5 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
0
List of Adjustment (Attachment Constant Change) ATT6—11 Item
Unit
Initial Value
0—7
Minimum Adjustment -
Adjustable Range
ATT6—11 Type
0—7
0
ATT6—11 No.
1—5
-
1—5
0
ATT6—11 Pump 1 Maximum Flow Rate
L/min
0.5
74—212
212
ATT6—11 Pump 2 Maximum Flow Rate
L/min
0.5
74—212
212
ATT6—11 Pump 3 Maximum Flow Rate
L/min
0.5
42—189
189
ATT6—11 Engine Speed
min-1
-500—200
0
ATT6—11 Relief Valve
0—2
10 -
0—2
1
ATT6—11 Selector Valve*
0, 1
-
0, 1
0
ATT6—11 Auxiliary Flow Combiner Valve*
0, 1
-
0, 1
0 RH60123,0000991 -19-23APR13-5/4
TM12660 (18APR18)
9015-16-12
041818
PN=584
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
0: System Starting 1: HITACHI 2: John Deere 3: System Starting (fixed) 4: REC
Details -
1
Startup Screen Control
0: Auto-control: OFF 1: Auto-control: ON
-
1
Counterweight Remove/Install
0: Void 1: Exist
With or without function
1
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
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
1
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
0
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
TM12660 (18APR18)
9015-16-13
Initial Value
JB3888,0000672 -19-12APR13-1/2
041818
PN=585
Monitor Operation List of Monitor Setting Items Item
Unit
Details -
Initial Value
Operation Permission
0: Inhibited 1: Permission
Engine Oil
0: Un-displayed 1:0 Permission
Display
1
Engine Oil Filter
0: Un-displayed 1:0 Permission
Display
1
Hydraulic Oil
0: Un-displayed 1:0 Permission
Display
1
Pilot Hydraulic Oil Filter
0: Un-displayed 1:0 Permission
Display
1
Hydraulic Oil Full-Flow Filter
0: Un-displayed 1:0 Permission
Display
1
Pump Transmission Oil
0: Un-displayed 1:0 Permission
Display
1
Travel Reduction Gear Oil
0: Un-displayed 1:0 Permission
Display
1
Swing Reduction Gear Oil
0: Un-displayed 1:0 Permission
Display
1
Swing Drain Filter
0: Un-displayed 1:0 Permission
Display
1
Swing Bearing Grease
0: Un-displayed 1:0 Permission
Display
1
Air Cleaner Element
0: Un-displayed 1:0 Permission
Display
1
Fuel Filter
0: Un-displayed 1:0 Permission
Display
1
Air Conditioner Filter
0: Un-displayed 1:0 Permission
Display
1
Exhaust Filter
0: Un-displayed 1:0 Permission
Display
1
Line Filter
0: Un-displayed 1:0 Permission
Display
1
Water Separator Filter
0: Un-displayed 1:0 Permission
Display
1
User Setting 1
0: Un-displayed 1:0 Permission
Display
1
User Setting 2
0: Un-displayed 1:0 Permission
Display
1
Troubleshooting
0: Void 1: Exist
With or without function
1
Monitoring
0: Void 1: Exist
With or without function
1
Antenna Symbol
0: Void 1: Exist
With or without function
0
1
4. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.) JB3888,0000672 -19-12APR13-2/2
TM12660 (18APR18)
9015-16-14
041818
PN=586
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
• Manual Exhaust Filter Regeneration (Forcible) • Auto Exhaust Filter Regeneration • Fault Code Clear
Engine Setting 1. Access service menu. See Service Menu. (Group 9015-16.)
Press monitor dial to select an appropriate exhaust filter regeneration process.
2. Rotate monitor dial to highlight troubleshooting. Press monitor dial to enter the Troubleshooting menu.
4. Use the BACK button to return to the service menu. See Service Menu. (Group 9015-16.)
3. Rotate monitor dial to highlight the following:
• Manual Exhaust Filter Regeneration (Slow) JB3888,0000673 -19-12APR13-1/1
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.) JB3888,0000674 -19-12APR13-1/1
TM12660 (18APR18)
9015-16-15
041818
PN=587
Monitor Operation
TM12660 (18APR18)
9015-16-16
041818
PN=588
Group 20
References • Monitor (00) • 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 Main Controller (MCZ) Diagnostic Trouble
NOTE: The monitor can display up to 20 diagnostic trouble codes for each controller.
Codes. (Group 9001-10.)
• See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)
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:
• Engine (00) • Main (00)
• See Monitor Controller (DSZ) Diagnostic Trouble Codes. (Group 9001-30.)
• See Air Conditioner Controller (ACF) Diagnostic Trouble Codes. (Group 9001-40.)
5. Use the BACK button to return to the troubleshooting screen and select another system. DW9628,0000534 -19-03MAY12-1/1
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 DW9628,0000535 -19-30AUG12-1/1
TM12660 (18APR18)
9015-20-1
041818
PN=589
References
Service ADVISOR™ Connection Procedure Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 1. Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated.
TX1120365A —UN—14AUG12
2. Open left-side compartment behind cab and remove cap from diagnostic connector (1). 3. Connect service laptop (2) 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 4. 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. 5. Turn machine key switch to ON position.
Service ADVISOR™ Machine Connection (EDL shown) 1— Diagnostic Connector 2— Service Laptop 3— EDL-to-Service Laptop Cable
4— EDL 5— Diagnostic 9-Pin Connector Cable
6. 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.) Service ADVISOR is a trademark of Deere & Company DW9628,0000536 -19-22FEB13-1/1
TM12660 (18APR18)
9015-20-2
041818
PN=590
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
Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 1. Connect service laptop to machine. See Park and Prepare for Service Safely. (Group 9015-20.)
3. From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1). 4. Click the Connected Diagnostic Trouble Codes folder (2).
2. Open Service ADVISOR™ and display appropriate model information. Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9015-20-3
DW9628,0000537 -19-22FEB13-1/3
041818
PN=591
References
TX1002997A —UN—26JAN06
5. Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.
Connection Options Dialog Box
TX1003001A —UN—26JAN06
DW9628,0000537 -19-22FEB13-2/3
Select Readings Adapter Dialog Box 5— Available Adaptors Drop-Down List
6— Selected Models List
7— Change Selected Models Button
6. 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:
10. 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.
7. Make sure to select the correct machine to connect to in the displays section in the Selected Models list (6). If not, click the Change Selected Models button (7). 8. Click OK to connect to machine.
11. Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.
9. After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab (4) display. DW9628,0000537 -19-22FEB13-3/3
TM12660 (18APR18)
9015-20-4
041818
PN=592
References
Clearing Engine Diagnostic Trouble Codes
ECO
NOTE: Engine diagnostic trouble codes (DTCs) must be cleared using two separate menus. One menu will clear engine codes from engine control module (ECM) and the other will clear codes from monitor. 1. Access service menu on monitor. See Service Menu. (Group 9015-16.)
50.0h
10:00 AM
Service Menu
2. Select Engine Setting (5) on Service Menu screen.
10/10
Communication Terminal Status
5— Engine Setting Selection
Machine Setting Monitor Setting Engine Setting Muffler Filter No. CH1
24.0˚C
FM VOL
81.3 STMHz
TX1142903 —UN—27AUG13
5
Service Menu Screen Continued on next page
TM12660 (18APR18)
9015-20-5
MB00333,00001BB -19-07MAY14-1/6
041818
PN=593
References
3. Select Fault Code Clear (6) on Engine Setting screen.
ECO
6— Fault Code Clear Selection
50.0h
10:00 AM
Engine Setting 1/4
Manual Muffler Filter Regeneration (Slow) Manual Muffler Filter Regeneration (Forcible) Auto Muffler Filter Regeneration
CH1
24.0˚C
FM VOL
81.3 STMHz
TX1142905 —UN—27AUG13
6
Fault Code Clear
Engine Setting Screen Continued on next page
TM12660 (18APR18)
9015-20-6
MB00333,00001BB -19-07MAY14-2/6
041818
PN=594
References
4. Select check mark (7) on Fault Code Clear screen.
ECO
5. Select check mark again. Engine codes are now cleared from ECM.
50.0h
10:00 AM
6. Press Back button on right console panel until Service Menu screen displays.
Fault Code Clear
7— Check Mark
CH1
24.0˚C
FM VOL
81.3 STMHz
TX1142906 —UN—27AUG13
7
Fault Code Clear Screen Continued on next page
TM12660 (18APR18)
9015-20-7
MB00333,00001BB -19-07MAY14-3/6
041818
PN=595
References
7. Select Troubleshooting (8) on Service Menu screen.
ECO
8— Troubleshooting Selection
50.0h
10:00 AM
Service Menu 1/10 8
Troubleshooting Monitoring Controller Version
Operation CH1
24.0˚C
FM VOL
81.3 STMHz
TX1142907 —UN—01OCT13
Issued Warning Record
Service Menu Screen Continued on next page
TM12660 (18APR18)
9015-20-8
MB00333,00001BB -19-07MAY14-4/6
041818
PN=596
References
8. Select Engine (9) on Troubleshooting screen.
ECO
9— Engine Selection
50.0h
10:00 AM
Troubleshooting 1/ 5
(05)
Main
(00)
Monitor
(05)
Information
(01)
Air Conditioner
(00) CH1
24.0˚C
FM VOL
81.3 STMHz
9
TX1142909 —UN—30SEP13
Engine
Troubleshooting Screen Continued on next page
TM12660 (18APR18)
9015-20-9
MB00333,00001BB -19-07MAY14-5/6
041818
PN=597
References
9. Select Clear (10) on Main screen. Engine codes are now cleared from monitor.
50.0h
ECO
10— Clear Selection
10:00 AM
Engine
10007-02 10023-12
CLEAR
TX1142910 —UN—30SEP13
10005-02 10022-02 10026-15
10
CH1
24.0˚C
FM VOL
81.3 STMHz
Main Screen MB00333,00001BB -19-07MAY14-6/6
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. DW9628,0000538 -19-03MAY12-1/1
TM12660 (18APR18)
9015-20-10
041818
PN=598
References
MPDr Connection Procedure Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 1. Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is being operated. 2. Remove fuse box cover (1).
TX1119324A —UN—06AUG12
1— Cover
Fuse Box Cover DW9628,0000539 -19-22FEB13-1/2
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. 3. 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. 4. Turn machine key switch to the ON position. 5. Refer to the MPDr Operation Manual to complete connection procedure. 5— 4668565 RS232C Cable 6— USB-to-Serial Adapter Cable
TX1120375A —UN—14AUG12
2— MPDr Connector 3— Service Laptop 4— TH3100010 MPDr Cable
MPDr Connection Procedure (USB-to-serial adapter cable shown) DW9628,0000539 -19-22FEB13-2/2
TM12660 (18APR18)
9015-20-11
041818
PN=599
References
Fuse Test
F1— Work and Boom Lights 20 A Fuse (marked LAMP) F2— Windshield Wiper and Washer 10 A Fuse (marked WIPER) F3— Air Conditioner and Heater 20 A Fuse (marked HEATER) F4— Solenoid 20 A Fuse (marked SOLENOID) F5— Travel Alarm 5 A Fuse (marked OPT. 1 ALT) F6— 12 Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT) F7— Start Position Signal 5 A Fuse (marked START) F8— Engine Control Unit (ECU) 30 A Fuse (marked ECU) F9— Radio Backup 10 A Fuse (marked BACK UP) F10— Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F10 F9 F8 F7 F6 F5 F4 F3 F2 F1
F11— Not Used F12— Radio and Dome 5 A Fuse (marked RADIO) F13— Lighter 10 A Fuse (marked LIGHTER) F14— Monitor 5 A Fuse (marked MONITOR) F15— Cab Auxiliary Power Connector One 10 A Fuse (marked AUX) F16— Not Used F17— Power On 5 A Fuse (marked POWER ON) F18— Idle Stop 5 A Fuse (marked IDLE STOP) F19— Horn 10 A Fuse (marked HORN) F20— Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
F20 F19 F18 F17 F16 F15 F14 F13 F12 F11
TX1086711 —UN—28JUN13
Some symptoms may indicate an expensive component malfunction, when in fact a fuse has failed. Machine functions can be performed without test equipment to determine if fuses have failed. If certain circuits or components operate, fuses are considered to be OK.
Fuse Block 1
Fuse Test Fuse
Test
Results of Fuse Failure
F1—Work and Boom Lights 20 A Fuse (marked Turn key switch ON. LAMP) Turn light switch to first or second position. If work or boom lights operate, fuse is OK.
Work and boom lights will not operate.
F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER)
Turn key switch ON. Turn windshield wiper ON. If wiper operates, fuse is OK.
Windshield wiper will not operate.
F3—Air Conditioner and Heater 20 A Fuse (marked HEATER)
Turn key switch ON. Press blower speed switch. If blower operates in any speed, fuse is OK.
Heater or air conditioner blower will not operate.
F4—Solenoid 20 A Fuse (marked SOLENOID)
If hydraulic system functions normally, fuse is OK.
Travel and stick functions will not operate.
F5—Travel Alarm 5 A Fuse (marked OPT. 1 ALT)
Turn key switch to START. Place pilot shutoff lever to unlocked (DOWN) position. Push travel pedals or levers forward. If travel alarm sounds, fuse is OK.
Travel alarm will not operate.
F6—12 Volt Power Outlet 20 A Fuse (marked OPT. 2 ALT)
Check with multimeter.
12 volt power outlet will not operate.
F7—Start Position Signal 5 A Fuse (marked START)
If start aid works, fuse is OK.
Engine starts hard when cold. Start aid will not operate.
F8—Engine Control Unit (ECU) 30 A Fuse (marked ECU)
Turn key switch to START. If engine starts and display lights, fuse is OK.
Display will not light and engine will not start.
F9—Radio Backup 10 A Fuse (marked BACK UP)
Turn key switch to ON. If radio presets are retained, fuse is OK.
Radio will not retain presets.
F10—Data Converter and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
Turn engine ON. If monitor alarm does not sound continuously, fuse is OK.
Monitor alarm will sound continuously.
F12—Radio and Dome 5 A Fuse (marked RADIO)
Turn key switch ON. If radio operates, fuse is OK.
Radio and dome light will not operate.
F13—Lighter 10 A Fuse (marked LIGHTER)
Turn key switch ON. Push lighter. If lighter gets hot, fuse is OK.
Lighter will not operate.
Continued on next page
TM12660 (18APR18)
9015-20-12
DW9628,000053A -19-03MAY12-1/3
041818
PN=600
References F14—Monitor 5 A Fuse (marked MONITOR)
Turn key switch ON. If monitor operates, fuse is OK.
Monitor will not operate.
F15—Cab Auxiliary Power Connector One 10 A Fuse (marked AUX)
Check with multimeter.
Cab auxiliary power connector will not operate.
F16—Start Aid 5A Fuse (marked SA)
If start aid works, fuse is OK..
Glow Relay Switch start aid will not operate.
F17—Power On 5 A Fuse (marked POWER ON) Turn key switch to START. If engine starts, fuse is OK.
Engine will not start.
F18—Idle Stop 5 A Fuse (marked IDLE STOP)
Check with multimeter.
Controller feedback protection will not operate.
F19—Horn 10 A Fuse (marked HORN)
Horn will not operate. Turn key switch ON. Press horn switch. If horn operates, fuse is OK.
F20—Optional Equipment 5 A Fuse (marked OPT. 3 BATT)
Check with multimeter. Continued on next page
TM12660 (18APR18)
9015-20-13
Optional equipment will not operate. DW9628,000053A -19-03MAY12-2/3
041818
PN=601
F21— Heated Air Seat 10 A Fuse (marked SEAT HEATER) F22— Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT) F23— Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) F24— 12 Volt Power Unit 10 A Fuse (marked 12V UNIT) F25— IMOBI 5 A Fuse (marked IMOBI) F26— Quick Hitch 5 A Fuse (marked QUICK HITCH) F27— Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3) F28— Not Used F29— Not Used F30— Not Used
F31— Seat Compressor 10 A Fuse (marked SEAT COMPR) F32— Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2) F33— Warning Lamp 10 A Fuse (marked WARNING LAMP) F34— Cab Auxiliary Power Connector Two 10 A Fuse (marked AUX. 2) F35— Not Used F36— Not Used F37— Not Used F38— Not Used F39— Not Used F40— Not Used
F30 F29 F28 F27 F26 F25 F24 F23 F22 F21
F40 F39 F38 F37 F36 F35 F34 F33 F32 F31
TX1086712 —UN—28JUN13
References
Fuse Block 2 Fuse Test Fuse
Test
Results of Fuse Failure
F21—Heated Air Seat 10 A Fuse (marked SEAT HEATER)
Check with multimeter.
Optional equipment will not operate.
F22—Front Cab Light One 10 A Fuse (marked CAB LAMP FRONT)
Check with multimeter.
Optional equipment will not operate.
F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
Check with multimeter.
Optional equipment will not operate.
F24—12 Volt Power Unit 10 A Fuse (marked 12V UNIT)
Check with multimeter.
Optional equipment will not operate.
F25—IMOBI 5 A Fuse (marked IMOBI)
Check with multimeter.
Optional equipment will not operate.
F26—Quick Hitch 5 A Fuse (marked QUICK HITCH)
Check with multimeter.
Optional equipment will not operate.
F27—Cab Auxiliary Power Connector Three 5 A Fuse (marked AUX. 3)
Check with multimeter.
Optional equipment will not operate.
F31—Seat Compressor 10 A Fuse (marked SEAT COMPR)
Check with multimeter.
Optional equipment will not operate.
F32—Front Cab Light Two 10 A Fuse (marked CAB LAMP FRONT +2)
Check with multimeter.
Optional equipment will not operate.
F33—Warning Lamp 10 A Fuse (marked WARNING LAMP)
Check with multimeter.
Optional equipment will not operate.
F34—Cab Auxiliary Power Connector Two 10 A Check with multimeter. Fuse (marked AUX. 2)
Optional equipment will not operate.
Fuse Test Fuse
Test
Results of Fuse Failure
F60—Alternator 65 A Fuse
Check with multimeter.
Alternator will not charge electrical system.
F61—Battery 45 A Fuse
Turn key switch to START. If engine cranks, fuse is OK.
Engine will not crank.
F63—Glow Plug 50 A Fuse
Check with multimeter.
Engine starts hard when cold. Start aid will not operate.
F5002—Fuel Transfer Pump 15 A Fuse
Check with multimeter.
Engine will run out of fuel.
F6000—JDLink™ Unswitched Power 7.5 A Fuse
Check with multimeter.
JDLink will not operate.
F6001—JDLink™ Ground 7.5 A Fuse
Check with multimeter.
JDLink will not operate.
F6002—JDLink™ Switched Power 7.5 A Fuse
Check with multimeter.
JDLink will not operate.
JDLink is a trademark of Deere & Company DW9628,000053A -19-03MAY12-3/3
TM12660 (18APR18)
9015-20-14
041818
PN=602
References
Relay Test For location of relays:
• See Cab Harness (W1) Component Location. (Group 9015-10.)
T141788 —UN—27APR01
• See Machine Harness (W2) Component Location. (Group 9015-10.)
• See Heated Air Seat Harness (W14) Component Location. (Group 9015-10.)
• See Multi-Function Pilot Control Lever Harness (W15) Component Location. (Group 9015-10.)
• See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Relay Test
Connect a multimeter to terminals 1 and 2. About 420—460 ohms must be measured. If not, relay has failed.
CAUTION: Do not connect relay directly to battery. Use a fused power source such as auxiliary power connector (X25) in cab or external power supply.
Connect multimeter to terminals 3 and 4. Less than 0.4 ohms must be measured. If not, relay has failed. Connect multimeter to terminals 3 and 5, then 4 and 5. Multimeter must read open in both connections. If not, relay has failed.
Connect 24 volts (+) to terminal 1, ground (-) terminal 2. Connect multimeter to terminals 3 and 5. Multimeter must read less than 0.4 ohms. If not, relay has failed. DW9628,000053B -19-29AUG12-1/1
Glow Plug Relay Test
TX1087353A —UN—27JAN11
Disconnect glow plug relay (K16) from machine harness (W2). See Machine Harness (W2) Component Location. (Group 9015-10.) Connect 24 volts to terminal 1 and ground terminal 2. Listen for the relay to click. If relay clicks, relay is good. If no click replace relay. NOTE: When testing terminals 3 and 4 for continuity you must have terminals 1 and 2 connected to power and ground.
Glow Plug Relay
Measure continuity at terminal 3 and 4. If continuity is measured, relay is good. If no continuity is measured, replace relay.
1— Terminal 1 2— Terminal 2
3— Terminal 3 4— Terminal 4 DW9628,000064C -19-29AUG12-1/1
TM12660 (18APR18)
9015-20-15
041818
PN=603
References
Pressure Sensor Test Pressure Sensor Resistance Test 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. A suspect pressure sensor can be checked by switching positions with a known good sensor. If the problem follows the suspect pressure sensor, pressure sensor has malfunctioned. If the problem remains, the harness has malfunctioned. 3. To check a pressure sensor using a multimeter, remove pressure sensor from the machine. NOTE: Resistance values for pump 1 delivery pressure sensor (B35), pump 2 delivery pressure sensor (B37), and pump 3 delivery pressure sensor (B56) may vary widely. 4. To verify the sensor's functionality, use the on-board monitor or in Service ADVISOR™ check for diagnostic trouble codes (DTCs) to monitor the sensor's output. See Monitoring. (Group 9015-16.) See Service ADVISOR™ Diagnostic Application. (Group 9015-20.) 5. Measure resistance as indicated. Resistance may vary from one sensor to another. Pressure Sensor Resistance Ranges—Specification Pump 1 Control Pressure Sensor (B36)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Pump 2 Control Pressure Sensor (B38)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Pump 3 Control Pressure Sensor (B57)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Boom Up Pressure Sensor (B30)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Front Attachment Pressure Sensor (B32)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Travel Pressure Sensor (B34)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3)
Swing Pressure Sensor (B33)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Arm In Pressure Sensor (B31)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Bucket In Pressure Sensor (B39)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Attachment Pressure Sensor (B60)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Arm Out Pressure Sensor (B61)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Attachment Pressure Sensor 2 (B62)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Attachment Pressure Sensor 3 (B63)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3) Auxiliary Function Lever (AFL) Pressure Sensor (B85)—Resistance..................................................5—15 kΩ (pins 1—2) 30—50 kΩ (pins 2—3)
For location of pressure sensors:
• See Machine Harness (W2) Component Location. (Group 9015-10.)
• See Pump Harness (W8) Component Location. (Group 9015-10.)
• See Attachment Harness (W17) Component Location. (Group 9015-10.)
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location. (Group 9015-10.)
Pressure Sensor Voltage Test 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. No voltage at pressure sensors will generate DTCs. Disconnect harness connector from a pressure sensor.
Continued on next page
TM12660 (18APR18)
9015-20-16
DW9628,000053C -19-15MAR16-1/2
041818
PN=604
References
3. With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector. Pressure Sensor Voltage Ranges—Specification Pump 1 Control Pressure Sensor (B36)—Voltage............................................................ 4.5—5.5 V Pump 1 Delivery Pressure Sensor (B35)—Voltage........................................................................ 4.5—5.5 V Pump 2 Control Pressure Sensor (B38)—Voltage............................................................ 4.5—5.5 V Pump 2 Delivery Pressure Sensor (B37)—Voltage........................................................................ 4.5—5.5 V Pump 3 Control Pressure Sensor (B57)—Voltage............................................................ 4.5—5.5 V Pump 3 Delivery Pressure Sensor (B56)—Voltage........................................................................ 4.5—5.5 V Boom Up Pressure Sensor (B30)—Voltage............................................................ 4.5—5.5 V Arm In Pressure Sensor (B31)—Voltage........................................................................ 4.5—5.5 V Front Attachment Pressure Sensor (B32)—Voltage........................................................................ 4.5—5.5 V Travel Pressure Sensor (B34)—Voltage........................................................................ 4.5—5.5 V Swing Pressure Sensor (B33)—Voltage........................................................................ 4.5—5.5 V Bucket In Pressure Sensor (B39)—Voltage............................................................ 4.5—5.5 V Attachment Pressure Sensor (B60)—Voltage............................................................ 4.5—5.5 V Arm Out Pressure Sensor (B61)—Voltage........................................................................ 4.5—5.5 V
Attachment Pressure Sensor 2 (B62)—Voltage........................................................................ 4.5—5.5 V Attachment Pressure Sensor 3 (B63)—Voltage........................................................................ 4.5—5.5 V Auxiliary Function Lever (AFL) Pressure Sensor (B85)—Voltage........................................................................ 4.5—5.5 V
4. If voltage is lower than specification or no voltage is present, check wiring. IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification. Specification 100-Pin Connector (X3)—Torque.................................................................................10 N·m 89 lb·in
• See Cab Harness (W1) Wiring Diagram. (Group 9015-10.)
• See Machine Harness (W2) Wiring Diagram. (Group 9015-10.)
• See Pump Harness (W8) Wiring Diagram. (Group 9015-10.)
• See Attachment Harness (W17) Wiring Diagram. (Group 9015-10.)
• See 2-Speed Harness (W32) Wiring Diagram. (Group 9015-10.)
• See Auxiliary Function Lever (AFL) Solenoid
Harness (W76) Wiring Diagram. (Group 9015-10.)
Service ADVISOR is a trademark of Deere & Company DW9628,000053C -19-15MAR16-2/2
Solenoid Test 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem follows the suspect solenoid, solenoid has malfunctioned.
4. Measure resistance as indicated. Resistance may vary from one solenoid to another. Solenoid Resistance Ranges—Specification Pilot Shutoff Solenoid (Y10)—Resistance.................................................................... 42—58 Ω Secondary Pilot Shutoff Solenoid Valve (marked PiC) (Y66)—Resistance...................................................... 54.5—64.5 Ω
If the problem remains, the harness has malfunctioned. 3. To check a solenoid using an ohmmeter, remove solenoid from the machine.
For location of solenoids, see Pilot Shutoff Valve Harness (W21) Component Location and see Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location. (Group 9015-10.) DW9628,000062F -19-15MAR16-1/1
TM12660 (18APR18)
9015-20-17
041818
PN=605
References
Proportional Solenoid Test 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. A solenoid with a potential problem may be tested by switching connections with a known properly functioning solenoid. If the problem follows the solenoid, replace solenoid. If the problem remains, inspect connections and test appropriate harness.
• See Machine Harness (W2) Component Location. (Group 9015-10.)
• See Pump Harness (W8) Component Location. (Group 9015-10.)
• See Attachment Harness (W17) Component Location. (Group 9015-10.)
• See Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location. (Group 9015-10.)
3. Remove solenoid from machine prior to testing with an ohmmeter. 4. Measure resistance between pins on the solenoid and record results. Compare recorded resistance value to specification below. If solenoid is not within specification, replace solenoid. Main Controller Solenoids—Specification Exhaust Filter Regulator Solenoid (pump 1) (marked SZ) (Y12)—Resistance.................................................................... 20—24 Ω Exhaust Filter Regulator Solenoid (bypass cut-off valve) (marked SJ) (Y13)—Resistance.................................................................... 20—24 Ω Pump 2 Flow Rate Limit Solenoid (marked SB) (Y20)—Resistance.................................................................... 20—24 Ω Torque Control Solenoid (marked ST) (Y21)—Resistance.................................................................... 20—24 Ω
Dig Regenerative Solenoid (marked SF) (Y22)—Resistance.................................................................... 20—24 Ω Arm Regenerative Solenoid (marked SC) (Y23)—Resistance.................................................................... 20—24 Ω Power Dig Solenoid (marked SG) (Y24)—Resistance.................................................................... 20—24 Ω Arm 2 Flow Control Solenoid (marked SD) (Y27)—Resistance.................................................................... 20—24 Ω Pump 3 Torque Control Solenoid (marked SU) (Y28)—Resistance.................................................................... 20—24 Ω Arm 1 Flow Rate Control Solenoid (marked SE) (Y29)—Resistance.................................................................... 20—24 Ω Arm 3 Spool Control Solenoid (marked A2) (Y31)—Resistance.................................................................... 20—24 Ω Boom 3 Spool Control Solenoid (marked A1) (Y32)—Resistance.................................................................... 20—24 Ω Selector Valve Solenoid Valve (Y40)—Resistance.................................................................... 44—54 Ω Secondary Relief Solenoid Valve (Y41)—Resistance.............................................................. 17.5—21.5 Ω 2-Speed Activation Solenoid Valve (Y43)—Resistance.............................................................. 17.5—21.5 Ω Flow Rate Adjustment Solenoid Valve (Y44)—Resistance.............................................................. 17.5—21.5 Ω Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61)—Resistance.............................................................. 20—24 Ω Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62)—Resistance.............................................................. 20—24 Ω DW9628,000053E -19-15MAR16-1/1
TM12660 (18APR18)
9015-20-18
041818
PN=606
References Air Recirculation Sensor (B55) Ranges
Temperature Sensor Test SERVICE EQUIPMENT AND TOOLS JDG1478 Digital Multimeter
1. Park and prepare for machine service. See Park and Prepare for Service Safely. (Group 9000-01.)
Resistance
Temperature
9900 Ω
0°C 32°F
1600 Ω
40°C 104°F
Secondary Hydraulic Oil Temperature Sensor (B68) Ranges
2. To check a temperature sensor using a JDG1478 Digital Multimeter, remove sensor from machine. 3. Measure resistance as indicated. Resistance may vary from one sensor to another. Ambient Air Temperature Sensor (B22) Ranges
Resistance
Temperature
13 840—16 330 Ω
-20°C -4°F
5740 Ω
0°C 32°F
2320—2590 Ω
20°C 68°F
Resistance
Temperature
9900 Ω
0°C 32°F
1150 Ω
40°C 104°F
1600 Ω
40°C 104°F
584 Ω
60°C 140°F
310—326 Ω
80°C 176°F
Hydraulic Oil Temperature Sensor (B40) Ranges Resistance
Temperature
13 840—16 330 Ω
-20°C -4°F
5740 Ω
0°C 32°F
2320—2590 Ω
20°C 68°F
1150 Ω
40°C 104°F
584 Ω
60°C 140°F
310—326 Ω
80°C 176°F
• For ambient air temperature sensor (B22) and hydraulic
oil temperature sensor (B40) location, see Machine Harness (W2) Component Location. (Group 9015-10.) • For air recirculation sensor (B55) location, see Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.) • For secondary hydraulic oil temperature sensor (B68) location, see Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location. (Group 9015-10.)
DW9628,000053F -19-15MAR16-1/1
TM12660 (18APR18)
9015-20-19
041818
PN=607
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)
regulator/brush assembly. Replace brush/regulator assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 1. 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater1.
1. 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater2.
2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater1. 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). 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
2. With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater2. 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
TM12660 (18APR18)
16— To Display Module (indicator lamp)
9015-20-20
DW9628,0000540 -19-26FEB13-1/2
041818
PN=608
References
6. If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator
assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
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. DW9628,0000540 -19-26FEB13-2/2
TM12660 (18APR18)
9015-20-21
041818
PN=609
References
TM12660 (18APR18)
9015-20-22
041818
PN=610
References
Controller Area Network (CAN) Circuit Test TX1249917 —UN—26MAR18
W41 HEATER AND AIR CONDITIONER HARNESS
W1 CAB HARNESS
A = X20
9
E9
BLU
GRN
CAN 1 GRN
GRN
4
-
GRN
CAN 0 A24
BLU
132
A1 ENGINE CONTROL UNIT (ECU)
A2 VARIABLE GEOMETRY TURBOCHARGER (VGT)
GRN
A6 RADIO
15
16
GRN
110
BLU
88
A3 D2 D5 MAIN CONTROLLER D4 (MCZ)
BLU CAN 1 GRN
X42
BLU
= X15
BLU
D3
GRN
-
W30 DATA CONVERTER HARNESS
E3
120
12
GRN BLU
154
+
BLU CAN 1
+
+
A7 AIR CONDITIONER CONTROLLER (ACF)
A26
A23
GRN CAN 0
-
VLT/WHT
VLT/WHT
BLU
120
10
A25
CAN 1
120
CAN 1
BLU
CAN 0
BLU
-
10
120
VLT/RED
VLT/RED
X3 +
X52 11
W2 MACHINE HARNESS
A4 MONITOR CONTROLLER (DSZ)
CAN 0 GRN
BLU
GRN
B1
INTERFACE CAN GRN
C12
+
BLU
C6
120
B11
BLU CAN 1
R8 ENGINE CAN TERMINATION RESISTOR
B = X11
A5 DATA CONVERTER
W31 DATA CONVERTER INTERFACE HARNESS
W20 SERVICE ADVISOR™ HARNESS
BLU
D
BLU
7
BLU
GRN
3
GRN
4
GRN
8
BLU
CAN 0 GRN
C J
BLU
ENGINE CAN
INTERFACE CAN
+ 120
2
BLU
GRN
1
GRN
INTERFACE CAN
120
B
-
BLU
GRN
YEL
YEL
H1
LT GRN
H2
CAN 0 2
BLU 3
1
LT GRN
R11 INTERFACE CAN RESISTOR 2
A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROLLER
X6021
+
R10 INTERFACE CAN RESISTOR 1
A
1
GRN CAN 0
X72
INTERFACE CAN
GRN
W6004 JDLINK™ HARNESS
X6020
X71 BLU
BLK
-
GRN
A
GRN
BLU INTERFACE CAN
A
GRN
BLU
BLU
H
X1 SERVICE ADVISOR™ DIAGNOSTIC CONNECTOR
X70 B
BLU
ENGINE CAN
ENGINE CAN
- 120
2
BLU
GRN
A
BLU
C11
A11 MACHINE CONTROLLER (BCZ)
CAN 0
D = X34
CAN 0
GRN
-
1
GRN CAN 1
B
+
GRN
C5
GRN
1
YEL
YEL
G1
LT GRN
G2
INTERFACE CAN BLU
2
LT GRN
= X6014
TX1249917 Controller Area Network (CAN) Circuit Test Schematic
Continued on next page
TM12660 (18APR18)
9015-20-23
041818
PN=611
MB00333,0000394 -19-14MAR18-1/10
References
TM12660 (18APR18)
9015-20-24
041818
PN=612
References
A1—Engine Control Unit (ECU) A2—Variable Geometry Turbocharger (VGT) A3—Main Controller (MCZ) A4—Monitor Controller (DSZ) A5—Data Converter A6—Radio A7—Air Conditioner Controller (ACF) A11— Machine Controller (BCZ) A6000—Modular Telematics Gateway (MTG) Controller R8—Engine CAN Termination Resistor R10— Interface CAN Resistor 1
R11— Interface CAN Resistor 2 X3— Cab Harness-to-Machine W1—Cab Harness Harness 100-Pin Connector W2—Machine Harness X11— Machine Controller 20-Pin W20—Service ADVISOR™ Connector B Harness X15— Engine Control Unit W30—Data Converter Harness (ECU)-to-Machine Harness W31—Data Converter Interface 94-Pin Connector Harness X20— Monitor Controller 28-Pin W41—Heater and Air Conditioner Connector A Harness X34— Cab Harness-to-Main W6004—JDLink™ Harness Controller 30-Pin X1— Service ADVISOR™ Connector D Diagnostic Connector X42— CAN 1 Connector X52— Air Conditioner 10-Pin Connector X70— Data Converter Interface Connector
X71— Machine Harness-toService ADVISOR™ Harness 8-Pin Connector X72— Data Converter Interface Harness-to-Service ADVISOR™ Harness 3-Pin Connector X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector X6020—CAN 0 Connector (marked CAN) X6021—Interface CAN Connector (marked N-CAN)
Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company MB00333,0000394 -19-14MAR18-2/10
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.) MB00333,0000394 -19-14MAR18-3/10
Controller Area Network (CAN) Diagnostics Continued on next page
TM12660 (18APR18)
9015-20-25
MB00333,0000394 -19-14MAR18-4/10
041818
PN=613
References
• 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 MB00333,0000394 -19-14MAR18-5/10
• 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. MB00333,0000394 -19-14MAR18-6/10
• 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. Continued on next page
TM12660 (18APR18)
9015-20-26
MB00333,0000394 -19-14MAR18-7/10
041818
PN=614
References
• 4
CAN Resistor Check
Key switch in OFF position.
Disconnect the following resistors:
• Machine harness (W2). See Machine Harness (W2) Component Location. (Group 9015-10.) - Engine CAN termination resistor (R8).
• Data converter harness (W30). See Data Converter Harness (W30) Component Location. (Group 9015-10.) - Interface CAN resistor 1 (R10).
• Data converter interface harness (W31). See Data Converter Interface Harness (W31) Component Location. (Group 9015-10.) - Interface CAN resistor 2 (R11).
Measure the resistance of each resistor.
YES: Go to CAN Wire Voltage Check.
Is the resistance of each resistor between 110—130 ohms?
NO: Replace resistor. MB00333,0000394 -19-14MAR18-8/10
• 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. MB00333,0000394 -19-14MAR18-9/10
• 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. MB00333,0000394 -19-14MAR18-10/10
Electrical Component Checks The following checks can be used to test electrical components in all machine circuits.
See Park and Prepare for Service Safely. (Group 9000-01.) DW9628,0000541 -19-14AUG12-1/11
• 1
Component Checks
Continued on next page
TM12660 (18APR18)
9015-20-27
DW9628,0000541 -19-14AUG12-2/11
041818
PN=615
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 failed. Replace the key switch. See Key Switch Remove and Install. (Group 9015-20.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. Continued on next page
TM12660 (18APR18)
9015-20-28
DW9628,0000541 -19-14AUG12-3/11
041818
PN=616
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 has failed. Replace the relay.
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. DW9628,0000541 -19-14AUG12-4/11
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
TM12660 (18APR18)
9015-20-29
DW9628,0000541 -19-14AUG12-5/11
041818
PN=617
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 has failed. Replace the fuse. See Fuse and Relay Specifications. (Group 9015-10.)
Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in.
DW9628,0000541 -19-14AUG12-6/11
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 has failed in a shorted mode. Replace the diode.
Reverse multimeter probes.
NO: If multimeter does not beep in either check, diode has failed in an open mode. 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
TM12660 (18APR18)
9015-20-30
DW9628,0000541 -19-14AUG12-7/11
041818
PN=618
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. See Travel Alarm Remove and Install. (Group 9015-20.)
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.
DW9628,0000541 -19-14AUG12-8/11
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
TM12660 (18APR18)
9015-20-31
DW9628,0000541 -19-14AUG12-9/11
041818
PN=619
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 has failed. Replace the CAN bus terminator.
Continued on next page
TM12660 (18APR18)
9015-20-32
DW9628,0000541 -19-14AUG12-10/11
041818
PN=620
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 1350—1650 ohms?
NO: Alternator resistor has failed. Replace the alternator resistor. DW9628,0000541 -19-14AUG12-11/11
Battery Remove and Install
TX1119352A —UN—02AUG12
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 cap screws (1) and bracket (2). Bracket Removal 1— Cap Screw (2 used)
2— Bracket Continued on next page
TM12660 (18APR18)
9015-20-33
DW9628,0000542 -19-22FEB13-1/4
041818
PN=621
References
3. Remove wing nuts (3), washers (4), rubber mat (5), and battery cover (6). 5— Rubber Mat 6— Battery Cover
TX1119382A —UN—03AUG12
3— Wing Nut (2 used) 4— Washer (2 used)
Cover Removal DW9628,0000542 -19-22FEB13-2/4
4. Remove washers (7), nuts (8), and J-bolts (9). 9— J-Bolt (2 used)
TX1119384A —UN—03AUG12
7— Washer (2 used) 8— Nut (4 used)
Battery Hold Down Bracket Removal Continued on next page
TM12660 (18APR18)
9015-20-34
DW9628,0000542 -19-22FEB13-3/4
041818
PN=622
References
5. Disconnect cables (11—13), remove battery hold-down bracket (10), and remove batteries (G1 and G2).
TX1119387A —UN—06AUG12
6. Check cables and clamps for wear or corrosion. Verify batteries are fully charged. IMPORTANT: Prevent electrical system damage. If one battery in a 24-volt system has failed, replace both batteries. 7. Install batteries. 8. Connect cables. 9. Install hold-down bracket, J-bolts, nuts, and washers.
Battery Removal
10. Install cover, rubber mat, washers, and wing nuts. 11. Install bracket and cap screws.
10— Battery Hold-Down Bracket 11— Positive Cable 12— Jumper Cable
13— Negative Cable G1—Battery G2—Battery
DW9628,0000542 -19-22FEB13-4/4
TM12660 (18APR18)
9015-20-35
041818
PN=623
References
TX1128389A —UN—19DEC12
Rear Cover Remove and Install
Rear Cover Panel (shown with fuse panel removed) 1— Cap Screw (7 used)
2— Cap Screw (2 used)
3— Rear Cover Panel
1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 9000-01.)
3. Loosen cap screws (2) enough to remove rear cover panel (3).
2. Remove plugs and cap screws (1).
4. Tilt rear cover panel towards front of cab.
NOTE: Holes behind cap screws (2) are slotted, only loosen enough to remove rear cover panel (3). Continued on next page
TM12660 (18APR18)
9015-20-36
DW9628,0000543 -19-08JAN13-1/2
041818
PN=624
References
5. Install identification tags and disconnect lighter (R9), 12-volt power outlet (G5), and right and left speakers (B25 and B26) from cab harness. 6. Remove rear cover panel (3). 7. Repair or replace parts as necessary. 8. Connect lighter, 12-volt power outlet, and speakers to cab harness. 9. Install rear cover panel (3). 10. Tighten cap screws (2).
3— Rear Cover Panel B25— Right Speaker B26— Left Speaker
TX1120487A —UN—08JAN13
11. Install cap screws (1) and plugs. G5—12-Volt Power Outlet R9—Lighter
Speakers and Power Outlet DW9628,0000543 -19-08JAN13-2/2
Main Controller (MCZ) Remove and Install CAUTION: Do not install controller from another machine. Machine data will be incorrect and machine may not operate correctly. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Disconnect battery negative (-) cable. 3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.)
1— Cap Screw (4 used)
TX1120431A —UN—14AUG12
4. Remove cap screws (1) and set aside data converter bracket (2). 2— Data Converter Bracket
Data Converter Continued on next page
TM12660 (18APR18)
9015-20-37
DW9628,0000544 -19-02APR18-1/3
041818
PN=625
References
5. Install identification tags and disconnect electrical connectors (X31— X33, and X36). See Cab Harness (W1) Component Location. (Group 9015-10.)
3— Cap Screw (9 used) 4— Fuse and Relay Bracket 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
TX1120432A —UN—15AUG12
6. Remove cap screws (3) and bring top of fuse and relay bracket (4) towards front of the cab.
Fuse and Relay Bracket DW9628,0000544 -19-02APR18-2/3
7. Remove screws (5). Remove main controller (MCZ) (A3) from fuse and relay bracket. 8. Repair or replace as necessary. 9. Install main controller in bracket. Install cap screws. 10. Install fuse and relay bracket and cap screws. 11. Connect electrical connectors. See Cab Harness (W1) Component Location. (Group 9015-10.) 12. Install data converter bracket and cap screws.
TX1120439A —UN—14AUG12
13. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 14. Connect battery negative (-) cable. 5— Cap Screw (4 used)
A3—Main Controller (MCZ)
Main Controller (MCZ) DW9628,0000544 -19-02APR18-3/3
TM12660 (18APR18)
9015-20-38
041818
PN=626
References
Machine Controller (BCZ) Remove and Install CAUTION: Do not install controller from another machine. Machine data will be incorrect and machine may not operate correctly. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Disconnect battery negative (-) cable. 3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.)
1— Screw (2 used)
TX1119391A —UN—03AUG12
4. Remove screws (1) and lift up machine controller (BCZ) (A11). A11— Machine Controller (BCZ)
Machine Controller (BCZ) DW9628,0000545 -19-02APR18-1/2
5. Install identification tags and disconnect machine controller 8-pin connector A (X10) and machine controller 20-pin connector B (X11). 6. Remove machine controller. 7. Repair or replace as necessary. 8. Connect electrical connectors and install machine controller. 9. Install screws.
TX1119392A —UN—06AUG12
10. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 11. Connect battery negative (-) cable. A11— Machine Controller (BCZ) X10— Machine Controller 8-Pin Connector A
X11— Machine Controller 20-Pin Connector B
Machine Controller (BCZ) DW9628,0000545 -19-02APR18-2/2
TM12660 (18APR18)
9015-20-39
041818
PN=627
References
Engine Control Unit (ECU) Remove and Install CAUTION: Do not install controller from another machine. Machine data will be incorrect and machine may not operate correctly. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Disconnect battery negative (-) cable.
1— Cap Screw (3 used) 2— Bracket
TX1119343A —UN—15AUG12
3. Remove cap screws (1) and bracket (2). X1— Service ADVISOR™ Connector
JDLink™ Controller JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company TZ24494,0000F6B -19-02APR18-1/3
4. Remove cap screws (3) and cover panel (4). 4— Cover Panel
TX1119345A —UN—15AUG12
3— Cap Screw (3 used)
ECU Cover Panel Continued on next page
TM12660 (18APR18)
9015-20-40
TZ24494,0000F6B -19-02APR18-2/3
041818
PN=628
References
5. Install identification tags and disconnect engine control unit (ECU) electrical connectors (X14 and X15) from ECU (A1). See Machine Harness (W2) Component Location. (Group 9015-10.) 6. Remove cap screws (5) and ECU (A1) with brackets. 7. Remove cap screws and brackets. 8. Repair or replace as necessary. 9. Install ECU, brackets, and cap screws.
TX1119346A —UN—15AUG12
10. Connect ECU electrical connectors. See Machine Harness (W2) Component Location. (Group 9015-10.) 11. Install cover panel and cap screws. 12. Install bracket and cap screws. 13. Connect battery negative (-) cable. 14. If ECU was replaced, perform exhaust differential pressure sensor zero point calibration procedure. See Exhaust Differential Pressure Sensor Zero Point Calibration. (Group 9015-20.) 5— Cap Screw (4 used) A1—Engine Control Unit (ECU)
Engine Control Unit (ECU)
X14— Engine Control Unit (ECU)-to-Machine Harness 60-Pin Connector X15— Engine Control Unit (ECU)-to-Machine Harness 94-Pin Connector TZ24494,0000F6B -19-02APR18-3/3
TM12660 (18APR18)
9015-20-41
041818
PN=629
References
Exhaust Differential Pressure Sensor Zero Point Calibration 898193375
Coolant Temperature (less than)
100°C 212°F
Exhaust Temperature (less than)
100°C 212°F TX1134988A —UN—17APR13
SPECIFICATIONS Software Pin—First Nine Characters From Left Side
1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Locate engine control module (ECM) (A1) and software pin label (2). See Machine Harness (W2) Component Location. (Group 9015-10.) 3. Determine if software pin matches specification. Engine Control Module (ECM) Software Pin Location
Specification Software Pin—First Nine Characters From Left Side........................................................................................ 898193375
2— Software Pin Label
A1—Engine Control Module (ECM)
4. If software pin matches, calibration is completed by normal cycling of key switch (S1) between ON and OFF positions.
b. Turn key to ON position.
5. If software pin does not match, calibration is completed by performing following procedure:
c. Connect MPDr to machine. See MPDr Connection Procedure. (Group 9015-20.)
a. Machine coolant and exhaust temperatures must be less than specification. Specification Coolant—Temperature (less than)....................................................................................... 100°C 212°F Exhaust—Temperature (less than)....................................................................................... 100°C 212°F
d. Follow on-screen exhaust differential pressure sensor learning procedure. e. Disconnect MPDr from machine. f. Turn key to OFF position.
TZ24494,0000F4E -19-20JUL15-1/1
TM12660 (18APR18)
9015-20-42
041818
PN=630
References
Ash Reset Ash reset is used to set new serial numbers of the diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) when replacement is required. IMPORTANT: Prevent possible machine damage. Neglect to perform ash reset procedure will result in delay of pressure activated regenerations. Delay will cause excess particulate matter (PM) to accumulate in the filter. Excess PM may lead to additional heat build up during regeneration causing filter to burn out. If ash reset is completed without replacing the DPF, frequent regenerations will occur. 1. Replace DOC or DPF. See Exhaust Filter Disassemble and Assemble. (Group 0530.) 2. Connect to machine using MPDr application. See MPDr Connection Procedure. (Group 9015-20.)
3. Go to Functions>Engine/MF>MF Maintenance>Change the DOC, Change the CSF or Change the DOC and CSF, or Cleaning. Follow on-screen procedure. NOTE: Internet access will be needed to complete the following steps and can be done after disconnecting from the machine. 4. When appropriate on-screen procedure is complete, upload information using MPDr. 5. Go to Upload. 6. Select Global e-Service, Upload all, OK. 7. Select OK. 8. Wait for upload to complete. Once upload is complete, confirmation should be received and select OK.
NOTE: Make appropriate selection based on work performed on machine. BD53302,0001A45 -19-02MAR15-1/1
TM12660 (18APR18)
9015-20-43
041818
PN=631
References
No Load Max The no load max (NLM) test is used to determine the condition of the filter by measuring the differential pressure (DP) across the filter under specified temperature and exhaust flow conditions. This is measured with MPDr using an interactive test. This procedure will also calculate the estimated operation time to ash maintenance (estimated remaining life of the filter). IMPORTANT: In order for test to run correctly, be sure ECM and MPDr software is up to date with latest version. 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. To ensure that the remaining exhaust filter life is accurately calculated, perform an exhaust filter parked cleaning before starting the no load max test procedure. See Exhaust Filter Parked Cleaning. (Operator’s Manual.) 3. Access the Setting menu in the monitor to disable automatic exhaust filter cleaning. See Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) 4. Connect to machine using MPDr application. See MPDr Connection Procedure. (Group 9015-20.) IMPORTANT: In order to reach desired engine speed to perform test, value of ECO control suspend must be changed using monitor or MPDr. NOTE: The ECO control suspend value will always reset to 0 after the key switch is turned OFF. 5. Turn key switch ON, go to machine setting in the monitor. Change value of ECO control suspend to 1. See Machine Setting. (Group 9015-16.) 6. Verify exhaust differential pressure sensor is calibrated. See Exhaust Differential Pressure Sensor Zero Point Calibration. (Group 9015-20.) NOTE: Filter maintenance interval is 4500 hours. At 4500 hours, the ECM will automatically begin to reset the differential pressure threshold point at which pressure regenerations are triggered. The reset will complete at 5000 hours at which point
the pressure threshold will be reset to new or cleaned filter levels. If filter hours are at or above the 4500 hour level, it is recommended the filter be cleaned or replaced and hours reset. 7. Verify filter hours on machine. IMPORTANT: Before running test, be sure machine power mode is in either PWR (power) or H/P (high power) mode. NOTE: When a test condition is met, the highlighted test step will automatically advance to the next step. 8. Go to Functions >> Engine/MF >> No Load Max Differential Pressure Measurement. A message will display as a reminder that a forced (parked) regeneration must be performed prior to calculating the remaining filter life. If a forced (parked) regeneration was performed, select Yes. Follow on-screen no load max differential pressure measurement procedure 9. When no load max differential pressure measurement procedure is complete, select Start to go to next screen. 10. Enter the hour level of previous filter cleaning or replacement. If filter has never been replaced or sent out for ash removal, enter 0. NOTE: If the current hour level of the filter is less than 1000 hours, it may not be possible to calculate the remaining filter life. The result of the calculation may be displayed as “-”. 11. Select Calculate to calculate estimated operation time to ash maintenance (estimated remaining filter life). 12. Record the following values at end of test.
• No load max differential pressure • Estimated operation time to ash maintenance (estimated remaining filter life)
13. Access the Setting menu in the monitor to enable automatic exhaust filter cleaning. See Main Menu—Setting Menu—Auto Exhaust Filter Cleaning. (Operator’s Manual.) 14. Interpret results:
Continued on next page
TM12660 (18APR18)
9015-20-44
JL58967,00002CC -19-15SEP16-1/2
041818
PN=632
References 245GLC—4HK1 Filter Hours
NLM Differential Pressure (DP)
0
1.5
1000
1.5
2000 3000
DP1, less than or equal to
4000
1.5 1.5 1.5
0
1.8
1000
1.8
3000
1.8
DP2
1.8
4000
1.8
4500
1.8
0
2.6
1000
2.6
2000 3000
2.6 2.7
4500
2.7
0
3.8
1000
3.8
3000
15. If NLM is less than DP1 and no additional issues are experienced, then exhaust filter has been sufficiently cleaned. If NLM is greater than DP1, then filter is plugged and will need to be cleaned or replaced if damaged. See Ash Reset. (Group 9015-20.)
2.6
DP3
4000
2000
cleaned. If no other issues are experienced, no additional work is needed. • If NLM is between DP2 and DP3, use MPDr and perform a forced regeneration. After regeneration is completed, perform another NLM measurement and compare to DP1 values. • If NLM is greater than DP3 and less than DP4, use MPDr and perform a slow regeneration. After regeneration is complete, perform another NLM measurement and compare to DP1 values. • If NLM is greater than DP 4, then replace the filter.
1.5
4500
2000
• If NLM is below DP2, then the filter is sufficiently
kPa
3.8
DP4
3.9
4000
3.9
4500
3.9 JL58967,00002CC -19-15SEP16-2/2
Data Converter Remove and Install 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Disconnect battery negative (-) cable. 3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 4. Disconnect data converter harness connector. 5. Remove screws (1) and data converter (A5). 6. Repair or replace as necessary. TX1119331A —UN—30AUG12
7. Install data converter and screws. 8. Connect data converter harness connector. 9. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 10. Connect battery negative (-) cable. 1— Screw (3 used)
A5—Data Converter
Data Converter DW9628,0000547 -19-18FEB13-1/1
TM12660 (18APR18)
9015-20-45
041818
PN=633
References
Monitor Adjustable Relief Bleed Procedure
1
SPECIFICATIONS Air Bleed Valve Torque
4.5—5.5 N·m 40—49 lb·in
1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9001-01.) 2. Remove cap from air bleed valve (1). 3. Attach drain hose to air bleed valve. Place opposite end of drain line in a suitable container. 4. Loosen air bleed valve 270—360 degrees. 5. Start machine.
Y38/Y39
6. Enable variable attachment relief valves. a. Access Service Menu. See Service Menu. (Group 9015-16.) TX1247904 —UN—30NOV17
b. Select Machine Setting. c. Select ATT Hard Relief Setting. d. Change setting from 0 (fixed) to 1 (variable). e. Press home button to return to main screen. 7. Enable attachment relief air release mode. a. Access Service Menu. See Service Menu. (Group 9015-16.) b. Select Machine Setting.
Attachment Relief Valve 1— Air Bleed Valve Y38— Attachment Relief Solenoid (marked REL1)
c. Select Variable Relief Valve Check.
Y39— Attachment Relief Solenoid 2 (marked REL2)
d. Change setting from 0 (normal) to 4 (attachment relief air release mode). e. Press home button to return to main screen. NOTE: Verify attachment relief pressure setting is set to ON for Pulverizer 1 work mode. 8. Switch work mode to Pulverizer 1. See Main Menu—Work Mode. (Operator’s Manual.)
10. Tighten air bleed valve to specification. Specification Air Bleed Valve—Torque...................................................... 4.5—5.5 N·m 40—49 lb·in
11. Detach drain hose and install cap.
9. Increase engine speed to fast idle. After 20 seconds, lower engine speed to slow idle and shut off machine. JN86345,00002AB -19-12FEB18-1/1
TM12660 (18APR18)
9015-20-46
041818
PN=634
References
Monitor Controller (DSZ) Remove and Install CAUTION: Do not install controller from another machine. Machine data will be incorrect and machine may not operate correctly. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Remove battery negative (-) cable. 3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.) TX1120270A —UN—15AUG12
4. Disconnect electrical connectors (X20—X24) from monitor controller (DSZ) (A4). 5. Remove cap screws (1) and monitor controller (DSZ). 6. Repair or replace as necessary. 7. Install monitor controller (DSZ) and cap screws. 8. Connect electrical connectors to monitor controller (DSZ). See Cab Harness (W1) Component Location and see Monitor Harness (W3) Component Location. (Group 9015-10.) 9. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 10. Connect battery negative (-) cable.
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
X22— Monitor Controller 16-Pin Connector D X23— Monitor Controller 12-Pin Connector C X24— Monitor Controller 2-Pin Connector G DW9628,0000548 -19-02APR18-1/1
Air Conditioner Controller (ACF) Remove and Install CAUTION: Do not install controller from another machine. Machine data will be incorrect and machine may not operate correctly. 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Disconnect battery negative (-) cable.
TX1120257A —UN—15AUG12
3. Remove rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 4. Remove cap screw (2) and cover panel (1). 1— Cover Panel
2— Cap Screw
Cover Panel Continued on next page
TM12660 (18APR18)
9015-20-47
DW9628,0000549 -19-02APR18-1/3
041818
PN=635
References
5. Remove cap screws (3) and move relay block (4) aside. 4— Relay Block
TX1119333A —UN—14AUG12
3— Cap Screw (2 used)
Relay Block DW9628,0000549 -19-02APR18-2/3
6. Disconnect electrical connector from air conditioner controller (ACF) (A7). 7. Remove cap screws (4) and remove ACF. 8. Repair or replace as necessary. 9. Install ACF and caps screws. 10. Connect electrical connector to ACF. 11. Install relay block and cap screws. 12. Install cover panel and cap screw. TX1119334A —UN—30AUG12
13. Install rear cover. See Rear Cover Remove and Install. (Group 9015-20.) 14. Connect battery negative (-) cable. 5— Cap Screw (2 used)
A7—Air Conditioner Controller (ACF)
Air Conditioner Controller DW9628,0000549 -19-02APR18-3/3
TM12660 (18APR18)
9015-20-48
041818
PN=636
References
Key Switch Remove and Install 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) TX1089252A —UN—09MAR11
Remove right switch console. See Right Switch Console Remove and Install. (Group 9015-20.) 2. Disconnect cab harness (W1) from key switch (S1). See Cab Harness (W1) Component Location. (Group 9015-10.) 3. Remove cap screws (1) and remove key switch. 4. Repair or replace as necessary.
Key Switch
5. Install key switch and cap screws. 6. Connect cab harness to key switch. See Cab Harness (W1) Component Location. (Group 9015-10.)
1— Cap Screw (3 used)
S1— Key Switch
7. Install right switch console. See Right Switch Console Remove and Install. (Group 9015-20.) DW9628,000054A -19-22FEB13-1/1
TM12660 (18APR18)
9015-20-49
041818
PN=637
References
Right Switch Console Remove and Install 2
3
4
4 4 9 1
5
8
1
6
10 8
7 TX1087365 —UN—16MAR11
6
TX1087365 Right Switch Console (pilot control lever not shown) 1— Cap Screw (2 used) 2— Armrest 3— Storage Compartment 4— Cap Screw (3 used)
5— Rear Switch Console 6— Cap Screw (2 used) 7— Pilot Control Lever Bezel
8— Cap Screw (2 used) 9— Right Switch Console 10— Right Switch Console Bezel
(5). See Cab Harness (W1) Component Location. (Group 9015-10.)
1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Remove cap screws (1) and armrest (2).
5. Remove rear switch console.
3. Remove storage compartment (3).
6. Pull pilot control lever boot up and remove cap screws (6).
4. Remove cap screws (4) and disconnect cab harness (W1) electrical connectors from rear switch console Continued 7. on Remove pilot control lever bezel (7). next page DW9628,000054B -19-30AUG12-1/2 TM12660 (18APR18)
9015-20-50
041818
PN=638
References
8. Remove cap screws (8) and disconnect cab harness (W1) electrical connectors from right switch console (9). See Cab Harness (W1) Component Location. (Group 9015-10.)
12. Install pilot control lever bezel and pilot control lever boot.
9. Remove right switch console.
13. Connect cab harness electrical connectors to rear switch console and install cap screws. See Cab Harness (W1) Component Location. (Group 9015-10.)
10. Repair or replace as necessary.
14. Install storage compartment.
11. Connect cab harness electrical connectors to right switch console and install cap screws. See Cab Harness (W1) Component Location. (Group 9015-10.)
15. Install armrest.
DW9628,000054B -19-30AUG12-2/2
TM12660 (18APR18)
9015-20-51
041818
PN=639
References
Left Switch Console Remove and Install 3
4
4
5
TX1089277 —UN—10MAR11
4
2 TX1089277
2
1
1 Left Switch Console (pilot control lever not shown)
1— Cap Screw (2 used) 2— Washer (2 used)
3— Armrest 4— Cap Screw (3 used)
5— Left Switch Console
1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.)
7. Repair or replace as necessary.
2. Remove cap screws (1) and washers (2).
8. Connect cab harness electrical connectors. See Cab Harness (W1) Component Location. (Group 9015-10.)
3. Remove armrest (3).
9. Install left switch console.
4. Pull pilot control lever boot up and remove cap screws (4).
10. Install cap screws and pilot control lever boot.
5. Tag and disconnect cab harness (W1) electrical connectors. See Cab Harness (W1) Component Location. (Group 9015-10.)
11. Install armrest. 12. Install cap screws and washers.
6. Remove left switch console (5). DW9628,000054C -19-22FEB13-1/1
TM12660 (18APR18)
9015-20-52
041818
PN=640
References
Travel Alarm Remove and Install 1. Park machine and prepare for service. See Park and Prepare for Service Safely. (Group 9000-01.) NOTE: Travel alarm (H4) is located in the compartment below the front of the engine. 2. Remove cap screws (1) and cover panel (2). 2— Cover Panel
TX1120283A —UN—15AUG12
1— Cap Screw (4 used)
Cover Panel DW9628,000054D -19-26FEB13-1/2
3. Disconnect electrical connector (X86) from travel alarm (H4). See Travel Alarm Harness (W26) Component Location. (Group 9015-10.) 4. Remove cap screws (3) and remove travel alarm. 5. Repair or replace as necessary. 6. Install travel alarm and cap screws. 7. Connect electrical connector to travel alarm harness. 8. Install cover panel and cap screws. H4—Travel Alarm TX1120284A —UN—29AUG12
3— Cap Screw (2 used)
Travel Alarm DW9628,000054D -19-26FEB13-2/2
TM12660 (18APR18)
9015-20-53
041818
PN=641
References
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
Disconnect Tab Retainer Connectors
T7535AE —UN—22MAY91
IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to controllers or other components may result. Disconnect connectors only when instructed during a test or check. DO NOT pull on wires to disconnect connector or damage to wires or connector may result. Grasp both halves of the connector to pull connector apart. 1. Push retainer tab (A). 2. While holding tab in, grasp other half of connector and pull connector halves apart.
A—Retainer Tab
3. To connect, push connector halves together until retainer “clicks”. LD30992,00001A4 -19-15MAY14-1/1
Disconnecting Spring Wire Clip Connectors 1. Remove wire clip from connector. Grasp connector; move connector halves from side-to-side as they're being pulled apart. Do not pull on wiring leads.
T8197AO —UN—14MAR94
2. To reconnect, install wire clip on connector half, push connector halves together until wire retainer “clicks” over tabs.
LD30992,00001A5 -19-15MAY14-1/1
TM12660 (18APR18)
9015-20-54
041818
PN=642
References
Replace DEUTSCH™ Connectors 1. Select correct size extractor tool for size of wire to be removed: TS0124 —UN—23AUG88
• JDG361 Extractor Tool for 12 to 14 gauge wire. • JDG362 Extractor Tool for 16 to 18 gauge wire. • JDG363 Extractor Tool for 20 gauge wire. 2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire. IMPORTANT: Do NOT twist tool when inserting in connector.
Deutsch® Connector Extractor Tool
4. Slide extractor tool along wire into connector body until it is positioned over terminal contact. TS120 —UN—23AUG88
5. Pull wire out of connector body, using extractor tool.
Slide Extractor Tool Deutsch is a trademark of Deutsch Co. LD30992,00001A6 -19-15MAY14-1/2
IMPORTANT: Install contact in proper location using correct size grommet. 6. Push contact straight into connector body until positive stop is felt. TS122 —UN—23AUG88
7. Pull on wire slightly to be certain contact is locked in place. 8. Transfer remaining wires to correct terminal in new connector.
Push Contact LD30992,00001A6 -19-15MAY14-2/2
TM12660 (18APR18)
9015-20-55
041818
PN=643
References
NOTE: Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch™ connectors can be serviced using the same procedure. 1. Pull connector (1) apart. Inspect and clean connector seal and contacts. 2. Remove locking wedge (2) from connector using hook on JDG1383 service tool. 1— Connector
T130688B —UN—01MAY00
Replace DEUTSCH™ Rectangular or Triangular Connectors
2— Locking Wedge LD30992,00001A7 -19-29MAY14-1/2
3. Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool.
5. Replace connector contact as necessary. See Install DEUTSCH™ Contact. (Group 9015-20.) 6. Install wire terminal back into connector until it clicks into place. NOTE: Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to terminals.
T130689B —UN—01MAY00
4. Gently pull wire out from back of connector.
7. Install locking wedge until it snaps into place.
T130690B —UN—01MAY00
3— Primary Locking Latches
LD30992,00001A7 -19-29MAY14-2/2
TM12660 (18APR18)
9015-20-56
041818
PN=644
References
Install DEUTSCH™ Contact 1. Strip 6 mm (1/4 in.) insulation from wire. 2. Adjust selector (A) on JDG360 Crimper for correct wire size. TS117 —UN—23AUG88
3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
Crimper LD30992,00001A8 -19-15MAY14-1/4
IMPORTANT: Select proper size contact "sleeve" or "pin" to fit connector body. 4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B). TS0134 —UN—23AUG88
5. Tighten lock nut (C).
Adjusting Screw LD30992,00001A8 -19-15MAY14-2/4
IMPORTANT: Contact must remain centered between indentors while crimping. 6. Insert wire in contact and crimp until handle touches stop. TS118 —UN—23AUG88
7. Release handle and remove contact.
Crimp Continued on next page
TM12660 (18APR18)
9015-20-57
LD30992,00001A8 -19-15MAY14-3/4
041818
PN=645
References
IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.
TS0135 —UN—23AUG88
NOTE: Readjust crimping tool for each crimping procedure. 8. Inspect contact to be certain all wires are in crimped barrel.
Inspect Deutsch® Contact Deutsch is a trademark of Deutsch Co. LD30992,00001A8 -19-15MAY14-4/4
Replace WEATHER PACK™ Connector IMPORTANT: Identify wire color locations with connector terminal letters. TS0128 —UN—23AUG88
1. Open connector body. 2. Insert JDG364 Extraction Tool over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body. NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.
Terminal Contact
LD30992,00001A9 -19-15MAY14-1/2
IMPORTANT: Carefully spread contact lances to assure good seating on connector body. NOTE: Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment. TS0130 —UN—23AUG88
4. Push contact into new connector body until fully seated. 5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector. 7. Close connector body.
Weather Pack™ Connector Body
Weather Pack is a trademark of Delphi-Packard LD30992,00001A9 -19-15MAY14-2/2
TM12660 (18APR18)
9015-20-58
041818
PN=646
References
Install WEATHER PACK™ Contact NOTE: Cable seals are color coded for three sizes of wire:
TS0136 —UN—23AUG88
• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire 1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation. NOTE: Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18 to 20 gauge wire
Correct Size Cable
TS1623 —UN—02NOV94
3. Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.
Strip Insulation LD30992,00001AA -19-15MAY14-1/2
IMPORTANT: Proper contact installation for "sleeve" (A) and "pin” (B) is shown.
TS0139 —UN—02DEC88
4. Secure cable seal to contact as shown, using JDG783 Terminal Applicator.
Weather Pack™ Contact Installation Weather Pack is a trademark of Delphi-Packard LD30992,00001AA -19-15MAY14-2/2
TM12660 (18APR18)
9015-20-59
041818
PN=647
References
Replace (Pull Type) Metri-Pack™ Connectors Disconnect the Metri-Pack® connector (A). Remove tie bands and tape. RW16933 —UN—26APR89
Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C). NOTE: Use JDG7771 Terminal Extraction Tool or “T” pin to remove terminals. Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward. Remove “T” pin and push terminal (E) out of socket.
Connector
Remove terminal, cut strip and crimp wire through connector.
RW16934 —UN—26APR89
Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body socket. NOTE: Terminal will seat only one way. If terminal does not pull into the connector body socket, check to make sure terminal is aligned correctly. D—Locking Tab E—Push Terminal Socket
RW16935 —UN—26APR89
A—Connector B—“T” Pin C—Body Socket
Terminals Metri-Pack is a trademark of Delphi Connection Systems 1
Included in JT07195A Electrical Repair Kit LD30992,00001AB -19-15MAY14-1/1
TM12660 (18APR18)
9015-20-60
041818
PN=648
References
Replace (Push Type) Metri-Pack™ Connectors Disconnect the Metri-Pack® connector. Remove the tie bands and tape. RW21325 —UN—29JUN92
Remove the connector lock (A), and mark wire colors for identification. Identify wire color locations with connector terminal letters. Insert JDG776 or JDG7771 Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward. NOTE: Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK® terminals. Use JDG777 Extraction Tool with 150 series METRI-PACK® terminals.
Push Type Connector A—Connector Lock B—Extraction Tool JDG777 C—Connector Body Socket
D—Terminal E—Locking Tab
Remove extraction tool and pull terminal (D) out of the socket. Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.
terminal into connector body socket until terminal locks.
Metri-Pack is a trademark of Delphi Connection Systems 1
Included in JT07195A Electrical Repair Kit LD30992,00001AC -19-15MAY14-1/1
Replace CINCH™ Connectors 1. Remove extraction tool (1) from the loading side of connector. 2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab.
1— Extraction Tool 2— Secondary Lock Locking Tabs
T132105B —UN—29JUN00
NOTE: After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to hold it in the unlocked position while unlocking the second locking tab. 3— Secondary Lock
Unlock Secondary Lock of Cinch™ Connector Cinch is a trademark of Cinch Inc. Continued on next page
TM12660 (18APR18)
9015-20-61
LD30992,00001AD -19-15MAY14-1/3
041818
PN=649
References
3. Remove secondary lock (3).
T132301B —UN—29JUN00
3— Secondary Lock
Remove Secondary Lock LD30992,00001AD -19-15MAY14-2/3
4. Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will release the primary contact locking tab. T132107B —UN—29JUN00
5. Gently pull wire out of the connector. 6. Repair/Replace terminals as necessary using procedure in this group. 7. Insert contact and wire into connector until it clicks. 8. Install secondary lock. Removing Terminals LD30992,00001AD -19-15MAY14-3/3
TM12660 (18APR18)
9015-20-62
041818
PN=650
References
T138057 —UN—14FEB01
Install CINCH™ Contact
Tool Position For Insertion A—Top of Tool B—Contact Support C—Locator
D—Wire E—Micro Timer Slot F— Junior Timer Slot
G—Contact I— Wire Tab J— Insulation Tab
1. Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool handles together and allow them to open fully. IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned contact. 2. Position the contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire and insulation tabs (I and J) should point to top of tool (A). Butt wire tab (I) against the movable locator (C).
hold the contact in position. Do NOT deform wire and insulation tabs (I and J). 4. Insert stripped wire into contact insulation and wire tabs until it is butted against locator (C). 5. Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. 6. Install contact into connector. (Go to procedure in this group.)
3. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to LD30992,00001AE -19-15MAY14-1/1
TM12660 (18APR18)
9015-20-63
041818
PN=651
References
Repair 32 and 48 Way CINCH™ Connectors 1. Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox. RXA0070459 —UN—10SEP03
2. Move cover locks (C) slightly outward with a small screwdriver. 3. Remove cover (D) away from wires. A—Tab B—Locking Cam
C—Cover Locks D—Cover
RXA0070462 —UN—10SEP03
Cinch™ Connector
RXA0070463 —UN—10SEP03
CINCH™ Cover Lock Tabs
CINCH™ Cover Cinch is a trademark of Cinch Inc. Continued on next page
TM12660 (18APR18)
9015-20-64
LD30992,00001AF -19-15MAY14-1/4
041818
PN=652
References
4. Pull terminal lock (A) out as far as it will go, but do not force its removal.
RXA0070464 —UN—10SEP03
A—Terminal Lock
Terminal Lock LD30992,00001AF -19-15MAY14-2/4
NOTE: JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for smaller 20 gauge holes (A), and 1.5 for larger 16 and 18 gauge holes (B). RXA0070471 —UN—10SEP03
5. Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal opening (D) to unlock terminal. 6. Pull wire and terminal (E) from connector body. A—20 Gauge Holes B—16 & 18 Gauge Holes C—Holes
D—Terminal Hole E—Terminal
RXA0070472 —UN—10SEP03
Connector Holes
RXA0070473 —UN—10SEP03
CINCH™ Connector Terminal Holes
CINCH™ Terminal Extraction Tool Continued on next page
TM12660 (18APR18)
9015-20-65
LD30992,00001AF -19-15MAY14-3/4
041818
PN=653
References
7. Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
RXA0070479 —UN—10SEP03
8. Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism until it bottoms out. Then allow it to open completely 9. With tool in ready position (open handle), open terminal receptacle (B). 10. Insert terminal (C) into proper wire gauge window, crimp wings facing up. 11. Close terminal receptacle (B). Crimp terminal
12. Squeeze handle until two clicks are heard. 13. Insert stripped wire (D) into terminal.
RXA0070480 —UN—10SEP03
14. Hold wire stationary and squeeze tool together until ratchet releases. 15. Remove terminated wire from tool. 16. Terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position. 17. Push terminal lock closed. 18. Install cover. 19. Install connector to controller and close connector body locking cam. C—Terminal D—Wire RXA0070481 —UN—10SEP03
A—CINCH™ Terminal Crimping Tool B—Terminal Receptacle
CINCH™ Terminal Crimping Tool
Terminal Crimping Tool LD30992,00001AF -19-15MAY14-4/4
Remove Connector Body from Blade Terminals 1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off. RW4218 —UN—23AUG88
2. Be sure to bend locking tang back to its original position (B) before installing connector body.
Blade Terminals LD30992,00001B0 -19-29MAY14-1/1
TM12660 (18APR18)
9015-20-66
041818
PN=654
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
TM12660 (18APR18)
9020-1
041818
PN=1
Contents
TM12660 (18APR18)
9020-2
041818
PN=2
Group 05
Theory of Operation Track Adjuster and Recoil Spring Operation 2 1
3 6
9
8
TX1031305 —UN—06NOV07
5
4
7
TX1031305 Track Adjuster and Recoil Spring 1— Grease Fitting 2— Valve 3— Grease Relief Passage
7— Piston 8— Recoil Spring 9— Grease
4— Cylinder 5— Yoke 6— Front Idler
The track adjuster and recoil spring is supported by the track frame. Shock loads on the track and front idler (6) are absorbed by the recoil spring (8). To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease pushes the piston (7) against the yoke (5) moving the front idler (6) out, reducing track sag. The grease fitting (1) is protected from excess pressure by a check ball.
CAUTION: Prevent possible injury from high pressure grease. DO NOT remove grease fitting (1) from valve (2). Increasing track sag is accomplished by loosening the valve (2) to release grease from the cylinder through the grease relief passage (3). When releasing grease from the cylinder, only loosen the valve. TZ24494,000091C -19-25JUN12-1/1
TM12660 (18APR18)
9020-05-1
041818
PN=657
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
TM12660 (18APR18)
15— Second Stage Planetary Gear 16— Third Stage Planetary Gear 17— Drum 18— Sprocket
9020-05-2
TZ24494,000091D -19-25JUN12-1/2
041818
PN=658
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. TZ24494,000091D -19-25JUN12-2/2
TM12660 (18APR18)
9020-05-3
041818
PN=659
Theory of Operation
TM12660 (18APR18)
9020-05-4
041818
PN=660
Group 15
Diagnostic Information Noisy or Loose Track Chain TZ24494,00008ED -19-23JAN13-1/5
Noisy or Loose Track Chain Diagnostic Procedure TZ24494,00008ED -19-23JAN13-2/5
• 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. TZ24494,00008ED -19-23JAN13-3/5
• 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: Clean and install track shoes properly. TZ24494,00008ED -19-23JAN13-4/5
• 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. For seal replacement, see Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.)
YES: Replace grease fitting, relief valve, or seals as necessary.
Are grease fittings, relief valves, or seals leaking?
NO: Diagnostic checkout complete. TZ24494,00008ED -19-23JAN13-5/5
Tight Track Chain TZ24494,00008EE -19-21JUN12-1/4
Tight Track Chain Diagnostic Procedure TZ24494,00008EE -19-21JUN12-2/4
• 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. TZ24494,00008EE -19-21JUN12-3/4
• 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. TZ24494,00008EE -19-21JUN12-4/4
TM12660 (18APR18)
9020-15-1
041818
PN=661
Diagnostic Information
Frequent Track Chain Sag Adjustment Required TZ24494,00008EF -19-23JAN13-1/3
Frequent Track Chain Sag Adjustment Required Diagnostic Procedure TZ24494,00008EF -19-23JAN13-2/3
• 1
Grease Leaking From Track Adjuster Seals, Grease Fittings, or Relief Valve
Check grease fittings and valve are tight. Replace grease fittings or relief valve. For seal replacement, see Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.)
YES: Replace grease fitting, relief valve, or seals as necessary.
Are grease fittings, relief valves, or seals leaking?
NO: Diagnostic checkout complete. TZ24494,00008EF -19-23JAN13-3/3
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers TZ24494,00008F0 -19-21JUN12-1/3
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure TZ24494,00008F0 -19-21JUN12-2/3
• 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. TZ24494,00008F0 -19-21JUN12-3/3
Bent Track Shoes TZ24494,00008F1 -19-21JAN13-1/5
Bent Track Shoes Diagnostic Procedure TZ24494,00008F1 -19-21JAN13-2/5
• 1
Excessive Grouser Wear
Measure grouser height specification for rebuilding or replacing track shoes. See 245GLC 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
TM12660 (18APR18)
9020-15-2
TZ24494,00008F1 -19-21JAN13-3/5
041818
PN=662
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. TZ24494,00008F1 -19-21JAN13-4/5
• 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 speed (turtle) mode?
YES: Diagnostic checkout complete.
NO: Place travel speed switch in slow speed (turtle) mode. TZ24494,00008F1 -19-21JAN13-5/5
“Popping” of Track TZ24494,00008F2 -19-21JUN12-1/5
“Popping” of Track Diagnostic Procedure TZ24494,00008F2 -19-21JUN12-2/5
• 1
Fast Reverse Travel Speed With Load
Fast reverse travel speed with load can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize travel loads in reverse.
YES: Go to Material Packing in Sprocket.
Are travel loads in reverse minimized?
NO: Minimize travel loads in reverse. TZ24494,00008F2 -19-21JUN12-3/5
• 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. TZ24494,00008F2 -19-21JUN12-4/5
• 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. TZ24494,00008F2 -19-21JUN12-5/5
Cracked Track Link TZ24494,00008F3 -19-21JUN12-1/6
Cracked Track Link Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9020-15-3
TZ24494,00008F3 -19-21JUN12-2/6
041818
PN=663
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. TZ24494,00008F3 -19-21JUN12-3/6
• 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. TZ24494,00008F3 -19-21JUN12-4/6
• 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 speed (turtle) mode?
YES: Go to Track Shoes Too Wide for Ground Conditions.
NO: Place travel speed switch in slow speed (turtle) mode. TZ24494,00008F3 -19-21JUN12-5/6
• 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. TZ24494,00008F3 -19-21JUN12-6/6
Chipped Link Rails TZ24494,00008F4 -19-21JUN12-1/5
Chipped Link Rails Diagnostic Procedure TZ24494,00008F4 -19-21JUN12-2/5
• 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
TM12660 (18APR18)
9020-15-4
TZ24494,00008F4 -19-21JUN12-3/5
041818
PN=664
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. TZ24494,00008F4 -19-21JUN12-4/5
• 3
Correct Track Chain Pitch
Check track chain pitch specifications. See 245GLC 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.) TZ24494,00008F4 -19-21JUN12-5/5
Individual Undercarriage Component Wear TZ24494,00008F5 -19-29AUG12-1/3
Individual Undercarriage Component Wear Diagnostic Procedure TZ24494,00008F5 -19-29AUG12-2/3
• 1
Some Wear is Normal
Measure components to determine if they can be rebuilt using weld. See 245GLC Component Rebuild. (SP326VOL1 Undercarriage Appraisal Manual.)
YES: Diagnostic checkout complete.
Is component wear within specification?
NO: Repair or replace components as necessary. TZ24494,00008F5 -19-29AUG12-3/3
TM12660 (18APR18)
9020-15-5
041818
PN=665
Diagnostic Information
Measure Swing Bearing Wear SPECIFICATIONS Cap Screw Torque
510 N·m 376 lb.-ft.
Swing Bearing Play (normal)
0.2—1.00 mm 0.008—0.039 in.
Swing Bearing Play (maximum allowable)
2.80 mm 0.110 in.
SERVICE EQUIPMENT AND TOOLS Dial Indicator
T140090 —UN—17MAY01
CAUTION: Avoid personal injury or death. Stay clear of moving parts. Position dial indicator so it can be seen while the technician is visible to the operator. NOTE: Two people are needed to take this measurement. One to operate the machine and one to take readings. T140090
1. Check swing bearing-to-main frame cap screws are tightened to specification.
Dial Indicator Location
Specification Cap Screw—Torque....................................................................510 N·m 376 lb.-ft.
2. Check swing bearing is lubricated with the specified grease. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator's Manual.) 3. Check 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. T7886AJ —UN—23NOV92
5. Move boom and arm to the position shown with bucket off the ground. Bucket must be empty. 6. Turn dial indicator to zero. 7. Lower the boom to raise front idlers off the ground approximately 500 mm (20 in.). 8. Record dial indicator readings. Machine Positions for Check
Specification Swing Bearing—Play (normal)..............................................................................0.2—1.00 mm 0.008—0.039 in. Swing Bearing—Play (maximum allowable)................................................................. 2.80 mm 0.110 in.
If play exceeds specification, check for wear to balls, spacers, and bearing race. See Swing Bearing Remove and Install. (Group 4350.)
TZ24494,00008F6 -19-21JUN12-1/1
TM12660 (18APR18)
9020-15-6
041818
PN=666
Section 9025 Hydraulic System Contents Page Page
Group 05—Theory of Operation Hydraulic System Operation...................... 9025-05-1 Pilot System Operation.............................. 9025-05-1 Pilot Pump, Pressure Regulating Valve, and Filter Operation .................... 9025-05-2 Pilot Shutoff Solenoid Valve Operation............................................... 9025-05-3 Pilot Control Valve Operation .................... 9025-05-6 Travel Pilot Control Valve Operation............................................... 9025-05-8 Pilot Operation of Control Valve Operation............................................. 9025-05-11 Pilot Signal Manifold Operation ............... 9025-05-14 Pump 1, Pump 2, Pump 3, and Drive Gear Case Operation ................. 9025-05-24 Pump 1, Pump 2, and Pump 3 Regulator Operation ............................ 9025-05-27 Engine Speed Sensing Control Circuit Operation.................................. 9025-05-33 Control Valve Operation .......................... 9025-05-35 Control Valve Check Valves Identification and Operation................. 9025-05-49 Main Relief Valve Circuit Operation............................................. 9025-05-53 Circuit Relief and Anticavitation Valve Operation ................................... 9025-05-57 Travel Flow Combiner Valve Operation............................................. 9025-05-58 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation............................................. 9025-05-62 Boom Lower Meter-In Cut Valve Operation............................................. 9025-05-65 Boom Regenerative Valve Circuit Operation............................................. 9025-05-67 Dig Regenerative Valve Circuit Operation............................................. 9025-05-69 Arm Regenerative Valve Circuit Operation............................................. 9025-05-75 Bucket Regenerative Valve Circuit Operation............................................. 9025-05-80 Boom and Arm Reduced Leakage Valves Operation ................................. 9025-05-84 Arm 1 Flow Rate Control Valve Circuit Operation.................................. 9025-05-86 Arm 2 Flow Rate Control Valve Circuit Operation.................................. 9025-05-90 Auxiliary Flow Rate Control Valve Circuit Operation.................................. 9025-05-92 Arm 3 and Boom 3 Spool Control Solenoid Valve Operation .................... 9025-05-95
Swing Reduction Gear Case Operation............................................. 9025-05-98 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation ................................... 9025-05-99 Swing Motor Damper Valve ................... 9025-05-102 Swing Motor Park Brake Release Circuit Operation................................ 9025-05-110 Center Joint Operation ...........................9025-05-111 Travel Motor and Park Brake Valve Operation........................................... 9025-05-112 Travel Motor Speed Circuit Operation........................................... 9025-05-121 Diesel Particulate Filter (DPF) Burn Solenoid Valves ................................. 9025-05-125 Cylinder Operation................................. 9025-05-128 Return Filter Operation .......................... 9025-05-129 Auxiliary System Operation ................... 9025-05-130 Auxiliary Pilot Control Valve Operation........................................... 9025-05-130 Flow Rate Select Solenoid Valve Operation........................................... 9025-05-140 Flow Rate Pressure Reducing Valve Operation ................................. 9025-05-141 Secondary Auxiliary Relief Valve Solenoid Valve Operation .................. 9025-05-141 Secondary Auxiliary Relief Control Valve Operation ................................. 9025-05-142 Secondary Auxiliary Relief Valve Operation........................................... 9025-05-142 Selector Valve Solenoid Valve Operation........................................... 9025-05-143 Selector Valve Operation....................... 9025-05-143 Auxiliary Shuttle Valve Operation .......... 9025-05-144 Auxiliary High Flow Line Kit Operation........................................... 9025-05-145 Two Way Solenoid Kit Operation........... 9025-05-149 Two Pump Combined Flow Kit Operation........................................... 9025-05-153 Secondary Auxiliary Relief Kit Operation........................................... 9025-05-159 Low Flow Kit Operation ......................... 9025-05-163 Group 15—Diagnostic Information All Hydraulic Functions Slow .....................9025-15-1 All Hydraulic Functions Slow Diagnostic Procedure..............................................9025-15-1 Hydraulic Oil Overheats.............................9025-15-3 Hydraulic Oil Overheats Diagnostic Procedure..............................................9025-15-3 No Hydraulic Functions .............................9025-15-5 Continued on next page
TM12660 (18APR18)
9025-1
041818
PN=1
Contents
Page
Page
No Hydraulic Functions Diagnostic Procedure..............................................9025-15-5 Poor Combined Operation.........................9025-15-6 Poor Combined Operation Diagnostic Procedure..............................................9025-15-6 All Functions Cannot Be Operated ...............................................9025-15-7 All Functions Cannot Be Operated Diagnostic Procedure............................9025-15-7 Function Does Not Stop When Control Lever Released .....................................9025-15-8 Function Does Not Stop When Control Lever Released Diagnostic Procedure..............................................9025-15-8 Some Functions Cannot Be Operated, All Others Are Normal ...........................9025-15-8 Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure..............................................9025-15-8 All Functions Slow .....................................9025-15-9 All Functions Slow Diagnostic Procedure..............................................9025-15-9 Functions Move in Opposite Direction ..............................................9025-15-10 Functions Move in Opposite Direction Diagnostic Procedure..........................9025-15-10 All Dig Functions Slow or No Power ..................................................9025-15-10 All Dig Functions Slow or No Power ..................................................9025-15-11 Some Dig Functions Slow (Not All) .......................................................9025-15-11 Some Dig Functions Slow (Not All) Diagnostic Procedure..........................9025-15-11 Load Drifts Down When Control Lever is in Neutral Position ...........................9025-15-13 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure............................................9025-15-13 Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle ...........................9025-15-13 Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle Diagnostic Procedure............................................9025-15-14 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal.................................................9025-15-14 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure............................................9025-15-14 Swing Speed Slow in Both Directions ............................................9025-15-15 Swing Speed Slow in Both Directions Diagnostic Procedure..........................9025-15-16
Swing Speed Slow or Does Not Operate in One Direction ....................9025-15-17 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure............................................9025-15-17 Upperstructure Drift With Swing Valve in Neutral.............................................9025-15-18 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure............................................9025-15-18 Swing Function Does Not Operate ...............................................9025-15-19 Swing Function Does Not Operate Diagnostic Procedure..........................9025-15-19 Travel Park Brakes Do Not Apply ...................................................9025-15-20 Travel Park Brakes Do Not Apply Diagnostic Procedure..........................9025-15-20 Track Will Not Move in One Direction ..............................................9025-15-21 Track Will Not Move in One Direction Diagnostic Procedure..........................9025-15-21 Track Will Not Move in Either Direction ..............................................9025-15-22 Track Will Not Move in Either Direction Diagnostic Procedure..........................9025-15-22 Machine Mistracks at All Speeds in Both Directions....................................9025-15-23 Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure............................................9025-15-23 Slow Travel Speed or Low Power ..................................................9025-15-25 Slow Travel Speed or Low Power Diagnostic Procedure..........................9025-15-25 Combined Travel and Dig Functions Slow or No Power ...............................9025-15-26 Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure............................................9025-15-26 Travel is “Jerky” .......................................9025-15-27 Travel is “Jerky” Diagnostic Procedure............................................9025-15-27 Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline.............................................9025-15-28 Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure..........................9025-15-28 Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs ..................................................9025-15-28 Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure..........................9025-15-28
Continued on next page
TM12660 (18APR18)
9025-2
041818
PN=2
Contents
Page
Page
Pump 1, Pump 2, Pump 3, 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 Travel System Component Location ............................................... 9025-15-46 Travel Hydraulic System Line Connection .......................................... 9025-15-49 Hydraulic System Schematic................... 9025-15-53 Hydraulic System Component Location ............................................... 9025-15-70 Hydraulic System Line Connections......................................... 9025-15-73
Travel Motor Crossover Relief Valve Test and Adjustment .................. 9025-25-38 Pump Regulator Test and Adjustment—Minimum Flow................ 9025-25-41 Pump Regulator Test and Adjustment—Maximum Flow............... 9025-25-43 Pump Flow Test ....................................... 9025-25-45 Swing Motor Leakage Test ...................... 9025-25-52 Travel Motor Leakage Test ...................... 9025-25-53 Cylinder Drift Test—Boom, Arm, and Bucket........................................... 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 Cleanup Procedure .............. 9025-25-6 Hydraulic Oil Tank Pressure Release Procedure................................ 9025-25-7 Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-8 Pilot Pressure Regulating Valve Test and Adjustment ............................ 9025-25-10 Control Valve Spool Actuating Pilot Pressure Test....................................... 9025-25-12 Dig Regenerative Solenoid Valve Test and Adjustment ............................ 9025-25-14 Arm Regenerative Solenoid Valve Test and Adjustment ............................ 9025-25-16 Power Dig Solenoid Valve Test and Adjustment........................................... 9025-25-18 Arm 2 Flow Control Solenoid Valve Test and Adjustment ............................ 9025-25-20 Torque Control Solenoid Valve Test and Adjustment.................................... 9025-25-22 Arm 3 and Boom 3 Control Solenoid Valve Test and Adjustment .................. 9025-25-25 Pump Control Pilot Pressure Signal Test ...................................................... 9025-25-27 Main Relief and Power Dig Valve Test and Adjustment ............................ 9025-25-29 Circuit Relief Valve Test and Adjustment........................................... 9025-25-33 Swing Motor Crossover Relief Valve Test and Adjustment .................. 9025-25-36
TM12660 (18APR18)
9025-3
041818
PN=3
Contents
TM12660 (18APR18)
9025-4
041818
PN=4
Group 05
Theory of Operation Hydraulic System Operation Main hydraulic system is an open-center hydraulic system. The main hydraulic pump housing contains a pilot pump (28), pump 1 (15), pump 2 (16), and pump 3 (149). Engine output is transmitted to pump 1, pump 2, pump 3, and pilot pump through a flex coupling. Engine output is transmitted from pump 1, pump 2, pump 3 drive shaft, and then to pilot pump drive shaft. The pilot pump is mounted on pump 2 end of housing. The pumps are driven at engine speed. See Pump 1, Pump 2, Pump 3, and Drive Gear Case Operation. (Group 9025-05.) See Pilot Pump, Pressure Regulating Valve, and Filter Operation. (Group 9025-05.) Hydraulic oil flow is through suction screen, out of hydraulic oil tank, and through suction line to pumps. Pump 1 delivers high pressure oil to front control valve (6-spool). Pump 2 delivers high pressure oil to rear control valve (6-spool). Pump 3 delivers high pressure oil to swing
spool, boom 3 spool, arm 3 spool, and auxiliary 2 spool in the control valve. High pressure oil is routed to the motors and cylinders by valve spools for their respective function. Hydraulic oil tank is pressurized to ensure that oil flows from the tank, through the suction line, and into the pumps. See Control Valve Operation. (Group 9025-05.) See Control Valve Check Valves Identification and Operation. (Group 9025-05.) Return oil from the motors and cylinders is routed into return passages in control valve by valve spools. From the return passages, return oil flows out of control valve, through hydraulic oil cooler, through restriction valve, and then through the return filter in the hydraulic oil tank. The restriction valve is used in the return line after the hydraulic oil cooler to create some back pressure in return passage of control valve. The back pressure ensures a flow of make-up oil to keep the swing motor case full of oil and a flow of oil through the anticavitation valves to prevent cylinder cavitation. JB3888,0000964 -19-30AUG12-1/1
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 from pump 1, pump 2, and pump 3 regulators to shift the front and rear control valve spools, to release the swing park brake, and as a supply source for functions of the solenoid valve manifold.
The pilot pump supplies to the pilot system. From the pilot pump, oil flows to the pilot pressure regulating valve, which houses the pilot oil filter and pilot bypass valve. 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.
JB3888,0000965 -19-30MAR16-1/1
TM12660 (18APR18)
9025-05-1
041818
PN=671
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 2— Driven Gear Manifold 3— From Hydraulic Pump Suction 7— Plug (port PC) Line 8— Plug (port PG) 4— Drive Gear 10— Regulated Pilot Oil (marked 5— Port PE-to-Pump 1 and 2 PD)-to-Solenoid Valve Servo Pistons and Regulators Manifold
11— Test Port (marked PF) 12— From Pilot Pump Outlet (marked PA) 13— Pilot Filter Element 14— Pilot Pressure Regulating Valve Spool
Pilot filter element (13), bypass valve, and pilot pressure regulating valve (30) are incorporated into one assembly.
in pilot oil circuit. When pressure in pilot circuit increases to pressure setting of spring (15), spool is pushed against spring. Regulated pilot oil flows from port PD to solenoid valve manifold (10) and from port PE to pump 1 and 2 servo pistons and regulators (5). Oil not needed to maintain pressure in pilot circuit flows out port TA to hydraulic return manifold (6).
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.
15— Spring 16— Shim (as required) 28— Pilot Pump 30— Pilot Pressure Regulating Valve
For pilot filter, bypass valve, and pilot pressure regulating valve in pilot control valves and pilot signal manifold. See Hydraulic System 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 JB3888,0000966 -19-30AUG12-1/1
TM12660 (18APR18)
9025-05-2
041818
PN=672
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
TM12660 (18APR18)
9025-05-3
JB3888,0000967 -19-15JUN12-1/3
041818
PN=673
Theory of Operation
With the pilot control shutoff lever in the locked position, the lever is up. The solenoid for the pilot shutoff solenoid 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
HT
A4
T3
T1
T2
A1
A2
A3
604 609
TX1107920 —UN—13FEB12
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
TM12660 (18APR18)
9025-05-4
JB3888,0000967 -19-15JUN12-2/3
041818
PN=674
Theory of Operation
With the pilot control shutoff lever in the unlocked position, the lever is down. The solenoid for the pilot shutoff solenoid is energized. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI (A4) are now open to pilot oil from pilot pump (P). Now, operating a control lever actuates a function.
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
HT
A4
T3
T1
T2
A1
A2
A3
604 609
TX1107914 —UN—15FEB12
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 JB3888,0000967 -19-15JUN12-3/3
TM12660 (18APR18)
9025-05-5
041818
PN=675
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
TM12660 (18APR18)
13— Deadband Area 14— Initial Movement 604— Return Oil 609— Pilot Oil
9025-05-6
JB3888,0000968 -19-16AUG12-1/2
041818
PN=676
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. JB3888,0000968 -19-16AUG12-2/2
TM12660 (18APR18)
9025-05-7
041818
PN=677
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
TM12660 (18APR18)
9025-05-8
JB3888,0000969 -19-29MAY12-1/3
041818
PN=678
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), and push against plunger (4). The ports (10, 11, and 12) in housing are identified by numbers and letters next to each port. In neutral, the spool is pushed up by the return spring (9) pushing the plunger up. The return springs hold the pedal in the neutral position. With the spool up, ports 1, 2, 3, and 4 to control valve pilot cap (12) are open to port T to the hydraulic oil tank (10) through the passage and holes in spool. Port P for pilot oil from the pilot shutoff solenoid valve (11) is blocked by the spool.
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.
JB3888,0000969 -19-29MAY12-2/3
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. 18— Bracket 19— Gear 2 20— Gear 1 TX1105628 —UN—19JAN12
14— Travel Pedal 15— Spring Pin 16— Damper 17— Support
Travel Pilot Pedal (shockless function) JB3888,0000969 -19-29MAY12-3/3
TM12660 (18APR18)
9025-05-9
041818
PN=679
Theory of Operation
TM12660 (18APR18)
9025-05-10
041818
PN=680
Theory of Operation
Pilot Operation of Control Valve Operation TX1131335 —UN—31MAY13
11
4
117
1
120
118
110 A3
A2
A1
T2
T1
11
T3
75 A4
HT
Y10
3
P
T
4
2
1
2
P
T
4
1
3
2
P
T
4
1
107
3
166
108 91
P
157
T4
76
90
159 158 41 I
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
97
42
87
4 84
98
1
94 85 81
104
85
93
DF PI
152 9
10
TR
11
SR
12
47
11
B34
153
44 155
48
95 Y24
28
Y29
Y22
Y23
151
Y27 45
4 SA
SI
SE
TX1131335
SF
SC
SD
66
SN
SP
4
3
2
SB
1
SH SL
1
170 SX
SQ
8
7
6
S3
5
13
SM
B33 Pilot Operation of Control Valve Operation
Continued on next page
TM12660 (18APR18)
9025-05-11
041818
PN=681
14
15
16
609 JB3888,000068E -19-29MAY13-1/2
Theory of Operation
TM12660 (18APR18)
9025-05-12
041818
PN=682
Theory of Operation 1— Boom Up Function 4— Arm In Function 11— Right Travel Forward Function 28— Pilot Pump 41— Pilot Signal Manifold 42— Boom Down Shockless Valve 44— Travel Flow Combiner Pilot Valve (port SL) 45— Swing Park Brake Release Pilot Valve (port SH) 47— Pump 2 Flow Rate Pilot Valve (port SB) 48— Pump 1 Flow Rate Pilot Valve (port SA) 75— Right Travel Spool 76— Bucket Spool 81— Boom 1 Spool 84— Dig Regenerative Valve
85— Boom Reduced Leakage Valve 87— Boom Lower Meter-In Cut Valve 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (valve and poppet) 93— Bypass Shutoff Valve 94— Arm Regenerative Valve 95— Swing Spool 97— Arm 1 Spool 98— Arm 1 Flow Rate Control Valve (valve and poppet) 104— Boom 2 Spool 107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve (valve and poppet) 110— Left Travel Spool 117— Main Relief and Power Dig Valve (P1, P2)
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. Boom up function (1), arm in function (4), and right travel forward function (11) are shown. Pilot oil also flows through the shuttle valves in the pilot signal manifold and shifts the pilot valves. The following valves in the control valve are controlled by pilot oil from the pilot control valves and pilot valves in the pilot signal manifold:
• Left and Right Travel Valve Spools (75 and 110) • Bucket Spool (76) • Auxiliary Spool (107) • Auxiliary 2 Spool (151) • Boom 1, Boom 2, and Boom 3 Valve Spools (81, 104, and 153)
• Arm 1, Arm 2, and Arm 3 Spools (152, 90, and 97) • Bypass Shutoff Valve (93)
118— Auxiliary Function Flow Combiner Valve 120— Travel Flow Combiner Valve 151— Auxiliary 2 Spool 152— Arm 3 Spool 153— Boom 3 Spool 155— Pump 3 Flow Rate Pilot Valve (port SX) 157— Arm Rod Anti-Drift Valve (check valve) 158— Arm Rod Anti-Drift Valve (selector valve) 159— Arm Bottom Anti-Drift Valve (selector valve) 166— Bucket Regenerative Cut Valve 170— Main Relief Valve and Power Dig Valve (P3)
609— Pilot Oil B33— Swing Pressure Sensor B34— Travel Pressure Sensor (port TR) Y10— Pilot Shutoff Solenoid Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig Solenoid (marked SI) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
• Swing Spool (95) • Arm 1 and Arm 2 Flow Rate Control Valve (98 and 91) • Boom Reduced Leakage Valve (85) • Boom Lower Meter-In Cut Valve (87) • Arm Regenerative Valve (94) • Pump 3 Flow Rate Pilot Valve (155) • Arm Reduced Leakage Valve (101) • Arm In Pressure Sensor (B31) • Boom Up Pressure Sensor (B30) • Auxiliary Flow Rate Control Valve (108) • Auxiliary Function Flow Combiner Valve (118) • Travel Flow Combiner Valve (120) The solenoids (Y22, Y23, Y24, Y27, and Y29) in the solenoid valve manifold control the power dig solenoid (marked SI), dig regenerative solenoid (marked SF), arm regenerative solenoid (marked SC), arm 1 flow control solenoid (marked SE), and arm 2 flow control solenoid (marked SD) in the control valve. JB3888,000068E -19-29MAY13-2/2
TM12660 (18APR18)
9025-05-13
041818
PN=683
Theory of Operation
Pilot Signal Manifold Operation C
D
1
A
SA
4
3
5
N
41B
41A SM
6
E 13
F M
B
B33
14
2
SQ
SR
SX
O
7 15
8 P
H
DR
K
G PI SH
9 10
16
SL
TR
J
L SB
DF
11
I
SN
12
SP
129 42
48
47
45
44
TX1116087
TX1116087 —UN—14AUG12
46
Pilot Signal Manifold Pilot Valves and Ports
Continued on next page
TM12660 (18APR18)
9025-05-14
JB3888,000096B -19-30MAR16-1/11
041818
PN=684
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 8, G— Bucket Curl 7, 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— Auxiliary 1 Open Pilot Pressure 14, N— Auxiliary 1 Close Pilot Pressure 15, O— Auxiliary 2 Open Pilot Valve
16, P— Auxiliary 2 Close Pilot Valve 41A— Control Valve Side of Pilot Signal Manifold 41B— Pilot Control Valve Side of Pilot Signal Manifold 42— Boom Down Shockless Valve 44— Travel Flow Combiner Pilot Valve (port SL) 45— Swing Park Brake Release Pilot Valve (port SH) 46— Pump 3 Flow Rate Pilot Valve (port SX) 47— Pump 2 Flow Rate Pilot Valve (port SB)
NOTE: The numbers 1—14 and letters A—N, DF, TR, S3, SA, SB, SH, 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
48— Pump 1 Flow Rate Pilot SM—To Hydraulic Oil Tank Valve (port SA) SN—Plug (not used) 129— Orifice SP—To Solenoid Valve Manifold DF—To Hydraulic Oil Tank (port DP) DR—To Hydraulic Oil Tank SQ—To Hydraulic Oil Tank PH—Plug SR—Pump 1 Flow Rate Control PI— From Pilot Shutoff Solenoid Valve Control Pressure Valve SX—To Pump Regulator Remote S3— Swing Pressure Sensor Port Control Spool SA—To Pump 1 Regulator TR—Travel Pressure Sensor Port Remote Control Spool SB—To Pump 2 Regulator Remote Control Spool SH—To Swing Park Brake SL—To Travel Flow Combiner Valve
other sends a signal to the regulators through pump 3 flow rate pilot valve (46), 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
TM12660 (18APR18)
9025-05-15
JB3888,000096B -19-30MAR16-2/11
041818
PN=685
TX1086701 —UN—07FEB11
Theory of Operation
Boom Down Shockless Valve
Continued on next page
TM12660 (18APR18)
9025-05-16
JB3888,000096B -19-30MAR16-3/11
041818
PN=686
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 Pilot 141— Orifice Valve 142— Spring B 50— Shuttle Valve 143— Passage 3 138— Spring A 144— Oil Chamber 139— Passage 1 145— Passage 2 140— Tapered Land 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 tapered land to restrict and 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
TM12660 (18APR18)
9025-05-17
JB3888,000096B -19-30MAR16-4/11
041818
PN=687
Theory of Operation
SA SB SX
41B
SA SB SX
151
47 48
151 150
150
146
146 47 48
149 50
147
147 149 50 50
50
148 148
TX1116113 —UN—25JUN12
148
148
41A TX1116113 Pump 1, Pump 2, or Pump 3 Flow Rate Pilot Valve 41A— Control Valve Side of Pilot Signal Manifold 41B— Pilot Control Valve Side of Pilot Signal Manifold 47— Pump 2 Flow Rate Pilot Valve Spool (port SB)
48— Pump 1 Flow Rate Pilot Valve Spool (port SA) 50— Shuttle Valve 146— To Hydraulic Oil Tank by Port DF 147— Pilot Oil From Actuated Pilot Control Valves
148— Pilot Oil From Actuated Pilot Control Valves 149— Pilot Oil From Port PI 150— Spring Chamber 151— Passage A SA—Port SA-to-Pump 1 Regulator
Pump 1 Flow Rate Pilot Valve (SA), Pump 2 Flow Rate Pilot Valve (SB), and Pump 3 Flow Rate Pilot Valve (SX) The function of pump 1, pump 2, and pump 3 flow rate pilot valves is to deliver a regulated amount of pilot oil to the pump 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. Pump 3 flow rate pilot valve delivers regulated pilot oil to pump 3 through port SX. The pilot oil from the actuated pilot control valve is routed to the flow rate pilot valves by the shuttle valves. Actuating a function sends pilot oil from the pilot control valve to the pilot signal manifold. The pilot oil flows through the manifold to the control valve pilot cap and within the manifold to the spring chamber (150). The pilot oil pressure in the spring chamber increases, shifting the flow rate pilot valve spool to the right and allowing
a regulated amount of pilot oil to flow past the spool to the right end of spool and out the port (SA, SB, or SX) 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, Pump 2, and Pump 3 Regulator Operation. (Group 9025-05.) NOTE: Ports SA, SB, and SX 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
TM12660 (18APR18)
SB—Port SB-to-Pump 2 Regulator SX—Port SX-to-Pump 3 Regulator
9025-05-18
JB3888,000096B -19-30MAR16-5/11
041818
PN=688
Theory of Operation
TX1086703 —UN—10JAN11
Bucket Flow Rate Pilot Valve (Port SK) Bucket flow rate pilot valve is shifted by the pilot oil pressure (152) from arm in to port D and through the shuttle valves. The pilot valve routes pilot oil pressure from boom up (port A) (155) to the bucket flow rate valve in the control valve. The bucket flow rate valve restricts the flow of high-pressure oil to the bucket spool during arm in and boom up operation to ensure a flow of high-pressure oil to the boom 1 spool. 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
JB3888,000096B -19-30MAR16-6/11
TX1086703 —UN—10JAN11
Travel Flow Combiner Pilot Valve (Port SL) Travel flow combiner pilot valve is shifted by pilot oil pressure (152) from right travel to port L (right reverse) or port K (right forward) and through the shuttle valves. The pilot valve then routes control pressure pilot oil (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
JB3888,000096B -19-30MAR16-7/11
TX1086703 —UN—10JAN11
Swing Park Brake Release Pilot Valve (Port SH) Swing park brake release pilot valve is shifted by pilot oil pressure (152) from boom up to port A, boom down to port B, arm out to port C, arm in to port D, bucket curl to port G, bucket dump to port H, or auxiliary to port M or N and through the shuttle valves. The pilot valve routes control pressure pilot oil (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
TM12660 (18APR18)
9025-05-19
155— Control Pressure Pilot Oil 156— Spring
JB3888,000096B -19-30MAR16-8/11
041818
PN=689
Theory of Operation
Arm 1 Swing Priority Flow Rate Control Pilot Valve (Port 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— Control Pressure Pilot Oil 156— Spring
Arm 1 Flow Rate Control Pilot Valve
Continued on next page
TM12660 (18APR18)
9025-05-20
JB3888,000096B -19-30MAR16-9/11
041818
PN=690
Theory of Operation
TX1118518 —UN—24JUL12
PROPEL LH LF
LR
J
P
SWING
RR
R
RF
I
3
PROPEL RH
T
K
4
L
2
F
1
2
ARM L
P2
P
IN
T5
E
T
OUT
D
4
BOOM DOWN
C
1
BUCKET
B
3
2
P3
P
UP
T6
T
OUT
A
IN
H
4
G
1
3 50I
50D
50H
50F I A3
A2
A1
A4
T1
K
L D
C
B
A
H
G
F
E
M
N
O
DR
50Q
P
T3
50O
HT
Y10
GATE LOCK VALVE
T2
J
50P 50K P
T4
50L 50G DF PI
50C
12
4
SA
SN
SP
3
2
SB
1
SH SL
SX
SQ
8
7
SWING LEFT SWING RIGHT
SR
BUCKET IN
11
BUCKET OUT
TR
BOOM UP
10
BOOM DOWN
ARM IN
9
ARM OUT
VALVE SHUTTLE
6
S3
50J
50E
5
13
SM
14
15
50B
50M
50N
50A
16
TX1118518
JB3888,000096B -19-30MAR16-10/11
Continued on next page
TM12660 (18APR18)
9025-05-21
041818
PN=691
Theory of Operation 50F— Boom, Arm 50G— Booom, Arm, Bucket, Right Travel 50H— Boom 50I— Arm, Boom Up 50J— Boom, Arm, Bucket, Left Travel, Swing
50A— Left Travel 50B— Left Travel, Right Travel 50C— Right Travel 50D— Arm 50E— Boom, Arm, Bucket, Right 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
Shuttle Valves (50A—50W) 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
Pump 3 Flow Rate Pilot Valve
Boom Up, A
X
X
X
Travel Flow Combiner Valve Pilot Valve
Bucket Flow Rate Pilot Valve
Swing Park Brake Release Pilot Valve
Boom Down, B
X
Arm In, D
X
X
Arm Out, C
X
X
Bucket Curl, G
X
X
Bucket Dump, H
X
X
X X
X
X
Left Swing, E
X
X
X
X X
X
X X
Left Travel, I, J Auxiliary 1, N, M
X X
Right Swing, F Right Travel, L, K
Arm 1 (Swing Priority) Flow Rate Pilot Valve
X
X
X
Auxiliary 2
X
X
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
P3 Flow Rate Control
Boom, Swing, or Auxiliary 2
JB3888,000096B -19-30MAR16-11/11
TM12660 (18APR18)
9025-05-22
041818
PN=692
Theory of Operation
TM12660 (18APR18)
9025-05-23
041818
PN=693
Theory of Operation
Pump 1, Pump 2, Pump 3, and Drive Gear Case Operation 4 B57
3
B38
150
2
18 28 17
13 5
B36
Y20
Y28
Y21 149 16
15
TX1114946
B35
B56
B37
TX1114946 —UN—13JUN12
28
Pumps and Gear Case
Continued on next page
TM12660 (18APR18)
9025-05-24
JB3888,000096C -19-23APR14-1/3
041818
PN=694
Theory of Operation 2— Pump Drive Gear Case 3— Damper Drive (flex coupling) 4— Drive Shaft 5— Air Bleed Plug 13— Dipstick 15— Pump 1 16— Pump 2 17— Pump 1 Regulator
18— Pump 2 Regulator 28— Pilot Pump 149— Pump 3 150— Pump 3 Regulator B35— Pump 1 Delivery Pressure Sensor B36— Pump 1 Control Pressure Sensor B37— Pump 2 Delivery Pressure Sensor
B38— Pump 2 Control Pressure Y21— Pump 1 and 2 Torque Control Solenoid (marked Sensor ST) B56— Pump 3 Delivery Pressure Y28— Pump 3 Torque Control Sensor Solenoid (marked SU) B57— Pump 3 Control Pressure Sensor Y20— Pump 2 Flow Rate Limit Solenoid (marked SB)
Continued on next page
TM12660 (18APR18)
9025-05-25
JB3888,000096C -19-23APR14-2/3
041818
PN=695
TX1114890 —UN—07JUN12
Theory of Operation
Pump Cross Section 4— Drive Shaft 17— Pump 1 Regulator
22— Valve Plate 24— Drive Gear
19— Servo Piston 21— Cylinder Block
26— Feedback Link
Pump 1 (15), pump 2 (16), pump 3 (149), and pilot pump (28) are variable displacement, bent-axis, axial piston pumps. Pump 1, pump 2, and pump 3 are identical pumps in an in-line configuration in one housing. The pump 1 drive shaft is connected to the engine flywheel through a damper drive (flex coupling) (3). Pilot pump (28) is a gear pump connected to the output shaft of pump 2. Pump 1, pump 2, pump 3, and the pilot pump are driven at engine speed. Pump 1, pump 2, and pump 3 pressure sensors (B35—B38, B56 and B57) and solenoids (Y20, Y21, and Y28) are used to control the pump operation.
maximum displacement servo pistons. The servo piston (19) 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 and load sleeve in the regulators. The remote control sleeve blocks the flow of pilot 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, Pump 2, and Pump 3 Regulator Operation. (Group 9025-05.) See Hydraulic System Schematic for more information. (Group 9025-15.)
The pumps vary from minimum to maximum displacement, generating the supply oil flow in the hydraulic system depending on the hydraulic demand of the system. Pump 1 regulator (17), pump 2 regulator (18), and pump 3 regulator (150) control the movement of the minimum displacement servo piston by sending or releasing oil from the piston bores. A constant pilot oil pressure from the pilot pressure regulating valve port is supplied to the
The pump displacement, or flow rate, is varied by changing the angle of the valve plate with respect to the drive shaft. Increasing the angle increases the distance that each piston travels into and out of the bore, which increases displacement. Decreasing the angle reduces the distance that each piston travels into and out of the bore, which decreases displacement. JB3888,000096C -19-23APR14-3/3
TM12660 (18APR18)
9025-05-26
041818
PN=696
Theory of Operation
Pump 1, Pump 2, and Pump 3 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 high pressure oil from pump 1 and pump 2. High pressure oil 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
TM12660 (18APR18)
11— Outer Spring 12— Load Sleeve 13— Load Spool 14— Load Piston
9025-05-27
JB3888,000096D -19-13MAR18-1/6
041818
PN=697
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). Reduced 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. High pressure oil (600) from pump 1 and pump 2 is sensed through drilled passages in pump housing to pump 1 pressure inlet (20) and pump 2 pressure inlet (21) in each pump regulator.
21— Pump 2 Pressure Inlet 22— Torque Sensing Port 23— Return to Pump Housing 600— High Pressure Oil 603— Lubrication Oil
609— Pilot Oil 611— Charge Oil 613— Reduced 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.
Charge 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
TM12660 (18APR18)
9025-05-28
JB3888,000096D -19-13MAR18-2/6
041818
PN=698
Theory of Operation
Maximum Flow Rate (Displacement)—When control 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 control lever or pedal is returned to neutral, flow rate valve pilot Continued on next page
TM12660 (18APR18)
9025-05-29
JB3888,000096D -19-13MAR18-3/6
041818
PN=699
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 High Pressure 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— High Pressure Oil 603— Lubrication Oil
Pump Regulator Control by High Pressure Oil—High pressure 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 high pressure 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.
Increasing high pressure oil (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
For decreasing high pressure oil, pressure (load) springs push load spool and pistons to right against high pressure oil, 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. Engine output is not exceeded, even if one pump is loaded relatively high while other pump stays relatively low.
Continued on next page
TM12660 (18APR18)
609— Pilot Oil 611— Charge Oil 613— Reduced Pilot Oil
9025-05-30
JB3888,000096D -19-13MAR18-4/6
041818
PN=700
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
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 charge oil (611) pressure to torque sensing port (22) and load piston (14). 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 high pressure oil 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 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.
21— Pump 2 Pressure Inlet 22— Torque Sensing Port 23— Return to Pump Housing 600— High Pressure Oil 603— Lubrication 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.) 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 output power. Pump 1, pump 2, and pump 3 are equipped with a regulator and perform different functions.
Continued on next page
TM12660 (18APR18)
609— Pilot Oil 611— Charge Oil 613— Reduced Pilot Oil
9025-05-31
JB3888,000096D -19-13MAR18-5/6
041818
PN=701
Theory of Operation
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.)
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.
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 high pressure oil from pump 1 and pump 2. High pressure oil 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.)
• See Pump Regulator Test and Adjustment—Minimum
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.
See the following tests and adjustments for minimum flow adjusting screw (7): 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.)
Pump 3 regulator controls the pump control pressure, pump delivery pressure, and pilot pressure from torque control solenoid. Pump 3 regulator received own pump delivery pressure as control signal pressure. JB3888,000096D -19-13MAR18-6/6
TM12660 (18APR18)
9025-05-32
041818
PN=702
Theory of Operation
Engine Speed Sensing Control Circuit Operation B30 B31 B34
B35
B1
B56
B37
R15
REG
17
150
REG 18
Y21
600
Y28
609 650
TX1117710
TX1117710 —UN—03AUG12
REG A3
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 17— Pump 1 Regulator 18— Pump 2 Regulator
150— Pump 3 Regulator B31— Arm In Pressure Sensor R15— Engine Speed Dial 600— High Pressure Oil B34— Travel Pressure Sensor Y21— Pump 1 and 2 Torque 604— Return Oil B35— Pump 1 Delivery Pressure Control Solenoid (marked 609— Pilot Oil Sensor ST) 650— Electrical Voltage B37— Pump 2 Delivery Pressure Y28— Pump 3 Torque Control A3—Main Controller (MCZ) Sensor Solenoid (marked SU) B1—Crankshaft Position Sensor B56— Pump 3 Delivery Pressure B30— Boom Up Pressure Sensor Sensor
Engine Speed Sensing Control (torque control solenoid)—The function of the engine speed sensing control is to control pump flow rate in response to engine
speed changes caused by load variations, so that the engine output is used efficiently.
Continued on next page
TM12660 (18APR18)
9025-05-33
JB3888,000096E -19-31JUL12-1/2
041818
PN=703
Theory of Operation
The main controller (MCZ) (A3) calculates the speed difference between target and actual engine speed. The MCZ then actuates pump 1 and 2 torque control solenoid (Y21) and pump 3 torque control solenoid (Y28) to change the pump displacement to increase or decrease pump flow rate. Target engine speed is a value set by the position of engine speed dial (R15). Actual engine speed is sensed by the crankshaft position sensor (B1). As a load on the engine increases, the actual engine speed becomes less than the target engine speed. The MCZ decreases the electrical voltage to the torque control solenoid valve, which increases the pilot oil (609) pressure to the load piston 1 in the pump 1, pump 2, and pump 3 regulators (17, 18, and 150). Pilot oil pressure on load piston 1 and high pressure oil (600) pressure on load piston 2 shifts the load spool (6) so pilot oil flows to the large end of servo piston, decreasing the pump displacement. As the flow rate is reduced, the load on the engine is reduced. As the load on the engine decreases, the actual engine speed becomes greater than the target engine speed. The MCZ increases the electrical voltage to the torque control solenoid valve, which decreases the pilot oil pressure to the load piston in the regulators. The spring (1) shifts the load spool in response to the decreasing pilot oil pressure, releasing oil from the large end of servo piston allowing the pump displacement to increase. As the pump flow rate increases, the engine output is used more efficiently. See Pump 1, Pump 2, and Pump 3 Regulator Operation. (Group 9025-05.)
Travel Torque-Up Control (slow speed sensing)—The function of travel torque-up control is to increase the pump flow rate when the travel function is actuated at slow engine speed. Actuating travel function with the engine at slow idle causes the pump to go to maximum displacement. Therefore, pump 1 and 2 flow rates are increased to prevent mistracking, which can occur at the lower flow rate if there are differences between pumps 1 and 2. When the engine speed requested by the engine speed dial (R15) is slow, the main controller processes the electrical signals from the travel pressure sensor (B34), pump 1 delivery pressure sensor (B35), pump 2 delivery pressure sensor (B37), and pump 3 delivery pressure sensor (B56). The main controller sends an increasing electrical voltage to the torque control solenoid, which decreases the pilot oil pressure to load piston 1 in the regulators. The springs shift the load spool in response to the decreasing pilot oil pressure, releasing oil from the large end of servo piston allowing pump displacement to increase. At the increased flow rate, the machine does not mistrack at slow engine speed. See Pump 1, Pump 2, and Pump 3 Regulator Operation. (Group 9025-05.) The increased flow rate continues even if a dig function is actuated while traveling at slow engine speed.
JB3888,000096E -19-31JUL12-2/2
TM12660 (18APR18)
9025-05-34
041818
PN=704
Theory of Operation
Control Valve Operation 95 170
153
151
152
81
85
90
104 97
107 110
76 88
75
117
79 166
87
73 165 173 163
93 89
TX1119401
111
167 80
TX1119401 —UN—30AUG12
156
172
74
121
118
120 Control Valve Component Identifications—Rear Side and Top
73— Front Control Valve (6-spool) 88— Boom Up Circuit Relief and 74— Rear Control Valve (6-spool) Anticavitation Valve 75— Right Travel Spool 89— Boom Down Circuit Relief 76— Bucket Spool and Anticavitation Valve 79— Bucket Dump Circuit Relief 90— Arm 2 Spool and Anticavitation Valve 93— Bypass Shutoff Valve 80— Bucket Curl Circuit Relief 95— Swing Spool and Anticavitation Valve 97— Arm 1 Spool 81— Boom 1 Spool 104— Boom 2 Spool 85— Boom Reduced Leakage 107— Auxiliary Spool Valve (valve and check 110— Left Travel Spool valve) 111— Load Check Valve (Left 87— Boom Lower Meter-In Cut Travel Tandem Circuit) Valve 117— Main Relief and Power Dig Valve (P1, P2)
118— Auxiliary Function Flow 166— Bucket Regenerative Cut Combiner Valve Valve 120— Travel Flow Combiner 167— Load Check Valve (Bucket Valve Tandem Circuit) 121— Check Valve—Travel Flow 170— Main Relief Valve (P3) Combiner Valve Circuit 172— Check Valve (Main Relief 151— Auxiliary 2 Spool Circuit P1,P2) 152— Arm 3 Spool 173— Check Valve (Main Relief 153— Boom 3 Spool Circuit P3) 156— Load Check Valve (Arm 2 Tandem Circuit) 163— Load Check Valve (Boom 3 Parallel Circuit) 165— Load Check Valve (Swing Tandem Circuit)
Continued on next page
TM12660 (18APR18)
9025-05-35
JJ03229,00004C4 -19-09DEC13-1/13
041818
PN=705
TX1119402 —UN—29AUG12
Theory of Operation
Control Valve Component Identification—Front Side and Bottom 73— Front Control Valve (6-spool) 101— Arm Reduced Leakage Valve (valve and poppet) 74— Rear Control Valve (6-spool) 102— Arm In Circuit Relief and 84— Dig Regenerative Valve Anticavitation Valve 98— Arm 1 Flow Rate Control 103— Arm Out Circuit Relief and Valve (valve and poppet) Anticavitation Valve 100— Check Valve (lift check)—Dig Regenerative 105— Check Valve (lift check)—Boom 2 Power Circuit Circuit
The control valve consists of two monoblock valves referred to as the rear control valve (6-spool) (74) and front control valve (6-spool) (73). The 6-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 booms 1, 2, and 3 (81, 104 and 153), arms 1, 2, and 3 (90, 97, and 152), and right and left travel functions (75 and 110) and auxiliary and auxiliary 2 (107 and 151). 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 high pressure oil between the front control valve (6-spool) and rear control valve (6-spool) 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.
108— Auxiliary Flow Rate 159— Arm Bottom Anti-Drift Control Valve (valve and Valve (Selector Valve) poppet) 161— Load Check Valve 112— Check Valve (lift (Auxiliary 2 Tandem check)—Left Travel Power Circuit) Passage 162— Load Check Valve 118— Auxiliary Function Flow (Auxiliary 3 Tandem Combiner Valve Circuit) 119— Check Valve—Flow Combiner Valve 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.) See Travel Flow Combiner Valve Operation for check valve (lift check)—travel and bucket combiner circuit (122) and check valve—travel flow combiner valve circuit (121). (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9025-05-36
JJ03229,00004C4 -19-09DEC13-2/13
041818
PN=706
Theory of Operation
63
61 73
74
117 110 174
75
126
107 79 103
76
127 90
102
80
125
97 88 81
104 89
153
152
52
154 175
95
176
170 600 604 15
TX1119466
149
612
16
TX1119466 —UN—30AUG12
151
Neutral and Power Passages Operation
Continued on next page
TM12660 (18APR18)
9025-05-37
JJ03229,00004C4 -19-09DEC13-3/13
041818
PN=707
Theory of Operation 15— Pump 1 (front, 6-spool) 80— Bucket Curl Circuit Relief 16— Pump 2 (rear, 6-spool) and Anticavitation Valve 52— Swing Motor 81— Boom 1 Spool 61— Right Travel Motor 88— Boom Up Circuit Relief and 63— Left Travel Motor Anticavitation Valve 73— Front Control Valve (6-spool) 89— Boom Down Circuit Relief 74— Rear Control Valve (6-spool) and Anticavitation Valve 75— Right Travel Spool 90— Arm 2 Spool 76— Bucket Spool 95— Swing Spool 79— Bucket Dump Circuit Relief 97— Arm 1 Spool and Anticavitation Valve 102— Arm In Circuit Relief and Anticavitation Valve
103— Arm Out Circuit Relief and Anticavitation Valve 104— Boom 2 Spool 107— Auxiliary Spool 110— Left Travel Spool 125— Boom Cylinder (2 used) 126— Bucket Cylinder 127— Arm Cylinder 149— Pump 3 151— Auxiliary 2 Spool 152— Arm 3 Spool 153— Boom 3 Spool 154— Positioning Cylinder
High pressure oil (600) from pump 1 (15) flows to the front control valve (73). High pressure oil from pump 2 (16) flows to the rear control valve (74). High pressure oil from pump 3 (149) flows to the rear control valve and front control valve. When all functions are in neutral, high pressure oil flows through the neutral and power passages for each valve spool section and then into return oil (604) through the return passage. Neutral and power passages in the front and rear control valves are used
to route high pressure oil for the combined operation of functions. A parallel circuit is provided in each main circuit of pump 1, pump 2, and pump 3 except the arm 3 circuit, and makes the combined operation possible. Combiner oil (612) is connected in combiner passages between arm 1, arm 2, and arm 3 spools (90, 97, and 152), and boom 1, boom 2, and boom 3 spools (81, 104, and 153), so high pressure oil from both pump 1 pump 2 and pump 3 flows to the cylinders during a single operation.
Continued on next page
TM12660 (18APR18)
9025-05-38
170— Main Relief Valve and Power Dig Valve (P3) 174— Attachment (if equipped) 175— Positioning Cylinder Circuit Relief and Anticavitation Valve 176— Positioning Cylinder Circuit Relief and Anticavitation Valve 600— High Pressure Oil 604— Return Oil 612— Combiner Oil
JJ03229,00004C4 -19-09DEC13-4/13
041818
PN=708
Theory of Operation
117
119
TX1012161 —UN—21SEP06
73
74
TX1012161
118
120 Control Valve Cross Section From Rear
73— Front Control Valve (6-spool) 117— Main Relief and Power Dig 119— Check Valve—Flow 74— Rear Control Valve (6-spool) Valve Combiner Valve Circuit 118— Auxiliary Flow Combiner 120— Travel Flow Combiner Valve Valve
See Main Relief Valve Circuit Operation for main relief and power dig valve (117). (Group 9025-05.)
check valve—auxiliary flow combiner valve (118). (Group 9025-05.)
Auxiliary flow combiner valve (118) is used when optional attachments are installed on the machine. See Control Valve Check Valves Identification and Operation for
See Travel Flow Combiner Valve Operation for travel flow combiner valve (120). (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9025-05-39
JJ03229,00004C4 -19-09DEC13-5/13
041818
PN=709
TX1119468 —UN—03AUG12
Theory of Operation
Left and Right Travel Valve Cross Section From Rear 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) 75— Right Travel Spool 110— Left Travel Spool Continued on next page
TM12660 (18APR18)
9025-05-40
JJ03229,00004C4 -19-09DEC13-6/13
041818
PN=710
Theory of Operation
14
76
107
78
109
167
TX1119476 —UN—03AUG12
108
73
74
109
13
TX1119476
78
80
Auxiliary and Bucket Valve Cross Sections From Rear 13— Plug—Auxiliary (pilot) 76— Bucket Spool 14— Plug—Auxiliary (pilot) 78— Bucket Regenerative Valve 73— Front Control Valve (6-spool) 80— Bucket Curl Circuit Relief 74— Rear Control Valve (6-spool) and Anticavitation Valve
107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve (valve and poppet) 109— Plug 167— Load Check Valve (Bucket Tandem Circuit)
See Bucket Regenerative Valve Circuit Operation for bucket regenerative valve (78). (Group 9025-05.)
attachments are installed on the machine. See Auxiliary Flow Rate Control Valve Circuit Operation for auxiliary flow rate control valve. (Group 9025-05.)
Auxiliary spool (107) and auxiliary flow rate control valve (valve and poppet) (108) are used when optional
Continued on next page
TM12660 (18APR18)
9025-05-41
JJ03229,00004C4 -19-09DEC13-7/13
041818
PN=711
Theory of Operation
97
90
79 101
98
TX1119486 —UN—03AUG12
91
TX1119486 Arm 2 and Arm 1 Valve Cross Section From Rear 73— Front Control Valve (6-spool) 90— Arm 2 Spool 74— Rear Control Valve (6-spool) 91— Arm 2 Flow Rate Control 79— Bucket Dump Circuit Relief Valve (valve and poppet) and Anticavitation Valve 97— Arm 1 Spool
98— Arm 1 Flow Rate Control Valve (valve and poppet) 101— Arm Reduced Leakage Valve (valve and poppet)
See Arm 1 Flow Rate Control Valve Circuit Operation for arm 1 flow rate control valve (valve and poppet) (98). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for bucket dump circuit relief and anticavitation valve (89). (Group 9025-05.)
See Arm 2 Flow Rate Control Valve Circuit Operation for arm 2 flow rate control valve (91).
Also see Control Valve Check Valves Identification and Operation for bucket dump circuit relief and anticavitation valve (89). (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and check valve) (85). (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9025-05-42
JJ03229,00004C4 -19-09DEC13-8/13
041818
PN=712
TX1119497 —UN—30AUG12
Theory of Operation
Arm Regenerative Cross Section From Rear 73— Front Control Valve (6-spool) 84— Dig Regenerative Valve 74— Rear Control Valve (6-spool) 87— Boom Lower Meter-In Cut Valve 94— Arm Regenerative Valve
See Dig Regenerative Valve Circuit Operation for dig regenerative valve (84). (Group 9025-05.) See Arm Regenerative Valve Circuit Operation for arm regenerative valve (94). (Group 9025-05.)
99— Check Valve (lift check)—Arm 1 Regenerative Circuit 100— Check Valve (lift check)—Dig Regenerative Circuit
See Control Valve Check Valves Identification and Operation for check valve (lift check)—dig regenerative circuit (100) and check valve (lift check)—arm 1 regenerative circuit (99). (Group 9025-05.)
See Boom Lower Meter-In Cut Valve Operation for boom lower meter-in cut valve (87). (Group 9025-05.) Continued on next page
TM12660 (18APR18)
9025-05-43
JJ03229,00004C4 -19-09DEC13-9/13
041818
PN=713
TX1119498 —UN—30AUG12
Theory of Operation
Boom 1 and Boom 2 Cross Section From Rear 73— Front Control Valve (6-spool) 89— Boom Down Circuit Relief 104— Boom 2 Spool 74— Rear Control Valve (6-spool) and Anticavitation Valve 105— Check Valve (lift 81— Boom 1 Spool 103— Arm Out Circuit Relief and check)—Boom 2 Power 88— Boom Up Circuit Relief and Anticavitation Valve Circuit Anticavitation Valve 159— Arm Bottom Anti-Drift Valve (Selector Valve)
See Circuit Relief and Anticavitation Valve Operation for boom up, boom down, and arm out circuit relief and anticavitation valves (88, 89, and 103). (Group 9025-05.)
169— Arm Bottom Anti-Drift Valve (Check Valve)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—arm 2 neutral passage (92). (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and poppet) (101). (Group 9025-05.) Continued on next page
TM12660 (18APR18)
9025-05-44
JJ03229,00004C4 -19-09DEC13-10/13
041818
PN=714
Theory of Operation
74
73 TX1119499 —UN—30AUG12
93 102
TX1119499 Bypass Shut-out Cross Section From Rear 73— Front Control Valve (6-spool) 93— Bypass Shutoff Valve 74— Rear Control Valve (6-spool) 102— Arm In Circuit Relief and Anticavitation Valve
Bypass shutoff valve (93) is used when optional attachments are installed on the machine.
See Circuit Relief and Anticavitation Valve Operation for arm in circuit relief and anticavitation valves (102). (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9025-05-45
JJ03229,00004C4 -19-09DEC13-11/13
041818
PN=715
Theory of Operation
152
153 85
85
163
162
TX1119509 —UN—30AUG12
164
73
74 82 TX1119509 Arm 3 and Boom 3 Cross Section from Rear 73— Front Control Valve (6-spool) 85— Boom Reduced Leakage Valve (valve and check 74— Rear Control Valve (6-spool) valve) 82— Boom Regenerative Valve 152— Arm 3 Spool 153— Boom 3 Spool
See Control Valve Check Valves Identification and Operation for check valve (load check) in arm 3 tandem circuit and boom 3 parallel and tandem circuit. (Group 9025-05.)
162— Load Check Valve (Arm 3 164— Load Check Valve (Boom 3 Tandem Circuit) Tandem Circuit) 163— Load Check Valve (Boom 3 Parallel Circuit)
See Boom Regenerative Valve Circuit Operation for boom regenerative valve (82). (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (valve and poppet) (101). (Group 9025-05.)
Continued on next page
TM12660 (18APR18)
9025-05-46
JJ03229,00004C4 -19-09DEC13-12/13
041818
PN=716
Theory of Operation
151
95
74
73
TX1119510
TX1119510 —UN—30AUG12
165
161
Auxiliary 2 and Swing Cross Section From Rear 73— Front Control Valve (6-spool) 95— Swing Spool 74— Rear Control Valve (6-spool) 151— Auxiliary 2 Spool 161— Load Check Valve (Auxiliary 2 Tandem Circuit)
165— Load Check Valve (Swing Tandem Circuit)
See Control Valve Check Valves Identification and Operation for check valve (lift check) in auxiliary 2 tandem circuit and swing tandem circuit. (Group 9025-05.)
JJ03229,00004C4 -19-09DEC13-13/13
TM12660 (18APR18)
9025-05-47
041818
PN=717
TX1119512 —UN—30AUG12
Theory of Operation
Main Relief P3 Cross Section From Rear 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) 170— Main Relief Valve and Power Dig Valve (P3)
See Main Relief Valve Circuit Operation for main relief and power dig valve (P3) (170). (Group 9025-05.) JJ03229,00004C4 -19-09DEC13-14/13
TM12660 (18APR18)
9025-05-48
041818
PN=718
Theory of Operation
Control Valve Check Valves Identification and Operation TX1115220 —UN—24AUG12
120
119
116
117
115
75 113
110
111
112
118 122
108
119 123
166
167
107
76
157
103
79 91 158
159
92
80
90 169
102
97
100
94
84
98
99
87 88
81
104 85
85
105
89
93
162
153
163 152 164
161 95 15 149
168 165
160 151
170
16
TX1115220 Control Valve Check Valves Continued on next page
TM12660 (18APR18)
9025-05-49
041818
PN=719
JJ03229,00004C5 -19-09DEC13-1/3
Theory of Operation
TM12660 (18APR18)
9025-05-50
041818
PN=720
Theory of Operation
15— Pump 1 (front, 6-spool) 16— Pump 2 (rear, 6-spool) 44— Flow Combiner Valve Spool 75— Right Travel Spool 76— Bucket Spool 79— Bucket Dump Circuit Relief and Anticavitation Valve 80— Bucket Curl Circuit Relief and Anticavitation Valve 81— Boom 1 Spool 84— Dig Regenerative Valve 85— Boom Reduced Leakage Valve (valve and check valve) 87— Boom Lower Meter-In Cut Valve 88— Boom Up Circuit Relief and Anticavitation Valve 89— Boom Down Circuit Relief and Anticavitation Valve 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (valve and poppet) 92— Check Valve (lift check)—Arm 2 Neutral Passage
93— Bypass Shutoff Valve 113— Orifice—Left Travel Power 161— Load Check Valve 94— Arm Regenerative Valve Passage (Auxiliary 2 Tandem 95— Swing Spool 115— Main Relief Valve Isolation Circuit) 97— Arm 1 Spool Check Valve (P1) 162— Load Check Valve (Arm 3 98— Arm 1 Flow Rate Control 116— Main Relief Valve Isolation Tandem Circuit) Valve (valve and poppet) Check Valve (P2) 163— Load Check Valve (Boom 3 99— Check Valve (lift 117— Main Relief and Power Dig Parallel Circuit) check)—Arm 1 Regenerative Valve 164— Load Check Valve (Boom 3 Circuit 118— Auxiliary Function Flow Tandem Circuit) 100— Check Valve (lift Combiner Valve 165— Load Check Valve (Swing check)—Dig Regenerative 119— Check Valve—Auxiliary Tandem Circuit) Circuit Function Flow Combiner 166— Bucket Regenerative Cut 102— Arm In Circuit Relief and Valve Circuit Valve Anticavitation Valve 120— Travel Flow Combiner 167— Load Check Valve (Bucket 103— Arm Out Circuit Relief and Valve Tandem Circuit) Anticavitation Valve 123— Orifice—Bucket Power 168— Overload Relief Valve 104— Boom 2 Spool Circuit With Make-Up Function 105— Check Valve (lift 149— Pump 3 (Auxiliary 2) (2 used) check)—Boom 2 Power 151— Auxiliary 2 Spool 169— Arm Bottom Anti-Drift Circuit 152— Arm 3 Spool Valve (Check Valve) 107— Auxiliary Spool 153— Boom 3 Spool 170— Main Relief Valve and 108— Auxiliary Flow Rate 157— Arm Rod Anti-Drift Valve Power Dig Valve (P3) Control Valve (valve and (Check Valve) poppet) 158— Arm Rod Anti-Drift Valve 110— Left Travel Spool (Selector Valve) 111— Check Valve (lift 159— Arm Bottom Anti-Drift check)—Left Travel Neutral Valve (Selector Valve) Passage 160— Load Check Valve 112— Check Valve (lift (Auxiliary 2 Parallel Circuit) check)—Left Travel Power Passage
For location of check valves and orifices in control valves, see Control Valve Operation. (Group 9025-05.) Check Valves (92, 111, 164, and 165): Check valves function as lift checks in the neutral passages. Check Valves (105, 112, 160, 161, 162, 163, and 167): 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 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.) 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. Main Relief Valve Isolation Check Valve (P1) (115): Pump 1 and pump 2 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 pump 2 side of control valve is high because oil is flowing past the isolation check valve (115). Main Relief Valve Isolation Check Valve (P2) (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 pump 1 side of control valve is high because oil is flowing past the isolation check valve (116).
Continued on next page
TM12660 (18APR18)
9025-05-51
JJ03229,00004C5 -19-09DEC13-2/3
041818
PN=721
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 rear control valve (74) power passage becomes higher than high pressure oil pressure in the front control valve (73) neutral passage. Check Valve—Travel Flow Combiner Valve Circuit (121): Blocks a higher high pressure oil pressure in the rear control valve (6-spool) (74) from flowing to the front control valve (6-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).
return oil pressure becomes greater than high pressure oil pressure to provide makeup oil to prevent cavitation in the cylinder. Check Valve (lift check) (122) and Orifice (123): The check valve functions as a lift check for the bucket spool (76). High pressure oil flow from pump 1 to the bucket spool is blocked by the right travel spool (75) when actuated. High pressure oil flow from pump 1 to the bucket spool is now through the travel flow combiner valve (120), check valve (121), check valve (122), and orifice (123). The orifice restricts the flow of pump 1 high pressure oil to the bucket spool. Operational Check: Actuate left and right travel and bucket functions. If bucket does not move, inspect check valve and orifice.
Circuit Relief and Anticavitation Valves (79, 80, 88, 89, 102, 103 and 168): The anticavitation valves open when JJ03229,00004C5 -19-09DEC13-3/3
TM12660 (18APR18)
9025-05-52
041818
PN=722
Theory of Operation
Main Relief Valve Circuit Operation 1 2
3 5
4
6 7 8 9 TX1087551 —UN—03FEB11
10 600
11
604 12 TX1087551
13
609
14 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
Main Relief and Power Dig Valves (117 and 170)—The function of the main relief and power dig valves are to limit the main hydraulic system operating pressure. Main relief and power dig valves are pilot operated poppet type relief valve with a piston (5). When the high pressure oil (600) in the power passage (12) pressure 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.
600— High Pressure Oil 604— Return Oil 609— Pilot Oil
bore, increasing the pressure setting of pilot poppet spring (7). The main hydraulic system can now operate at a higher operating pressure for approximately 8 seconds. Main relief valve isolation check valves are used in the left and right control valve to route the higher high pressure oil pressure 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. See Control Valve Check Valves Identification and Operation for main relief valve isolation check valves. (Group 9025-05.)
For power dig operation (14), pilot oil (609) from the power dig solenoid pushes the piston down to the bottom of its Continued on next page
TM12660 (18APR18)
9025-05-53
JJ03229,00004C6 -19-30AUG12-1/4
041818
PN=723
Theory of Operation
S7
A3 16
149
SG
TX1119540 —UN—17AUG12
15
609
Y24 170
TX1119540
117
650
Power Dig Control Circuit 15— Pump 2 149— Pump 3 16— Pump 1 170— Main Relief Valve and 117— Main Relief and Power Dig Power Dig Valve (P3) Valve (P1, P2) 609— Pilot Oil
650— Electrical Voltage A3—Main Controller (MCZ) S7— Power Dig Switch
Power Dig Control Circuit—The function of circuit is to increase the system operating pressure temporarily.
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 an electrical voltage (650) to energize the power dig solenoid (Y24) coil. Pilot oil (609) flows from the valve to the pistons in main relief and power dig valve (P1, P2) (117) and main relief and power dig valve (P3) (170). The pilot oil pressure pushes the piston in the main relief valve and power dig valve
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
TM12660 (18APR18)
9025-05-54
Y24— Power Dig Solenoid (marked SG)
JJ03229,00004C6 -19-30AUG12-2/4
041818
PN=724
Theory of Operation
B30 B31 B37
B35
B56
S7
A3 16
149
SG
TX1119550 —UN—17AUG12
15
609 Y24 170
TX1119550
117
650
Auto-Power Dig Control Circuit 15— Pump 1 16— Pump 2 117— Main Relief and Power Dig Valve (P1, P2) 149— Pump 3 170— Main Relief Valve and Power Dig Valve (P3)
B35— Pump 1 Delivery Pressure S7— Power Dig Switch 609— Pilot Oil Sensor 650— Electrical Voltage Y24— Power Dig Solenoid B37— Pump 2 Delivery Pressure A3—Main Controller (MCZ) (marked SG) Sensor B30— Boom Up Pressure Sensor B56— Pump 3 Delivery Pressure B31— Arm In Pressure Sensor Sensor
Auto-Power Dig Control Circuit—The function of 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 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 solenoid coil allowing pilot oil (609) to flow to the pistons in main relief and power dig valve (P1, P2) (117) and main relief valve and power dig valve (P3) (170). The pilot oil pressure shifts the piston in the main relief and power dig valves against spring pressure to increase the pressure setting. The main hydraulic system now operates at the higher operating pressure.
Continued on next page
TM12660 (18APR18)
9025-05-55
JJ03229,00004C6 -19-30AUG12-3/4
041818
PN=725
Theory of Operation
Y23 Y22
Y29
Y27
Y24
24
20 23 24
22 19
22
21
TX1119572 —UN—06AUG12
17 604 18
20 TX1119572
21
609 613
19 Power Dig Solenoid Operation (marked SG/SI)
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 Magnetic Force 24— Solenoid Coil 604— Return Oil 609— Pilot Oil 613— Reduced Pilot Oil
Power Dig Solenoid (marked SG) Operation—The power dig 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.
Y22— Dig Regenerative Solenoid Y27— Arm 2 Flow Control (marked SF) Solenoid (marked SD) Y23— Arm Regenerative Y29— Arm 1 Flow Control Solenoid (marked SC) Solenoid (marked SE) Y24— Power Dig Solenoid (marked SG)
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 becomes equal to or greater than the 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. JJ03229,00004C6 -19-30AUG12-4/4
TM12660 (18APR18)
9025-05-56
041818
PN=726
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 11— Relief Operation
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.
12— Anticavitation Operation 600— High-Pressure Oil 602— Low-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, low-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. JJ03229,00004C7 -19-30MAR16-1/1
TM12660 (18APR18)
9025-05-57
041818
PN=727
Theory of Operation
Travel Flow Combiner Valve Operation 63
61
110 75
120
81
125
104
600 604 15 TX1120321
149
609
16
TX1120321 —UN—28AUG12
153
Travel Flow Combiner Valve Operation
Continued on next page
TM12660 (18APR18)
9025-05-58
JJ03229,00004C8 -19-30AUG12-1/3
041818
PN=728
Theory of Operation 15— Pump 1 (right, 4-spool) 16— Pump 2 (left, 5-spool) 61— Right Travel Motor 63— Left Travel Motor
75— Right Travel Spool 81— Boom 1 Spool 104— Boom 2 Spool 110— Left Travel Spool
120— Travel Flow Combiner Valve 125— Boom Cylinder 149— Pump 3 153— Boom 3 Spool
600— High Pressure Oil 604— Return Oil 609— Pilot Oil
NOTE: The combined operation of travel and boom raise is explained here.
flows from pump 1 to both left and right travel motors to prevent mistracking.
When boom up function is 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.)
When travel is not actuated spring force keeps the travel flow combiner valve closed.
High pressure oil (600) from pump 1 (15) flows to right travel spool (75) and now through the travel flow combiner valve (120) to the left travel spool (110). High pressure oil
High pressure oil from pump 2 (16) and pump 3 (149) is combined and used for arm, and boom functions. Swing function is supplied high pressure oil from pump 3 only and front attachment high pressure oil is supplied from pump 2 only.
Continued on next page
TM12660 (18APR18)
9025-05-59
JJ03229,00004C8 -19-30AUG12-2/3
041818
PN=729
Theory of Operation
117
73
74
151 152
153 121
147 TX1001466
TX1001466 —UN—17DEC05
120
Travel Flow Combiner Valve and Check Valve 73— Right Control Valve (6-spool) 120— Travel Flow Combiner 151— To Control Valve Return 74— Left Control Valve (6-spool) Valve Passage 117— Main Relief and Power Dig 121— Check Valve—Travel Flow 152— From Pump 1 (6-spool) Valve Combiner Valve Circuit 153— To Left Travel Spool By 147— Pilot Oil From Travel Flow Combiner Passage Combiner Pilot Valve (port SL) JJ03229,00004C8 -19-30AUG12-3/3
TM12660 (18APR18)
9025-05-60
041818
PN=730
Theory of Operation
TM12660 (18APR18)
9025-05-61
041818
PN=731
Theory of Operation
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation 157
156
150 118
119
14
13
74 73
107 108
143 131
DH
600 15 TX1203211
604
16
609
149
TX1203211 —UN—16OCT15
93
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Schematic
Continued on next page
TM12660 (18APR18)
9025-05-62
DF89619,00B5D49 -19-27MAY16-1/4
041818
PN=732
Theory of Operation 13— Auxiliary (pilot) 107— Auxiliary Spool 14— Auxiliary (pilot) 108— Auxiliary Flow Rate 15— Pump 1 Control Valve (valve and 16— Pump 2 poppet) 73— Front Control Valve (6-spool) 118— Auxiliary Flow Combiner 74— Rear Control Valve (6-spool) Valve 93— Bypass Shutoff Valve 119— Check Valve—Flow Combiner Valve Circuit
131— To Exhaust Aftertreatment Manifold 143— Auxiliary Shuttle Valve 149— Pump 3 150— Auxiliary Attachment 156— From Flow Rate Select Solenoid Valve 157— To Flow Rate Select Reducing Valve
NOTE: Auxiliary flow combiner valve (118) and bypass shutoff valve (93) will not work properly unless appropriate kits are installed on machine.
flow from pump 1 (15) with pump 2 (16) at the auxiliary spool (107) to increase hydraulic oil flow to auxiliary attachment (150).
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 supply oil DF89619,00B5D49 -19-27MAY16-2/4
Auxiliary Flow Combiner Valve Operation
107
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 supply oil in neutral passage flow to return passage is blocked. Supply oil now flows through the auxiliary flow combiner valve and combines with pump 2 oil at the auxiliary spool (107). Check valve—flow combiner valve circuit (119) prevents backflow of oil through the auxiliary flow combiner valve.
156
15 119
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
TM12660 (18APR18)
609
TX1148757 —UN—04DEC13
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.
9025-05-63
DF89619,00B5D49 -19-27MAY16-3/4
041818
PN=733
Theory of Operation Bypass Shutoff Valve Operation
31
When an auxiliary function is actuated, or during manual or auto regeneration, pilot pressure is applied to bypass shutoff valve, causing the valve to shift. When the bypass shutoff valve is shifted, pump 1 supply oil in neutral passage flow to return passage is blocked.
143
Supply oil from pump 1 can then be routed through the auxiliary flow combiner valve if equipped with two pump combined flow kit.
15— From Pump 1 31— To Hydraulic Oil Tank 93— Bypass Shutoff Valve 143— From Auxiliary Shuttle Valve
600— High-Pressure Oil 604— Return Oil 609— Pilot Oil DH—To Solenoid Valve Manifold (port DH)
15
93
600 604 DH
609
TX1203652 —UN—15OCT15
For more information, see Exhaust Aftertreatment Burn Solenoid Valves or see Two Pump Combined Flow Kit Operation. (Group 9025-05.)
Bypass Shutoff Valve DF89619,00B5D49 -19-27MAY16-4/4
TM12660 (18APR18)
9025-05-64
041818
PN=734
Theory of Operation
Boom Lower Meter-In Cut Valve Operation
127
90 87
97
125 81
104
153 152
600 604 609 15 TX1119640
149
610
16
TX1119640 —UN—30AUG12
82
Boom Lower Meter-In Cut Valve Circuit Operation Schematic
Continued on next page
TM12660 (18APR18)
9025-05-65
JJ03229,00004C9 -19-28APR16-1/3
041818
PN=735
Theory of Operation 15— Pump 1 16— Pump 2 81— Boom 1 Spool 82— Boom Regenerative Valve 87— Boom Lower Meter-In Cut Valve
90— Arm 2 Spool 97— Arm 1 Spool 104— Boom 2 Spool 125— Boom Cylinder (2 used) 127— Arm Cylinder
During boom down operation, the boom lower meter-in cut valve is shifted by regenerative oil (610) from the boom cylinders. Regenerative oil from the boom cylinder bottom side is divided into two directions. One is routed to boom lower meter-in cut valve spool (87) through an orifice shifting the spool left, which allows pilot oil (609) pressure to
149— Pump 3 152— Arm 3 Spool 153— Boom 3 Spool 600— High-Pressure Oil 604— Return Oil
609— Pilot Oil 610— Regenerative Oil
boom spool 1 and 2 to be directed to the hydraulic oil tank returning the spools to neutral. The other is directed to boom 3 spool regenerative valve and combined with pump 3 high-pressure oil suppling boom cylinder rod side, allowing more pressure oil to be supplied to other actuators during combined operation. See Boom Regenerative Valve Circuit Operation. (Group 9025-05.) JJ03229,00004C9 -19-28APR16-2/3
During boom down operation, pilot oil (609) that flows to the boom 1 and boom 2 spools is sent to hydraulic oil tank through boom lower meter-in cut valve (87).
604
6
Regenerative oil (610) from the boom cylinders flows to the spring chamber (3) in boom lower meter-in cut valve through the orifice (2).
7
609
87
610
1
When pressure in the spring chamber becomes larger than the spring force, the boom lower meter-in cut valve is shifted.
During combined operation of boom lower and any other function, more high-pressure oil is available to the other functions to ensure priority to them. 1— Boom Lower Meter-In Cut Valve Spool 2— Orifice 3— Spring Chamber 4— From Boom Cylinder 5— To Hydraulic Oil Tank 6— To Boom 1 Spool and Boom 2 Spool
2
3
7— Boom Lower Pilot Pressure 87— Boom Lower Meter-In Cut Valve 604— Return Oil 609— Pilot Oil 610— Regenerative Oil
5
4
TX1120441 —UN—30AUG12
Therefore, pilot oil (609) pressure to boom spool 1 and 2 is directed to the hydraulic oil tank returning boom 1 and boom 2 spool to neutral.
Boom Lower Meter-In Cut Valve
JJ03229,00004C9 -19-28APR16-3/3
TM12660 (18APR18)
9025-05-66
041818
PN=736
Theory of Operation
Boom Regenerative Valve Circuit Operation 87
125
81
88
85
89
57 82 153
TX1119645 —UN—30AUG12
600 604 609 610 TX1119645 Boom Regenerative Valve Circuit Schematic 57— Orifice 81— Boom 1 Spool 82— Boom Regenerative Valve 85— Boom Reduced Leakage Valve
87— Boom Lower Meter-In Cut Valve 88— Boom Up Circuit Relief and Anticavitation Valve 89— Boom Down Circuit Relief and Anticavitation Valve
The boom regenerative valve (82) is located inside the boom 3 spool (153). The boom regenerative valve improves boom control and prevents boom cylinder cavitation during boom down operation.
125— Boom Cylinder (2 used) 153— Boom 3 Spool 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil
The boom regenerative valve operates under the following operating conditions.
• Low pump 3 delivery pressure • Low pilot oil pressure to the pilot cap for boom down Continued on next page
TM12660 (18APR18)
610— Regenerative Oil
9025-05-67
JJ03229,00004CA -19-10MAY16-1/3
041818
PN=737
Theory of Operation
• The weight of boom, arm, and bucket causing the boom to lower faster than the pump can supply oil to the boom cylinder rod end
Pilot oil (609) shifts the boom 3 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 Leakage Valves Operation. (Group 9025-05.) Return oil from the boom cylinder bottom end shifts boom lower meter-in cut valve (87). See Boom Lower Meter-In Cut Valve Operation. (Group 9025-05.) Oil then flows to the boom 3 spool. At the boom 3 spool, oil flows through a drilled passage to the center of the spool.
When regenerative oil (610) pressure is more than pump 3 high-pressure oil (600), the boom regenerative valve (82) is open. Regenerative oil is combined with pump 3 high-pressure oil and both are supplied to the boom cylinders rod end. When pump 3 high-pressure oil is more than regenerative oil pressure, the boom regenerative valve is closed. Pump 3 high-pressure oil only flows to the boom cylinders rod end. Regenerative oil passes through an orifice (57) and on to the hydraulic oil tank.
JJ03229,00004CA -19-10MAY16-2/3
85
1
600 604 609 82
2
TX1119650
610
TX1119650 —UN—30AUG12
153
Boom Regenerative Valve Circuit Cross Section 1— Returning Oil From Boom Cylinder Bottom Side 2— Pressure Oil to Boom Cylinder Rod Side
82— Boom Regenerative Valve 85— Boom Reduced Leakage Valve 153— Boom 3 Spool
600— High-Pressure Oil 604— Return Oil 609— Pilot Oil 610— Regenerative Oil JJ03229,00004CA -19-10MAY16-3/3
TM12660 (18APR18)
9025-05-68
041818
PN=738
Theory of Operation
Dig Regenerative Valve Circuit Operation TX1119690 —UN—21AUG12
B30 B31
16
B37 149
B56
B35 15
A3
127
REG
REG
REG
90 97
125
84
SI SD SE SF SC
81
Y22
104
600 604 609 650 TX1119690 Dig Regenerative Valve Schematic Continued on next page
TM12660 (18APR18)
9025-05-69
041818
PN=739
JJ03229,00004CB -19-10MAR16-1/5
Theory of Operation
TM12660 (18APR18)
9025-05-70
041818
PN=740
Theory of Operation 15— Pump 1 16— Pump 2 81— Boom 1 Spool 84— Dig Regenerative Valve 90— Arm 2 Spool 97— Arm 1 Spool 104— Boom 2 Spool 125— Boom Cylinder (2 used)
B30— Boom Up Pressure Sensor B56— Pump 3 Delivery Pressure Sensor B31— Arm In Pressure Sensor B35— Pump 1 Delivery Pressure Y22— Dig Regenerative Solenoid (marked SF) Sensor B37— Pump 2 Delivery Pressure Sensor
127— Arm Cylinder 149— Pump 3 600— High Pressure Oil 604— Return Oil 609— Pilot Oil 650— Electrical Voltage A3—Main Controller (MCZ)
The dig regenerative valve (84) improves arm control and prevents arm cylinder cavitation during the combined operations of boom up and arm in, by combining the return oil (604) from boom cylinder rod end with the pump high pressure oil (600) to the arm cylinder. Under the following operating conditions; high hydraulic pump 1 (15) and pump 2 (16) delivery pressure, pilot oil pressure to the pilot cap for arm in, and boom up actuated, gravity can pull the arm in faster than the pump can supply oil to the arm cylinder head end. The operating conditions are sensed by the pump 1 delivery pressure sensor (B35) and pump 2 delivery pressure sensor (B37), arm
in pressure sensor (B31), and boom up pressure sensor (B30). The sensors send electrical voltage (650) signals to the main controller (MCZ) (A3). The main controller sends a voltage signal to the dig regenerative solenoid (Y22) to energize the coil. The solenoid valve then sends pilot oil pressure signal to shift the dig regenerative valve spool. The return oil from the boom cylinder (125) rod end is combined with high pressure oil from hydraulic pump 2 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
TM12660 (18APR18)
9025-05-71
JJ03229,00004CB -19-10MAR16-2/5
041818
PN=741
Theory of Operation
201
100
200
203
603
202
604 609 TX1119710
TX1119710 —UN—06AUG12
84
Dig Regenerative Valve Section 84— Dig Regenerative Valve 200— Return Oil From Boom Spool Cylinder Rod End 100— Check Valve (lift 201— To Arm 1 Spool check)—Dig Regenerative 202— Spring Circuit
203— Pilot Oil From Dig Regenerative Valve (marked SF) 603— Lubrication Oil Continued on next page
TM12660 (18APR18)
9025-05-72
604— Return Oil 609— Pilot Oil
JJ03229,00004CB -19-10MAR16-3/5
041818
PN=742
Theory of Operation
Y23
Y24
Y22
Y29
Y27
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1119711
609 30
613 6
TX1119711 —UN—06AUG12
30
Dig Regenerative Solenoid Operation
Continued on next page
TM12660 (18APR18)
9025-05-73
JJ03229,00004CB -19-10MAR16-4/5
041818
PN=743
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
Y23— Arm Regenerative 31— To Hydraulic Oil Tank Solenoid (marked SC) 604— Return Oil Y24— Power Dig Solenoid 609— Pilot Oil (marked SG/SI) 613— Reduced Pilot Oil Y22— Dig Regenerative Solenoid Y27— Arm 2 Flow Rate Control Solenoid (marked SD) (marked SF)
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 verses 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.
Y29— Arm 1 Flow Rate Control Solenoid (marked SE)
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.) 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 JJ03229,00004CB -19-10MAR16-5/5
TM12660 (18APR18)
9025-05-74
041818
PN=744
Theory of Operation
Arm Regenerative Valve Circuit Operation TX1119776 —UN—29AUG12
B30 B31 B39 B33 B34 B58 B59
15
B35 149
B37
B56 16
A3
127
REG
REG
REG
90 97
98
94 SI SD SE SF SC
104
Y23
600 604 609 650 TX1119776 Arm Regenerative Valve Schematic
JJ03229,00004CC -19-30AUG12-1/5
Continued on next page
TM12660 (18APR18)
9025-05-75
041818
PN=745
Theory of Operation 15— Pump 1 16— Pump 2 90— Arm 2 Spool 94— Arm Regenerative Valve 97— Arm 1 Spool 98— Arm 1 Flow Rate Control Valve (valve and poppet) 127— Arm Cylinder 149— Pump 3
600— High Pressure Oil 604— Return Oil 609— Pilot Oil 650— Electrical Voltage A3—Main Controller (MCZ) B30— Boom Up Pressure Sensor B31— Arm In Pressure Sensor B33— Swing Pressure Sensor
B34— Travel Pressure Sensor B35— Pump 1 Delivery Pressure Sensor B37— Pump 2 Delivery Pressure Sensor B39— Bucket In Pressure Sensor B56— Pump 3 Delivery Pressure Sensor
B58— Auxiliary 1 Pressure Sensor (if equipped) B59— Auxiliary 2 Pressure Sensor (if equipped) Y23— Arm Regenerative Solenoid (marked SC)
The arm regenerative valve (94) improves arm control and prevents arm cylinder cavitation during arm in operation by combining the return oil (604) from arm cylinder rod end with the pump high pressure oil (600) to the arm cylinder. Under the following operating conditions: low hydraulic pump 2 (16) delivery pressure, pilot oil pressure to the pilot cap for arm in, and boom up actuated, gravity can pull the arm in faster than the pump can supply oil to arm cylinder head end. The operating conditions are sensed by the pump 2 delivery pressure sensor (B37), arm in pressure sensor (B31), and boom up pressure sensor (B30). The sensors send electrical voltage (650) to the main controller (MCZ) (A3). The main controller sends a voltage signal to the arm regenerative solenoid (marked SC) (Y23) to energize the coil. The solenoid valve then sends pilot oil pressure signal to shift the arm regenerative valve spool. The return oil from the arm cylinder (127) rod end is combined with high pressure oil from hydraulic pump 2 and routed through the arm cylinder head end increasing cylinder speed and preventing cavitation. Continued on next page JJ03229,00004CC -19-30AUG12-2/5
TM12660 (18APR18)
9025-05-76
041818
PN=746
Theory of Operation
97
200— High Pressure Oil From Pump 2 201— Return Oil From Arm Cylinder Rodside to Hydraulic Oil Tank 202— Return Oil From Arm Cylinder Rodside 203— Pump 2 High Pressure Oil to Arm Regenerative Valve 600— High Pressure Oil 604— Return Oil 609— Pilot Oil
101
90 201 202
200 98
91
600 604 203
609
TX1119792 —UN—07AUG12
90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (valve and poppet) 94— Arm Regenerative Valve 97— Arm 1 Spool 98— Arm 1 Flow Rate Control Valve (valve and poppet) 99— Check Valve (lift check)—Arm 1 Regenerative Circuit 101— Arm Reduced Leakage Valve (valve and poppet)
Arm Regenerative Valve Section
99
94
202
600 604 609
TX1119793 —UN—07AUG12
203
Arm Regenerative Valve Section Continued on next page
TM12660 (18APR18)
9025-05-77
JJ03229,00004CC -19-30AUG12-3/5
041818
PN=747
Theory of Operation
Y23
Y24
Y22
Y29
Y27
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1119711
609 30
613 6
TX1119711 —UN—06AUG12
30
Arm Regenerative Solenoid Valve Operation
Continued on next page
TM12660 (18APR18)
9025-05-78
JJ03229,00004CC -19-30AUG12-4/5
041818
PN=748
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
Y23— Arm Regenerative 31— To Hydraulic Oil Tank Solenoid (marked SC) 604— Return Oil Y24— Power Dig Solenoid 609— Pilot Oil (marked SG/SI) 613— Reduced Pilot Oil Y22— Dig Regenerative Solenoid Y27— Arm 2 Flow Control Solenoid (marked SD) (marked SF)
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 verses 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.
Y29— Arm 1 Flow Control Solenoid (marked SE)
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 JJ03229,00004CC -19-30AUG12-5/5
TM12660 (18APR18)
9025-05-79
041818
PN=749
Theory of Operation
Bucket Regenerative Valve Circuit Operation 600 77
603
15
604 76
609
57 126 7
79
86
TX1088013 —UN—14FEB11
78 201 202 80
TX1088013 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
The bucket regenerative valve (78) is located inside the bucket spool (76). The bucket regenerative valve combines return oil (604) 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. Return oil passes through an orifice (86) in the
86— Orifice 126— Bucket Cylinder 201— Return Oil From Bucket Cylinder Rod End 202— Return Oil -to- Bucket Cylinder Head End
bucket spool. If pressure of the oil returning from the bucket cylinder rod end is higher than the pump 1 delivery pressure, the bucket regenerative valve is opened. Return oil (604) is combined with high pressure oil from hydraulic pump 1 and routed to the bucket cylinder head end. Return oil not used flows through orifice (57) to return oil. 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 return oil from the bucket cylinder rod end then flows through the orifice to return oil. Continued on next page
TM12660 (18APR18)
600— High Pressure Oil 603— Lubrication Oil 604— Return Oil 609— Pilot Oil
9025-05-80
JJ03229,00004CD -19-30AUG12-1/3
041818
PN=750
Theory of Operation
600
7
603 604 609
79
86 76 201
57
15
77
78
80 TX1088014
TX1088014 —UN—14FEB11
202
Bucket Regenerative Valve Section
Continued on next page
TM12660 (18APR18)
9025-05-81
JJ03229,00004CD -19-30AUG12-2/3
041818
PN=751
Theory of Operation 7— From Bucket Curl Pilot Oil 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 201— Return Oil From Bucket Cylinder Rod End 202— Return Oil -to- Bucket Cylinder Head End 600— High Pressure Oil
603— Lubrication Oil 604— Return Oil 609— Pilot Oil
JJ03229,00004CD -19-30AUG12-3/3
TM12660 (18APR18)
9025-05-82
041818
PN=752
Theory of Operation
TM12660 (18APR18)
9025-05-83
041818
PN=753
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
85
606 609
85
TX1105791
TX1105791 —UN—23JAN12
604
31
Boom Reduced Leakage Valve Operation
Continued on next page
TM12660 (18APR18)
9025-05-84
JJ03229,00004BE -19-27MAY16-1/2
041818
PN=754
Theory of Operation 1— Pilot Pressure From Pilot Control Valve 2— Manual Boom Lower Screw 31— To Hydraulic Oil Tank
81— Boom 1 Spool 85— Boom Reduced Leakage Valve 104— Boom 2 Spool 125— Boom Cylinder (2 used)
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, circuit and arm rod end circuit, and arm head 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 Oil 604— Return Oil 606— Trapped Oil
609— Pilot Oil
When a function is actuated, the pilot oil (609) pressure from pilot control valve (1) shifts the switch valve. The 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 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.) JJ03229,00004BE -19-27MAY16-2/2
TM12660 (18APR18)
9025-05-85
041818
PN=755
Theory of Operation
Arm 1 Flow Rate Control Valve Circuit Operation
150
107
125
98
97
602 604 606 15 TX1149362
149
609
16
TX1149362 —UN—16DEC13
600
Arm 1 Flow Rate Control Valve Circuit Schematic
Continued on next page
TM12660 (18APR18)
9025-05-86
JJ03229,00004CE -19-14MAR16-1/4
041818
PN=756
Theory of Operation 15— Pump 1 16— Pump 2 97— Arm 1 Spool 98— Arm 1 Flow Rate Control Valve (valve and poppet)
107— Auxiliary Spool 125— Boom Cylinder 149— Pump 3 150— Auxiliary Attachment
600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil
The function of arm 1 flow rate control valve (valve and poppet) (98) is to restrict the flow of high-pressure oil (600) from pump 2 (16) to the arm 1 spool (97) to ensure
609— Pilot Oil
a priority flow of high-pressure oil to the auxiliary spool (107) during combined operation. JJ03229,00004CE -19-14MAR16-2/4
Normal Operation—High-pressure oil (600) from pump 2 opens the check valve (200) in the poppet (201) of arm 1 flow rate control valve (98) because the switch valve (203) is open. High-pressure 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 high-pressure oil flows through the poppet to arm 1 spool. 202— To Solenoid Valve Manifold (port DE) 203— Switch Valve 204— From Arm 1 Flow Rate Pilot Valve (port SE) 600— High-Pressure Oil 604— Return Oil
200
201
204 97 16 203 97 202
600 604
TX1088030 —UN—07MAR11
16— High-Pressure Oil From Pump 2 97— To Arm 1 Spool 98— Arm 1 Flow Rate Control Valve 200— Check Valve 201— Poppet
98
Arm 1 Flow Rate Control Valve Normal Operation Continued on next page
TM12660 (18APR18)
9025-05-87
JJ03229,00004CE -19-14MAR16-3/4
041818
PN=757
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 high-pressure oil (600) to arm 1 spool. High-pressure oil now flows through the auxiliary spool to the attachment. 16— High-Pressure 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— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
600
606
602
609
604
TX1088031 —UN—07MAR11
Combined Operation—During auxiliary and arm in combined operation, the pilot oil (609) from arm 1 flow rate pilot valve (port SE) (204), in the pilot signal manifold, is shifted by arm in. The pilot valve then routes a portion of pilot oil (609) from auxiliary 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 JJ03229,00004CE -19-14MAR16-4/4
TM12660 (18APR18)
9025-05-88
041818
PN=758
Theory of Operation
TM12660 (18APR18)
9025-05-89
041818
PN=759
Theory of Operation
Arm 2 Flow Rate Control Valve Circuit Operation
126 76
91 127
90
97
152
602 604 606 15 TX1119956
149
609
16
TX1119956 —UN—28AUG12
600
Arm 2 Flow Rate Control Valve Circuit Schematic
Continued on next page
TM12660 (18APR18)
9025-05-90
JJ03229,00004CF -19-18MAY16-1/3
041818
PN=760
Theory of Operation 15— Pump 1 16— Pump 2 76— Bucket Spool 90— Arm 2 Spool 91— Arm 2 Flow Rate Control Valve (valve and poppet)
97— Arm 1 Spool 126— Bucket Cylinder 127— Arm Cylinder 149— Pump 3 152— Arm 3 Spool
NOTE: The degrees of priority to arm operation can be adjusted by monitor.
600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil
609— Pilot Oil
(600) from pump 1 (15) to the arm 2 spool (90) during combined operation of arm roll-in and bucket roll-in and of auxiliary and arm roll-out.
The function of arm 2 flow rate control valve (valve and poppet) (91) is to restrict the flow of high-pressure oil JJ03229,00004CF -19-18MAY16-2/3
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.)
6
93
204
98 17
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 DM)
204— From Arm 2 Flow Control Solenoid Valve (SD) 600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
TX1148439 —UN—12DEC13
92
99
6
93
98
204 17
92
98 202 600
606
602
609
604
TX1148442 —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
Arm 2 Flow Rate Control Valve (combined operation) JJ03229,00004CF -19-18MAY16-3/3
TM12660 (18APR18)
9025-05-91
041818
PN=761
Theory of Operation
Auxiliary Flow Rate Control Valve Circuit Operation 157
156
150 118
107
14
13 156
108 90 3 97
127
74
3
125
81 1
73
104 1 93 DH 143 153
152 3
1
602 604 606 TX1203655
15
16
609
149
TX1203655 —UN—20OCT15
600
Auxiliary Flow Rate Control Valve Circuit Schematic (auxiliary and arm out active)
Continued on next page
TM12660 (18APR18)
9025-05-92
JJ03229,00004D0 -19-03NOV15-1/4
041818
PN=762
Theory of Operation 1— Boom Up (pilot) 90— Arm 2 Spool 3— Arm Out (pilot) 93— Bypass Shutoff Valve 13— Auxiliary (pilot) 97— Arm 1 Spool 14— Auxiliary (pilot) 104— Boom 2 Spool 15— Pump 1 107— Auxiliary Spool 16— Pump 2 108— Auxiliary Flow Rate 73— Front Control Valve (6-spool) Control Valve (valve and 74— Rear Control Valve (6-spool) poppet) 81— Boom 1 Spool 118— Auxiliary Flow Combiner Valve 125— Boom Cylinder (2 used)
127— Arm Cylinder 143— From Auxiliary Shuttle Valve 149— Pump 3 150— Auxiliary Attachment 152— Arm 3 Spool 153— Boom 3 Spool 156— From Flow Rate Select Solenoid Valve (2 used) 157— To Flow Rate Select Reducing Valve
Auxiliary flow rate control valve (108) is used when two pump combined flow kit is installed on the machine.
Combined with any of these inputs:
600— High-Pressure Oil 602— Low-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil DH—To Solenoid Valve Manifold (port DH)
• 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), arm in
pressure sensor (B31), and boom up pressure sensor (B30). • 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).
JJ03229,00004D0 -19-03NOV15-2/4
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 and 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
TX1203647 —UN—15OCT15
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
TM12660 (18APR18)
9025-05-93
JJ03229,00004D0 -19-03NOV15-3/4
041818
PN=763
Theory of Operation
Control Operation—Auxiliary flow rate valve is shifted by pilot oil from flow rate select solenoid valve (156) when an auxiliary function is combined with one of the following operations:
• Boom up and arm out • Swing, arm in, and boom up • 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 left travel 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
TX1203651 —UN—15OCT15
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)
JJ03229,00004D0 -19-03NOV15-4/4
TM12660 (18APR18)
9025-05-94
041818
PN=764
Theory of Operation
Arm 3 and Boom 3 Spool Control Solenoid Valve Operation TX1136015 —UN—06MAY13
B30 B31
16
B37 149
B56
B35 15
A3
127
REG
REG
REG
125 SI SD SE SF SC
Y32 A1 A2
Y31
152 153
600 604 609 650 TX1136015 Arm 3 and Boom 3 Spool Control Solenoid Valve Schematic Continued on next page
TM12660 (18APR18)
9025-05-95
041818
PN=765
JB3888,0000682 -19-14MAR16-1/2
Theory of Operation
TM12660 (18APR18)
9025-05-96
041818
PN=766
Theory of Operation 15— Pump 1 16— Pump 2 125— Boom Cylinder (2 used) 127— Arm Cylinder 149— Pump 3 152— Arm 3 Spool 153— Boom 3 Spool 600— High-Pressure Oil
B35— Pump 1 Delivery Pressure Y32— Boom 3 Spool Control 604— Return Oil Sensor 609— Pilot Oil Solenoid (marked A1) B37— Pump 2 Delivery Pressure 650— Electrical Voltage Sensor A3—Main Controller (MCZ) B30— Boom Up Pressure Sensor B56— Pump 3 Delivery Pressure Sensor B31— Arm In Pressure Sensor Y31— Arm 3 Spool Control Solenoid (marked A2)
Arm 3 spool (152) valve and boom 3 spool (153) valve are proportional solenoid valves that control pressure oil flowing from control valve and pilot valve. Pilot pressure control (pump 3 flow rate control) cuts off pilot pressure routed to the boom 3 spool or arm 3 spool and reduces the load of pump 3 when digging is at high loaded. Boom raise pilot pressure is blocked by boom 3 control valve. Arm roll-in pilot pressure is blocked by arm 3 control valve. Therefore, boom 3 spool and arm 3 spool do not move. The load of pump 3 is reduced, and flow rate of pump 1 and pump 2 increases.
The operating conditions are sensed by pump 1 delivery pressure sensor (B35), pump 2 delivery pressure sensor (B37), arm in pressure sensor (B31), and boom up pressure sensor (B30). The sensors send electrical voltage (650) signals to the main controller (MCZ) (A3). The main controller sends a voltage to arm 3 spool control solenoid (marked A2) (Y31) and boom 3 spool control solenoid (marked A1) (Y32) to energize the coils.
JB3888,0000682 -19-14MAR16-2/2
TM12660 (18APR18)
9025-05-97
041818
PN=767
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
The swing gear case is a two-stage planetary type gear case. The ring gear (3) is attached to gear case housing (5). The swing motor shaft (1) rotates first stage sun gear (10). Power is transferred from first stage sun gear to second stage sun gear (8) through first stage planetary gear (2) and first stage carrier (9). The second stage sun
52— Swing Motor
gear rotates shaft (6) through second stage planetary gear (4) and 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. JB3888,000079B -19-13JUN12-1/1
TM12660 (18APR18)
9025-05-98
041818
PN=768
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), swing park brake 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
TM12660 (18APR18)
9025-05-99
JB3888,000079C -19-20APR16-1/3
041818
PN=769
Theory of Operation
12
53
53
22
21
13
20
TX1088115 —UN—16FEB11
19 18 17 54
54
16 15 14
TX1088115 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
Continued on next page
TM12660 (18APR18)
9025-05-100
54— Crossover Relief Valve
JB3888,000079C -19-20APR16-2/3
041818
PN=770
Theory of Operation
21 22
20
15
16
17
54
TX1088116 —UN—16FEB11
24 14 19
23
18
TX1088116 (exploded view) Crossover Relief Valve 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 will reach set pressure. High-Pressure Relief Operation (Overload Prevention):
54— Crossover Relief Valve
set-pressure. If high-pressure at port (24) increases more than the spring set-pressure, the poppet is open and low-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 will continue to turn the swing motor, which causes it to act like a pump. The flow caused by the pumping action of the swing motor cannot flow through the control valve because the work ports are blocked by the valve spool. The high-pressure oil is forced through the crossover relief valve. The make-up check valve (53) provides oil to the low-pressure side of the swing motor to prevent cavitation.
After the piston is moved full stroke, the spring is compressed and circuit pressure becomes the JB3888,000079C -19-20APR16-3/3
TM12660 (18APR18)
9025-05-101
041818
PN=771
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
TM12660 (18APR18)
9025-05-102
JB3888,000079D -19-20APR16-1/8
041818
PN=772
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 the 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 high-pressure oil (600) 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), the 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
TM12660 (18APR18)
9025-05-103
JB3888,000079D -19-20APR16-2/8
041818
PN=773
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
TM12660 (18APR18)
9025-05-104
JB3888,000079D -19-20APR16-3/8
041818
PN=774
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
TM12660 (18APR18)
9025-05-105
JB3888,000079D -19-20APR16-4/8
041818
PN=775
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
TM12660 (18APR18)
9025-05-106
JB3888,000079D -19-20APR16-5/8
041818
PN=776
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), the 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
TM12660 (18APR18)
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
9025-05-107
JB3888,000079D -19-20APR16-6/8
041818
PN=777
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
TM12660 (18APR18)
9025-05-108
JB3888,000079D -19-20APR16-7/8
041818
PN=778
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 this operation 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. JB3888,000079D -19-20APR16-8/8
TM12660 (18APR18)
9025-05-109
041818
PN=779
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 plate (7), which acts on the inside of the swing motor housing, securing the upperstructure from moving. JB3888,000079E -19-13JUN12-1/1
TM12660 (18APR18)
9025-05-110
041818
PN=780
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 upper structure is rotated. The blade is optional. The inner spindle is connected to the upper structure and the housing is connected to the undercarriage. The housing rotates about the spindle during swing operation.
72— Center Joint 600— High-Pressure 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 and the blade cylinders (optional). Sealing rings stop oil from leaking between the spindle and housing into adjacent passages. JB3888,000097F -19-14MAR16-1/1
TM12660 (18APR18)
9025-05-111
041818
PN=781
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
TM12660 (18APR18)
9025-05-112
JB3888,0000980 -19-20APR16-1/9
041818
PN=782
Theory of Operation 37— From Solenoid Valve Manifold 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 (2 used) 69— Check Valve (2 used) 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
TM12660 (18APR18)
9025-05-113
110B— From Left Travel Spool Bottom Port—Reverse 604— Return Oil 606— Trapped Oil
JB3888,0000980 -19-20APR16-2/9
041818
PN=783
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 consists of the following components:
and hydraulically-released (negative type). The brake is released when travel function is actuated and high-pressure oil is routed to the park brake piston by the counterbalance valve. The brake is applied when no functions or only the dig and swing functions are actuated.
• 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 high-pressure oil acting on park brake piston (9). The disc 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 (64)—The travel park brake is a wet-type, multi-disc brake. The brake is spring-applied
Continued on next page
TM12660 (18APR18)
9025-05-114
JB3888,0000980 -19-20APR16-3/9
041818
PN=784
Theory of Operation
37
67
66
10
65 4
2
70
TX1088188 —UN—17FEB11
604
TX1088188 Travel Motor Slow Speed Operation 2— Swash Plate 4— Piston (9 used) 10— Spring
37— From Solenoid Valve Manifold 65— Servo Piston
66— Travel Speed Change Valve 67— Shuttle Valve
Continued on next page
TM12660 (18APR18)
9025-05-115
70— Orifice 604— Return Oil
JB3888,0000980 -19-20APR16-4/9
041818
PN=785
Theory of Operation Travel Motor Slow Speed—At slow speed (turtle), the oil acting on the travel speed change valve (66) is open to return through the solenoid valve manifold (37). Travel speed change valve is held up by the spring (10). For more information, see Travel Motor Speed Circuit Operation. (Group 9025-05.) The oil acting on the servo piston (65) is routed to return through the center of travel speed change valve. The
travel speed change valve blocks the flow of high-pressure oil to the servo piston. High-pressure oil from the pressurized motor work port is routed to the valve by the shuttle valve (67). The swash plate (2) is held at maximum displacement. At maximum displacement the motor turns at slow speed with high torque. Continued on next page
TM12660 (18APR18)
9025-05-116
JB3888,0000980 -19-20APR16-5/9
041818
PN=786
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
TM12660 (18APR18)
9025-05-117
JB3888,0000980 -19-20APR16-6/9
041818
PN=787
Theory of Operation 2— Swash Plate 4— Piston (9 used) 10— Spring 37— From Solenoid Valve Manifold
65— Servo Piston 66— Travel Speed Change Valve 67— Shuttle Valve
Travel Motor Fast (Rabbit) Speed—At fast (rabbit) speed, pilot oil (609) from solenoid valve manifold (37) pushes the travel speed change valve (66) down. For more information, see Travel Motor Speed Circuit Operation. (Group 9025-05.)
70— Orifice 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil
orifice (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 high-pressure oil to the piston to modulate the change in speed.
High-pressure oil (600) flows from the motor work port, through the shuttle valve (67), travel speed change valve, Continued on next page
TM12660 (18APR18)
9025-05-118
JB3888,0000980 -19-20APR16-7/9
041818
PN=788
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
TM12660 (18APR18)
9025-05-119
JB3888,0000980 -19-20APR16-8/9
041818
PN=789
Theory of Operation 11— Restriction 12— Poppet 13— Orifice 14— Piston 15— Spring 16— To Fast Speed Servo Piston 17— Spring (2 used) 37— From Solenoid Valve Manifold—Power Dig Solenoid (marked SG/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 (2 used)
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, high-pressure 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. High-pressure oil flows to the park brake piston (14) to release the travel park brake (64). High-pressure oil flows around counterbalance valve and opens the check valve to supply the motor. When a machine is traveling down a hill, the weight can cause it to overrun the travel motors. Overrunning would cause faster travel than desired and cavitation in the motors. As pressure decreases in the work port
69— Check Valve (2 used) 70— Orifice 71— Counterbalance Valve 75A— Travel Motor Work Port 75B— Travel Motor Work Port 110— To Travel Motor 600— High-Pressure 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. JB3888,0000980 -19-20APR16-9/9
TM12660 (18APR18)
9025-05-120
041818
PN=790
Theory of Operation
Travel Motor Speed Circuit Operation B34
B37
B32
B35
1 A3
S11 2 47 B38 48
TX1212621 —UN—24MAR16
B36
Y24 63
66
61 609 650
TX1212621 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 SI) 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 (marked SI) (Y24) is de-energized. The travel speed change valve (66) is open to return through the power dig/travel speed solenoid (marked SI) (Y24), and the travel motors are at slow speed. See Travel Motor and Park Brake Valve Operation. (Group 9025-05.)
9025-05.) The power dig/travel speed solenoid (marked SI) (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 (marked SI) (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
• Either pump 1 or pump 2 control pressure sensor must
• Travel mode switch is in fast (rabbit) speed position. • Travel pressure sensor is on. • Front attachment pressure sensor is off. • Either pump 1 or pump 2 delivery pressure sensor must indicate low pressure.
indicate high pressure.
For electrical circuit information, see System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.)
Continued on next page
TM12660 (18APR18)
9025-05-121
JB3888,0000981 -19-25APR16-1/4
041818
PN=791
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 (marked FRT) (B32).
Continued on next page
TM12660 (18APR18)
9025-05-122
JB3888,0000981 -19-25APR16-2/4
041818
PN=792
Theory of Operation
Y23
Y24
Y22
Y29
Y27
1 3 2
1
30
2
31
31
3 30
7
1 3
5
31
1 2
604 3 31
TX1119711
609 30
613 6
TX1119711 —UN—06AUG12
30
Power Dig/Travel Speed Solenoid Operation
Continued on next page
TM12660 (18APR18)
9025-05-123
JB3888,0000981 -19-25APR16-3/4
041818
PN=793
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
Y23— Arm Regenerative 31— To Hydraulic Oil Tank Solenoid (marked SC) 604— Return Oil Y24— Power Dig/Travel Speed 609— Pilot Oil Solenoid (marked SI) 613— Reduced Pilot Oil Y22— Dig Regenerative Solenoid Y27— Arm 2 Flow Control Solenoid (marked SD) (marked SF)
Power Dig/Travel Solenoid Speed (marked SI) (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 hydraulic oil tank (31).
Y29— Arm 1 Flow Control Solenoid (marked SE)
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.) 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 JB3888,0000981 -19-25APR16-4/4
TM12660 (18APR18)
9025-05-124
041818
PN=794
Theory of Operation
Diesel Particulate Filter (DPF) Burn Solenoid Valves TX1139438 —UN—26JUN13
Y12
Y13
131
37
Y24
Y27
Y29
Y22
Y23
93
15
28 TX1139438
149
16
Y21 Diesel Particulate Filter (DPF) Burn System Continued on next page
TM12660 (18APR18)
9025-05-125
041818
PN=795
JB3888,0000690 -19-25NOV13-1/2
Theory of Operation
TM12660 (18APR18)
9025-05-126
041818
PN=796
Theory of Operation 15— Pump 1 16— Pump 2 28— Pilot Pump 37— Solenoid Valve Manifold 93— Bypass Shut-Out Valve 131— Diesel Particulate Filter (DPF) Solenoid Manifold
149— Pump 3 Y21— Torque Control Solenoid Y27— Arm 2 Flow Control Y12— Exhaust Filter Regulator (marked ST) Solenoid (marked SD) Solenoid (pump 1) (marked Y22— Dig Regenerative Solenoid Y29— Arm 1 Flow Control SZ) (marked SF) Solenoid (marked SE) Y13— Exhaust Filter Regulator Y23— Arm Regenerative Solenoid (bypass cut-off Solenoid (marked SC) valve) (marked SJ) Y24— Power Dig Solenoid (marked SI)
The diesel particulate filter (DPF) solenoid manifold (131) consists of two proportional solenoid valves. When manual or automatic regeneration of the exhaust filter is required, the main controller (MCZ) sends a signal to each solenoid valve. Exhaust filter regulator solenoid (pump 1) (marked SZ) (Y12) controls the pump 1 regulator. Exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) controls the bypass cut-off valve in the control valve. During a manual or auto regeneration, the MCZ sends a signal to the exhaust filter regulator solenoid (pump 1) (marked SZ) (Y12), which is shifted. Pilot pressure
from the pilot pump (28) is supplied to pump 1 regulator, increasing the delivery flow rate of pump 1. The MCZ also sends a signal to the exhaust filter regulator solenoid (bypass cut-off valve) (marked SJ) (Y13) and shifts the spool. Pilot pressure from the pilot pump (28) is routed to the bypass shut-out valve (93). The bypass shut-out valve is shifted to block the neutral passage in the control valve. The neutral passage is blocked by increasing pressure in pump 1, creating a load on the engine. JB3888,0000690 -19-25NOV13-2/2
TM12660 (18APR18)
9025-05-127
041818
PN=797
Theory of Operation
Cylinder Operation
2
9
3
1
4
5
6
10
11
10
12
7 8
16
17
15
14
13 TX1113156 —UN—03MAY12
18
TX1113156 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 bucket cylinder (18) is illustrated. The rod guide (17) is fastened to the cylinder barrel with cap screws and is fitted with a wear ring (6) held in place by a snap ring (7). A buffer ring (5), U-cup seal (4), backup ring (3), and wiper seal (2) are used in the rod guide. A snap ring (1) is used to help hold wiper seal in place. The U-cup seal (4) is protected against high pressure by the buffer ring (5) and stops the small amount of oil that may pass by the buffer ring. The piston (8) is a slip fit on the cylinder rod (16) and is retained with a nut (13). A set screw (12) prevents
11— Cap Seal 12— Set Screw 13— Nut 14— Cushion 15— Barrel 16— Cylinder Rod
17— Rod Guide 18— Bucket Cylinder
loosening of the nut. The piston is fitted with a cap seal (11), wear rings (10), and buffer rings (9). Boom, bucket, and arm cylinders have a cushion (14) in front of the piston to provide cushioning action in cylinder extension. As the cylinder nears the end of its stroke, the cushion enters a bore in the rod guide. The remaining return oil ahead of the piston must flow through a small clearance between the cushion and rod guide. Only the arm cylinder is cushioned in 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. JB3888,0000982 -19-15MAR16-1/1
TM12660 (18APR18)
9025-05-128
041818
PN=798
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 the filter element to prevent leakage. A spring holds the filter element on its seat. Return oil from the oil cooler (5) and the control valve (6) flow through the filter element from the outside to the center. Filtered oil flows out the bottom of filter into the hydraulic oil tank.
6— Return Oil From Control Valve
surges in the return circuit and allows a path for return oil if the filter element becomes plugged. During bypass operation, oil flows into the chamber faster than it can flow through the filter element causing the pressure to increase. The higher pressure forces the bypass valve open allowing oil to flow down the center of the filter element and into the hydraulic oil tank. The bypass valve closes when the pressure decreases below the pressure setting of the bypass valve.
A bypass valve (3) is located at the top of the filter. The valve opens to protect the filter element against pressure JB3888,0000983 -19-18JUN12-1/1
TM12660 (18APR18)
9025-05-129
041818
PN=799
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.) JJ03229,00008E2 -19-16MAR16-1/1
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
TM12660 (18APR18)
9025-05-130
DF89619,00B5D4B -19-03NOV15-1/9
041818
PN=800
Theory of Operation
TX1202733 —UN—19OCT15
110
117
120
118
75 A3
A2
A1
T2
T1
T3
A4
HT
Y10 108
107 604 P
T4
609
76
28 41
90
I
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
97
81
104
DF PI
9
10
TR
11
SR
47
12
152
45
153
95 151 4 SA
SN
SP
3
2
SB
18
TX1202733
1
SH SL
56
SX
SQ
8
7
6
S3
5
13
SM
14
TM12660 (18APR18)
9025-05-131
041818
PN=801
16
170
B60 Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)
Continued on next page
15
DF89619,00B5D4B -19-03NOV15-2/9
Theory of Operation
TM12660 (18APR18)
9025-05-132
041818
PN=802
Theory of Operation 18— To Pump 2 Regulator 28— Pilot Pump 41— Pilot Signal Manifold 45— Swing Park Brake Release Pilot Valve (port SH) 47— Pump 2 Flow Rate Pilot Valve (port SB) 56— To Swing Park Brake
75— Right Travel Spool 76— Bucket Spool 81— Boom 1 Spool 90— Arm 2 Spool 95— Swing Spool 97— Arm 1 Spool 104— Boom 2 Spool 107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve
110— Left Travel Spool 117— Main Relief and Power Dig Valve (P1, P2) 118— Auxiliary Flow Combiner Valve 120— Travel Flow Combiner Valve 151— Auxiliary 2 Spool 152— Arm 3 Spool Continued on next page
TM12660 (18APR18)
9025-05-133
153— Boom 3 Spool 170— Main Relief Valve and Power Dig Valve (P3) 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y10— Pilot Shutoff Solenoid
DF89619,00B5D4B -19-03NOV15-3/9
041818
PN=803
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
TM12660 (18APR18)
9025-05-134
DF89619,00B5D4B -19-03NOV15-4/9
041818
PN=804
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 A2
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 A2 (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. Pilot oil pressure shifts 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 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
TM12660 (18APR18)
604— Return Oil 609— Pilot Oil
9025-05-135
DF89619,00B5D4B -19-03NOV15-5/9
041818
PN=805
Theory of Operation
TM12660 (18APR18)
9025-05-136
041818
PN=806
Theory of Operation
TX1202927 —UN—19OCT15
110 149
117
120
118
148 75
A3
A2
A1
T2
T1
T3
A4
HT
Y10 108
107 604 P
T4
609
76
28 41
90
I
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
97
81
104
DF PI
9
10
TR
11
SR
47
12
152
45
153
95 151 4 SA
SN
SP
3
2
SB
18
TX1202927
1
SH SL
56
SX
SQ
8
7
6
S3
5
13
SM
14
15
TM12660 (18APR18)
9025-05-137
041818
PN=807
170
B60 Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
Continued on next page
16
DF89619,00B5D4B -19-03NOV15-6/9
Theory of Operation
TM12660 (18APR18)
9025-05-138
041818
PN=808
Theory of Operation 18— To Pump 2 Regulator 28— Pilot Pump 41— Pilot Signal Manifold 45— Swing Park Brake Release Pilot Valve (port SH) 47— Pump 2 Flow Rate Pilot Valve (port SB) 56— To Swing Park Brake 75— Right Travel Spool
76— Bucket Spool 81— Boom 1 Spool 90— Arm 2 Spool 95— Swing Spool 97— Arm 1 Spool 104— Boom 2 Spool 107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve 110— Left Travel Spool 117— Main Relief and Power Dig Valve (P1, P2)
118— Auxiliary Flow Combiner Valve 120— Travel Flow Combiner Valve 148— Auxiliary Pilot Solenoid Valve 149— Auxiliary Pilot Pressure Reducing Valve 151— Auxiliary 2 Spool 152— Arm 3 Spool 153— Boom 3 Spool
170— Main Relief Valve and Power Dig Valve (P3) 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y10— Pilot Shutoff Solenoid
DF89619,00B5D4B -19-03NOV15-7/9
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 DF89619,00B5D4B -19-03NOV15-8/9
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 DF89619,00B5D4B -19-03NOV15-9/9
TM12660 (18APR18)
9025-05-139
041818
PN=809
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. DF89619,00B5D4D -19-16OCT15-1/1
TM12660 (18APR18)
9025-05-140
041818
PN=810
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 left control valve (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 left control valve exceeds set pressure of flow rate reducing valve, the valve shifts allowing pilot oil to left control valve to flow to hydraulic oil tank (31) 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
TX1147652 —UN—14NOV13
31
41
Flow Rate Pressure Reducing Valve Schematic 31— To Hydraulic Oil Tank 41— From Pilot Signal Manifold Port SN
74— To Left Control Valve (5-spool) 157— Flow Rate Reducing Valve JJ03229,00008E5 -19-20DEC13-1/1
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 (37) 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 (31). This shifts the secondary auxiliary relief control valve to stop routing high-pressure oil to the secondary auxiliary relief valve.
TX1147647 —UN—14NOV13
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.
37
31
Secondary Relief Valve Solenoid Valve 31— To Hydraulic Oil Tank 37— From Solenoid Valve Manifold Port PE
158— Secondary Auxiliary Relief Valve Solenoid Valve 160— To Secondary Auxiliary Relief Control Valve
For more information, see Secondary Auxiliary Relief Kit Operation. (Group 9015-15.)
Service ADVISOR is a trademark of Deere & Company JJ03229,00008E6 -19-25NOV13-1/1
TM12660 (18APR18)
9025-05-141
041818
PN=811
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
JJ03229,00008E7 -19-25NOV13-1/1
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 (150) 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 JJ03229,00008E8 -19-25NOV13-1/1
TM12660 (18APR18)
9025-05-142
041818
PN=812
Theory of Operation
Selector Valve Solenoid Valve Operation 155
154
TX1147649 —UN—14NOV13
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 (37) 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 (31). For more information, see Auxiliary High Flow Line Kit Operation. (Group 9025-05.)
37
31
Selector Valve Solenoid Valve Schematic 154— Selector Valve Solenoid Valve 155— To Selector Valve
31— To Hydraulic Oil Tank 37— From Solenoid Valve Manifold Port PE
Service ADVISOR is a trademark of Deere & Company JJ03229,00008E9 -19-25NOV13-1/1
Selector Valve Operation 155
NOTE: Selector valve control will not work properly unless appropriate kits are installed on machine.
154
150
A
P T
One-Way Flow Operation
DR
TX1147650 —UN—14NOV13
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
Pilot oil from selector valve solenoid valve (154) shifts selector valve (155) allowing high-pressure oil from auxiliary attachment (150) to flow directly to hydraulic oil tank (31).
31 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.
31— To Hydraulic Oil Tank 37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7
150— From Auxiliary Attachment 154— From Selector Valve Solenoid Valve 155— Selector Valve
For more information, see Auxiliary High Flow Line Kit Operation. (Group 9025-05.) JJ03229,00008EA -19-25NOV13-1/1
TM12660 (18APR18)
9025-05-143
041818
PN=813
Theory of Operation
Auxiliary Shuttle Valve Operation
93
118
The auxiliary shuttle valve (143) allows pilot oil from flow rate select solenoid valve (156) or from diesel particulate filter (DPF) manifold (131) to shift bypass shutoff valve (93). Pilot oil from flow rate select solenoid valve (156) for combined flow, or diesel particulate filter (DPF) manifold for pump loading for diesel particulate filter (DPF) burn, is routed to bypass shutoff valve (93) without backfeeding between the circuits.
• See Control Valve Operation. (Group 9025-05.) • See Two Pump Combined Flow Kit Operation. (Group 9025-05.)
• See Diesel Particulate Filter (DPF) Burn Solenoid Valves. (Group 9025-05.)
93— To Bypass Shutoff Valve 109— Plug 118— To Auxiliary Flow Combiner Valve
131 131— From Diesel Particulate Filter (DPF) Manifold 143— Auxiliary Shuttle Valve 156— From Flow Rate Select Solenoid Valve
156 143
TX1203945 —UN—19OCT15
For more information:
Auxiliary Shuttle Valve Schematic
156 109
131
118
93
TX1203946 —UN—19OCT15
143
Auxiliary Shuttle Valve DF89619,00B5D55 -19-03NOV15-1/1
TM12660 (18APR18)
9025-05-144
041818
PN=814
Theory of Operation
Auxiliary High Flow Line Kit Operation TX1196007 —UN—17JUN15
150
14
13 Y40
107
154 155
30
TA
PA
28 PD
PC
PG
PF
PE
37 PD D1 DD DE DH
PE
DP PJ
DK
PP
DY
DN
DZ
D2 DS
PF
Y27
Y23
Y22
Y29
Y24
600 SD
SC
SF
SE
SG
SI
DM
15 149
TX1196007 Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted by auxiliary pilot oil) Continued on next page
TM12660 (18APR18)
16
9025-05-145
041818
PN=815
604 609 JJ03229,00008ED -19-15JUL15-1/6
Theory of Operation
TM12660 (18APR18)
9025-05-146
041818
PN=816
Theory of Operation
13— Auxiliary (pilot) 14— Auxiliary (pilot) 15— Pump 1 16— Pump 2 28— Pilot Pump 30— Pilot Pressure Regulating Valve 37— Solenoid Valve Manifold
107— Auxiliary Spool 149— Pump 3 150— Auxiliary Attachment 154— Selector Valve 155— Selector Valve Solenoid Valve 600— High-Pressure Oil 604— Return Oil
609— Pilot Oil Y29— Arm 1 Flow Control Y22— Dig Regenerative Solenoid Solenoid (marked SE) (marked SF) Y40— Selector Valve Solenoid Y23— Arm Regenerative Valve Solenoid (marked SC) Y24— Power Dig Solenoid (marked SI) Y27— Arm 2 Flow Control Solenoid (marked SD)
The function of the auxiliary high flow line kit is to operate auxiliary function in one-way flow operation or two-way flow operation. NOTE: Auxiliary attachments will not work properly unless appropriate kits are installed on machine.
The selector valve solenoid valve (Y40) is controlled by Settings in the monitor. For more information, see Attachment Control Circuit Theory of Operation. (Group 9015-15.) JJ03229,00008ED -19-15JUL15-2/6
154— Selector Valve 155— Selector Valve Solenoid 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 (154), see Selector Valve Solenoid Valve Operation. (Group 9025-05.)
Selector Valve Solenoid Valve De-Energized JJ03229,00008ED -19-15JUL15-3/6
154— Selector Valve 155— Selector Valve Solenoid 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 (154), see Selector Valve Solenoid Valve Operation. (Group 9025-05.)
Selector Valve Solenoid Valve Energized Continued on next page
TM12660 (18APR18)
9025-05-147
JJ03229,00008ED -19-15JUL15-4/6
041818
PN=817
Theory of Operation
37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7 154— From Selector Valve 155— Selector Valve Solenoid 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 JJ03229,00008ED -19-15JUL15-5/6
37— To Solenoid Valve Manifold Port DM 74— Control Valve Port A7 154— From Selector Valve 155— Selector Valve Solenoid 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 JJ03229,00008ED -19-15JUL15-6/6
TM12660 (18APR18)
9025-05-148
041818
PN=818
Theory of Operation
Two Way Solenoid Kit Operation TX1202927 —UN—19OCT15
110 149
117
120
118
148 75
A3
A2
A1
T2
T1
T3
A4
HT
Y10 108
107 604 P
T4
609
76
28 41
90
I
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
97
81
104
DF PI
9
10
TR
11
SR
47
12
152
45
153
95 151 4 SA
SN
SP
3
2
SB
18
TX1202927
1
SH SL
56
SX
SQ
8
7
6
S3
5
13
SM
14
15
TM12660 (18APR18)
9025-05-149
041818
PN=819
170
B60 Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
Continued on next page
16
DF89619,00B5D4C -19-03NOV15-1/4
Theory of Operation
TM12660 (18APR18)
9025-05-150
041818
PN=820
Theory of Operation 18— To Pump 2 Regulator 28— Pilot Pump 41— Pilot Signal Manifold 45— Swing Park Brake Release Pilot Valve (port SH) 47— Pump 2 Flow Rate Pilot Valve (port SB) 56— To Swing Park Brake 75— Right Travel Spool
76— Bucket Spool 81— Boom 1 Spool 90— Arm 2 Spool 95— Swing Spool 97— Arm 1 Spool 104— Boom 2 Spool 107— Auxiliary Spool 108— Auxiliary Flow Rate Control Valve 110— Left Travel Spool 117— Main Relief and Power Dig Valve (P1, P2)
NOTE: Two way solenoid kit can be used on auxiliary high flow and auxiliary low flow. The function of two way solenoid kit is to operate the auxiliary function from the left or right pilot control lever momentary and proportional switches. NOTE: The right pilot control lever switches are standard from the factory; left pilot control lever switches are a field kit installation.
118— Auxiliary Flow Combiner Valve 120— Travel Flow Combiner Valve 148— Auxiliary Pilot Solenoid Valve 149— Auxiliary Pilot Pressure Reducing Valve 151— Auxiliary 2 Spool 152— Arm 3 Spool 153— Boom 3 Spool
170— Main Relief Valve and Power Dig Valve (P3) 604— Return Oil 609— Pilot Oil B60— Attachment Pressure Sensor Y10— Pilot Shutoff Solenoid
Pressure Reducing Valve—The auxiliary pilot pressure reducing valve (149) reduces the pressure to the auxiliary pilot 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.
DF89619,00B5D4C -19-03NOV15-2/4
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 DF89619,00B5D4C -19-03NOV15-3/4
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 DF89619,00B5D4C -19-03NOV15-4/4
TM12660 (18APR18)
9025-05-151
041818
PN=821
Theory of Operation
TM12660 (18APR18)
9025-05-152
041818
PN=822
Theory of Operation
Two Pump Combined Flow Kit Operation TX1203306 —UN—16OCT15
150
131 Y44
157
143
156
Y43
118 107 B60
73 74
PE 108
41 56 16
15
14
SM
13
5
S3
6
7
8
SQ
SX
SL SH
1
45
18
17
SB
2
3
SP
SN
SA
47
4
12
SR
11
TR
10
9
48 DH
PI
A4
DF
93
P
15
DR
O
N
M
E
F
G
H
B
C
D L
K
J
I
600
16 604
149
609
TX1203306 Two Pump Combined Flow Kit Schematic (Y43 energized and Y44 de-energized) Continued on next page
TM12660 (18APR18)
A
9025-05-153
041818
PN=823
JJ03229,00008EF -19-03NOV15-1/7
Theory of Operation
TM12660 (18APR18)
9025-05-154
041818
PN=824
Theory of Operation 15— Pump 1 16— Pump 2 17— To Pump 1 Regulator 18— To Pump 2 Regulator 41— Pilot Signal Manifold 45— Swing Park Brake Release Pilot Valve (port SH) 47— Pump 2 Flow Rate Pilot Valve (port SB) 48— Pump 1 Flow Rate Pilot Valve (port SA) 56— To Swing Park Brake
73— Front Control Valve (6-spool) 143— Auxiliary Shuttle Valve DH—To Solenoid Valve Manifold 74— Rear Control Valve (6-spool) 149— Pump 3 (port DH) 93— Bypass Shutoff Valve 150— Auxiliary Attachment PE—From Solenoid Valve 107— Auxiliary Spool 156— Flow Rate Select Solenoid Manifold (port PE) 108— Auxiliary Flow Rate Valve Y43— 2-Speed Activation Control Valve (valve and 157— Flow Rate Select Reducing Solenoid Valve poppet) Valve Y44— Flow Rate Adjustment 118— Auxiliary Flow Combiner 600— High-Pressure Oil Solenoid Valve Valve 604— Return Oil 131— To Diesel Particulate Filter 609— Pilot Oil (DPF) Manifold A4—From Pilot Shutoff Valve (port A4) B60— Attachment Pressure Sensor
NOTE: Two pump combined flow kit will not work properly unless appropriate kits are installed on machine and appropriate work mode is enabled.
flow rate control valve (108) when multiple functions are used with auxiliary attachments.
The function of the two pump combined flow kit is to control auxiliary flow combiner valve (118) and auxiliary JJ03229,00008EF -19-03NOV15-2/7
Auxiliary Shuttle Valve—For more information, see Auxiliary Shuttle Valve Operation. (Group 9025-05.)
118
143— Auxiliary Shuttle Valve 156— From Flow Rate Select Solenoid Valve
131
156 143
TX1203945 —UN—19OCT15
93— To Bypass Shutoff Valve 118— To Auxiliary Flow Combiner Valve 131— From Diesel Particulate Filter (DPF) Manifold
93
Auxiliary Shuttle Valve Schematic Continued on next page
TM12660 (18APR18)
9025-05-155
JJ03229,00008EF -19-03NOV15-3/7
041818
PN=825
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
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 Rear Control Valve 74B— To Rear Control Valve 143— To Auxiliary Shuttle Valve
41C
Flow Rate Pressure Reducing Valve Operating Below Set Pressure JJ03229,00008EF -19-03NOV15-4/7
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
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 Rear Control Valve 74B— From Rear Control Valve 143— To Auxiliary Shuttle Valve
41C 74B
Flow Rate Pressure Reducing Valve Operating Above Set Pressure Continued on next page
TM12660 (18APR18)
9025-05-156
JJ03229,00008EF -19-03NOV15-5/7
041818
PN=826
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
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 Rear Control Valve 74B— To Rear Control Valve 143— To Auxiliary Shuttle Valve
41C
Flow Rate Select Solenoid Valve Energized JJ03229,00008EF -19-03NOV15-6/7
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
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— From Rear Control Valve 74B— To Rear Control Valve 143— To Auxiliary Shuttle Valve
41C 74B
Flow Rate Solenoid Valve De-Energized JJ03229,00008EF -19-03NOV15-7/7
TM12660 (18APR18)
9025-05-157
041818
PN=827
Theory of Operation
TM12660 (18APR18)
9025-05-158
041818
PN=828
Theory of Operation
Secondary Auxiliary Relief Kit Operation TX1148273 —UN—26NOV13
74
150 73
14
13 160
159
107
158
Y41
37
28
600 15 149
TX1148273 Secondary Auxiliary Relief Kit Schematic (auxiliary spool shifted by auxiliary (pilot) (13)) Continued on next page
TM12660 (18APR18)
16
9025-05-159
041818
PN=829
604 609 JJ03229,00008F0 -19-02JAN14-1/4
Theory of Operation
TM12660 (18APR18)
9025-05-160
041818
PN=830
Theory of Operation
13— Auxiliary (pilot) 74— Rear Control Valve (6-spool) 159— Secondary Auxiliary Relief 609— Pilot Oil 14— Auxiliary (pilot) 107— Auxiliary Spool Valve Y41— Secondary Relief Solenoid 15— Pump 1 149— Pump 3 160— Secondary Auxiliary Relief 16— Pump 2 150— Auxiliary Attachment Control Valve 28— Pilot Pump 158— Secondary Auxiliary Relief 600— High-Pressure Oil 37— Solenoid Valve Manifold Valve Solenoid Valve 604— Return Oil 73— Front Control Valve (6-spool)
Secondary auxiliary relief kit is used when optional attachments are installed on the machine needing work port pressure relief.
line of attachments. The secondary auxiliary relief valve solenoid valve (158) 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 Service ADVISOR is a trademark of Deere & Company
JJ03229,00008F0 -19-02JAN14-2/4
Auxiliary Secondary Relief Solenoid Valve De-Energized— When the secondary auxiliary relief valve solenoid valve (158) 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). 219— To Hydraulic Oil Tank 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
158
160 218
219
600
606
604
609
Auxiliary Secondary Relief Solenoid Valve De-Energized
Continued on next page
TM12660 (18APR18)
217 TX1135787 —UN—15MAY13
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
9025-05-161
JJ03229,00008F0 -19-02JAN14-3/4
041818
PN=831
Theory of Operation
159 158
217 TX1136506 —UN—19AUG13
Auxiliary Secondary Relief Solenoid Valve Energized— When the secondary auxiliary relief valve solenoid valve (158) 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).
600 160 218
For more information on secondary relief operation:
219
604 609
Auxiliary Secondary Relief Solenoid Valve Energized
• See Secondary Auxiliary Relief Valve Solenoid Valve Operation. (Group 9025-05.)
• See Secondary Auxiliary Relief Control Valve Operation. (Group 9025-05.)
• See Secondary Auxiliary Relief Valve Operation. (Group 9025-05.)
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 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil
JJ03229,00008F0 -19-02JAN14-4/4
TM12660 (18APR18)
9025-05-162
041818
PN=832
Theory of Operation
Low Flow Kit Operation TX1149215 —UN—19DEC13
R1
A3
141 144
M
A2
A1
T2
T1
AUX A1
14
13
T3
A4
HT
Y10 P
AUX B1
T
3
P
T
4
2
1
2
P
T
4
1
3
2
P
T
4
1
3
B1 P
T4
41 I
TA
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
PA
145 PD
PC
PG
PF
PE
DF PI
37
9
10
TR
11
SR
12
B34
600 4 SA
SN
SP
3
2
SB
1
SH SL
SX
SQ
8
7
6
B33 56 TX1149215 Low Flow Kit Schematic (foot pedal operated) Continued on next page
TM12660 (18APR18)
9025-05-163
041818
PN=833
S3
5
13
SM
14
15
16
604 606 609 JJ03229,00008F1 -19-06JAN14-1/4
Theory of Operation
TM12660 (18APR18)
9025-05-164
041818
PN=834
Theory of Operation
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
600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil B33— Swing Pressure Sensor Continued on next page
TM12660 (18APR18)
9025-05-165
B34— Travel Pressure Sensor
JJ03229,00008F1 -19-06JAN14-2/4
041818
PN=835
Theory of Operation
TM12660 (18APR18)
9025-05-166
041818
PN=836
Theory of Operation
TX1149217 —UN—19DEC13
R1
A3
141
A2
A1
T2
T1
AUX B1
AUX A1
14
13
T3
148 144
M
A4
HT
Y10 P
T
3
P
T
4
2
1
2
P
T
4
1
3
2
P
T
4
1
3
149
B1 P
T4
41 I
TA
J
K
L D
C
B
A
H
G
F
E
M
N
O
DR
P
PA
145 PD
PC
PG
PF
PE
DF PI
37
9
10
TR
11
SR
12
B34
600 4 SA
SN
SP
3
2
SB
1
SH SL
SX
SQ
8
7
6
B33 56
S3
5
13
SM
14
15
16
604 606 609
TX1149217 Low Flow Kit Schematic (solenoid operated) Continued on next page
TM12660 (18APR18)
9025-05-167
041818
PN=837
JJ03229,00008F1 -19-06JAN14-3/4
Theory of Operation
TM12660 (18APR18)
9025-05-168
041818
PN=838
Theory of Operation
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
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.
149— Auxiliary Pressure Reducing Valve 600— High-Pressure Oil 604— Return Oil 606— Trapped Oil 609— Pilot Oil
B33— Swing Pressure Sensor B34— Travel Pressure Sensor Y10— Pilot Shutoff Solenoid
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) JJ03229,00008F1 -19-06JAN14-4/4
TM12660 (18APR18)
9025-05-169
041818
PN=839
Theory of Operation
TM12660 (18APR18)
9025-05-170
041818
PN=840
Group 15
Diagnostic Information All Hydraulic Functions Slow JB3888,0000998 -19-21JAN13-1/15
All Hydraulic Functions Slow Diagnostic Procedure JB3888,0000998 -19-21JAN13-2/15
• 1
Low Hydraulic Oil Level
Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)
YES: Go to Cold Hydraulic Oil.
Is hydraulic oil at proper level?
NO: Fill hydraulic tank to proper level. JB3888,0000998 -19-21JAN13-3/15
• 2
Cold Hydraulic Oil
Check hydraulic oil temperature. See Hydraulic Oil Warm-up Procedure. (Group 9025-25.)
YES: Go to Oil Viscosity Too Heavy.
Does hydraulic oil temperature meet specification?
NO: Perform hydraulic oil warm-up procedure. JB3888,0000998 -19-21JAN13-4/15
• 3
Oil Viscosity Too Heavy
Check hydraulic oil for proper viscosity. See Hydraulic Oil. (Operator’s Manual.)
YES: Go to Slow Engine Speed.
Is specified hydraulic oil used?
NO: Use correct viscosity hydraulic oil for operating conditions. JB3888,0000998 -19-21JAN13-5/15
• 4
Slow Engine Speed
Check engine speed. See Engine Speed Control System Operation. (Group 9010-05.) Also see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
YES: Go to Air Leak in Pump Suction Line.
Does engine speed meet specification?
NO: Select correct engine speed. JB3888,0000998 -19-21JAN13-6/15
• 5
Air Leak in Pump Suction Line
Inspect pump suction line for leaks. See Hydraulic System Component Location. (Group 9025-15.)
YES: Go to Pump Control Pilot Pressure Signal Low.
Is pump suction line free of leaks?
NO: Repair or replace pump suction line. JB3888,0000998 -19-21JAN13-7/15
• 6
Pump Control Pilot Pressure Signal Low
Perform Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
YES: Go to Pilot Circuit Malfunction.
Does pump control pilot pressure meet specification?
NO: Check pump 1, pump 2, or pump 3 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9025-15-1
JB3888,0000998 -19-21JAN13-8/15
041818
PN=841
Diagnostic Information
• 7
Pilot Circuit Malfunction
Check pilot circuit for malfunction.
YES: Go to Restricted Hydraulic Oil Tank Suction Screen.
Is pilot circuit OK?
NO: Repair or replace pilot circuit. JB3888,0000998 -19-21JAN13-9/15
• 8
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 1, Pump 2, or Pump 3 Regulator Malfunction.
Is hydraulic oil tank suction screen free of restriction?
NO: Clean or replace hydraulic oil tank suction screen. JB3888,0000998 -19-21JAN13-10/15
• 9
Pump 1, Pump 2, or Pump 3 Regulator Malfunction
Check pump 1, pump 2, or pump 3 regulator. See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)
YES: Go to Worn Pump.
Does pump 1, pump 2, or pump 3 regulator meet specification?
NO: Repair or replace pump 1, pump 2, or pump 3 regulator. See Pump 1, 2, and 3 Regulator Disassemble and Assemble. (Group 3360.) JB3888,0000998 -19-21JAN13-11/15
•
10 Worn Pump
Slow travel cycle times may indicate a worn pump. Check travel cycle times. See Operational Checkout. (Group 9005-10.) If travel cycle times do not meet specification, check pump flow. See Pump Flow Test. (Group 9025-25.)
YES: Go to Main Relief Valve Setting Too Low or Malfunctioning.
Do travel cycle times and pump flow meet specification?
NO: Repair or replace pump. See Pump 1, 2, and 3 Remove and Install. (Group 3360.) JB3888,0000998 -19-21JAN13-12/15
•
11 Main Relief Valve Setting Too Low or Malfunctioning
Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Power Dig Solenoid Valve Setting Too Low or Malfunctioning.
Does main relief valve settings meet specification?
NO: Adjust or replace main relief valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9025-15-2
JB3888,0000998 -19-21JAN13-13/15
041818
PN=842
Diagnostic Information
•
12 Power Dig Solenoid Valve Setting Too Low or Malfunctioning
See Power Dig Solenoid Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Low Pilot Oil Pressure.
Does power dig solenoid valve setting meet specification?
NO: Adjust or replace power dig solenoid valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,0000998 -19-21JAN13-14/15
•
13 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: Diagnostic checkout complete. NO: Adjust, repair or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) JB3888,0000998 -19-21JAN13-15/15
Hydraulic Oil Overheats JB3888,0000999 -19-21JAN13-1/11
Hydraulic Oil Overheats Diagnostic Procedure JB3888,0000999 -19-21JAN13-2/11
• 1
Low Hydraulic Oil Level
Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)
YES: Go to Restricted Hydraulic Oil Cooler.
Is hydraulic oil at proper level?
NO: Fill hydraulic tank to proper level. JB3888,0000999 -19-21JAN13-3/11
• 2
Restricted Hydraulic Oil Cooler
Inspect hydraulic oil cooler.
YES: Go to Oil Viscosity Too Light.
Is hydraulic oil cooler free of restriction?
NO: Clean, repair or replace hydraulic oil cooler. JB3888,0000999 -19-21JAN13-4/11
• 3
Oil Viscosity Too Light Check hydraulic oil for correct viscosity. See Hydraulic Oil. (Operator’s Manual.)
Is specified hydraulic oil used?
NO: Use correct viscosity hydraulic oil for operating conditions. Continued on next page
TM12660 (18APR18)
YES: Go to Machine Lift Capacity Exceeded.
9025-15-3
JB3888,0000999 -19-21JAN13-5/11
041818
PN=843
Diagnostic Information
• 4
Machine Lift Capacity Exceeded
Check machine lift capacity. See Miscellaneous—Specifications. (Operator's Manual.)
YES: Go to Restricted Hydraulic Oil Return Filter.
Is amount of weight being lifted within machine lifting capacity?
NO: Reduce amount of weight being lifted. JB3888,0000999 -19-21JAN13-6/11
• 5
Restricted Hydraulic Oil Return Filter
Check hydraulic oil return filter for restriction. See Hydraulic System Component Location. (Group 9025-15.)
YES: Replace hydraulic oil tank return filter. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
Is hydraulic oil tank return filter restricted?
NO: Go to Main Relief Valve Setting Too Low or Malfunctioning. JB3888,0000999 -19-21JAN13-7/11
• 6
Main Relief Valve Setting Too Low or Malfunctioning
Perform main relief valve test and adjustment. See Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Power Dig Valve Setting Too Low or Malfunctioning.
Does main relief valve operate correctly?
NO: Replace main relief valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,0000999 -19-21JAN13-8/11
• 7
Power Dig Valve Setting Too Low or Malfunctioning
Perform Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Oil Cooler Bypass Valve Stuck Open.
Is power dig valve operating correctly?
NO: Replace power dig valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,0000999 -19-21JAN13-9/11
• 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 Pump Stuck at Maximum Displacement.
Does oil cooler bypass valve operate correctly?
NO: Replace oil cooler bypass valve.
Continued on next page
TM12660 (18APR18)
9025-15-4
JB3888,0000999 -19-21JAN13-10/11
041818
PN=844
Diagnostic Information
• 9
Pump Stuck at Maximum Displacement
See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)
YES: Diagnostic checkout complete.
Does pump control pilot pressure meet specification?
NO: Repair or replace pump 1, pump 2, or pump 3 regulator. See Pump 1, 2, and 3 Regulator Remove and Install. (Group 3360.) NO: Check pump 1, pump 2, or pump 3 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JB3888,0000999 -19-21JAN13-11/11
No Hydraulic Functions JB3888,000099A -19-21JAN13-1/7
No Hydraulic Functions Diagnostic Procedure JB3888,000099A -19-21JAN13-2/7
• 1
Pilot Shutoff Lever in Locked (UP) 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. JB3888,000099A -19-21JAN13-3/7
• 2
Pilot Shutoff Solenoid Malfunction
Check pilot shutoff solenoid. See Solenoid Test. (Group 9015-20.)
YES: Go to Low Hydraulic Oil Level.
Does pilot shutoff solenoid operate correctly?
NO: See Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.) JB3888,000099A -19-21JAN13-4/7
• 3
Low Hydraulic Oil Level
Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)
YES: Go to Pump Drive Malfunction.
Is hydraulic oil at proper level?
NO: Add proper hydraulic oil. See Hydraulic Oil. (Operator’s Manual.) JB3888,000099A -19-21JAN13-5/7
• 4
Pump Drive Malfunction
Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install. (Group 0752.)
YES: Go to Restricted Hydraulic Oil Tank Suction Screen.
Does damper drive (flex coupling) operate correctly?
NO: Repair or replace damper drive (flex coupling).
Continued on next page
TM12660 (18APR18)
9025-15-5
JB3888,000099A -19-21JAN13-6/7
041818
PN=845
Diagnostic Information
• 5
Restricted Hydraulic Oil Tank Suction Screen
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
YES: Diagnostic checkout complete.
Is hydraulic oil tank suction screen free of restriction?
NO: Clean or replace hydraulic oil tank suction screen. JB3888,000099A -19-21JAN13-7/7
Poor Combined Operation JB3888,000099B -19-21JAN13-1/5
Poor Combined Operation Diagnostic Procedure JB3888,000099B -19-21JAN13-2/5
• 1
Front Attachment Check front attachment pressure sensor (B32) or travel pressure sensor (B34). See Pressure Sensor Pressure Sensor Test. (Group 9015-20.) (B32) or Travel Pressure Sensor (B34) Malfunction
Does front attachment pressure sensor (B32) or travel pressure sensor (B34) operate correctly?
YES: Go to Pilot Control Valve Malfunction.
NO: Replace front attachment pressure sensor (B32) or travel pressure sensor (B34). JB3888,000099B -19-21JAN13-3/5
• 2
Pilot Control Valve Malfunction
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Check Valves or Pump 1, Pump 2, and Pump 3 Flow Rate Pilot Valve Stuck.
Does control valve spool actuating pressure meet specification?
NO: Inspect, repair or replace pilot control valve. See Pilot Shutoff Solenoid Valve Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9025-15-6
JB3888,000099B -19-21JAN13-4/5
041818
PN=846
Diagnostic Information
• 3
Check Valves or Pump Inspect check valves. See Control Valve Check Valves Identification and Operation. 1, Pump 2, and Pump (Group 9025-05.) 3 Flow Rate Pilot Valve Stuck
YES: Diagnostic checkout complete.
Inspect pump 1, pump 2, or pump 3 flow rate pilot valves. See Pilot Signal Manifold Operation. (Group 9025-05.)
NO: Repair or replace check valve. See Control Valve Front (6-Spool) Disassemble and Assemble Also See Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.)
Do check valves or flow rate pilot valves operate correctly?
NO: Repair or replace flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JB3888,000099B -19-21JAN13-5/5
All Functions Cannot Be Operated JB3888,000099C -19-29AUG12-1/5
All Functions Cannot Be Operated Diagnostic Procedure JB3888,000099C -19-29AUG12-2/5
• 1
Pilot Shutoff Lever in Unlocked (DOWN) Position
Check position of pilot shutoff lever.
YES: Go to Pilot Shutoff Solenoid Malfunction.
Is pilot shutoff lever in the unlocked (DOWN) position?
NO: Place pilot shutoff lever in unlocked (DOWN) position. JB3888,000099C -19-29AUG12-3/5
• 2
Pilot Shutoff Solenoid Malfunction
Check pilot shutoff solenoid. See Solenoid Test. (Group 9015-20.)
YES: Go to Low Pilot Oil Pressure.
Does pilot shutoff solenoid operate correctly?
NO: See Pilot Shutoff Circuit Theory of Operation. (Group 9015-15.)
Continued on next page
TM12660 (18APR18)
9025-15-7
JB3888,000099C -19-29AUG12-4/5
041818
PN=847
Diagnostic Information
• 3
Low Pilot Oil Pressure Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) Does pilot pressure meet specification?
YES: Diagnostic checkout complete. NO: Adjust, repair or replace pilot pressure valve. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) NO: Pilot pump worn. Inspect, repair or replace pilot pump. See Pilot Pump Remove and Install. (Group 3360.) JB3888,000099C -19-29AUG12-5/5
Function Does Not Stop When Control Lever Released JB3888,000099E -19-21JAN13-1/5
Function Does Not Stop When Control Lever Released Diagnostic Procedure JB3888,000099E -19-21JAN13-2/5
• 1
Control Valve Spool Stuck
Inspect control valve spool. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.)
YES: Go to Pilot Signal Manifold Malfunction.
Do control valve spools move freely?
NO: Repair or replace control valve components. JB3888,000099E -19-21JAN13-3/5
• 2
Pilot Signal Manifold Malfunction
Inspect pilot signal manifold for sticking spools. See Pilot Signal Manifold Disassemble YES: Go to Left and Right and Assemble. (Group 3360.) Pilot Valve Malfunction.
Do pilot signal manifold spools move freely?
NO: Repair or replace pilot signal manifold. JB3888,000099E -19-21JAN13-4/5
• 3
Left and Right Pilot Valve Malfunction
Inspect left and right pilot valve spools. See Pilot Valve (Left and Right) Disassemble and Assemble. (Group 3360.)
YES: Diagnostic checkout complete.
Do left and right pilot valve spools move freely?
NO: Repair or replace left and right pilot valves. JB3888,000099E -19-21JAN13-5/5
Some Functions Cannot Be Operated, All Others Are Normal JB3888,000099F -19-21JAN13-1/6
Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9025-15-8
JB3888,000099F -19-21JAN13-2/6
041818
PN=848
Diagnostic Information
• 1
Pilot Cap Loose
Inspect pilot cap for leakage or damage. Check pilot cap screws for proper torque specification. See Control Valve Halves Disassemble and Assemble. (Group 3360.)
YES: Go to Pilot Control Valve or Hydraulic Line Malfunction.
Do control valve components meet specification?
NO: Repair or replace control valve components. JB3888,000099F -19-21JAN13-3/6
• 2
Pilot Control Valve or Hydraulic Line Malfunction
Inspect pilot control valve or hydraulic lines for function that can not be operated. Check YES: Go to Pump 1, Pump for leaks or damage. See Pilot Control Valve-to-Pilot Signal Manifold Component 2, or Pump 3 Flow Rate Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Pilot Valve Spool Stuck. Component Location—Backhoe Pattern and see Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.) Are components free of leaks or damage?
NO: Inspect, repair or replace leaking or damaged components. JB3888,000099F -19-21JAN13-4/6
• 3
Pump 1, Pump 2, or Inspect pump 1, pump 2, or pump 3 flow rate pilot valves. See Pilot Signal Manifold Pump 3 Flow Rate Pilot Operation. (Group 9025-05.) Valve Spool Stuck
Do flow rate pilot spools move freely?
YES: Go to Control Valve Spool Stuck.
NO: Repair or replace pilot signal flow rate pilot spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JB3888,000099F -19-21JAN13-5/6
• 4
Control Valve Spool Stuck
Inspect control valve spools. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.)
YES: Diagnostic checkout complete.
Do control valve spools move freely?
NO: Repair or replace control valve components. JB3888,000099F -19-21JAN13-6/6
All Functions Slow JB3888,00009A0 -19-28AUG12-1/6
All Functions Slow Diagnostic Procedure JB3888,00009A0 -19-28AUG12-2/6
• 1
Restricted Pilot Filter
Inspect pilot filter for restriction. See Hydraulic System Component Location. (Group 9025-15.)
YES: Go to Torque Control Solenoid Malfunction.
Is pilot filter free of restriction?
NO: Replace pilot filter. See Replace Pilot Oil Filter. (Operator’s Manual.) Continued on next page
TM12660 (18APR18)
9025-15-9
JB3888,00009A0 -19-28AUG12-3/6
041818
PN=849
Diagnostic Information
• 2
Torque Control Solenoid Malfunction
Check torque control solenoid connection. Check torque control solenoid. See Proportional Solenoid Test. (Group 9015-20.)
Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Low Pilot Oil Pressure.
Is torque control solenoid and solenoid valve operate correctly?
NO: Repair or replace torque control solenoid and solenoid valve. JB3888,00009A0 -19-28AUG12-4/6
• 3
Low Pilot Oil Pressure Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) Does pilot pressure meet specification?
YES: Go to Restricted Pilot Shutoff Solenoid Valve. NO: Adjust or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) NO: Pilot pump worn. See Pilot Pump Remove and Install. (Group 3360.) JB3888,00009A0 -19-28AUG12-5/6
• 4
Restricted Pilot Inspect pilot shutoff solenoid valve for restriction. See Hydraulic System Component Shutoff Solenoid Valve Location. (Group 9025-15.)
Is pilot shutoff solenoid valve free of restriction?
YES: Diagnostic checkout complete.
NO: Repair or replace pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.) JB3888,00009A0 -19-28AUG12-6/6
Functions Move in Opposite Direction JB3888,00009A1 -19-08JUN12-1/3
Functions Move in Opposite Direction Diagnostic Procedure JB3888,00009A1 -19-08JUN12-2/3
• 1
Pilot Control Hoses Connected Incorrectly
Check pilot control hose connections. See Control Lever Pattern Operation. (Operator's Manual.)
See Pilot Signal Manifold-to-Control Valve Line Connection. Also see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.)
YES: Diagnostic checkout complete.
Are pilot control hoses connected correctly?
NO: Correct pilot control hose connections. JB3888,00009A1 -19-08JUN12-3/3
All Dig Functions Slow or No Power Continued on next page
TM12660 (18APR18)
9025-15-10
JB3888,00009A2 -19-21JAN13-1/5
041818
PN=850
Diagnostic Information All Dig Functions Slow or No Power JB3888,00009A2 -19-21JAN13-2/5
• 1
Hydraulic System Malfunction
Inspect hydraulic system for malfunctions. See All Hydraulic Functions Slow. (Group 9025-15.)
YES: Go to Pilot Circuit Malfunction.
Is hydraulic system operating correctly?
NO: Repair or replace hydraulic system component causing malfunction. JB3888,00009A2 -19-21JAN13-3/5
• 2
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated. (Group 9025-15.)
YES: Go to Pump 1, Pump 2, or Pump 3 Regulator Malfunction.
Is pilot circuit operating correctly?
NO: Repair or replace pilot circuit component causing malfunction. JB3888,00009A2 -19-21JAN13-4/5
• 3
Pump 1, Pump 2, and Pump 3 Regulator Malfunction
YES: Diagnostic checkout Check pump 1, pump 2, or pump 3 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test and Adjustment—Maximum complete. Flow. (Group 9025-25.)
Does pump 1, pump 2, or pump 3 regulator meet specification?
NO: Repair or replace pump 1, pump 2, or pump 3 regulator. See Pump 1, 2, and 3 Regulator Remove and Install. (Group 3360.) JB3888,00009A2 -19-21JAN13-5/5
Some Dig Functions Slow (Not All) JB3888,00009A3 -19-21JAN13-1/8
Some Dig Functions Slow (Not All) Diagnostic Procedure JB3888,00009A3 -19-21JAN13-2/8
• 1
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See All Functions Cannot Be Operated. (Group 9025-15.)
YES: Go to Control Valve Leakage.
Is pilot circuit operating correctly?
NO: Repair or replace pilot circuit component causing malfunction. Continued on next page
TM12660 (18APR18)
9025-15-11
JB3888,00009A3 -19-21JAN13-3/8
041818
PN=851
Diagnostic Information
• 2
Control Valve Leakage Inspect control valve for leakage. See Travel System Component Location. (Group 9025-15.) Is control valve free of leaks?
YES: Go to Cylinder Leakage. NO: Repair or replace control valve components. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A3 -19-21JAN13-4/8
• 3
Cylinder Leakage
Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket. (Group 9025-25.)
YES: Go to Circuit Relief Valve Setting Too Low or Malfunctioning.
Are cylinders free of leaks?
NO: Repair or replace cylinder. See Boom Cylinder Remove and Install, see Arm Cylinder Remove and Install or see Bucket Cylinder Remove and Install. (Group 3360.) JB3888,00009A3 -19-21JAN13-5/8
• 4
Circuit Relief Valve Setting Too Low or Malfunctioning
Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Control Valve Spool Stuck.
Do circuit relief valve settings meet specification?
NO: Adjust, repair or replace circuit relief valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A3 -19-21JAN13-6/8
• 5
Control Valve Spool Stuck
Inspect control valve for stuck spool. See Control Valve Operation. (Group 9025-05.)
YES: Go to Pump 1, Pump 2, or Pump 3 Flow Rate Pilot Valve Spool Stuck.
Do control valve spools move freely?
NO: Repair or replace control valve components. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A3 -19-21JAN13-7/8
• 6
Pump 1, Pump 2, or Inspect pump 1, pump 2, or pump 3 flow rate pilot valves? See Pilot Signal Manifold Pump 3 Flow Rate Pilot Operation. (Group 9025-05.) Valve Spool Stuck
Do flow rate pilot valve spools move freely?
YES: Diagnostic checkout complete.
NO: Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JB3888,00009A3 -19-21JAN13-8/8
TM12660 (18APR18)
9025-15-12
041818
PN=852
Diagnostic Information
Load Drifts Down When Control Lever is in Neutral Position JB3888,00009A4 -19-21JAN13-1/6
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure JB3888,00009A4 -19-21JAN13-2/6
• 1
Cylinder Leakage
Inspect cylinders for leaks. See Cylinder Drift Test—Boom, Arm, and Bucket. (Group 9025-25.)
YES: Go to Circuit Relief Valve Setting Too Low or Malfunctioning.
Are cylinders free of leaks?
NO: Repair or replace cylinder. See Boom Cylinder Remove and Install, see Arm Cylinder Remove and Install and see Bucket Cylinder Remove and Install. (Group 3360.) JB3888,00009A4 -19-21JAN13-3/6
• 2
Circuit Relief Valve Setting Too Low or Malfunctioning
Check circuit relief valve setting of slow function. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Boom Manual Lower Screw Loose.
Do circuit relief valve settings meet specification?
NO: Adjust, repair or replace circuit relief valve. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A4 -19-21JAN13-4/6
• 3
Boom Manual Lower Screw Loose
Inspect boom manual lower screw. See Lower Boom with Engine Stopped. (Operator’s YES: Go to Control Valve Manual.) Leakage.
Is boom manual lower screw tightened to specification?
NO: Tighten boom manual lower screw to specification. JB3888,00009A4 -19-21JAN13-5/6
• 4
Control Valve Leakage Inspect control valve for leakage. See Travel System Component Location. (Group 9025-15.) Is control valve free of leaks?
YES: Diagnostic checkout complete. NO: Repair or replace control valve components. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A4 -19-21JAN13-6/6
Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle Continued on next page
TM12660 (18APR18)
9025-15-13
JB3888,00009A5 -19-21JAN13-1/3
041818
PN=853
Diagnostic Information Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle Diagnostic Procedure JB3888,00009A5 -19-21JAN13-2/3
• 1
Lift Check Valve Leakage
Inspect control valve check valves for leakage. See Control Valve Check Valves Identification and Operation and see Control Valve Operation. (Group 9025-05.)
YES: Diagnostic checkout complete.
Are check valves operating correctly?
NO: Repair or replace control valve components. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A5 -19-21JAN13-3/3
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal 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.
JB3888,00009A6 -19-03JUL12-1/5
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure JB3888,00009A6 -19-03JUL12-2/5
• 1
Slow Engine Speed
Check engine speed and power mode setting. See Engine Speed Control System Operation. (Group 9010-05.)
YES: Go to Pressure Sensor Malfunction.
Does engine speed meet specification?
NO: Select correct engine speed and power mode setting. Continued on next page
TM12660 (18APR18)
9025-15-14
JB3888,00009A6 -19-03JUL12-3/5
041818
PN=854
Diagnostic Information
• 2
Pressure Sensor Malfunction
Check pressure readings of the following pressure sensors.
• Pump 1 Delivery Pressure • Pump 2 Delivery Pressure • Pump 3 Delivery Pressure • Boom Up Pilot Pressure • Arm In Pilot Pressure • Bucket In Pressure Pressure readings can be viewed using the monitor service menu. See Service Menu. (Group 9015-16.) Actuate arm in or boom up function to view reading. Compare pump 1, pump 2, and pump 3 pressure readings to main relief and power dig valve specification. See Main Relief and Power Dig Valve Test and Adjustment and see Power Dig Solenoid Valve Test and Adjustment. (Group 9025-25.)
YES: Go to Power Mode Button Malfunction.
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.)
NO: Replace pressure sensors as required. For pump 1, pump 2, and pump 3 pressure sensor locations, see Pump Harness (W8) Component Location. (Group 9015-10.) For boom up and arm in pressure sensor locations, see Machine Harness (W2) Component Location. (Group 9015-10.)
Do pressure readings meet specification?
NO: Check wiring harness for pump 1, pump 2, and pump 3 pressure sensors. See Pump Harness (W8) Component Location. (Group 9015-10.) Check wiring harness for boom up and arm in pressure sensors. See Machine Harness (W2) Component Location. (Group 9015-10.) JB3888,00009A6 -19-03JUL12-4/5
• 3
Power Mode Button Malfunction
Check power mode button using the monitor service menu. See Service Menu. (Group 9015-16.)
Select power mode to display switch position. Press power mode button to ECO, PWR YES: Diagnostic checkout and H/P positions. Monitor service display should correspond with switch position. complete. Does monitor service menu correspond with switch position?
NO: Check wiring harness. See Machine Harness (W2) Component Location. (Group 9015-10.) JB3888,00009A6 -19-03JUL12-5/5
Swing Speed Slow in Both Directions Continued on next page
TM12660 (18APR18)
9025-15-15
JB3888,00009A7 -19-21JAN13-1/8
041818
PN=855
Diagnostic Information Swing Speed Slow in Both Directions Diagnostic Procedure JB3888,00009A7 -19-21JAN13-2/8
• 1
Slow Engine Speed
Check engine speed. See Engine Speed Control System Operation. (Group 9010-05.) Also see Main Controller (MCZ) Circuit Theory of Operation. (Group 9015-15.)
YES: Go to Swing Motor Crossover Relief Valve Malfunction.
Does engine speed meet specification?
NO: Select correct engine speed. JB3888,00009A7 -19-21JAN13-3/8
• 2
Swing Motor Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Malfunction
YES: Go to Control Valve Leakage.
Does swing motor crossover relief valve meet specification?
NO: Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) JB3888,00009A7 -19-21JAN13-4/8
• 3
Control Valve Leakage Inspect swing valve spool in control valve for leakage. For component location, see Control Valve Operation. (Group 9025-05.) Is swing valve spool OK?
YES: Go to Swing Motor Leakage. NO: Repair or replace control valve components as necessary. See Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A7 -19-21JAN13-5/8
• 4
Swing Motor Leakage
Inspect swing motor for leakage. See Swing Motor Leakage Test. (Group 9025-25.)
YES: Go to Swing Park Brake Not Fully Released.
Does swing motor meet specification?
NO: Repair or replace swing motor. See Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake Assemble. (Group 4360.) JB3888,00009A7 -19-21JAN13-6/8
• 5
Swing Park Brake Not Fully Released
Inspect pump 1, pump 2, or pump 3 flow rate pilot valves. See Pilot Signal Manifold Operation. (Group 9025-05.)
YES: Go to Pump 1, Pump 2, and Pump 3 Worn.
Do flow rate pilot valve spools move freely?
NO: Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
Continued on next page
TM12660 (18APR18)
9025-15-16
JB3888,00009A7 -19-21JAN13-7/8
041818
PN=856
Diagnostic Information
• 6
Pump 1, Pump 2, and Pump 3 Worn
Slow travel cycle times may indicate worn pump. Check travel cycle times. See 245GLC 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: Diagnostic checkout complete.
Do travel cycle times and pump flow meet specification?
NO: Repair or replace pump. See Pump 1, 2, and 3 Remove and Install. (Group 3360.) JB3888,00009A7 -19-21JAN13-8/8
Swing Speed Slow or Does Not Operate in One Direction JB3888,00009A8 -19-21JAN13-1/6
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure JB3888,00009A8 -19-21JAN13-2/6
• 1
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See Pilot System Operation. (Group 9025-05.)
YES: Go to Swing Motor Make-Up Check Valve Leakage.
Is pilot circuit OK?
NO: Repair or replace pilot circuit malfunction. JB3888,00009A8 -19-21JAN13-3/6
• 2
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 valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) JB3888,00009A8 -19-21JAN13-4/6
• 3
Swing Motor Inspect swing motor crossover relief valve. See Swing Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Malfunction
YES: Go to Control Valve Sticking.
Does swing motor crossover relief valve meet specification?
NO: Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.)
Continued on next page
TM12660 (18APR18)
9025-15-17
JB3888,00009A8 -19-21JAN13-5/6
041818
PN=857
Diagnostic Information
• 4
Control Valve Sticking
Inspect control valve for sticking spool. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Diagnostic checkout complete.
Does control valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009A8 -19-21JAN13-6/6
Upperstructure Drift With Swing Valve in Neutral JB3888,00009A9 -19-04JUN13-1/9
Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure JB3888,00009A9 -19-04JUN13-2/9
• 1
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 not engaging.
Does swing continue to drift after releasing controller for 10 seconds?
NO: Go to Drift direction. JB3888,00009A9 -19-04JUN13-3/9
• 2
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. JB3888,00009A9 -19-04JUN13-4/9
• 3
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, see Swing Motor and Park Brake Disassemble, and see Swing Motor and Park Brake Assemble. (Group 4360.)
Continued on next page
TM12660 (18APR18)
9025-15-18
JB3888,00009A9 -19-04JUN13-5/9
041818
PN=858
Diagnostic Information
• 4
Damper valve malfunction
Inspect swing motor dampener valves. See Swing Motor Damper Valve. (Group 9025-05.)
YES: Diagnostic checkout 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.) JB3888,00009A9 -19-04JUN13-6/9
• 5
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 and see Make-Up Check Valve Disassemble and Assemble. (Group 4360.) JB3888,00009A9 -19-04JUN13-7/9
• 6
Swing motor crossover relief valve malfunction
Remove crossover relief valves and install in opposite ports in park brake housing. See YES: Repair or replace Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) crossover relief valves. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) Does swing drift change directions?
NO: Diagnostic checkout complete. JB3888,00009A9 -19-04JUN13-8/9
• 7
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: Diagnostic checkout 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, see Swing Motor and Park Brake Disassemble, and see Swing Motor and Park Brake Assemble. (Group 4360.) JB3888,00009A9 -19-04JUN13-9/9
Swing Function Does Not Operate JB3888,00009AA -19-21JAN13-1/6
Swing Function Does Not Operate Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9025-15-19
JB3888,00009AA -19-21JAN13-2/6
041818
PN=859
Diagnostic Information
• 1
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See Pilot System Operation. (Group 9025-05.)
YES: Go to Swing Park Brake Malfunction.
Is pilot circuit OK?
NO: Repair or replace pilot circuit malfunction. JB3888,00009AA -19-21JAN13-3/6
• 2
Swing Park Brake Malfunction
Inspect pump 1, pump 2, or pump 3 flow rate pilot valves. See Pilot Signal Manifold Operation. (Group 9025-05.)
YES: Go to Control Valve Stuck.
Do flow rate pilot valve spools move freely?
NO: Repair or replace pilot signal manifold flow rate pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) JB3888,00009AA -19-21JAN13-4/6
• 3
Control Valve Stuck
Inspect for stuck swing valve spool in control valve. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Go to Mechanical Malfunction of Swing Motor or Gear Case.
Does swing valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,00009AA -19-21JAN13-5/6
• 4
Mechanical Malfunction of Swing Motor or Gear Case
Inspect swing motor and gear case.
YES: Diagnostic checkout complete.
Are swing motor and gear case OK?
NO: Repair or replace swing motor and gear case. See Swing Gear Case Disassemble and Assemble. (Group 4350.) Also see Swing Motor and Park Brake Disassemble and see Swing Motor and Park Brake Assemble. (Group 4360.) JB3888,00009AA -19-21JAN13-6/6
Travel Park Brakes Do Not Apply JB3888,00009AB -19-21JAN13-1/4
Travel Park Brakes Do Not Apply Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9025-15-20
JB3888,00009AB -19-21JAN13-2/4
041818
PN=860
Diagnostic Information
• 1
Counterbalance Valve Spool Stuck, Oil Not Releasing From Piston Cavity
Inspect counterbalance valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Go to Mechanical Malfunction of Travel Motor and Gear Case.
NO: Repair or replace counterbalance valve. JB3888,00009AB -19-21JAN13-3/4
• 2
Mechanical Malfunction of Travel Motor and Gear Case
Inspect travel motor and gear case for mechanical malfunction. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) Also see Travel Gear Case Disassemble and Assemble. (Group 0250.)
YES: Diagnostic checkout complete.
Is travel motor and gear case OK?
NO: Repair or replace travel motor or gear case. JB3888,00009AB -19-21JAN13-4/4
Track Will Not Move in One Direction JB3888,00009AC -19-21JAN13-1/7
Track Will Not Move in One Direction Diagnostic Procedure JB3888,00009AC -19-21JAN13-2/7
• 1
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See Pilot System Operation. (Group 9025-05.)
YES: Go to Travel Motor Crossover Relief Valve Malfunction.
Is pilot circuit OK?
NO: Repair or replace pilot circuit malfunction. JB3888,00009AC -19-21JAN13-3/7
• 2
Travel Motor Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Malfunction
Is travel motor crossover relief valve OK?
YES: Go to Control Valve Stuck.
NO: Repair or replace travel motor crossover relief valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,00009AC -19-21JAN13-4/7
• 3
Control Valve Stuck
Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Go to Counterbalance Valve Spool Stuck.
Does travel valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve Front (6-Spool) Disassemble and Assemble. (Group 3360.) Continued on next page
TM12660 (18APR18)
9025-15-21
JB3888,00009AC -19-21JAN13-5/7
041818
PN=861
Diagnostic Information
• 4
Counterbalance Valve Spool Stuck
Inspect counterbalance valve. See Travel Motor and Park Brake Valve Operation. (Group 9025-05.)
YES: Go to Center Joint Leakage.
Does counterbalance valve spool move freely?
NO: Repair or replace counterbalance valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,00009AC -19-21JAN13-6/7
• 5
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 4360.)
YES: Diagnostic checkout complete.
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Disassemble and Assemble. (Group 4360.) JB3888,00009AC -19-21JAN13-7/7
Track Will Not Move in Either Direction JB3888,0000997 -19-21JAN13-1/8
Track Will Not Move in Either Direction Diagnostic Procedure JB3888,0000997 -19-21JAN13-2/8
• 1
Pilot Circuit Malfunction
Inspect pilot circuit for malfunction. See Pilot System Operation. (Group 9025-05.)
YES: Go to Travel Motor Crossover Relief Valve Malfunction.
Is pilot circuit OK?
NO: Repair or replace pilot circuit malfunction. JB3888,0000997 -19-21JAN13-3/8
• 2
Travel Motor Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Malfunction
Is travel motor crossover relief valve OK?
Continued on next page
TM12660 (18APR18)
9025-15-22
YES: Go to Control Valve Stuck.
NO: Repair or replace travel motor crossover relief valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,0000997 -19-21JAN13-4/8
041818
PN=862
Diagnostic Information
• 3
Control Valve Stuck
Inspect for stuck travel valve spool in control valve. For component location, see Control Valve Operation. (Group 9025-05.)
YES: Go to Counterbalance Valve Spool Stuck.
Does travel valve spool move freely?
NO: Repair or replace control valve components as necessary. See Control Valve Front (6-Spool) Disassemble and Assemble Also See Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,0000997 -19-21JAN13-5/8
• 4
Counterbalance Valve Spool Stuck
Inspect counterbalance valve.
YES: Go to Mechanical Malfunction of Travel Motor or Gear Case.
Does counterbalance valve spool move freely?
NO: Repair or replace counterbalance valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,0000997 -19-21JAN13-6/8
• 5
Mechanical Malfunction of Travel Motor or Gear Case
Inspect travel motor and gear case for mechanical malfunction. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) Also see Travel Gear Case Disassemble and Assemble. (Group 0250.)
YES: Go to Center Joint Leakage.
Is travel motor and gear case OK?
NO: Repair or replace travel motor or gear case. JB3888,0000997 -19-21JAN13-7/8
• 6
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 0260.)
YES: Diagnostic checkout complete.
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Remove and Install. (Group 4360.) JB3888,0000997 -19-21JAN13-8/8
Machine Mistracks at All Speeds in Both Directions JB3888,0000996 -19-21JAN13-1/9
Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure JB3888,0000996 -19-21JAN13-2/9
• 1
Incorrect Track Sag Adjustment
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Pilot Control Valve Malfunction.
Is track sag within specification?
NO: Adjust track sag. Continued on next page
TM12660 (18APR18)
9025-15-23
JB3888,0000996 -19-21JAN13-3/9
041818
PN=863
Diagnostic Information
• 2
Pilot Control Valve Malfunction
Check control valve spool actuating pilot pressure. See Control Valve Spool Actuating Pilot Pressure Test. (Group 9025-25.)
YES: Go to Travel Motor Crossover Relief Valve.
Does control valve spool actuating pilot pressure meet specification?
NO: Inspect, repair or replace pilot control valve. See Pilot Valve (Left and Right) Disassemble and Assemble and see Travel Pilot Valve Disassemble and Assemble. (Group 3360.) JB3888,0000996 -19-21JAN13-4/9
• 3
Travel Motor Inspect travel motor crossover relief valves. See Travel Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.)
Are travel motor crossover relief valves OK?
YES: Go to Servo Piston Shuttle Valve Leakage.
NO: Repair or replace travel motor crossover relief valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,0000996 -19-21JAN13-5/9
• 4
Servo Piston Shuttle Valve Leakage
Inspect servo piston shuttle valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Go to Travel Motor Leakage.
Does shuttle valve operate correctly?
NO: Repair or replace servo piston shuttle valve. JB3888,0000996 -19-21JAN13-6/9
• 5
Travel Motor Leakage
Check tracking while descending a hill. If tracking is within specification when descending a hill, but not when on the level or going up hill, travel motor leakage is indicated. See Travel System Tracking Check. (Group 9005-10.) If tracking does not meet specification, check travel motor leakage. See Travel Motor Leakage Test. (Group 9025-25.)
YES: Go to Center Joint Leakage.
Does tracking and motor leakage meet specification?
NO: If travel motor leakage does not meet specification, repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,0000996 -19-21JAN13-7/9
• 6
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 0260.)
YES: Go to Pump 1, Pump 2, or Pump 3 Regulator Malfunction.
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Disassemble and Assemble. (Group 0260.) Continued on next page
TM12660 (18APR18)
9025-15-24
JB3888,0000996 -19-21JAN13-8/9
041818
PN=864
Diagnostic Information
• 7
Pump 1, Pump 2, or Pump 3 Regulator Malfunction
YES: Diagnostic checkout Check pump 1, pump 2, or pump 3 regulator. See Pump Regulator Test and Adjustment—Minimum Flow and see Pump Regulator Test and Adjustment—Maximum complete. Flow. (Group 9025-25.)
Does pump 1, pump 2, and pump 3 regulator meet specification?
NO: Repair or replace pump 1, pump 2, and pump 3 regulator. See Pump 1, 2, and 3 Regulator Disassemble and Assemble. (Group 3360.) JB3888,0000996 -19-21JAN13-9/9
Slow Travel Speed or Low Power JB3888,0000995 -19-21JAN13-1/9
Slow Travel Speed or Low Power Diagnostic Procedure JB3888,0000995 -19-21JAN13-2/9
• 1
Incorrect Track Sag Adjustment
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Travel Motor Crossover Relief Valve Malfunction.
Is track sag within specification?
NO: Adjust track sag. JB3888,0000995 -19-21JAN13-3/9
• 2
Travel Motor Inspect travel motor crossover relief valve. See Travel Motor Crossover Relief Valve Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Malfunction
Is travel motor crossover relief valve OK?
YES: Go to Travel Park Brake Not Releasing.
NO: Repair or replace travel motor crossover relief valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) JB3888,0000995 -19-21JAN13-4/9
• 3
Travel Park Brake Not Releasing
Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Go to Travel Motor Leakage.
Is travel park brake OK?
NO: Repair or replace travel park brake. JB3888,0000995 -19-21JAN13-5/9
• 4
Travel Motor Leakage
Inspect travel motor for leakage. See Travel Motor Leakage Test. (Group 9025-25.)
YES: Go to Center Joint Leakage.
Does travel motor meet specification?
NO: Repair or replace travel motor. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) Continued on next page
TM12660 (18APR18)
9025-15-25
JB3888,0000995 -19-21JAN13-6/9
041818
PN=865
Diagnostic Information
• 5
Center Joint Leakage
Inspect center joint for leakage. See Center Joint Air Test. (Group 0260.)
YES: Go to Worn Pump.
Is center joint OK?
NO: Repair or replace center joint. See Center Joint Disassemble and Assemble . (Group 0260.) JB3888,0000995 -19-21JAN13-7/9
• 6
Worn Pump
Slow travel cycle times may indicate worn pump. Check travel cycle times. See 245GLC 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: Go to Engine Performance Low.
Do travel cycle times and pump flow meet specification?
NO: Repair or replace pump. See Pump 1, 2, and 3 Remove and Install. (Group 3360.) JB3888,0000995 -19-21JAN13-8/9
• 7
Engine Performance Low
Check engine speed and power mode setting. See Engine Speed Control System Operation. (Group 9010-05.)
YES: Diagnostic checkout complete.
Does engine speed meet specification?
NO: Select desired engine speed and power mode. JB3888,0000995 -19-21JAN13-9/9
Combined Travel and Dig Functions Slow or No Power JB3888,0000994 -19-21JAN13-1/4
Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure JB3888,0000994 -19-21JAN13-2/4
• 1
Travel Flow Combiner Valve Circuit Malfunction
Inspect travel flow combiner pilot valve (SL) in pilot signal manifold for stuck spool. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)
Inspect travel flow combiner valve. see Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.)
YES: Go to Control Valve Stuck.
Is travel flow combiner valve circuit OK?
NO: Repair or replace travel flow combiner valve circuit components. Continued on next page
TM12660 (18APR18)
9025-15-26
JB3888,0000994 -19-21JAN13-3/4
041818
PN=866
Diagnostic Information
• 2
Control Valve Stuck
Inspect for stuck travel and boom valve spools in control valve. For component location, YES: Diagnostic procedure see Control Valve Operation. (Group 9025-05.) complete. Does travel and boom valve spools move freely?
NO: Repair or replace control valve components as necessary. See Control Valve Front (6-Spool) Disassemble and Assemble. Also see Control Valve Rear (6-Spool) Disassemble and Assemble. (Group 3360.) JB3888,0000994 -19-21JAN13-4/4
Travel is “Jerky” JB3888,0000993 -19-21JAN13-1/7
Travel is “Jerky” Diagnostic Procedure JB3888,0000993 -19-21JAN13-2/7
• 1
Incorrect Track Sag Adjustment
Check track sag. See Check and Adjust Track Sag. (Operator's Manual.)
YES: Go to Roller Malfunction.
Is track sag within specification?
NO: Adjust track sag. JB3888,0000993 -19-21JAN13-3/7
• 2
Roller Malfunction
Inspect rollers.
YES: Go to Travel Park Brake Leakage.
Is oil level to specification?
NO: Add oil as required. JB3888,0000993 -19-21JAN13-4/7
• 3
Travel Park Brake Leakage
Inspect travel park brake. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Go to Mechanical Malfunction of Travel Motor or Gear Case.
Is travel park brake OK?
NO: Repair or replace travel park brake. JB3888,0000993 -19-21JAN13-5/7
• 4
Mechanical Malfunction of Travel Motor or Gear Case
Inspect travel motor and gear case for mechanical malfunction. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) Also see Travel Gear Case Disassemble and Assemble. (Group 0250.)
YES: Go to Undercarriage Components Worn.
Is travel motor and gear case OK?
NO: Repair or replace travel motor or gear case. Continued on next page
TM12660 (18APR18)
9025-15-27
JB3888,0000993 -19-21JAN13-6/7
041818
PN=867
Diagnostic Information
• 5
Undercarriage Components Worn
Inspect undercarriage components. See SP326VOL1 Undercarriage Appraisal Manual YES: Diagnostic checkout for 245GLC undercarriage specifications. complete.
Do undercarriage components meet specification?
NO: Repair or replace undercarriage components. JB3888,0000993 -19-21JAN13-7/7
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline JB3888,0000991 -19-21JAN13-1/3
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure JB3888,0000991 -19-21JAN13-2/3
• 1
Counterbalance Valve Spool Stuck
Inspect counterbalance valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Diagnostic checkout complete.
Does counterbalance valve spool move freely?
NO: Repair or replace counterbalance valve. JB3888,0000991 -19-21JAN13-3/3
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs JB3888,0000992 -19-21JAN13-1/3
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure JB3888,0000992 -19-21JAN13-2/3
• 1
Counterbalance Valve Spool Stuck
Inspect counterbalance valve. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)
YES: Diagnostic checkout complete.
Does counterbalance valve spool move freely?
NO: Repair or replace counterbalance valve. JB3888,0000992 -19-21JAN13-3/3
TM12660 (18APR18)
9025-15-28
041818
PN=868
Diagnostic Information
Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification 3
4
2
8 7
TX1119326 —UN—23AUG12
10 6 5 1 9 TX1119326 Pump 1, Pump 2, Pump 3, and Pilot Pump Line Identification 1— Pilot Pump Outlet Port 2— From Pilot Signal Manifold (port SA) 3— From Pilot Signal Manifold (port SB)
4— From Pilot Signal Manifold (port SX) 5— Pump 1 Outlet Port 6— Pump 3 Outlet Port
7— Pump 2 Outlet Port 8— From Pilot Pressure Regulating Valve 9— Pump 1 and 3 Inlet Port
10— Pump 2 Inlet Port
JB3888,000098E -19-29AUG12-1/1
TM12660 (18APR18)
9025-15-29
041818
PN=869
Diagnostic Information
TX1120415 —UN—15AUG12
Control Valve Line Identification
Rear Control Valve (6-spool) 1— From Pilot Signal Manifold Swing Right (port 6) 2— Auxiliary 2 Spool 3— From 2-Spool Solenoid Arm 3 Spool 4— From Pilot Signal Manifold Boom Down (port 2) 5— Boom 1 Spool 6— From Pilot Signal Manifold Boom 2 Spool 7— To 2-Spool Solenoid (port P2) 8— From Pilot Signal Manifold Arm In (port 4)
9— From Pilot Signal Manifold 17— To Boom 3 Spool 26— To Bucket Cylinder Head Bucket Curl (port 7) 18— To Center Joint Front Left End 10— Auxiliary Spool Port—Left Travel Forward 27— To Hydraulic Oil Tank 11— From Pilot Signal Manifold 19— To Center Joint Rear Left 73— Front Control Valve (6-spool) Travel Right Reverse (port Port—Left Travel Reverse 74— Rear Control Valve (6-spool) 12) 20— To Pump 1 117— Main Relief and Power Dig 12— From Pilot Signal Manifold 21— To Swing Motor Valve (P1, P2) Left Travel Reverse (port 10) 22— To Swing Motor Swing Left 170— Main Relief and Power Dig 13— To Pump 3 23— To Boom Cylinder Rod End Valve (P3) 14— To Swing Motor Swing Right 24— To Solenoid Manifold 15— To Boom Cylinder Head End 25— To Bucket Cylinder Rod End 16— To Boom 1 Spool Continued on next page
TM12660 (18APR18)
9025-15-30
JB3888,000098D -19-24AUG12-1/3
041818
PN=870
TX1120416 —UN—16AUG12
Diagnostic Information
Front Control Valve (6-spool) 1— To Hydraulic Oil Cooler 2— To Pump 2 3— To Arm Cylinder Rod End 4— To Arm Cylinder Head End 5— To Arm 1 Flow Control Solenoid (marked SU)
6— To Arm 2 Flow Control Solenoid (marked SD) 7— To Center Joint Front Right Port—Right Travel Forward 8— To Center Joint Rear Right Port—Right Travel Reverse
9— To Solenoid Manifold 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) 170— Main Relief and Power Dig Valve (P3) Continued on next page
TM12660 (18APR18)
9025-15-31
JB3888,000098D -19-24AUG12-2/3
041818
PN=871
TX1120688 —UN—22AUG12
Diagnostic Information
Rear Control Valve—Bottom (6-spool) 38— From Pilot Signal Manifold Flow Combiner Control Valve (port SL) 39— From Pilot Signal Manifold Auxiliary Flow Combiner Valve (port TR) 40— From Pilot Signal Manifold Travel (Right Forward) (port 11)
41— From Pilot Signal Manifold 46— From Pilot Signal Manifold Travel (Left Forward) (port 9) Boom Up (port 1) 42— From Pilot Signal Manifold 47— To 2-Spool Solenoid Valve Bucket Roll Out (port 8) (port P1) 43— From Pilot Signal Manifold 48— To Auxiliary Flow Combiner Arm Roll Out (port 3) Valve (port TR) 45— To Solenoid Valve Manifold 49— To 2-Spool Solenoid Valve (port P2) 50— From Pilot Signal Manifold Swing Left (port 5)
73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) B30— Boom Up Pressure Sensor B31— Arm In Pressure Sensor
JB3888,000098D -19-24AUG12-3/3
TM12660 (18APR18)
9025-15-32
041818
PN=872
Diagnostic Information
Swing Motor Line Identification
5 4
2
3
1
51
6
TX1118874
TX1118874 —UN—07AUG12
B32
Swing Motor Line Identification 1— From Pilot Signal Manifold (port SH) 2— To Control Valve 3— From Control Valve Swing Right
4— From Control Valve Swing Left 5— To Hydraulic Oil Tank Return Manifold
6— Case Drain Line 51— Swing Motor B32— Front Attachment Pressure Sensor TZ24494,0000932 -19-13MAR18-1/1
TM12660 (18APR18)
9025-15-33
041818
PN=873
Diagnostic Information
TM12660 (18APR18)
9025-15-34
041818
PN=874
Diagnostic Information
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern TX1120570 —UN—16AUG12
41 40
D
C
A
E F B G
H P PI
3
T 2
1
4
39
A1 A3
5
A2 6
A4 P 3
4 T
2
T2
1
T3
T1
TX1120570 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern Continued on next page
TM12660 (18APR18)
9025-15-35
041818
PN=875
JB3888,000098B -19-16AUG12-1/2
Diagnostic Information
TM12660 (18APR18)
9025-15-36
041818
PN=876
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 JB3888,000098B -19-16AUG12-2/2
TM12660 (18APR18)
9025-15-37
041818
PN=877
Diagnostic Information
TM12660 (18APR18)
9025-15-38
041818
PN=878
Diagnostic Information
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern TX1120576 —UN—16AUG12
41 40
D
C
A
E F B G
H P PI
3
T 2
1
4
39
A1 A3
5
A2 6
A4 P 3
4 T
2
T2
1
T3
T1
TX1120576 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern Continued on next page
TM12660 (18APR18)
9025-15-39
041818
PN=879
JB3888,000098A -19-16AUG12-1/2
Diagnostic Information
TM12660 (18APR18)
9025-15-40
041818
PN=880
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 JB3888,000098A -19-16AUG12-2/2
TM12660 (18APR18)
9025-15-41
041818
PN=881
Diagnostic Information
Pilot Signal Manifold-to-Control Valve Line Connection
4 6
2
10 12
41
2 4 73 6
74
12 TX1119197
TX1119197 —UN—03AUG12
10
Pilot Signal Manifold-to-Control Valve Line Connection—Top
Continued on next page
TM12660 (18APR18)
9025-15-42
JB3888,0000989 -19-19MAY16-1/4
041818
PN=882
Diagnostic Information 2— Port 2-to-Boom Down Pilot Cap 4— Port 4-to-Arm In Pilot Cap 6— Port 6-to-Swing Right Pilot Cap
10— Port 10-to-Left Travel Reverse Pilot Cap 12— Port 12-to-Right Travel Reverse Pilot Cap
41— Pilot Signal Manifold 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool)
Continued on next page
TM12660 (18APR18)
9025-15-43
JB3888,0000989 -19-19MAY16-2/4
041818
PN=883
Diagnostic Information
74 73
5
1
3 8
9
41
11
TX1120236 —UN—15AUG12
B33
TX1120236 Pilot Signal Manifold-to-Control Valve Line Connection—Bottom
Continued on next page
TM12660 (18APR18)
9025-15-44
JB3888,0000989 -19-19MAY16-3/4
041818
PN=884
Diagnostic Information 1— Port 1-to-Boom Up Pilot Cap 8— Port 8-to-Bucket Dump Pilot 41— Pilot Signal Manifold B33— Swing Pressure Sensor Cap 3— Port 3-to-Arm Out Pilot Cap 73— Front Control Valve (6-spool) 5— Port 5-to-Swing Left Pilot Cap 9— Port 9-to-Left Travel Forward 74— Rear Control Valve (6-spool) Pilot Cap 11— Port 11-to-Right Travel Forward Pilot Cap JB3888,0000989 -19-19MAY16-4/4
TM12660 (18APR18)
9025-15-45
041818
PN=885
Diagnostic Information
Travel System Component Location
73 37 41
74 31 16 149 15 30 29
38
28 Y10
72 61 36
TX1161464 —UN—03JUN14
63
TX1161464 Travel System Component Location
Continued on next page
TM12660 (18APR18)
9025-15-46
JB3888,0000988 -19-03JUN14-1/2
041818
PN=886
Diagnostic Information 15— Pump 1 (left) 31— Hydraulic Oil Tank 16— Pump 2 (right) 36— Hydraulic Oil Cooler 28— Pilot Pump 37— Solenoid Valve Manifold 29— Pilot Filter and Bypass Valve 38— Travel Pilot Control Valve 30— Pilot Pressure Regulating 41— Pilot Signal Manifold Valve
61— Right Travel Motor 149— Pump 3 (center) 63— Left Travel Motor Y10— Pilot Shutoff Solenoid 72— Center Joint Valve 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) JB3888,0000988 -19-03JUN14-2/2
TM12660 (18APR18)
9025-15-47
041818
PN=887
Diagnostic Information
TM12660 (18APR18)
9025-15-48
041818
PN=888
Diagnostic Information
Travel Hydraulic System Line Connection TX1120591 —UN—24AUG12
75
L
41
41
PI
I
9
K
J
10
12
73
11
74
110
74 73 Y24 37
72 60
164 38
Y10 163 162
160 161
62
TX1120591 Travel Hydraulic System Line Connection Continued on next page
TM12660 (18APR18)
9025-15-49
041818
PN=889
JB3888,0000987 -19-24AUG12-1/2
Diagnostic Information
TM12660 (18APR18)
9025-15-50
041818
PN=890
Diagnostic Information 161— Right Travel Forward 9— Left Travel Forward Port (pilot 41— Pilot Signal Manifold 162— Left Travel Reverse side) 60— Right Travel Device 163— Right Travel Reverse 10— Left Travel Reverse Port 62— Left Travel Device 164— Return Line to Hydraulic (pilot side) 72— Center Joint Oil Tank 11— Right Travel Forward Port 73— Front Control Valve (6-spool) (pilot side) 74— Rear Control Valve (6-spool) I— Left Travel Forward Port (control side) 12— Right Travel Reverse Port 75— Right Travel Spool J— Left Travel Reverse Port (pilot side) 110— Left Travel Spool (control side) 37— Solenoid Valve Manifold 160— Left Travel Forward K—Right Travel Forward Port 38— Travel Pilot Control Valve (control side)
L— Right Travel Reverse Port (control side) PI— Pilot Shutoff Solenoid Valve Port Y10— Pilot Shutoff Solenoid Valve Y24— Power Dig Solenoid Valve (port SG)
JB3888,0000987 -19-24AUG12-2/2
TM12660 (18APR18)
9025-15-51
041818
PN=891
Diagnostic Information
TM12660 (18APR18)
9025-15-52
041818
PN=892
Diagnostic Information
Hydraulic System Schematic TX1194745 —UN—22JUL15
38 TRAVEL PILOT CONTROL VALVE LEFT LEFT RIGHT RIGHT FORWARD REVERSE FORWARD REVERSE
PILOT FILTER AND BYPASS VALVE 29
PILOT PRESSURE REGULATING VALVE 30
9
28 PILOT PUMP
TA
39 LEFT PILOT CONTROL VALVE
10
11
ARM OUT 3
12
ARM IN 4
SWING RIGHT 6
40 RIGHT PILOT CONTROL VALVE
SWING LEFT 5
BOOM DOWN 2
BOOM UP 1
BUCKET DUMP 8
604
BUCKET CURL 7
609
PA PD
PC
PG
PF
PE 3
P
T
4
2
2
1
P
T
4
1
3
2
P
T
4
1
3
17 18 150 131
D
Y13
PILOT 41 SIGNAL MANIFOLD
Y12 I
P A3
SZ
93
A1
T2 T1
A4
SA SJ
A2
J
K
L
D
C
B
A
H
G
F
49
E
M
N
O
DR
P
T3 HT
42
129
50
Y10
17
P
T4
159 93
98
PD D1 DD DE DH
PE
DP PJ
DK
PP
108
118
DY
DN
DZ
D2
DF DS PI
47
45
PF
37 SOLENOID VALVE MANIFOLD
Y27
Y23
Y22
Y29
48
Y24 9
10
TR 11
SR
12
4
SA
155 SN
SP 3
B34 SD
91
SC
94
SE
SF
84
98
SG
SI
2
SB
1
SH
SL
44
SX
SQ
8
7
6
S3
5
13
SM
14
15
16
104
DM
Y20
120
150
B33
156
66 117 170
TX1194745 Pilot Signal Manifold—Excavator Pattern Continued on next page
TM12660 (18APR18)
9025-15-53
041818
PN=893
JB3888,0000986 -19-15JUL15-1/10
Diagnostic Information
TM12660 (18APR18)
9025-15-54
041818
PN=894
Diagnostic Information
1— Boom Up (pilot) 39— Left Pilot Control Valve 2— Boom Down (pilot) 40— Right Pilot Control Valve 3— Arm Out (pilot) 41— Pilot Signal Manifold 4— Arm In (pilot) 42— Boom Down Shockless 5— Swing Left (pilot) (5-spool) Valve 6— Swing Right (pilot) (5-spool) 44— Travel Flow Combiner Pilot 7— Bucket Curl (pilot) Valve (port SL) 8— Bucket Dump (pilot) 45— Swing Park Brake Release 9— Left Forward (pilot) Pilot Valve (port SH) 10— Left Reverse (pilot) 47— Pump 2 Flow Rate Pilot 11— Right Forward (pilot) Valve (port SB) 12— Right Reverse (pilot) 48— Pump 1 Flow Rate Pilot 17— Pump 1 Regulator Valve (port SA) 18— Pump 2 Regulator 49— Filter Screen (27 used) 28— Pilot Pump 50— Shuttle Valve (22 used) 29— Pilot Filter and Bypass Valve 66— Travel Speed Change Valve 30— Pilot Pressure Regulating 84— Dig Regenerative Valve Valve 91— Arm 2 Flow Rate Control 37— Solenoid Valve Manifold Valve 38— Travel Pilot Control Valve 93— Bypass Shutoff Valve 94— Arm Regenerative Valve
98— Arm 1 Flow Rate Control Valve 104— Boom 2 Spool 108— Auxillary Flow Rate Control Valve 117— Main Relief and Power Dig Valve (P1, P2) 118— Auxillary Function Flow Combiner Valve 120— Travel Flow Combiner Valve 129— Orifice 131— Diesel Particulate Filter (DPF) Manifold 150— Pump 3 Regulator 155— Pump 3 Flow Rate Pilot Valve (port SX) 156— Check Valve—Boom 1 Power Circuit 159— Arm Bottom Anti-Drift Valve 170— Main Relief and Power Dig Valve (P3) 604— Return Oil 609— Pilot Oil
Continued on next page
TM12660 (18APR18)
9025-15-55
B33— Swing Pressure Sensor B34— Travel Pressure Sensor Y10— Pilot Shutoff Solenoid Y12— Exhaust Filter Regulator Solenoid (marked SZ) Y13— Exhaust Filter Regulator Solenoid (marked SJ) Y20— Pump 2 Flow Rate Limit Solenoid Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig Solenoid (marked SI) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
JB3888,0000986 -19-15JUL15-2/10
041818
PN=895
Diagnostic Information
TM12660 (18APR18)
9025-15-56
041818
PN=896
Diagnostic Information
TX1194832 —UN—22JUL15
38 TRAVEL PILOT CONTROL VALVE PILOT FILTER AND BYPASS VALVE 29
PILOT PRESSURE REGULATING VALVE 30
LEFT LEFT FORWARD REVERSE
RIGHT FORWARD
9
11
28 PILOT PUMP
TA
10
39 LEFT PILOT CONTROL VALVE
RIGHT REVERSE
BOOM DOWN 2
12
BOOM UP 1
SWING RIGHT 6
40 RIGHT PILOT CONTROL VALVE
SWING LEFT 5
ARM OUT 3
ARM IN 4
BUCKET DUMP 8
604
BUCKET CURL 7
609
PA PD
PC
PG
PF
PE
2 3
P
T
4
2
P
T
4
1
3
2
P
T
4
1
3
1
17 18 150 PILOT 41 SIGNAL MANIFOLD
D
Y13
Y12 131
I
J
K
L
D
C
B
A
H
G
F
E
M
N
O
DR
P
49
P A3
A2
T2 T1
A1
A4
HT
SA SJ
SZ
93
T3
42
129
50
Y10
17
P
T4
159 93 PD
D1 DD
108
98
DE DH
PE
DP
PJ
DK
PP
118
DY
DN
DZ
D2
DF DS PI
47
45
PF
37 SOLENOID VALVE MANIFOLD
Y27
Y23
Y22
Y29
48
Y24
9
10 TR 11
B34 SD
91
SC
94
SE
SF
84
98
SG
SI
SR
12
104
DM
4
SA
155 SN
SP 3
2
SB
Y20
1
SH
156
SL
120
44
SX
150
SQ
8
7
6
S3
5
13
SM
14
15
16
B33
66 117 170
TX1194832 Pilot Signal Manifold—Backhoe Pattern Continued on next page
TM12660 (18APR18)
9025-15-57
041818
PN=897
JB3888,0000986 -19-15JUL15-3/10
Diagnostic Information
TM12660 (18APR18)
9025-15-58
041818
PN=898
Diagnostic Information
1— Boom Up (pilot) 39— Left Pilot Control Valve 2— Boom Down (pilot) 40— Right Pilot Control Valve 3— Arm Out (pilot) 41— Pilot Signal Manifold 4— Arm In (pilot) 42— Boom Down Shockless 5— Swing Left (pilot) (5-spool) Valve 6— Swing Right (pilot) (5-spool) 44— Travel Flow Combiner Pilot 7— Bucket Curl (pilot) Valve (port SL) 8— Bucket Dump (pilot) 45— Swing Park Brake Release 9— Left Forward (pilot) Pilot Valve (port SH) 10— Left Reverse (pilot) 47— Pump 2 Flow Rate Pilot 11— Right Forward (pilot) Valve (port SB) 12— Right Reverse (pilot) 48— Pump 1 Flow Rate Pilot 17— Pump 1 Regulator Valve (port SA) 18— Pump 2 Regulator 49— Filter Screen (27 used) 28— Pilot Pump 50— Shuttle Valve (22 used) 29— Pilot Filter and Bypass Valve 66— Travel Speed Change Valve 30— Pilot Pressure Regulating 84— Dig Regenerative Valve Valve 91— Arm 2 Flow Rate Control 37— Solenoid Valve Manifold Valve 38— Travel Pilot Control Valve 93— Bypass Shutoff Valve 94— Arm Regenerative Valve
98— Arm 1 Flow Rate Control Valve 104— Boom 2 Spool 108— Auxillary Flow Rate Control Valve 117— Main Relief and Power Dig Valve (P1, P2) 118— Auxillary Function Flow Combiner Valve 120— Travel Flow Combiner Valve 129— Orifice 131— Diesel Particulate Filter (DPF) Manifold 150— Pump 3 Regulator 155— Pump 3 Flow Rate Pilot Valve (port SX) 156— Check Valve—Boom 1 Power Circuit 159— Arm Bottom Anti-Drift Valve 170— Main Relief and Power Dig Valve (P3) 604— Return Oil 609— Pilot Oil
Continued on next page
TM12660 (18APR18)
9025-15-59
B33— Swing Pressure Sensor B34— Travel Pressure Sensor Y10— Pilot Shutoff Solenoid Y12— Exhaust Filter Regulator Solenoid (marked SZ) Y13— Exhaust Filter Regulator Solenoid (marked SJ) Y20— Pump 2 Flow Rate Limit Solenoid Y22— Dig Regenerative Solenoid (marked SF) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig Solenoid (marked SI) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
JB3888,0000986 -19-15JUL15-4/10
041818
PN=899
Diagnostic Information
TM12660 (18APR18)
9025-15-60
041818
PN=900
Diagnostic Information
TX1177561 —UN—13NOV14
RIGHT TRAVEL 61 MOTOR
Y32 DD
44
SD
11 PUMP 1 15
DZ SF
120
79
8
1
5
DH SJ
Y31
126
SG2
80
75
88
87
90
121
153 86
89
85 166
125
REAR CONTROL 74 VALVE
170 91 78
216
122
93
81
95
124
123
10
2
B31
B39 7
12 SM
14
4
6
PI12
118 119 116
SG SI
149 PUMP 3
163
84
FRONT CONTROL 73 VALVE
96
164
76
167
36 HYDRAULIC OIL COOLER
160
117
115
112
114
107
151
97
113
LEFT TRAVEL 63 MOTOR
52 SWING MOTOR
98 105
111
158
108
128
162
161
100 16 PUMP 2
157
99
169
127
109 110
9
109
13 103
SN
94
159
SY DY
152
3
SC
DE
TM12660 (18APR18)
9025-15-61
041818
PN=901
600
606
B30
Control Valve Schematic Continued on next page
217
604
102 DB
TX1177561
104
JB3888,0000986 -19-15JUL15-5/10
Diagnostic Information
TM12660 (18APR18)
9025-15-62
041818
PN=902
Diagnostic Information
1— Boom Up (pilot) 90— Arm 2 Spool 119— Check Valve—Auxiliary 600— High-Pressure Oil 2— Boom Down (pilot) 91— Arm 2 Flow Rate Control Function Flow Combiner 604— Return Oil 3— Arm Out (pilot) Valve (valve and poppet) Valve Circuit 606— Trapped Oil 4— Arm In (pilot) 93— Bypass Shutoff Valve 120— Travel Flow Combiner B30— Boom Up Pressure Sensor 5— Swing Left (pilot) (6-spool) 94— Arm Regenerative Valve Valve B31— Arm In Pressure Sensor 6— Swing Right (pilot) (6-spool) 95— Swing Spool 121— Check Valve—Travel Flow B39— Bucket In Pressure Sensor 7— Bucket Curl (pilot) 96— Check Valve (lift Combiner Valve Circuit Y31— Arm 3 Spool Control 8— Bucket Dump (pilot) check)—Swing Neutral 122— Check Valve (lift Solenoid (marked A2) 9— Left Travel Forward (pilot) Passage check)—Bucket Y32— Boom 3 Spool Control 10— Left Travel Reverse (pilot) 97— Arm 1 Spool 123— Orifice—Bucket Power Solenoid (marked A1) 11— Right Travel Forward (pilot) 98— Arm 1 Flow Rate Control Circuit PI12— To Pilot Signal Manifold 12— Right Travel Reverse (pilot) Valve (valve and poppet) 124— Oil Cooler Bypass Valve (port SR) 13— Plug—Auxiliary (pilot) 99— Check Valve (lift 125— Boom Cylinder DB—To Solenoid Valve Manifold 14— Plug—Auxiliary (pilot) check)—Arm 1 Regenerative 126— Bucket Cylinder Port DB 15— Pump 1 Circuit 127— Arm Cylinder DD—To Solenoid Valve Manifold 16— Pump 2 100— Check Valve (lift 128— Check Valve Port DM 36— Hydraulic Oil Cooler check)—Dig Regenerative 149— Pump 3 DE—To Solenoid Valve Manifold 44— Travel Flow Combiner Pilot Circuit 151— Auxiliary 2 Spool Port DP Valve (port SL) 102— Arm In Circuit Relief and 152— Arm 3 Spool DH—To Solenoid Valve Manifold 52— Swing Motor Anticavitation Valve 153— Boom 3 Spool Port DH 61— Right Travel Motor 103— Arm Out Circuit Relief and 157— Arm Rod Anti-Drift Valve DY—To Solenoid Valve Manifold 63— Left Travel Motor Anticavitation Valve (Check Valve) Port DY 73— Front Control Valve (6-spool) 104— Boom 2 Spool 158— Arm Rod Anti-Drift Valve DZ—To Solenoid Valve Manifold 74— Rear Control Valve (6-spool) 105— Check Valve (lift (Selector Valve) Port DZ 75— Right Travel Spool check)—Boom 2 Power 159— Arm Bottom Anti-Drift SC—From Arm Regenerative 76— Bucket Spool Circuit Valve (Selector Valve) Solenoid Valve (marked SC) 78— Bucket Regenerative Valve 107— Auxiliary Spool 160— Load Check Valve SD—From Arm 2 Flow Control 79— Bucket Dump Circuit Relief 108— Auxiliary Flow Rate (Auxiliary 2 Parallel Circuit) Solenoid Valve (marked SD) and Anticavitation Valve Control Valve (valve and 161— Load Check Valve SF—From Dig Regenerative 80— Bucket Curl Circuit Relief poppet) (Auxiliary 2 Tandem Solenoid Valve (marked SF) and Anticavitation Valve 109— Plug (4 used) Circuit) SG—From Power Dig Solenoid 81— Boom 1 Spool 110— Left Travel Spool 162— Load Check Valve (Arm 3 Valve (marked SI) 84— Dig Regenerative Valve 111— Check Valve (lift Tandem Circuit) SG2— To Power Dig Solenoid 85— Boom Reduced Leakage check)—Left Travel Neutral 163— Load Check Valve (Boom 3 Valve (marked SI) Valve (valve and check Passage Parallel Circuit) SJ— From Exhaust Filter valve) 112— Check Valve (lift 164— Load Check Valve (Boom 3 Regulator Solenoid (marked 86— Orifice check)—Left Travel Power Tandem Circuit) SJ) 87— Boom Lower Meter-In Cut Passage 166— Bucket Regenerative Cut SM—To Solenoid Manifold Port Valve 113— Orifice—Left Travel Power Valve SM 88— Boom Up Circuit Relief and Passage 167— Load Check Valve (Bucket SN—From Travel Pressure Anticavitation Valve 114— Orifice—Air Bleed (9 used) Tandem Circuit) Sensor Port TR 89— Boom Down Circuit Relief 115— Main Relief Valve Isolation 169— Arm Bottom Anti-Drift SI— From Power Dig Solenoid and Anticavitation Valve Check Valve (P1) Valve (Check Valve) Valve (marked SI) 116— Main Relief Valve Isolation 170— Main Relief and Power Dig SY—To Solenoid Valve Manifold Check Valve (P2) Valve (P3) Port DY 117— Main Relief and Power Dig 216— Make-Up Port Swing Motor Valve (P1, P2) 217— From Arm 1 Flow Control 118— Auxiliary Function Flow Solenoid Valve (SE) Combiner Valve Continued on next page
TM12660 (18APR18)
9025-15-63
JB3888,0000986 -19-15JUL15-6/10
041818
PN=903
Diagnostic Information
55
51
55 54
53 52
95A 56
57
TX1139803 —UN—03JUL13
95B
58
B32
45
73 604
TX1139803 Swing Motor Schematic 45— Swing Park Brake Release 54— Swing Crossover Relief Pilot Valve (port SH) Valve (2 used) 51— Swing Device 55— Swing Damper Valve (2 52— Swing Motor used) 53— Swing Motor Make-Up Check 56— Swing Park Brake Valve (2 used) 57— Orifice
58— Check Valve 604— Return Oil 73— Front Control Valve (6-spool) B32— Front Attachment Pressure 95A— From Swing Spool Top Sensor Port Right Swing 95B— From Swing Spool Bottom Port Left Swing Continued on next page
TM12660 (18APR18)
9025-15-64
JB3888,0000986 -19-15JUL15-7/10
041818
PN=904
Diagnostic Information
60
61 B
75A A
75B
37
72
62
64 B
A
110A
71 65
66
67
68
70
69
604 606
TX1139804
TX1139804 —UN—09JUL13
63
110B
Travel Motor Schematic 37— From Solenoid Valve Manifold—Power Dig Solenoid Valve 60— Right Travel Device 61— Right Travel Motor 62— Left Travel Device 63— Left Travel Motor
64— Travel Park Brake 65— 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 Top Port—Forward 75B— From Right Travel Spool Bottom Port—Reverse 110A— From Left Travel Spool Top Port—Forward
Continued on next page
TM12660 (18APR18)
9025-15-65
110B— From Left Travel Spool Bottom Port—Reverse 604— Return Oil or Pressure-Free Oil 606— Trapped Oil
JB3888,0000986 -19-15JUL15-8/10
041818
PN=905
Diagnostic Information
TM12660 (18APR18)
9025-15-66
041818
PN=906
Diagnostic Information
TX1146516 —UN—31OCT13
600 604 37 155
47
609
37B 73C
74B 73A
73B
27
B35
74A
27
B37
B56
27
Y10
41 73D 72 52 124
RETURN FILTER 32
HYDRAULIC OIL COOLER 36
PUMP 1
PUMP 3
15
149
PUMP 2 16
PILOT PUMP 28
35
FILTER 34 BYPASS
128 HYDRAULIC OIL TANK 31
Y20
Y28
Y21
PILOT FILTER 29 AND BYPASS VALVE
PE PF PG
PUMP 1 17 REGULATOR
PUMP 2 18 REGULATOR
PUMP 3 150 REGULATOR
131
B38
B57
PC
PILOT PRESSURE REGULATING VALVE 30
PD
B36
TX1146516 Hydraulic Oil Pumps and Regulators Continued on next page
TM12660 (18APR18)
9025-15-67
041818
PN=907
JB3888,0000986 -19-15JUL15-9/10
Diagnostic Information
TM12660 (18APR18)
9025-15-68
041818
PN=908
Diagnostic Information
15— Pump 1 (left) 41— Pilot Signal Manifold 16— Pump 2 (right) 47— Pump 2 Flow Rate Pilot 17— Pump 1 Regulator Valve (port SB) 18— Pump 2 Regulator 52— From Swing Motor 27— Attenuator Hose 72— From Center Joint 28— Pilot Pump 73A— To Front Control Valve 29— Pilot Filter and Bypass Valve (6-spool) 30— Pilot Pressure Regulating 73B— To Front Control Valve Valve (6-spool) 31— Hydraulic Oil Tank 73C— From Front Control Valve 32— Return Filter (6-spool) 34— Filter Bypass 73D— From Front Control Valve 35— Suction Screen (6-spool) 36— Hydraulic Oil Cooler 74A— To Rear Control Valve 37— Solenoid Valve Manifold (6-spool) 37B— From Solenoid Valve 74B— From Rear Control Valve Manifold (6-spool)
124— Oil Cooler Bypass Valve 128— Check Valve 131— Diesel Particulate Filter (DPF) Solenoid Manifold 149— Pump 3 (center) 150— Pump 3 Regulator 155— Pump 3 Flow Rate Pilot Valve (port SX) 600— High-Pressure Oil 604— Return Oil 609— Pilot Oil B35— Pump 1 Delivery Pressure Sensor B36— Pump 1 Control Pressure Sensor B37— Pump 2 Delivery Pressure Sensor
B38— Pump 2 Control Pressure Sensor B56— Pump 3 Delivery Pressure Sensor B57— Pump 3 Control Pressure Sensor Y10— From Pilot Shutoff Solenoid Y20— Pump 2 Flow Rate Limit Solenoid (marked SB) Y21— Torque Control Solenoid (marked ST) Y28— Pump 3 Torque Control Solenoid (marked SU)
JB3888,0000986 -19-15JUL15-10/10
TM12660 (18APR18)
9025-15-69
041818
PN=909
Diagnostic Information
Hydraulic System Component Location
126 127
125 73
41
37 74 31
125
16
40
149 15
52
30
38
29
Y10
28
39
72
36
63
TX1159679
TX1159679 —UN—07MAY14
61
Hydraulic System Component Location
Continued on next page
TM12660 (18APR18)
9025-15-70
JB3888,0000985 -19-07MAY14-1/2
041818
PN=910
Diagnostic Information 15— Pump 1 (left) 37— Solenoid Valve Manifold 16— Pump 2 (right) 38— Travel Pilot Control Valve 28— Pilot Pump 39— Left Pilot Control Valve 29— Pilot Filter and Bypass Valve 40— Right Pilot Control Valve 30— Pilot Pressure Regulating 41— Pilot Signal Manifold Valve 52— Swing Motor 31— Hydraulic Oil Tank 36— Hydraulic Oil Cooler
61— Right Travel Motor 126— Bucket Cylinder 63— Left Travel Motor 127— Arm Cylinder 72— Center Joint 149— Pump 3 (center) 73— Front Control Valve (6-spool) Y10— Pilot Shutoff Solenoid 74— Rear Control Valve (6-spool) Valve 125— Boom Cylinder (2 used)
JB3888,0000985 -19-07MAY14-2/2
TM12660 (18APR18)
9025-15-71
041818
PN=911
Diagnostic Information
TM12660 (18APR18)
9025-15-72
041818
PN=912
Diagnostic Information
Hydraulic System Line Connections TX1120477 —UN—24AUG12
31 73 74
74
127
73
125
41 SB 126 SX
SA
SH 28
149 16
36 29
72 30
51 15
TX1120477 Hydraulic System Line Connections Continued on next page
TM12660 (18APR18)
9025-15-73
041818
PN=913
JB3888,0000984 -19-24AUG12-1/2
Diagnostic Information
TM12660 (18APR18)
9025-15-74
041818
PN=914
Diagnostic Information 15— Pump 1 36— Hydraulic Oil Cooler 125— Boom Cylinder (2 used) 16— Pump 2 41— Pilot Signal Manifold 126— Bucket Cylinder 28— Pilot Pump 51— Swing Device 127— Arm Cylinder 29— Pilot Filter and Bypass Valve 72— Center Joint 149— Pump 3 30— Pilot Pressure Regulating 73— Front Control Valve (6-spool) SA—Pump 1 Flow Rate Pilot Valve 74— Rear Control Valve (6-spool) Valve Port 31— Hydraulic Oil Tank SB—Pump 2 Flow Rate Pilot Valve Port
SH—Swing Park Brake Release Port SX—Pump 3 Flow Rate Pilot Valve Port
JB3888,0000984 -19-24AUG12-2/2
TM12660 (18APR18)
9025-15-75
041818
PN=915
Diagnostic Information
TM12660 (18APR18)
9025-15-76
041818
PN=916
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
JB3888,00009D3 -19-02JUL12-1/1
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. JB3888,00009D4 -19-02JUL12-1/1
TM12660 (18APR18)
9025-25-1
041818
PN=917
Tests
General Hydraulic Oil Cleanup Procedure ESSENTIAL TOOLS JDG10712 Super Caddy
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.
TX1129360A —UN—14JAN13
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. 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. 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).
Hydraulic Tank Cap
Super Caddy requires a 20-amp electric circuit. Use of electrical extension cord is not recommended. TX1035522A —UN—25JAN08
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.) 2. 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.
Hydraulic Tank and Wands 1— Hydraulic Oil Tank Pressure Release Button 2— Hydraulic Oil Tank Cap 3— Cover
3. Install JDG10712 Super Caddy discharge wand (5) and suction wand (4) into hydraulic oil tank. 4. Cover the wands and tank openings with a plastic tarp to prevent contamination. CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine. Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine while filter caddy is connected to machine. 5. Use JDG10712 Super Caddy to remove oil contaminants. Refer to the Super Caddy operator's manual or see Super Caddy in Service ADVISOR™ for operating procedure. 6. When cleaning process is done, disconnect Super Caddy from machine.
7. Make sure machine is parked in an area that will allow all hydraulic functions to be operated. 8. Fill hydraulic oil tank to operating level. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 9. 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. 10. Stop engine. Install Super Caddy to machine as before. 11. Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operator's manual or see Super Caddy in Service ADVISOR™ for operating procedure. Continued on next page
TM12660 (18APR18)
4— Suction Wand 5— Discharge Wand
9025-25-2
JB3888,0000661 -19-14JAN13-1/2
041818
PN=918
Tests
12. When oil reaches an acceptable level of cleanliness, disconnect Super Caddy from machine. 13. Install new hydraulic oil filters. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.) 14. Clean hydraulic oil tank pressure release button and install hydraulic oil tank cap.
15. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the filter when oil is warm. 16. Fill hydraulic oil tank to proper operating level. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 17. Return machine to service.
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. Service ADVISOR is a trademark of Deere & Company JB3888,0000661 -19-14JAN13-2/2
TM12660 (18APR18)
9025-25-3
041818
PN=919
Tests
• See Pump 1, 2, and 3 Regulator Remove and Install.
Hydraulic Component Failure Cleanup Procedure
(Group 3360.)
• See Pilot Pump Remove and Install. (Group 3360.) • See Pilot Pressure Regulating Valve and Filter
ESSENTIAL TOOLS JDG1770 Ultra Clean Hose Kit
Remove and Install. (Group 3360.)
JDG10712 Super Caddy
• See Pilot Shutoff Solenoid Valve Remove and Install.
This procedure is to be used on machines that have had a catastrophic hydraulic system component failure. Cleanup procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increases the need to monitor and filter oil to a safe contamination value.
• See Solenoid Valve Manifold Remove and Install.
(Group 3360.) (Group 3360.)
• See Solenoid Valve Remove and Install—Power Dig
(SG), Arm Regenerative (SC), Dig Regenerative (SF), Arm 1 Flow Control (SE), and Arm 2 Flow Control (SD) Valves. (Group 3360.) • See Pilot Valve (Left and Right) Remove and Install. (Group 3360.) • See Travel Pilot Valve Remove and Install. (Group 3360.) • See Pilot Signal Manifold Remove and Install. (Group 3360.) • See Control Valve Remove and Install. (Group 3360.) • See Restriction Valve Remove and Install. (Group 3360.) • See Hydraulic Oil Cooler Bypass Valve Remove and Install. (Group 3360.) • See Boom Cylinder Remove and Install. (Group 3360.) • See Arm Cylinder Remove and Install. (Group 3360.) • See Boom Cylinder Remove and Install. (Group 3360.) • See Travel Motor and Park Brake Remove and Install. (Group 0260.) • See Swing Gear Case Remove and Install. (Group 4350.) • See Center Joint Remove and Install. (Group 4360.) • See Swing Motor and Park Brake Remove and Install. (Group 4360.) • See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) • See Make-Up Check Valve Disassemble and Assemble. (Group 4360.) • See Swing Park Brake Check Valve and Orifice Remove and Install. (Group 4360.) • See Hydraulic Oil Cooler Remove and Install. (Group 0510.)
IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and Super Caddy filters must not be intermixed. Use Super Caddy filter element in same type oil to avoid intermixing of oils. Oil contamination could result if Super Caddy is used in dusty or wet conditions. Clean work practices and cleanliness of filter caddy and attachments are critical when filtering oil. 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. Hydraulic System Cleanup Procedure 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Disconnect battery negative (-) cable. 3. Remove hydraulic oil tank. See Hydraulic Oil Tank Remove and Install. (Group 3360.) IMPORTANT: To prevent hydraulic system contamination, after cleaning, disassembling, and assembling each hydraulic component, store component in a dry, dust-free area until installation.
IMPORTANT: Debris trapped and then later dislodged from oil coolers can cause premature hydraulic component failure. If system contains a large amount of debris, oil cooler cannot be completely cleaned of contamination and must be replaced.
4. Remove covers and clean hydraulic oil tank completely. See Hydraulic Oil Tank Disassemble and Assemble. (Group 3360.)
7. Replace hydraulic oil cooler when required. See Hydraulic Oil Cooler Remove and Install. (Group 0510.)
5. Install hydraulic oil tank. See Hydraulic Oil Tank Remove and Install. (Group 3360.) 6. Remove each hydraulic component from the machine. Disassemble, clean, inspect, and assemble each component, working one circuit at a time. Repair or replace damaged components.
• See Pump 1, 2, and 3 Remove and Install. (Group
IMPORTANT: Prevent hydraulic system blockage. Disconnect hydraulic hoses and lines from all tee fittings before cleaning. Cleaning sponge will become trapped in hose and lines as it passes through a tee fitting.
3360.)
Continued on next page
TM12660 (18APR18)
9025-25-4
JB3888,0000662 -19-21JAN13-1/2
041818
PN=920
Tests 8. Install identification tags and disconnect all hydraulic hoses and lines. Close all openings using caps and plugs.
11. Install new hydraulic oil filters. See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.)
9025-15.)
12. With all components installed, fill tank to proper level. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)
9025-15.)
13. Connect battery negative (-) cable.
• See Hydraulic System Component Location. (Group • See Travel System Component Location. (Group • See Pilot Control Valve-to-Pilot Signal Manifold
Component Location—Excavator Pattern. (Group 9025-15.) • See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.) IMPORTANT: Airborne debris can cause premature hydraulic component failure. After hoses and lines are cleaned, close all openings with caps and plugs to minimize additional contamination. 9. Clean all hydraulic hoses and lines using JDG1770 Ultra Clean Hose Kit. NOTE: During installation, fill hydraulic components, hoses, and lines with clean hydraulic oil to prevent a dry start-up.
IMPORTANT: Trapped air suddenly compressed in a cylinder can make 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 slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 14. Remove remaining air from hydraulic system. Slowly operate all hydraulic functions without holding over relief valves. 15. Remove residual oil contaminants using JDG10712 Super Caddy. Perform General Hydraulic Oil Cleanup Procedure. (Group 3360.)
10. Install all cleaned hydraulic components, hoses, and lines. JB3888,0000662 -19-21JAN13-2/2
TM12660 (18APR18)
9025-25-5
041818
PN=921
Tests
Hydraulic Oil Cleanup Procedure SERVICE EQUIPMENT AND TOOLS JDG10712 Super Caddy 3™ One Suction Hose 4.6 m (15 ft.) x 25 mm (1.0 in.) ID 100R1 Hose with 1.0 in. M NPT Ends One Discharge Hose 4.6 m (15 ft.) x 19 mm (0.75 in.) ID 100R1 Hose with 0.75 in. M NPT Ends 3 Foot Suction Wand 25 mm (1.00 in.) OD (with angle cut tip) 3 Foot Discharge Wand 19 mm (0.75 in.) OD
TX1116504 —UN—25JUN12
This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter procedure must be done prior to starting machine after a component has been repaired or replaced. IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils. Avoid oil contamination. Oil contamination could result if Super Caddy Super Caddy™ is used in dusty or wet conditions. Instrument cleanliness and clean work practices are critical when filtering or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing can affect results.
Hydraulic Oil Tank Pressure Relief Cover 1— Pressure Release Button 2— Cap Screw (6 used)
3— Hydraulic Oil Tank Cover
8. Install new hydraulic system oil filters for cleanup procedure. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter. (Operator’s Manual.)
Super Caddy 3 requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.
9. Install hydraulic oil tank cover and cap screws. 1. Filter oil at 27°C (80°F) or above is best for JDG10712 Super Caddy 3 performance. Reduce flow rate to filter oil below 27°C (80°F).
CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.
2. Clean surrounding area of hydraulic oil tank cover (3) to prevent hydraulic system contamination.
CAUTION: Avoid entanglement and possible electrocution from Super Caddy power cord. DO NOT operate machine while Super Caddy is connected to machine.
3. Press pressure release button (1) to relieve pressure from hydraulic oil tank. 4. Remove cap screws (2) and cover. NOTE: Ensure maximum oil movement during cleanup procedure. Orient submerged ends of suction and discharge wands as far away from each other as possible.
10. Make sure area is clear and large enough to operate all functions of machine.
5. Insert suction and discharge wands from Super Caddy into hydraulic oil tank opening. NOTE: Ensure suction and discharge wands maintain position in hydraulic reservoir. 6. Seal suction and discharge wands in opening of hydraulic oil tank to prevent contamination. 7. Use Super Caddy to remove oil contaminants. Refer to operator’s manual included with Super Caddy or see Super Caddy™ in Service ADVISOR™ for operating procedure.
11. Fill hydraulic oil tank to operating level. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Avoid hydraulic system damage or further oil contamination. DO NOT force hydraulic system over system relief or over return filter bypass. 12. Run machine at slow idle. Operate each circuit a minimum of 3—5 minutes in each direction to flush any remaining contaminants. 13. Stop machine and install suction and discharge wands.
Continued on next page
TM12660 (18APR18)
9025-25-6
JB3888,00009D5 -19-01AUG12-1/2
041818
PN=922
Tests
14. Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operation manual.
equipment is recommended for machines in extreme environments. Bypass filtration systems are available.
15. When oil reaches acceptable value of cleanliness, remove suction and discharge wands.
19. Check and record oil particle counts. After 100 hours of operation, check hydraulic oil to confirm system is within specification according to Super Caddy operation manual.
16. Install new hydraulic system oil filters. See Replace Hydraulic Tank Oil Filter and see Replace Pilot Oil Filter. (Operator’s Manual.) 17. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 18. Return machine to service. NOTE: Some hydraulic systems may not be able to maintain correct specification without additional filtration equipment. Additional filtration
Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also increase chances for contaminants to enter hydraulic system. Use care when connecting and removing components to prevent system contamination. Quick couplers must not be connected until they have been cleaned and capped when not in use.
Super Caddy is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company JB3888,00009D5 -19-01AUG12-2/2
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.
Machine Position JB3888,00009D6 -19-12JUL12-1/2
5. Press pressure release button (1) to relieve hydraulic oil tank pressure. 2— Hydraulic Oil Tank Cover TX1116496 —UN—25JUN12
1— Pressure Release Button
Hydraulic Oil Tank Cover JB3888,00009D6 -19-12JUL12-2/2
TM12660 (18APR18)
9025-25-7
041818
PN=923
Tests
• MPDr application. For instruction, see MPDr
Hydraulic Oil Warm-Up Procedure
Connection Procedure. (Group 9015-20.) Select the following items from the monitor display: - Coolant Temperature - Hydraulic Oil Temperature - Actual Engine Speed
SPECIFICATIONS Engine Speed
1300—1500 rpm (if below -18°C [0°F]) 1750—1850 rpm (if below -18°C [0°F])
Power Mode Button Position
ECO (economy) Mode (if below -18°C [0°F]) H/P (high power) Mode (if below -18°C [0°F])
Work Mode Switch Position
CAUTION: Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all bystanders before performing the warm-up procedure.
Bucket Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Slow (turtle)
Hydraulic Oil Temperature
45—55°C 113—131°F
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.)
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.
1. Connect one of the following test equipment to monitor the coolant temperature, hydraulic oil temperature, and actual engine speed.
• Monitor application. For instruction to actuate the
Specification Engine—Speed........................... 1300—1500 rpm (if below -18°C [0°F]) 1750—1850 rpm (if below -18°C [0°F]) Power Mode Button—Position................. ECO (economy) Mode (if below -18°C [0°F]) H/P (high power) Mode (if below -18°C [0°F]) Work Mode Switch—Position................................................................. Bucket Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position................................................................... Slow (turtle)
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items from monitoring list: - Coolant Temperature - 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: - Coolant Temperature - Hydraulic Oil Temperature - Actual Engine Speed
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 specification. 9. Stop periodically and operate all hydraulic functions to distribute the heated oil.
Continued on next page
TM12660 (18APR18)
9025-25-8
JB3888,00009D7 -19-26APR16-1/2
041818
PN=924
Tests
10. Continue procedure until oil temperature is within specification.
Specification Hydraulic Oil—Temperature......................................................................45—55°C 113—131°F
Service ADVISOR is a trademark of Deere & Company JB3888,00009D7 -19-26APR16-2/2
TM12660 (18APR18)
9025-25-9
041818
PN=925
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
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Pilot System Pressure (slow idle)
3.8—4.8 MPa 3805—4805 kPa 39.0—49.0 bar 552—697 psi
Pilot System Pressure (fast idle)
3.5—5.0 MPa 3509—5012 kPa 36.0—51.0 bar 509—727 psi
Pilot Pressure Regulating Valve Shim (approximate per 0.25 mm) (0.010 in. shim)
0.078 MPa 78 kPa 0.78 bar 11.3 psi
Pilot Pressure Regulating Valve Shim (approximate per 0.50 mm) (0.020 in. shim)
0.157 MPa 157 kPa 1.57 bar 22.8 psi
Pilot Pressure Regulating Valve Shim (approximate per 1.00 mm) (0.040 in. shim)
0.304 MPa 304 kPa 3.04 bar 44.1 psi
Plug-to-Pilot Pressure Regulating Valve Housing Torque
25 N·m 220 lb.-in.
TX1117285 —UN—06JUL12
Hydraulic Oil Temperature
Pilot Pressure Regulating Valve and Test Port 1— Test Port 2— Adapter
idle and then actuate arm in function over relief. The pressure reading displayed is from the arm in pressure sensor located in the pilot cap.
SERVICE EQUIPMENT AND TOOLS
Before making any adjustments, check the pilot pressure at the test port using a pressure gauge. For pilot filter and pressure regulating valve location, see Hydraulic System Component Location. (Group 9025-15.)
Adapter 1/4 M BSPP ORB x 7/16-20 M 37° JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
The purpose of this test is to check and, if necessary, adjust the pressure setting of the pilot pressure regulating valve. Pilot pressure is controlled by this valve.
5. Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.
• Monitor application. See Service Menu for instruction
Purpose of test is to also 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). 4. Connect the JT02162 Transducer (3) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter. NOTE: The monitor can be used to make a quick check of the pilot system pressure using the arm in function. Monitor arm in pilot pressure with the engine at fast
to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - 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 to display: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Arm Roll-In Pilot Pressure - Hydraulic Oil Temperature - Actual Engine Speed
Continued on next page
TM12660 (18APR18)
3— JT02162 Transducer 30— Pilot Pressure Regulating Valve
9025-25-10
JB3888,00009DB -19-26JUL12-1/3
041818
PN=926
Tests
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 7. Run machine at the following specifications: Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed....................................................Fast Idle and Slow Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Specification Pilot System Pressure (slow idle)—Pressure......................................................... 3.8—4.8 MPa 3805—4805 kPa 39.0—49.0 bar 552—697 psi Pilot System Pressure (fast idle)—Pressure........................................................... 3.5—5.0 MPa 3509—5012 kPa 36.0—51.0 bar 509—727 psi
9. 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.)
8. Compare pressure readings to specifications. Make adjustments as necessary. Service ADVISOR is a trademark of Deere & Company JB3888,00009DB -19-26JUL12-2/3
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 11.3 psi Pilot Pressure Regulating Valve Shim (approximate per 0.50 mm) (0.020 in shim)—Pressure Change....................................................................................0.157 MPa 157 kPa 1.57 bar 22.8 psi Pilot Pressure Regulating Valve Shim (approximate per 1.00 mm) (0.040 in. shim)—Pressure......................................................................0.304 MPa 304 kPa 3.04 bar 44.1 psi
11. Tighten pilot pressure regulating valve plug to specification.
TX1117285 —UN—06JUL12
10. Remove pilot pressure regulating valve (30). Add shims to increase pressure. Remove shims to decrease pressure.
Pilot Pressure Regulating Valve and Test Port 1— Test Port 2— Adapter
3— JT02162 Transducer 30— Pilot Pressure Regulating Valve
12. Check the pressure settings again to ensure they are within specification.
Specification Plug-to-Pilot Pressure Regulating Valve Housing—Torque...........................................................................25 N·m 220 lb.-in. JB3888,00009DB -19-26JUL12-3/3
TM12660 (18APR18)
9025-25-11
041818
PN=927
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
Dig 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
TX1117430 —UN—10JUL12
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Adaptor Tee 9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37° Gauge 7000 kPa (70 bar) (1000 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Control Valve Spool Actuating Pilot Pressure Test
The purpose of this test is to ensure that the pilot pressure to the valve spools is enough to completely shift the spools.
1— Adaptor 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.)
2— JT02162 Transducer
• MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to 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 adaptor tee (1) in pilot line for function being tested.
5. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
3. Install JT02162 Transducer (2) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge.
6. Run machine at the following 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 to display: - 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 to display: - 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 and Slow Idle Work Mode Switch—Position.......................................................................Dig 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
TM12660 (18APR18)
9025-25-12
JB3888,00009DC -19-17AUG12-1/2
041818
PN=928
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, check pressure at solenoid valve manifold, pilot control shutoff solenoid valve, pilot controllers, and pilot signal manifold.
Service ADVISOR is a trademark of Deere & Company JB3888,00009DC -19-17AUG12-2/2
TM12660 (18APR18)
9025-25-13
041818
PN=929
Tests
Dig Regenerative Solenoid Valve Test and Adjustment SPECIFICATIONS
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
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
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.111 MPa 111 kPa 1.11 bar 16.1 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in.
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
5.0 N·m 45 lb.-in.
TX1117944 —UN—16JUL12
45—55°C 110—130°F
Solenoid Valve Manifold Location
2 37
TX1120158 —UN—15AUG12
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Y23 Y22
Y29 Y27
Y24
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
1
Purpose of this test is to check that the output pressure for the dig regenerative solenoid valve (Y22) is within specification.
Solenoid Valve Manifold Detail 1— Power Dig Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold Y22— Dig Regenerative Solenoid Valve (marked SF)
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 dig regenerative solenoid valve fitting (2) from dig regenerative solenoid valve (Y22).
Y23— Arm Regenerative Solenoid Valve (marked SC) Y24— Power Dig Solenoid Valve (marked SI) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
3. Install adaptor tee into dig regenerative solenoid (Y22). Connect line to adaptor tee.
• Service ADVISOR™ application. See Service
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Digging Regen P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (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. See Service Menu for instruction to actuate the service menu on monitor in cab. (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
TM12660 (18APR18)
9025-25-14
JB3888,00009DD -19-15AUG12-1/3
041818
PN=930
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. NOTE: Actual reading from gauge must be within pressure range of monitor reading and tolerance. 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
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 JB3888,00009DD -19-15AUG12-2/3
11. Adjust the solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The length from end of adjusting screw-to-nut must not exceed 4 mm (0.157 in.). Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................ 0.111 MPa 111 kPa 1.11 bar 16.1 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in.
c. Hold adjusting screw and tighten nut to specification.
Solenoid Adjustment 4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................5.0 N·m 45 lb.-in.
12. Check pressure setting again. JB3888,00009DD -19-15AUG12-3/3
TM12660 (18APR18)
9025-25-15
041818
PN=931
Tests
Arm Regenerative Solenoid Valve Test and Adjustment SPECIFICATIONS
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
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
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.111 MPa 111 kPa 1.11 bar 16.1 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in.
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
5.0 N·m 45 lb.-in.
TX1117944 —UN—16JUL12
45—55°C 110—130°F
Solenoid Valve Manifold Location
2 37
TX1120158 —UN—15AUG12
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Y23 Y22
Y29 Y27
Y24
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
1
Purpose of this test is to check that the output pressure for the arm regenerative solenoid valve (Y23) is within specification.
Solenoid Valve Manifold Detail 1— Power Dig Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold Y22— Dig Regenerative Solenoid Valve (marked SF)
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 arm regenerative solenoid valve fitting (3) from arm regenerative solenoid valve (Y23).
Y23— Arm Regenerative Solenoid Valve (marked SC) Y24— Power Dig Solenoid Valve (marked SG) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
3. Install adaptor tee into arm regenerative solenoid (Y23). Connect line to adaptor tee.
• Service ADVISOR™ application. See Service
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Arm Regen P/S Output - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (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. See Service Menu for instruction to actuate the service menu on monitor in cab. (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
TM12660 (18APR18)
9025-25-16
JB3888,00009DE -19-15AUG12-1/3
041818
PN=932
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. NOTE: Actual reading from gauge must be within pressure range of monitor reading and tolerance. 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
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 JB3888,00009DE -19-15AUG12-2/3
11. Adjust the solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The length from end of adjusting screw-to-nut must not exceed specification. Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................ 0.111 MPa 111 kPa 1.11 bar 16.1 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in.
c. Hold adjusting screw and tighten nut to specification.
Solenoid Adjustment 4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................5.0 N·m 45 lb.-in.
12. Check pressure setting again. JB3888,00009DE -19-15AUG12-3/3
TM12660 (18APR18)
9025-25-17
041818
PN=933
Tests
Power Dig Solenoid Valve Test and Adjustment SPECIFICATIONS
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Power Dig Solenoid Valve (port SG) Pressure
Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance
Solenoid Valve Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.111 MPa 111 kPa 1.11 bar 16.1 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in.
Solenoid Valve Adjusting Screw-to-Housing Nut Torque
5.0 N·m 45 lb.-in.
TX1117944 —UN—16JUL12
45—55°C 110—130°F
Solenoid Valve Manifold Location
2 37
SERVICE EQUIPMENT AND TOOLS Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Y23 Y22
Y29 Y27
Y24
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
1
Purpose of this test is to check that the output pressure from the power dig solenoid valve (Y24) is within specification.
TX1120158 —UN—15AUG12
Hydraulic Oil Temperature
Solenoid Valve Manifold Detail 1— Power Dig Solenoid Valve Fitting 2— Dig Regenerative Solenoid Valve Fitting 37— Solenoid Valve Manifold Y22— Dig Regenerative Solenoid Valve (marked SF)
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 power dig solenoid valve fitting (2) from power dig solenoid valve (Y24).
Y23— Arm Regenerative Solenoid Valve (marked SC) Y24— Power Dig Solenoid Valve (marked SG) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
3. Install adaptor tee into power dig solenoid (Y24). Connect line to adaptor tee.
• Service ADVISOR™ application. See Service
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee.
ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Power Digging P/S Output - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Power Digging P/S Output - Hydraulic Oil Temperature - Actual Engine Speed
5. Connect one of the following test equipment to monitor the power dig control 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 to display: - Power Digging 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
TM12660 (18APR18)
9025-25-18
JB3888,00009DF -19-15AUG12-1/3
041818
PN=934
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. NOTE: Actual reading from gauge must be within pressure range of monitor reading and tolerance. . Specification Power Dig Solenoid Valve (port SG)—Pressure..................................... Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi
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 JB3888,00009DF -19-15AUG12-2/3
11. Adjust the solenoid valve (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The length from end of adjusting screw-to-nut must not exceed specification. Specification Solenoid Valve Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................ 0.111 MPa 111 kPa 1.11 bar 16.1 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in.
c. Hold adjusting screw and tighten nut to specification.
Solenoid Adjustment 4— Solenoid Valve 5— Nut
6— Adjusting Screw
Specification Solenoid Valve Adjusting Screw-to-Housing Nut—Torque.................................................................................5.0 N·m 45 lb.-in.
12. Check pressure setting again. JB3888,00009DF -19-15AUG12-3/3
TM12660 (18APR18)
9025-25-19
041818
PN=935
Tests
Arm 2 Flow Control Solenoid Valve Test and Adjustment SPECIFICATIONS
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
TX1117944 —UN—16JUL12
45—55°C 110—130°F
Arm 2 Flow Control Solenoid (port Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa SI) Pressure Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi Actual Reading From Gauge Must Be Within Pressure Range of Monitor Reading and Tolerance Solenoid Adjusting Screw Pressure Change (approximate per 1/4 turn)
0.111 MPa 111 kPa 1.11 bar 16.1 psi
End of Adjusting Screw-to-Nut Length (maximum)
4 mm 0.157 in.
Adjusting Screw-to-Nut Torque
5.0 N·m 45 lb.-in.
Solenoid Valve Manifold Location
2 37
TX1120158 —UN—15AUG12
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Adaptor Tee (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Y23 Y22
Y29 Y27
Y24
JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
1
Purpose of this test is to check that the output pressure for the arm 2 flow control solenoid (Y27) is within specification. 1. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)
Solenoid Valve Manifold Detail 1— Power Dig Solenoid Fitting 2— Dig Regenerative Solenoid Fitting 37— Solenoid Valve Manifold Y22— Dig Regenerative Solenoid (marked SF)
2. Remove arm 2 flow control solenoid fitting (4) from arm 2 flow control solenoid (Y27). 3. Install adaptor tee into arm 2 flow control solenoid (Y27). Connect line to adaptor tee.
Select the following items to display: - Arm 2 Flw Cont P/S Output - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Arm 2 Flw Cont P/S Output - Hydraulic Oil Temperature - Actual Engine Speed
4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to tee. 5. Connect one of the following test equipment to monitor the dig regenerative solenoid reading, hydraulic oil temperature, and actual engine speed.
• Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - Arm 2 Flw Cont P/S Output - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.)
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
Continued on next page
TM12660 (18APR18)
Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig Solenoid (marked SG) Y27— Arm 2 Flow Control Solenoid (marked SD) Y29— Arm 1 Flow Control Solenoid (marked SE)
9025-25-20
JB3888,0000AF8 -19-15AUG12-1/3
041818
PN=936
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
NOTE: Pressure reading displayed on the monitor is calculated from an electrical signal in the main controller (MCZ). The reading does not change when solenoid adjustment is made. 8. Perform combined operation of boom up and arm in functions. Record monitor and gauge pressure readings.
10. Verify that the actual reading from gauge is within the calculated pressure range from monitor. NOTE: Actual reading from gauge must be within pressure range of monitor reading and tolerance. Specification Arm 2 Flow Control Solenoid (port SI)—Pressure............................................... Monitor Reading ± 0.2 MPa Monitor Reading ± 200 kPa Monitor Reading ± 2.0 bar Monitor Reading ± 29.0 psi
NOTE: An example of monitor reading is given in the chart below for the arm 2 flow control solenoid. Example of Calculated Reading From Monitor Example Monitor Reading
Actuated
Non Actuated
3.19 MPa 3190 kPa 31.9 bar 463 psi
0.03 MPa 30 kPa 0.3 bar 4 psi
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. Service ADVISOR is a trademark of Deere & Company JB3888,0000AF8 -19-15AUG12-2/3
11. Adjust the solenoid (4) being tested as necessary.
TX1106359A —UN—25JAN12
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (5). b. Turn adjusting screw (6) IN to increase pressure setting; turn adjusting screw OUT to decrease pressure setting. The length from end of adjusting screw-to-nut must not exceed 4 mm (0.157 in.). Specification Solenoid Adjusting Screw—Pressure Change (approximate per 1/4 turn) ............................................................................ 0.111 MPa 111 kPa 1.11 bar 16.1 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in.
Solenoid Adjustment 4— Solenoid 5— Nut
6— Adjusting Screw
Specification Adjusting Screw-toNut—Torque.................................................................................5.0 N·m 45 lb.-in.
12. Check pressure setting again.
c. Hold adjusting screw and tighten nut to specification. JB3888,0000AF8 -19-15AUG12-3/3
TM12660 (18APR18)
9025-25-21
041818
PN=937
Tests
Torque Control Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 112—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Pump 3 Torque Control Solenoid Valve (Y28) 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
Torque Control Solenoid Valve (Y21) 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
TX1147999A —UN—25NOV13
Hydraulic Oil Temperature
Pump 1, 2, and 3 Regulators 1— Pump 2 Test Port 2— Plug 3— Pump 3 Test Port 4— Plug 5— Adjusting Screw 6— Nut
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
3.0 N·m 27 lb.-in.
17— Pump 1 Regulator 18— Pump 2 Regulator 150— Pump 3 Regulator Y21— Torque Control Solenoid (marked ST) Y28— Pump 3 Torque Control Solenoid (marked SU)
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of test is to check that the output pressure from the torque control solenoid (Y21) and pump 3 torque control solenoid (Y28) are 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 (4) from pump 3 torque control solenoid (Y28) test port (3) in pump 3 regulator (150). Continued on next page
TM12660 (18APR18)
9025-25-22
JB3888,0000AFE -19-12DEC13-1/3
041818
PN=938
Tests
3. Install adapter (19). 4. Connect JT02162 Transducer (20) and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter. 5. Connect one of the following test equipment to monitor the pump 3 or pump 1 and 2 torque proportional valve pressure reading, hydraulic oil temperature, and actual engine speed. to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display to test the pump 3 torque control solenoid: - Pump 3 Torque P/S Output - Hydraulic Oil Temperature - Actual Engine Speed Select the following items to display to test the pump 1 and 2 torque control solenoid: - Pump 1&2 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display the pump 3 torque control solenoid: - Pump 3 Torque P/S Output - Hydraulic Oil Temperature - Actual Engine Speed Select the following items to display the pump 1 and 2 torque control solenoid: - Pump 1&2 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display the pump 3 torque control solenoid: - Pump 3 Torque P/S Output - Hydraulic Oil Temperature - Actual Engine Speed Select the following items to display the pump 1 and 2 torque control solenoid: - Pump 1&2 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed
TX1147991A —UN—21NOV13
• Monitor application. See Service Menu for instruction
Pump 3 Regulator 19— Adapter 20— Transducer
150— Pump 3 Regulator
Specification Hydraulic Oil—Temperature......................................................................45—55°C 112—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig 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. Place all pilot control levers and pedals in the neutral position. Record the pressure readings from monitor and gauge.
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided.
7. Run machine at specification.
10. Verify that the actual reading from gauge is within the calculated pressure range from monitor.
Continued on next page
TM12660 (18APR18)
9025-25-23
JB3888,0000AFE -19-12DEC13-2/3
041818
PN=939
Tests
Specification Pump 3 Torque Control Solenoid Valve (Y28)—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
11. Adjust the pump 3 torque control solenoid valve (Y28) as needed. IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (6). b. Turn adjusting screw (5) out to increase pressure setting or turn adjusting screw in to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification.
Specification Torque Control Solenoid Valve (Y21)—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 torque proportional valve (torque control solenoid valve). When a function is actuated, the readings start to decrease. The reading will vary depending on the load on the function. Example of Calculated Reading From Monitor
Example Monitor Reading
Neutral (Non Actuated)
Actuated
3.79 MPa 3850 kPa 38.5 bar 558 psi
0.33 MPa 330 kPa 3.3 bar 48 psi
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...................................................................3.0 N·m 27 lb.-in.
12. Check the pressure setting again.
Service ADVISOR is a trademark of Deere & Company JB3888,0000AFE -19-12DEC13-3/3
TM12660 (18APR18)
9025-25-24
041818
PN=940
Tests
Arm 3 and Boom 3 Control Solenoid Valve Test and Adjustment SPECIFICATIONS 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Arm 3 and Boom 3 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
TX1118470 —UN—20JUL12
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
5.0 N·m 29 lb.-in.
Arm 3 and Boom 3 Control Solenoid Valve 1— Test Port (2 used)
2— Transducer (2 used)
SERVICE EQUIPMENT AND TOOLS Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)
Select the following items to display: - Pump 3 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 3 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02156A Digital Pressure/Temperature Analyzer Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of this test is to check the output pressure from the arm 3 and boom 3 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.)
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
2. Remove plugs from arm 3 and boom 3 control solenoid valve test port (1). 3. Install transducer (2) to upper and lower test ports. 4. Connect JT02162 Transducer and JT02156A Digital Pressure/Temperature Analyzer or 7000 kPa (70 bar) (1000 psi) gauge to adapter (2). 5. Connect the following test equipment to monitor the pump torque control valve pressure output 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 to display: - Pump 3 Torque P/S O/P - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.)
7. Run machine at the following specification: Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
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. Place all pilot control levers and pedals in the neutral position. Record the pressure readings from monitor and gauge. Continued on next page
TM12660 (18APR18)
9025-25-25
JB3888,00009E0 -19-27NOV13-1/2
041818
PN=941
Tests
9. Calculate pressure range using the calculated reading from monitor and the specific tolerance provided. 10. Verify that the actual reading from gauge is within the calculated pressure range from monitor. Specification Arm 3 and Boom 3 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 start to decrease. The reading will vary depending on the load on the function.
IMPORTANT: Avoid possible O-ring damage. Do not loosen adjusting screw more than two turns. Turning adjusting screw out too far may cause O-ring damage and leakage. a. Loosen nut (4). b. Turn adjusting screw (5) in to increase pressure setting or turn adjusting screw out to decrease pressure setting. The length from end of adjusting screw to nut must not exceed specification. Specification Adjusting Screw—Pressure Change (approximate per 1/4 turn).............................................................................0.069 MPa 111 kPa 0.69 bar 16 psi End of Adjusting Screw-to-Nut—Length (maximum)...................................................................................... 4 mm 0.157 in.
Example of Calculated Reading From Monitor
Example Monitor Reading
Neutral (Non Actuated)
Actuated
3.79 MPa 3850 kPa 38.5 bar 558 psi
0.33 MPa 330 kPa 3.3 bar 48 psi
c. Hold adjusting screw. Tighten nut to specification. Specification Adjusting Screw-toHousing Nut—Torque...................................................................5.0 N·m 29 lb.-in.
12. Check the pressure setting again. 11. Adjust the arm 3 and boom 3 control solenoid valve (3) as needed. Service ADVISOR is a trademark of Deere & Company JB3888,00009E0 -19-27NOV13-2/2
TM12660 (18APR18)
9025-25-26
041818
PN=942
Tests
Pump Control Pilot Pressure Signal Test
Select the following items to display: - Pump 1 and Pump 2 Pump Control Pressure - Pump 3 Pump Control Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 and Pump 2 Pump Control Pressure - Pump 3 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
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Pump 1 and Pump 2 Pump Control 0.55 MPa 55 kPa Pressure in Neutral Pressure 10.5 bar (approximate) 8 psi Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure (approximate)
2. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
3.78 MPa 3780 kPa 37.8 bar 558 psi
3. Run machine at specification.
Pump 3 Pump Control Pressure in 0.55 MPa 1050 kPa Neutral Pressure (approximate) 10.5 bar 8 psi Pump 3 Pump Control Pressure at Full Actuation Pressure (approximate)
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
3.78 MPa 3780 kPa 37.8 bar 558 psi
The function of pump 1 and pump 2 flow rate pilot valves (port SA), 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 function of pump 3 flow rate pilot valve (port SX)
4. Return all control levers and pedals to neutral position. Place pilot shutoff lever in the unlock (DOWN) position. 5. Record pressure readings from monitor.
Purpose of this test is to check regulated pump control pilot pressure signal from flow rate pilot valves to remote control spool in pump 1, pump 2, and pump 3 regulators. Pressure increases as a function is actuated and decreases when function is returned to neutral. The pressure signals are checked by monitoring the pump 1 and pump 2 control pressure sensors.
Specification Pump 1 and Pump 2 Pump Control Pressure in Neutral—Pressure (approximate)............................................................................1.05 MPa 1050 kPa 10.5 bar 152 psi
See Pilot Signal Manifold Operation for the flow rate pilot valves. (Group 9025-05.) See Pump 1, Pump 2, and Pump 3 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, pump 3 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 to display: - Pump 1 and Pump 2 Pump Control Pressure - Pump 3 Pump Control Pressure - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.)
Specification Pump 3 Pump Control Pressure in Neutral—Pressure (approximate)............................................................................1.05 MPa 1050 kPa 10.5 bar 152 psi
CAUTION: Prevent possible injury from machine movement. Ensure that area is clear of bystanders and large enough to operate all machine functions. 6. Slowly actuate control lever for boom up to full stroke while observing the monitor. The pressures must increase smoothly and evenly as function is actuated to full stroke.
Continued on next page
TM12660 (18APR18)
9025-25-27
JB3888,00009E1 -19-29AUG12-1/2
041818
PN=943
Tests
7. Hold control lever at full stroke. Record pressure readings from monitor.
8. Check the following if the pressure signal does not increase smoothly and evenly or is not to specification.
Specification Pump 1 and Pump 2 Pump Control Pressure at Full Actuation—Pressure (approximate)............................................................................3.85 MPa 3850 kPa 38.5 bar 558 psi Specification Pump 3 Pump Control Pressure at Full Actuation—Pressure (approximate)............................................................................3.85 MPa 3850 kPa 38.5 bar 558 psi
• Check hoses from pilot signal manifold to pump 1, pump 2, and pump 3 regulators for damage.
• Perform Pressure Sensor Test to check pump 1,
pump 2, and pump 3 control pressure sensors. (Group 9015-20.) • See Pilot Signal Manifold Disassemble and Assemble for instruction to remove and inspect pump 1, pump 2, and pump 3 flow rate pilot valves. (Group 3360.)
Service ADVISOR is a trademark of Deere & Company JB3888,00009E1 -19-29AUG12-2/2
TM12660 (18APR18)
9025-25-28
041818
PN=944
Tests
Main Relief and Power Dig Valve Test and Adjustment SPECIFICATIONS 45—55°C 113—131°F
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Main Relief Valve (pump 1 and pump 2) Pressure
33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4902—5265 psi
Main Relief Valve (pump 3) Pressure
33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4902—5265 psi
Power Dig Valve (pump 1 and pump 2) Pressure
36.5—40.0 MPa 36 500—40 000 kPa 365—400 bar 5294—5801 psi
Power Dig Valve (pump 3) Pressure
38.0—40.5 MPa 38 000—40 500 kPa 380—405 bar 5511—5874 psi
TX1148737A —UN—05DEC13
Hydraulic Oil Temperature
Pump 1, 2, and 3 Test Ports 1— Pump 1 Delivery Pressure Test Port 2— Pump 3 Delivery Pressure Test Port
7.1 MPa Second Adjusting Plug Pressure Change (approximate per 1/4 turn) 7100 kPa 71 bar 1030 psi 32 mm Nut Torque
- Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
80—90 N·m 59—66 lb.-ft.
First Adjusting Plug Pressure 5.3 MPa Change (approximate per 1/4 turn) 5300 kPa 53 bar 769 psi 27 mm Nut Torque
60—70 N·m 44—52 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) 17, 27, and 32 mm Combination Wrenches
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, 2, and 3 delivery pressure, hydraulic oil temperature, and actual engine speed.
• Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 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 plug from delivery pressure test port of pump being tested. 4. Install adapter. 5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer 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.)
Continued on next page
TM12660 (18APR18)
3— Pump 2 Delivery Pressure Test Port
9025-25-29
JB3888,00009E2 -19-20OCT15-1/4
041818
PN=945
Tests
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 113—131°F Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
8. Actuate arm in function over relief. Record main relief pressure reading on pump 1 or pump 2.
NOTE: If pressure adjustment in normal operation is required, adjust the low-pressure side of main relief valve. 10. Actuate boom up function over relief while pressing power dig switch. Record power dig pressure reading on pump 1 or pump 2. 11. Actuate boom up function over relief while pressing the power dig switch. Record power dig reading on pump 3. NOTE: If pressure adjustment in power dig operation is required, adjust the high-pressure side of main relief valve.
9. Actuate arm in function over relief. Record main relief pressure reading on pump 3. Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9025-25-30
JB3888,00009E2 -19-20OCT15-2/4
041818
PN=946
Tests
170 5 6 117 7 8
TX1148956 —UN—09DEC13
9 10
TX1203832 —UN—14OCT15
6-Spool Side Main Relief and Power Dig Valve
Main Relief and Power Dig Valve (117 and 170) 5— 17 mm Nut 6— First Adjusting Plug 7— 27 mm Nut
8— Second Adjusting Plug 170— Main Relief and Power Dig 9— 32 mm Nut Valve (pump 3) 10— Piston 117— Main Relief and Power Dig Valve (pump 1 and pump 2)
NOTE: Adjustment of the main relief and power dig valves (117 and 170) are adjusted the same. 12. Adjust pressures as needed for the main relief and power dig valve (117) for pump 1 and pump 2 or valve (170) for pump 3. Specification Main Relief Valve (pump 1 and pump 2)—Pressure................................................. 33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4902—5265 psi Main Relief Valve (pump 3)—Pressure.................................................................. 33.8—36.3 MPa 33 800—36 300 kPa 338—363 bar 4902—5265 psi Power Dig Valve (pump 1 and pump 2)—Pressure................................................. 36.5—40.0 MPa 36 500—40 000 kPa 365—400 bar 5294—5801 psi
Power Dig Valve (pump 3)—Pressure.................................................................. 38.0—40.5 MPa 38 000—40 500 kPa 380—405 bar 5511—5874 psi
13. Loosen 17 mm nut (5) to prevent twisting power dig pilot line. Tighten nut before starting engine. 14. Loosen 27 mm nut (7). 15. Turn first adjusting plug (6) in until plug contacts end of piston (10). Tighten nut finger tight. 16. Loosen 32 mm nut (9). 17. Start the engine. 18. Actuate appropriate function over relief while pressing the power dig switch, as needed for pump being tested.
Continued on next page
TM12660 (18APR18)
9025-25-31
JB3888,00009E2 -19-20OCT15-3/4
041818
PN=947
Tests
19. Turn second adjusting plug (8) in to increase power dig pressure or turn adjusting plug out to decrease pressure.
23. Turn first adjusting plug (6) out to decrease pressure or in to increase pressure within specified pressure for main relief valve.
Specification Second Adjusting Plug—Pressure Change (approximate per 1/4 turn).............................................................................................7.1 MPa 7100 kPa 71 bar 1030 psi
Specification First Adjusting Plug—Pressure Change (approximate per 1/4 turn).............................................................................................5.3 MPa 5300 kPa 53 bar 769 psi
20. Hold second adjusting plug (8). Tighten 32 mm nut (9) to specification.
24. Hold first adjusting plug (6). Tighten 27 mm nut (7) to specification.
Specification 32 mm Nut—Torque.............................................................. 80—90 N·m 59—66 lb.-ft.
Specification 27 mm Nut—Torque.............................................................. 60—70 N·m 44—52 lb.-ft.
21. Loosen 27 mm nut (7).
25. Tighten 17 mm nut (5).
22. Actuate appropriate function over relief, as needed for pump being tested.
26. Repeat test procedure and compare pressures to specification. JB3888,00009E2 -19-20OCT15-4/4
TM12660 (18APR18)
9025-25-32
041818
PN=948
Tests
Circuit Relief Valve Test and Adjustment 45—55°C 113—131°F
Engine Speed (approximate)
1300 rpm
Work Mode Switch Position
Dig 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
TX1147987A —UN—25NOV13
SPECIFICATIONS Hydraulic Oil Temperature
Pump 1, 2, and 3 Test Ports 1— Pump 1 Pilot Hose 2— Pump 3 Pilot Hose 3— Pump 2 Pilot Hose
- 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 - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. For instruction, see MPDr Connection Procedure. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
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
30 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)
Purpose of this test is to verify the swing motor crossover relief valve pressures are within specification. Circuit relief valves limit high pressure spikes caused by external forces when functions are in neutral. Valves are checked and adjusted to specification to protect components from damage. 1. Connect one of the following test equipment to monitor pump 1, 2, and 3 delivery pressure, hydraulic oil temperature, and actual engine speed.
• Monitor application. For instruction to actuate the
service menu on monitor in cab, see Service Menu. (Group 9015-16.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 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 pilot hoses (1—3) from pump 1, 2, and 3 delivery pressure test ports. 4. Install adapter. 5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter. 6. Turn second adjusting plug of main relief and power dig valve in 1/2 turn to increase pressure setting. For adjustment procedure, see Main Relief and Power Dig Valve Test and Adjustment. (Group 9025-25.)
Continued on next page
TM12660 (18APR18)
17— Pump 1 Regulator 18— Pump 2 Regulator 150— Pump 3 Regulator
9025-25-33
JB3888,00009E3 -19-14JAN16-1/3
041818
PN=949
Tests
7. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 8. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 113—131°F
Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9025-25-34
JB3888,00009E3 -19-14JAN16-2/3
041818
PN=950
Tests
9. Actuate the function over relief for circuit relief valve (79, 80, 88, 89, 102, and 103) being checked. Record pressure reading.
88
117
79
TX1148002 —UN—25NOV13
Specification 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.................................................. 39.2—40.2 MPa 39 200—40 200 kPa 392—402 bar 5685—5830 psi
170
89 80 6-Spool Side Circuit Relief and Anticavitation Valves (rear side shown)
NOTE: If the measured pressures for all functions are lower than the specified range, the probable cause is a decrease of main relief valve (117 and 170) setting pressure.
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..................................................................................30 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.)
TX1148003 —UN—21NOV13
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.
6-Spool Side Circuit Relief and Anticavitation Valves (front side shown) 73— Front Control Valve (6-spool) 74— Rear Control Valve (6-spool) 79— Bucket Dump Circuit Relief and Anticavitation Valve 80— Bucket Curl Circuit Relief and Anticavitation Valve 88— Boom Up Circuit Relief and Anticavitation Valve
89— Boom Down Circuit Relief and Anticavitation Valve 102— Arm In Circuit Relief and Anticavitation Valve 103— Arm Out Circuit Relief and Anticavitation Valve 117— Main Relief and Power Dig Valve (P1, P2) 170— Main Relief Valve (P3)
JB3888,00009E3 -19-14JAN16-3/3
TM12660 (18APR18)
9025-25-35
041818
PN=951
Tests
Swing Motor Crossover Relief Valve Test and Adjustment 45—55°C 110—130°F
Engine Speed (approximate)
1300 rpm
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Swing Motor Crossover Relief Valve Pressure
32.8—35.6 MPa 32 800—35 600 kPa 328—356 bar 4767—5174 psi
Crossover Relief Valve Shim Pressure Change (per 0.1 mm) (0.004 in.)
0.61 MPa 610 kPa 6.1 bar 88 psi
Crossover Relief Valve Plug Torque
180 N·m 133 lb.-ft.
TX1104353A —UN—10JAN12
SPECIFICATIONS Hydraulic Oil Temperature
Pump 1 and Pump 2 Test Ports
SERVICE EQUIPMENT AND TOOLS
1— Pump 1 Test Port 2— Pump 2 Test Port
Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)
3— Adapter 4— JT02160 Transducer
Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer
- Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)
Purpose of this test is to verify the swing motor crossover relief valve pressures are within specification.
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.)
Swing motor crossover relief valves limit system pressure in the swing circuit. They protect swing components from high stresses generated during the starting and stopping of the upperstructure. They also protect components against pressure spikes from external forces, when the control valve is in neutral.
4. Install adapter (3).
1. Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed.
5. Connect JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) gauge to adapter.
• Monitor application. See Service Menu for instruction
6. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)
to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure
3. Remove plug from pump 2 test port (2).
7. Run machine at specification. Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
8. Actuate the swing function over relief. Record pressure reading. Repeat for opposite direction.
Continued on next page
TM12660 (18APR18)
9025-25-36
JB3888,00009E4 -19-03JUN14-1/3
041818
PN=952
Tests
Make adjustments as necessary.
Specification Swing Motor Crossover Relief Valve—Pressure.................................................. 32.8—35.6 MPa 32 800—35 600 kPa 328—356 bar 4767—5174 psi
Service ADVISOR is a trademark of Deere & Company JB3888,00009E4 -19-03JUN14-2/3
9. Stop and turn off machine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. Specification Crossover Relief Valve Shim—Pressure Change................................................. 0.61 MPa per 0.1 mm (0.004 in.) 610 kPa per 0.1 mm (0.004 in.) 6.1 bar per 0.1 mm (0.004 in.) 88 psi per 0.1 mm (0.004 in.)
10. Add or remove shims (7) by removing plug (10), sleeve (9), and piston (8) to increase or decrease pressure. TX1117381 —UN—10JUL12
11. Tighten plug (10) to specification. Specification Crossover Relief Valve Plug—Torque...............................................................................180 N·m 133 lb.-ft.
12. Actuate the swing function over relief to check adjustment. Swing Crossover Relief Valve Location 9— Sleeve 10— Plug 54— Swing Crossover Relief Valve (2 used)
54
5
6
7
8
9
10
TX1117441 —UN—10JUL12
5— Spring 6— Spring Seat 7— Shim (as needed) 8— Piston
Swing Crossover Relief Valve Shims JB3888,00009E4 -19-03JUN14-3/3
TM12660 (18APR18)
9025-25-37
041818
PN=953
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
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Motor Crossover Relief Valve Pressure
34.9—36.3 MPa 34 900—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
TX1104353A —UN—10JAN12
Hydraulic Oil Temperature
Pump 1, Pump 2, and Pump 3 Test Ports
SERVICE EQUIPMENT AND TOOLS
1— Pump 1 Test Port 2— Pump 2 Test Port
Adapter (1/4 M BSPP ORB x 7/16-20 M 37°)
3— Pump 3 Test Port 4— JT02160 Transducer
Gauge 70 000 kPa (700 bar) (10 000 psi) JT02156A Digital Pressure/Temperature Analyzer
- Actual Engine Speed
JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi)
• MPDr application. See MPDr Application for
76.2 mm (3 in) O.D. Pin or Round Bar Stock (2 used)
instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed
Purpose of test is to check that the travel motor crossover relief valve pressure is within specification. 1. Connect one of the following test equipment to monitor pump 1, 2, and 3 delivery pressure, hydraulic oil temperature, and actual engine speed.
• Monitor application. See Service Menu for instruction to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Pump 1 Delivery Pressure - Pump 2 Delivery Pressure - Pump 3 Delivery Pressure - Hydraulic Oil Temperature
2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Remove the plug from pump 1, pump 2, and pump 3 test port (1—3). 4. Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer (4) or 70 000 kPa (700 bar) (10 000 psi) gauge. 5. 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.) 6. 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
TM12660 (18APR18)
9025-25-38
JB3888,00009E5 -19-05OCT16-1/4
041818
PN=954
Tests
7. Install 76.2 mm (3 in) O.D. pin (5) or round bar stock between the sprocket and track frame to stall travel motor. 8. Run machine at specification.
TX1104361A —UN—10JAN12
Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F Engine—Speed (approximate)............................................................................ 1300 rpm Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF 5— 76.2 mm (3 in) O.D. Pin
Travel Motor Stalled Using Pin JB3888,00009E5 -19-05OCT16-2/4
9. Slowly actuate the travel function for the crossover relief valve (68) being checked. Record the pressure reading. Make adjustments as necessary. Specification Travel Motor Crossover Relief Valve—Pressure.................................................. 34.9—36.3 MPa 34 900—36 300 kPa 349—363 bar 5055—5265 psi
TX1103151A —UN—08DEC11
10. Stop engine. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. 68— Travel Motor Crossover Relief Valve (2 used)
Travel Motor Crossover Relief Valve Location Continued on next page
TM12660 (18APR18)
9025-25-39
JB3888,00009E5 -19-05OCT16-3/4
041818
PN=955
Tests
23
24
25
TX1000689 —UN—29NOV05
22
TX1000689 Travel Motor Crossover Relief Valve Shims 22— Poppet 23— Spring Seat
24— Shim 25— Spring
11. 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
12. Install crossover relief valve. Tighten to specification.
Specification Crossover Relief Valve—Torque.............................................................................310 N·m 230 lb·ft
13. Actuate the travel function at stall to check adjustment. 14. 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.) JB3888,00009E5 -19-05OCT16-4/4
TM12660 (18APR18)
9025-25-40
041818
PN=956
Tests
Pump Regulator Test and Adjustment—Minimum Flow SPECIFICATIONS 45—55°C 112—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Slow (turtle)
One Revolution of Raised Track Cycle Time (with pump regulator pilot line disconnected)
32.8—34.8 seconds
TX1147987A —UN—25NOV13
Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Plug 7/16-20 M 37° Stop Watch
Pump 1, 2, and 3 Test Ports
17 mm Combination Wrench Flat Blade Screwdriver
Purpose of this test is to check and adjust the minimum flow rate of pumps 1, 2, and 3 using the cycle time for travel as an indicator of pump flow rate.
1— Pump 1 Pilot Hose 2— Pump 3 Pilot Hose 3— Pump 2 Pilot Hose
17— Hydraulic Pump 1 Regulator 18— Hydraulic Pump 2 Regulator 150— Hydraulic Pump 3 Regulator
1. Check and adjust track sag. See Check and Adjust Track Sag. (Operator's Manual.) 2. Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine speed.
plugs in pump 1 and 2 pilot lines. Leave the fittings on regulator open. Lay a shop towel over the fittings.
• Monitor application. See Service Menu for instruction
6. Raise right track off ground for pump 1 testing or left track for pump 2.
to actuate the service menu on monitor in cab. (Group 9015-16.) Select the following items to display: - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Hydraulic Oil Temperature - Actual Engine Speed
7. Run machine at specifications: Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position................................................................... Slow (turtle)
8. Actuate travel function to full speed. Record cycle time for one revolution.
3. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 112—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 1 and 2 regulator pilot lines (1 and 3) from pump 1 and 2 regulators (17 and 18). Install Continued on next page TM12660 (18APR18)
9025-25-41
JB3888,00009E6 -19-12DEC13-1/3
041818
PN=957
Tests Service ADVISOR is a trademark of Deere & Company JB3888,00009E6 -19-12DEC13-2/3
9. Adjust the minimum flow adjusting screw (5) 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 (6). Specification One Revolution of Raised Track (with pump regulator pilot line disconnected)—Cycle Time.......................................................................... 32.8—34.8 seconds
10. Repeat procedure for other pump. Adjust regulators so cycle times are approximately the same for each track. 6— 17 mm Nut
TX1103351 —UN—20DEC11
5— Minimum Flow Adjusting Screw
Minimum Flow Adjusting Screw JB3888,00009E6 -19-12DEC13-3/3
TM12660 (18APR18)
9025-25-42
041818
PN=958
Tests
Pump Regulator Test and Adjustment—Maximum Flow SPECIFICATIONS Hydraulic Oil Temperature
45—55°C 110—130°F
End of Maximum Flow Adjusting Screw to 13 mm Nut Distance
3 mm 0.125 in. (1/8 in.)
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
Travel Speed Switch Position
Fast (rabbit)
Track Raised—3 Revolutions
17.3—19.3 seconds
SERVICE EQUIPMENT AND TOOLS 13 mm Combination Wrench Flat Blade Screwdriver Stop Watch
T143804 —UN—10JUL01
30 mm Combination Wrench
Purpose of this test is to check and adjust the maximum flow rate of pump 1 and 2 using the cycle times for travel. Travel times for each side need to be the same. Maximum flow rate cannot be significantly increased by turning out the flow adjusting cartridge. 1. Check and adjust track sag. See Check and Adjust Track Sag. (Operator's Manual.)
Flow Adjusting Cartridge and Maximum Flow Adjusting Screw
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 to display: - Hydraulic Oil Temperature - Actual Engine Speed • Service ADVISOR™ application. See Service ADVISOR™ Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Hydraulic Oil Temperature - Actual Engine Speed • MPDr application. See MPDr Connection Procedure for instruction. (Group 9015-20.) Select the following items to display: - Hydraulic Oil Temperature - Actual Engine Speed 3. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature......................................................................45—55°C 110—130°F
4. Check distance from end of maximum flow adjusting screw (2) to 13 mm nut (3) for both pump 1 and pump 2 regulators. Adjust screw to specification as needed.
1— Distance 2— Maximum Flow Adjusting Screw 3— 13 mm Nut
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. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF Travel Speed Switch—Position...................................................................Fast (rabbit)
6. Raise the right track off ground to test pump 1 or left track for pump 2. 7. Actuate travel function to full speed with raised track. Record track cycle time for three revolutions. Repeat procedure for the other pump.
Continued on next page
TM12660 (18APR18)
4— Flow Adjusting Cartridge (track cycle time) 5— 30 mm Nut
9025-25-43
JB3888,00009E7 -19-12JUL12-1/2
041818
PN=959
Tests
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—Cycle Time.......................................................................... 17.3—19.3 seconds
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.
Service ADVISOR is a trademark of Deere & Company JB3888,00009E7 -19-12JUL12-2/2
TM12660 (18APR18)
9025-25-44
041818
PN=960
Tests
Pump Flow Test SPECIFICATIONS Hydraulic Oil Temperature
45—55°C
Hydraulic Oil
113—131°F
Engine Speed
Fast Idle
Work Mode Switch Position
Bucket Mode
Power Mode Switch 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
NOTE: Flow rate specification is for one pump. This test requires two people to perform. The purpose of 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:
• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)
• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)
• For information on pump control pressure operation,
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)
see Pump 1, Pump 2, and Pump 3 Regulator Operation. (Group 9025-05.) • See Torque Control Solenoid Valve Test and Adjustment. (Group 9025-25.) • See Pump Control Pilot Pressure Signal Test. (Group 9025-25.)
Continued on next page
TM12660 (18APR18)
9025-25-45
JJ03229,0001331 -19-28SEP17-1/7
041818
PN=961
Tests
4 6
1
7
3
2
TX1213385 —UN—30MAR16
5
TX1213385 Pump Flow Test 1— Pump 1 Delivery Port 2— Pump 2 Delivery Port
3— Pump 3 Delivery Port 4— Pump 1 Regulator
5— Return Manifold 6— Pump 3 Regulator
7— Pump 2 Regulator
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.)
NOTE: Both pumps can be connected as shown; however, only one pump at a time can be checked when only one return line is used.
2. Apply vacuum to hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)
An alternate method is to connect pump-to-control valve lines to outlet of flowmeters. Return oil then flows through the control valve and hydraulic oil cooler to the hydraulic oil tank.
3. Depending if one or three flowmeters are used, disconnect pump-to-control valve line from pump 1, 2, or 3 delivery ports (1—3).
Continued on next page
TM12660 (18APR18)
9025-25-46
JJ03229,0001331 -19-28SEP17-2/7
041818
PN=962
Tests 4. Connect the flowmeter. If available, connect flowmeters to all pumps as shown. JJ03229,0001331 -19-28SEP17-3/7
5. Disconnect pilot lines (8, 21, and 22) from pilot signal manifold (41) output side. Install cap to open port of pilot signal manifold. Leave fitting on pilot line open. Cover with shop towel to avoid contamination. NOTE: Pilot line is disconnected so arm and travel in function can be used to put pumps 1, 2, and 3 into stroke and not move arm or travel. 6. Remove vacuum from hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 7. Verify flowmeter loading valve is open. TX1215612A —UN—18MAY16
8. Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil temperature, and actual engine speed.
• Monitor application. For instruction to activate the
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 - Pump 3 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 - Pump 3 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 - Pump 3 Delivery Pressure - Hydraulic Oil Temperature - Actual Engine Speed 9. Warm the hydraulic oil to specification by closing flowmeter loading valve to increase pressure.
Arm In Pilot Line 8— Arm In Pilot Line 21— Right Travel Forward Pilot Line
22— Left Travel Forward Pilot Line 41— Pilot Signal Manifold
Specification Hydraulic Oil—Temperature......................................................................45—55°C 113—131°F
10. Run machine at specifications. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position................................................................. Bucket Mode Power Mode Switch—Position.......................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
11. Actuate right travel forward for pump 1, left travel forward for pump 2, and arm in for pump 3 to full actuation. Hold throughout test.
Service ADVISOR is a trademark of Deere & Company Continued on next page
TM12660 (18APR18)
9025-25-47
JJ03229,0001331 -19-28SEP17-4/7
041818
PN=963
Tests
A B
C
D
E
TX1206780 —UN—13JAN16
F
Q P TX1206780 PQ Curve P—Pressure
Q—Flow Rate Points on Pump 3 PQ Curve
12. Slowly close loading valve on flowmeter to obtain specified pressures. Record actual engine speed and flow rate at each pressure. Points on Pump 1 and Pump 2 PQ Curve
A B
P
Q
Delivery Pressure MPa (bar) [psi]
Flow Rate* L/min (gal/min)
A
4.9 (49) [711]
189 (49.9)
P
Q
Delivery Pressure MPa (bar) [psi]
Flow Rate* L/min (gal/min)
B
19.6 (196) [2842]
185 (48.9)
C
21.5 (215) [3118]
163 (43.1)
4.9 (49) [711]
213 (56.3)
D
24.5 (245) [3553]
145 (38.3)
210 (55.5)
E
30.0 (300) [4350]
118 (31.2)
34.3 (343) [4974]
98 (25.9)
14.7 (147) [2132]
C
17.0 (170) [2465]
186 (49.1)
F
D
21.0 (210) [3045]
147 (38.8)
*Approximate at 1800 engine rpm
E
28.0 (280) [4060]
110 (29.1)
F
34.3 (343) [4974]
83 (21.9)
*Approximate at 1800 engine rpm
13. Open loading valve and stop engine. NOTE: Formula is used to standardize measured flow rates due to engine speed variations. 14. Convert measured flow rates to those at specified engine speed by using formula:
• Qc = 1800 x Q/Ne Qc : Converted pump flow rate • Continued on next page JJ03229,0001331 -19-28SEP17-5/7 TM12660 (18APR18)
9025-25-48
041818
PN=964
Tests
• Q : Measured pump flow rate • 1800 : Specified engine speed • Ne : Measured engine speed
15. Adjust pump 1, pump 2, or pump 3 regulators as needed. Continued on next page
TM12660 (18APR18)
9025-25-49
JJ03229,0001331 -19-28SEP17-6/7
041818
PN=965
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)
5— Load Adjusting Cartridge (pressure to flow control-torque adjustment)
6— 30 mm Nut P—Pressure Q—Flow Rate
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.
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 13 mm nut (2).
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.
JJ03229,0001331 -19-28SEP17-7/7
TM12660 (18APR18)
9025-25-50
041818
PN=966
Tests
3. Hold load adjusting screw. Tighten 17 mm nut to specification.
Specification Load Adjusting Screw 17 mm Nut—Torque...........................................................................10 N·m 89 lb·in JJ03229,0001331 -19-28SEP17-8/7
TM12660 (18APR18)
9025-25-51
041818
PN=967
Tests
Swing Motor Leakage Test 45—55°C 110—130°F
Engine Speed
Fast Idle
Work Mode Switch Position
Dig Mode
Power Mode Button Position
PWR (power) Mode
Auto-Idle Switch Position
OFF
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 TX1104694A —UN—11JAN12
SPECIFICATIONS Hydraulic Oil Temperature
SERVICE EQUIPMENT AND TOOLS Cap (9/16-18 F 37°) Calibrated Container
1. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) 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 return line (1) from hydraulic oil tank return manifold (2). Place return line in calibrated container (3). Install cap on return manifold fitting. 4. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle Switch—Position............................................................................... OFF
Return Line 1— Return Line (swing motor to hydraulic oil tank return manifold) 2— Hydraulic Oil Tank Return Manifold
3— Calibrated Container
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.
CAUTION: To avoid personal injury, clear area of all bystanders before doing test. Slowly swing through one complete revolution to ensure that the area is clear of objects before testing. 5. Raise and lower boom to pressurize hydraulic oil tank.
Specification Swing Motor Stalled—Leakage..............................................................2.0—5.0 L/min 0.5—1.3 gpm
8. Remove cap and connect return line to hydraulic oil tank return manifold.
6. Operate swing function for 1 minute. Record amount of leakage. Repeat procedure in opposite swing direction. Record amount of leakage.
9. Swing motor leakage over specified allowable amount, can be caused by a malfunction in the swing motor crossover relief valves.
Compare amount of leakage for each direction to specification.
See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) 10. Repair or replace swing motor if the leakage is over specified amount and crossover relief valves are OK. Continued on next page
TM12660 (18APR18)
9025-25-52
JB3888,00009DA -19-16JUL12-1/2
041818
PN=968
Tests
See Swing Motor and Park Brake Remove and Install. (Group 4360.) JB3888,00009DA -19-16JUL12-2/2
Travel Motor Leakage Test 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.) TX1104692A —UN—11JAN12
3. Disconnect return line (1) from hydraulic oil tank return manifold (2). Place return line in a calibrated container (3). Install cap on hydraulic oil tank return manifold fitting. 4. Raise track off the ground for side being tested. 5. Run machine at specification. Specification Engine—Speed.......................................................................... Fast Idle Work Mode Switch—Position.......................................................................Dig Mode Power Mode Button—Position........................................................PWR (power) Mode Auto-Idle—Position............................................................................ OFF Travel Speed Switch—Position...................................................................Fast (rabbit)
6. For travel motor being tested, actuate travel forward function at full speed for 1 minute. Record amount of fluid leakage. Repeat procedure for reverse travel. Compare leakage to specification. Repair or replace travel motor as necessary. See Travel Motor and Park Brake Remove and Install. (Group 0260.)
Center Joint Return Line 1— Return Line (center joint to hydraulic oil tank return manifold) 2— Hydraulic Oil Tank Return Manifold
Specification Travel Motor with Track Raised—Leakage (maximum)...................................................................10.0 L/min or less 2.6 gpm or less
Continued on next page
TM12660 (18APR18)
3— Calibrated Container
9025-25-53
JB3888,00009D9 -19-19JUL12-1/3
041818
PN=969
Tests
7. To test 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 tested to full stroke for 1 minute. Record the amount of fluid leakage. Repeat procedure by stalling the motor in several different positions and then take an average of readings. Repeat procedure for reverse travel.
TX1104361A —UN—10JAN12
Specification Travel Motor Stalled—Leakage (maximum)...................................................................15.0 L/min or less 4.0 gpm
9. Remove cap and connect return line to hydraulic oil tank return manifold. 5— 76.2 mm (3 in.) Outside Diameter Pin Travel Motor Stalled Using Pin
JB3888,00009D9 -19-19JUL12-2/3
10. For leakage that is substantially more in one direction than the other, a seal in the center joint may be leaking. To isolate leakage in travel motor or center joint, check leakage at the travel motor. 11. Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)
7 8
12. Disconnect travel motor drain line (6) at travel motor. Install plug in the line. Connect a test hose (7) to fitting on travel motor. Put line in a calibrated container (8). 13. Repeat test procedure. Record and compare results. 14. Remove test hose and plug. Connect travel motor drain line to travel motor. 15. Travel motor leakage over specified allowable amount can be caused by a malfunction in travel motor crossover relief valve.
T144148 —UN—19JUL01
6
Travel Motor Drain Line 6— Travel Motor Drain Line 7— Test Hose
8— Calibrated Container
16. Repair or replace travel motor if leakage is over specified amount and the crossover relief valves are OK.
See Travel Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)
See Travel Motor and Park Brake Remove and Install. (Group 0260.) JB3888,00009D9 -19-19JUL12-3/3
TM12660 (18APR18)
9025-25-54
041818
PN=970
Tests
Cylinder Drift Test—Boom, Arm, and Bucket SPECIFICATIONS Cylinder Drift Test—Boom, Arm, and Bucket 45—55°C 110—130°F
TX1095487 —UN—28JUN13
Hydraulic Oil Temperature
Bucket Load Weight (approximate) 1050 kg 2315 lb. Boom Cylinder Drift (maximum allowable for 5 minutes)
20 mm 0.79 in.
Arm Cylinder Drift (maximum allowable for 5 minutes)
20 mm 0.79 in.
Bucket Cylinder Drift (maximum allowable for 5 minutes)
20 mm 0.79 in.
Machine Position—Loaded Bucket
Bottom of Bucket-to-Ground Drift 150 mm (maximum allowable for 5 minutes) 5.91 in. Boom Cylinder—Bucket Empty Drift (maximum allowable for 5 minutes)
4. Position bucket cylinder so rod is retracted 50 mm (2.00 in.) from extended position.
5 mm 0.20 in.
Arm Cylinder—Bucket Empty Drift 10 mm (maximum allowable for 5 minutes) 0.39 in.
5. Position boom cylinders so bucket pivot pin is at same height as boom-to-main frame pin.
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)
90 mm 3.54 in.
6. After 5 minutes, measure the amount of movement for boom, arm, and bucket cylinders. Also measure from bottom of bucket to the ground.
SERVICE EQUIPMENT AND TOOLS Tape Measure
Procedure is used to check the 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)...................................................................................... 20 mm 0.79 in. Arm Cylinder—Drift (maximum allowable for 5 minutes)...................................................................................... 20 mm 0.79 in. Bucket Cylinder—Drift (maximum allowable for 5 minutes)...................................................................................... 20 mm 0.79 in. Bottom of Bucket-toGround—Drift (maximum allowable for 5 minutes).............................................................. 150 mm 5.91 in.
2. Fill bucket with material. Specification Loaded Bucket—Weight (approximate)—Weight............................................................... 1050 kg 2315 lb.
3. Position arm cylinder so rod is extended approximately 50 mm (2.00 in.) from retracted position. Continued on next page
TM12660 (18APR18)
9025-25-55
JB3888,00009D8 -19-07AUG12-1/2
041818
PN=971
Tests
TX1109902 —UN—28JUN13
Drift Test—Bucket Empty 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
Machine Position—Bucket Empty
2. Empty bucket of material. 3. Position arm and bucket so rod is fully extended. 4. Lower boom until arm tip position above ground (1) is 1 m (40 in.). 5. Position bucket cylinder so rod is retracted 50 mm (2 in.) from extended position.
1— Arm Tip Position Above Ground
6. After 5 minutes, measure the amount of movement for boom, arm and bucket cylinders and arm tip to ground.
Item
Measurement
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)10 mm 0.39 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)90 mm 3.54 in. JB3888,00009D8 -19-07AUG12-2/2
TM12660 (18APR18)
9025-25-56
041818
PN=972
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 No Air Flow From Heater and Air Conditioner Vents..................................9031-15-2 No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure..............................................9031-15-2 Air Conditioning Does Not Cool Interior of Cab....................................................9031-15-4 Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure ................9031-15-4 Air Conditioning Runs Constantly, Too Cold.......................................................9031-15-6 Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure ...................9031-15-6 Interior Windows Continue to Fog Using Air Conditioner ............................9031-15-7 Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure..............................................9031-15-7 Heater System Does Not Operate .................................................9031-15-7 Heater System Does Not Operate Diagnostic Procedure............................9031-15-8 Heater Does Not Warm Interior of Cab......................................................9031-15-10 Heater Does Not Warm Interior of Cab Diagnostic Procedure..........................9031-15-10 Interior Windows Continue to Fog Using Heater .......................................9031-15-11 Interior Windows Continue to Fog Using Heater Diagnostic Procedure............................................9031-15-11 Heater and Air Conditioner Component Location ........................... 9031-15-13
Refrigerant Hoses and Tubing Inspection .............................................. 9031-25-3 Air Conditioner Compressor Belt Check .................................................... 9031-25-4 Air Conditioner High/Low-Pressure Switch Test ............................................ 9031-25-5 Air Conditioner Freeze Control Switch Test ............................................ 9031-25-6 R134a Air Conditioning System Test ........................................................ 9031-25-7 Operating Pressure Diagnostic Chart...................................................... 9031-25-8
Group 25—Tests Refrigerant Cautions and Proper Handling ................................................ 9031-25-1 Heater and Air Conditioner Operational Checks ............................... 9031-25-1 Visual Inspection of Components .....................................................9031-25-1 Air Conditioner Compressor Clutch Test ........................................................ 9031-25-3 Refrigerant Leak Test ................................ 9031-25-3
TM12660 (18APR18)
9031-1
041818
PN=1
Contents
TM12660 (18APR18)
9031-2
041818
PN=2
Group 05
Theory of Operation Air Conditioning System Cycle of Operation
2
1
5
4
3
7 6
T142307 —UN—28JUN13
8 9 10 11 T142307
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
TM12660 (18APR18)
11— Air Flow
9031-05-1
TZ24494,0000927 -19-03JUL12-1/2
041818
PN=975
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 15°C (60°F) and air conditioner is on.
TZ24494,0000927 -19-03JUL12-2/2
TM12660 (18APR18)
9031-05-2
041818
PN=976
Group 15
Diagnostic Information Air Conditioning System Does Not Operate TZ24494,00008A7 -19-29AUG12-1/7
Air Conditioning System Does Not Operate Diagnostic Procedure TZ24494,00008A7 -19-29AUG12-2/7
• 1
Diagnostic Trouble Code Check
Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display. (Group 9015-20.)
YES: Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes. (Group 9001-40.)
Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?
NO: Go to Monitor Settings Check. TZ24494,00008A7 -19-29AUG12-3/7
• 2
Monitor Settings Check
Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting. (Group 9015-16.)
YES: Go to Fuse Check.
Is the correct setting selected?
NO: Select the correct setting. TZ24494,00008A7 -19-29AUG12-4/7
• 3
Fuse Check
Remove heater and air conditioner 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of heater and air conditioner 20 amp fuse (F3). See Fuse Test. (Group 9015-20.)
YES: Go to Air Conditioner Compressor Belt Check.
Is continuity indicated?
NO: Replace heater and air conditioner 20 amp fuse (F3) (marked HEATER). TZ24494,00008A7 -19-29AUG12-5/7
• 4
Air Conditioner Compressor Belt Check
Check air conditioner compressor belt for proper pulley alignment and damage. See Inspect Belts. (Operator's Manual.)
YES: Go to Vent Air Flow Check.
Is the belt properly aligned and in good condition?
NO: Replace belt. See Serpentine Belt Remove and Install. (Group 0400.) TZ24494,00008A7 -19-29AUG12-6/7
• 5
Vent Air Flow Check
Turn key switch to ON position. Turn fan speed switch to maximum speed.
YES: Checks complete.
Is cool air coming from vents?
NO: See No Air Flow From Heater and Air Conditioner Vents or see Air Conditioning Does Not Cool Interior of Cab. (Group 9031-15.) TZ24494,00008A7 -19-29AUG12-7/7
TM12660 (18APR18)
9031-15-1
041818
PN=977
Diagnostic Information
No Air Flow From Heater and Air Conditioner Vents TZ24494,00008A8 -19-21JAN13-1/15
No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure TZ24494,00008A8 -19-21JAN13-2/15
• 1
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. TZ24494,00008A8 -19-21JAN13-3/15
• 2
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions.
YES: Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Evaporator Core Air Flow Restriction Check. TZ24494,00008A8 -19-21JAN13-4/15
• 3
Evaporator Core Air Flow Restriction Check
Check evaporator core fins for debris.
YES: Clean evaporator core fins.
Are the evaporator core fins clogged with debris?
NO: Go to Evaporator Core Fins Check. TZ24494,00008A8 -19-21JAN13-5/15
• 4
Evaporator Core Fins Check
Check evaporator core fins for frosting or freezing.
YES: Air conditioner freeze control switch not positioned correctly in evaporator core. Reposition switch.
Is there any ice or frost on evaporator fins?
NO: Go to Air Conditioner Compressor Clutch Check. TZ24494,00008A8 -19-21JAN13-6/15
• 5
Air Conditioner Compressor Clutch Check
Check air conditioner compressor clutch for proper operation. See Air Conditioner Compressor Clutch Test. (Group 9031-25.)
YES: Go to Heater and Air Conditioner Blower Motor Operation Check.
Does air conditioner compressor clutch operate properly?
NO: Replace air conditioner compressor clutch. See Air Conditioner Compressor Remove and Install. (Group 1830.)
Continued on next page
TM12660 (18APR18)
9031-15-2
TZ24494,00008A8 -19-21JAN13-7/15
041818
PN=978
Diagnostic Information
• 6
Heater and Air Conditioner Blower Motor Operation Check
Turn key switch to ON position. Set fan speed switch to maximum speed.
YES: Checks complete.
Does the heater and air conditioner blower motor fan operate?
NO: Go to Fuse Check. TZ24494,00008A8 -19-21JAN13-8/15
• 7
Fuse Check
Remove heater and air conditioner 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of heater and air conditioner 20 amp fuse (F3). See Fuse Test. (Group 9015-20.)
YES: Go to Heater and Air Conditioner Blower Motor Circuit Check.
Is continuity indicated?
NO: Replace heater and air conditioner 20 amp fuse (F3) (marked HEATER). TZ24494,00008A8 -19-21JAN13-9/15
• 8
Heater and Air Conditioner Blower Motor Circuit Check
Disconnect heater and air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Turn key switch to ON position. Check for voltage between terminal 1 and ground. See YES: Replace blower Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.) motor resistor and thermofuse (R16). Is 24 volts present?
NO: Go to Heater and Air Conditioner Blower Motor Relay Check. TZ24494,00008A8 -19-21JAN13-10/15
• 9
Heater and Air Conditioner Blower Motor Relay Check
Remove heater and air conditioner blower motor relay (K17). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test heater and air conditioner blower motor relay. See Relay Test. (Group 9015-20.)
YES: Go to Heater and Air Conditioner Blower Motor Check.
Does heater and air conditioner blower motor relay test good?
NO: Replace heater and air conditioner blower motor relay (K17). TZ24494,00008A8 -19-21JAN13-11/15
•
10 Heater and Air Conditioner Blower Motor Check
Disconnect heater and air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Supply 24 volts and ground to blower motor (M7).
YES: Go to Air Conditioner Fan Speed Switch and Circuit Check.
Does blower motor run?
NO: Replace heater and air conditioner blower motor (M7). Continued on next page
TM12660 (18APR18)
9031-15-3
TZ24494,00008A8 -19-21JAN13-12/15
041818
PN=979
Diagnostic Information
•
11 Air Conditioner Fan Speed Switch and Circuit Check
Disconnect blower motor resistor and thermofuse (R16). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Turn key switch to the ON position. Set fan speed switch to maximum speed. Check voltage at terminal 3. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Go to Heater and Air Conditioner Controller (ACF) Signal Check. (Group 9031-15.)
Is 24 volts present?
NO: Go to Wiring Harness Check. TZ24494,00008A8 -19-21JAN13-13/15
•
12 Wiring Harness Check Check heater and air conditioner harness (W41) for open or short circuits. See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.) Is heater and air conditioner harness (W41) in good condition?
YES: Go to Air Conditioner Controller (ACF) Signal Check. NO: Repair or replace heater and air conditioner harness (W41). See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.) TZ24494,00008A8 -19-21JAN13-14/15
•
13 Air Conditioner Controller (ACF) Signal Check
Disconnect blower motor resistor and thermofuse (R16). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Turn key switch to ON position. Set fan speed switch to maximum speed. Check for voltage at terminal 2. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Checks complete.
Is 17 volts present?
NO: Replace air conditioner controller (ACF). See Air Conditioner Controller (ACF) Remove and Install. (Group 9015-20.) TZ24494,00008A8 -19-21JAN13-15/15
Air Conditioning Does Not Cool Interior of Cab TZ24494,00008A9 -19-31MAY12-1/10
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure TZ24494,00008A9 -19-31MAY12-2/10
• 1
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check.
Continued on next page
TM12660 (18APR18)
9031-15-4
TZ24494,00008A9 -19-31MAY12-3/10
041818
PN=980
Diagnostic Information
• 2
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions.
YES: Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Cab Seals Check. TZ24494,00008A9 -19-31MAY12-4/10
• 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. TZ24494,00008A9 -19-31MAY12-5/10
• 4
Refrigerant Hose Restriction Check
Check refrigerant hoses. See Refrigerant Hoses and Tubing Inspection. (Group 9031-25.)
YES: Reroute or re-index 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. TZ24494,00008A9 -19-31MAY12-6/10
• 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. TZ24494,00008A9 -19-31MAY12-7/10
• 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 Evaporator Core Fins Check. TZ24494,00008A9 -19-31MAY12-8/10
• 7
Evaporator Core Fins Check
Check evaporator core fins for frosting or freezing.
YES: Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control switch.
Is there any ice or frost on evaporator core fins?
NO: Go to System Operating Pressures Check.
Continued on next page
TM12660 (18APR18)
9031-15-5
TZ24494,00008A9 -19-31MAY12-9/10
041818
PN=981
Diagnostic Information
• 8
System Operating Pressures Check
Check air conditioner system operating pressures. See R134a Air Conditioning System YES: Checks complete. Test. (Group 9031-25)
Are air conditioner system operating pressures within range?
NO: Check conditions. See Operating Pressure Diagnostic Chart. ( Group 9031-15.) TZ24494,00008A9 -19-31MAY12-10/10
Air Conditioning Runs Constantly, Too Cold TZ24494,00008AA -19-31AUG12-1/6
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure TZ24494,00008AA -19-31AUG12-2/6
• 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: Go to Air Conditioning System Does Not Operate. (Group 9031-15.) TZ24494,00008AA -19-31AUG12-3/6
• 2
Evaporator Core Component Check
Check evaporator core fins for frosting or freezing.
YES: Air conditioner freeze control switch not positioned correctly on evaporator core. Reposition air conditioner freeze control switch.
Is there any ice or frost on evaporator core fins?
NO: Go to Air Conditioner Compressor Clutch Relay Check. TZ24494,00008AA -19-31AUG12-4/6
• 3
Air Conditioner Compressor Clutch Relay Check
Remove air conditioner compressor clutch relay (K18). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test air conditioner compressor clutch relay (K18). See Relay Test. (Group 9015-20.)
YES: Go to Wiring Harness Check.
Does air conditioner compressor clutch relay test good?
NO: Replace air conditioner compressor clutch relay (K18). TZ24494,00008AA -19-31AUG12-5/6
• 4
Wiring Harness Check Check heater and air conditioner harness (W41) for open and short circuits. See Heater YES: Checks complete. and Air Conditioner Harness (W41) Component Location. (Group 9015-10.) Is heater and air conditioner harness in good condition?
NO: Repair or replace heater and air conditioner harness (W41). TZ24494,00008AA -19-31AUG12-6/6
TM12660 (18APR18)
9031-15-6
041818
PN=982
Diagnostic Information
Interior Windows Continue to Fog Using Air Conditioner TZ24494,00008AB -19-31MAY12-1/7
Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure TZ24494,00008AB -19-31MAY12-2/7
• 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 Cab Fresh Air Filter Restriction Check.
Is the air conditioning system operating correctly?
NO: Go to Air Conditioning System Does Not Operate. (Group 9031-15.) TZ24494,00008AB -19-31MAY12-3/7
• 2
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. TZ24494,00008AB -19-31MAY12-4/7
• 3
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions.
YES: Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Check Air Conditioner Drain Hoses. TZ24494,00008AB -19-31MAY12-5/7
• 4
Check Air Conditioner Drain Hoses
See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Unplug or replace hoses.
Are the hoses plugged or pinched?
NO: Go to Heater Core Check. TZ24494,00008AB -19-31MAY12-6/7
• 5
Heater Core Check
Check to see if heater core is leaking engine coolant. See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Replace heater core.
Is heater core leaking engine coolant?
NO: Checks complete. TZ24494,00008AB -19-31MAY12-7/7
Heater System Does Not Operate Continued on next page
TM12660 (18APR18)
9031-15-7
TZ24494,00008AC -19-03JUN13-1/13
041818
PN=983
Diagnostic Information Heater System Does Not Operate Diagnostic Procedure TZ24494,00008AC -19-03JUN13-2/13
• 1
Diagnostic Trouble Code Check
Check air conditioner controller (ACF) for diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Monitor Display. (Group 9015-20.)
YES: Follow diagnostic procedure for trouble code displayed. See Air Conditioner Controller (ACF) Diagnostic Trouble Codes. (Group 9001-30.)
Are diagnostic trouble codes displayed in the air conditioner controller (ACF)?
NO: Go to Monitor Settings Check. TZ24494,00008AC -19-03JUN13-3/13
• 2
Monitor Settings Check
Check machine settings in the monitor for proper air conditioner control mode setting. See Machine Setting. (Group 9015-16.)
YES: Go to Fuse Check.
Is the correct setting selected?
NO: Select the correct setting. TZ24494,00008AC -19-03JUN13-4/13
• 3
Fuse Check
Remove heater and air conditioner 20 amp fuse (F3) (marked HEATER). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of heater and air conditioner 20 amp fuse (F3). See Fuse Test. (Group 9015-20.)
YES: Go to Cab Fresh Air Filter Restriction Check.
Is continuity indicated?
NO: Replace heater and air conditioner 20 amp fuse (F3). TZ24494,00008AC -19-03JUN13-5/13
• 4
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. TZ24494,00008AC -19-03JUN13-6/13
• 5
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions.
YES: Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Heater and Air Conditioner Blower Motor Relay Check.
Continued on next page
TM12660 (18APR18)
9031-15-8
TZ24494,00008AC -19-03JUN13-7/13
041818
PN=984
Diagnostic Information
• 6
Heater and Air Conditioner Blower Motor Relay Check
Remove heater and air conditioner blower motor relay (K17). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Test heater and air conditioner blower motor relay. See Relay Test. (Group 9015-20.)
YES: Go to Heater and Air Conditioner Blower Motor Check.
Does heater and air conditioner blower motor relay test good?
NO: Replace heater and air conditioner blower motor relay (K17). TZ24494,00008AC -19-03JUN13-8/13
• 7
Heater and Air Conditioner Blower Motor Check
Disconnect heater and air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Supply 24 volts and ground to heater and air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Go to Heater and Air Conditioner Blower Motor Circuit Check.
Does heater and air conditioner blower motor run?
NO: Replace heater and air conditioner blower motor. TZ24494,00008AC -19-03JUN13-9/13
• 8
Heater and Air Conditioner Blower Motor Circuit Check
Disconnect heater and air conditioner blower motor (M7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
Turn key switch to ON position, check for voltage between terminal 1 and ground. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Replace blower motor resistor and thermofuse (R16).
Is 24 volts present?
NO: Go to Heater Air Conditioner Fan Speed Switch and Circuit Check. TZ24494,00008AC -19-03JUN13-10/13
• 9
Heater Air Conditioner Disconnect blower motor resistor and thermofuse (R16). See Heater and Air Fan Speed Switch and Conditioner Harness (W41) Component Location. (Group 9015-10.) Circuit Check
Turn key switch to the ON position. Set fan speed switch to maximum speed. Check voltage at terminal 3. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Go to Heater and Air Conditioner Controller (ACF) Signal Check.
Is 24 volts present?
NO: Go to Wiring Harness Check. Continued on next page
TM12660 (18APR18)
9031-15-9
TZ24494,00008AC -19-03JUN13-11/13
041818
PN=985
Diagnostic Information
•
10 Wiring Harness 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. Specification 100-Pin Connector (X3)—Torque..........................................................................10 N·m 89 lb.-in. Check cab harness (W1) heater and air conditioner harness (W41) for open or short circuits. See Cab Harness (W1) Component Location and see Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.)
YES: Go to Heater and Air Conditioner Controller (ACF) Signal Check.
Is cab harness (W1) and heater and air conditioner harness (W41) OK?
NO: Repair or replace cab harness or heater and air conditioner harness. TZ24494,00008AC -19-03JUN13-12/13
•
11 Heater and Air Disconnect blower motor resistor and thermofuse (R16). See Heater and Air Conditioner Controller Conditioner Harness (W41) Component Location. (Group 9015-10.) (ACF) Signal Check
Turn key switch to ON position. Set fan speed switch to maximum speed. Check for voltage at terminal 2. See Heater and Air Conditioner Harness (W41) Wiring Diagram. (Group 9015-10.)
YES: Checks complete.
Is 17 volts present?
NO: Replace heater and air conditioner controller (ACF). See Air Conditioner Controller (ACF) Remove and Install. (Group 9015-20.) TZ24494,00008AC -19-03JUN13-13/13
Heater Does Not Warm Interior of Cab TZ24494,00008AD -19-29AUG12-1/9
Heater Does Not Warm Interior of Cab Diagnostic Procedure TZ24494,00008AD -19-29AUG12-2/9
• 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: Go to Heater System Does Not Operate. (Group 9031-15.) TZ24494,00008AD -19-29AUG12-3/9
• 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. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) Continued on next page
TM12660 (18APR18)
9031-15-10
TZ24494,00008AD -19-29AUG12-4/9
041818
PN=986
Diagnostic Information
• 3
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Cab Recirculating Air Filter Restriction Check. TZ24494,00008AD -19-29AUG12-5/9
• 4
Cab Recirculating Air Filter Restriction Check
Check cab recirculating air filter for debris or air flow restrictions.
YES: Clean or replace cab recirculating air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab recirculating air filter dirty or clogged with debris?
NO: Go to Heater Hose Restriction Check. TZ24494,00008AD -19-29AUG12-6/9
• 5
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. TZ24494,00008AD -19-29AUG12-7/9
• 6
Heater Door Servo Motor Check
Inspect heater servo motor and door.
YES: Go to Heater Core Air Flow Restriction Check.
Is the servo motor and door working correctly?
NO: Repair or replace servo motor or door. TZ24494,00008AD -19-29AUG12-8/9
• 7
Heater Core Air Flow Restriction Check
Check heater core fins for debris.
YES: Clean heater core fins.
Are the heater core fins clogged with debris?
NO: Checks complete. TZ24494,00008AD -19-29AUG12-9/9
Interior Windows Continue to Fog Using Heater TZ24494,00008AE -19-31MAY12-1/7
Interior Windows Continue to Fog Using Heater Diagnostic Procedure Continued on next page
TM12660 (18APR18)
9031-15-11
TZ24494,00008AE -19-31MAY12-2/7
041818
PN=987
Diagnostic Information
• 1
Cab Fresh Air Filter Restriction Check
Check cab fresh air filter for debris or air flow restrictions.
YES: Clean or replace cab fresh air filter. See Clean Cab Fresh Air and Cab Recirculating Air Filters. (Operator’s Manual.)
Is cab fresh air filter dirty or clogged with debris?
NO: Go to Heater Core Leak Check. TZ24494,00008AE -19-31MAY12-3/7
• 2
Heater Core Leak Check
Check to see if the heater core is leaking coolant. See Heater and Air Conditioner Component Location. (Group 9031-15.)
YES: Replace heater core.
Is the heater core leaking coolant?
NO: Go to Cab Seals Check. TZ24494,00008AE -19-31MAY12-4/7
• 3
Cab Seals Check
Check windows and doors to make sure seals are good.
YES: Go to Air Conditioner Check.
Are seals on all windows and doors functioning properly?
NO: Repair or replace malfunctioning seals. TZ24494,00008AE -19-31MAY12-5/7
• 4
Air Conditioner Check
Check to see if the air conditioner is working properly.
YES: Go to Door Servo Motor Check.
Is air conditioner working properly?
NO: Correct air conditioner problem. See Air Conditioning System Does Not Operate. (Group 9031-15.) TZ24494,00008AE -19-31MAY12-6/7
• 5
Door Servo Motor Check
Check to make sure the servo motor(s) are opening doors correctly.
YES: Checks complete.
Are the servo motor(s) operating correctly?
NO: Repair or replace servo motor(s). TZ24494,00008AE -19-31MAY12-7/7
TM12660 (18APR18)
9031-15-12
041818
PN=988
Diagnostic Information
Heater and Air Conditioner Component Location TX1120954 —UN—23AUG12
B21
M10 K17
M11
K15 A4
B41 M7
11
R16
A7 10
9 11
10
B55 6
M9
7
8
12
Y11 14
5
2
13
4 13
12
B20 14 TX1120954 Heater and Air Conditioner Component Location Continued on next page
TM12660 (18APR18)
9031-15-13
041818
PN=989
TZ24494,00008AF -19-23AUG12-1/2
Diagnostic Information
TM12660 (18APR18)
9031-15-14
041818
PN=990
Diagnostic Information 2— Fresh Air Filter 4— Air Conditioner Condenser 5— Receiver-Dryer 6— Recirculated Air Filter 7— Evaporator 8— Expansion Valve 9— Heater Core 10— Heater Core-to-Coolant Return Manifold Hose 11— Cylinder Head-to-Heater Core Hose 12— Expansion Valve-to-Air Conditioner Compressor Hose
13— Air Conditioner Compressor-to-Air Conditioner Condenser Hose 14— Air Conditioner Condenser-to-Expansion Valve Hose A4—Monitor Controller (DSZ) A7—Air Conditioner Controller (ACF) B20— Air Conditioner High/Low Pressure Switch B21— Solar Sensor
B41— Air Conditioner Freeze M10— Air Conditioner and Heater Control Switch Blower Port Change B55— Air Recirculation Sensor Servomotor K15— Air Conditioner M11— Air Conditioner and Heater Compressor Off Relay Mixer Servomotor K17— Air Conditioner and Heater R16— Blower Motor Resistor Blower Motor Relay Y11— Air Conditioner M7—Air Conditioner and Heater Compressor Clutch Blower Motor M9—Air Conditioner and Heater Internal and External Servomotor
TZ24494,00008AF -19-23AUG12-2/2
TM12660 (18APR18)
9031-15-15
041818
PN=991
Diagnostic Information
TM12660 (18APR18)
9031-15-16
041818
PN=992
Group 25
Tests 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 JT02167A Prism Pro Refrigerant Identification Instrument
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.
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.
Use correct refrigerant recovery, recycling and charging stations. Never 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. JT02167A refrigerant test instrument 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 your bare hands. Skin may freeze to container. Wear gloves.
TZ24494,0000839 -19-18MAY12-1/2
Prism Pro Refrigerant Identification Instrument .......................................................................... JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems. TZ24494,0000839 -19-18MAY12-2/2
Heater and Air Conditioner Operational Checks TZ24494,0000840 -19-18JUN12-1/9
Visual Inspection of Components TZ24494,0000840 -19-18JUN12-2/9
• 1
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 Air Conditioner Compressor 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.
Continued on next page
TM12660 (18APR18)
9031-25-1
TZ24494,0000840 -19-18JUN12-3/9
041818
PN=993
Tests
• 2
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 Condenser Check.
LOOK/FEEL: Are electrical connections to compressor clean and tight? Is wiring in good condition?
NO: Repair or replace components as necessary. TZ24494,0000840 -19-18JUN12-4/9
• 3
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 Engine Fan 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. TZ24494,0000840 -19-18JUN12-5/9
• 4
Engine Fan Check
Inspect engine fan.
LOOK/FEEL: Are fan blades in good condition, not worn, bent, broken, or missing?
YES: Go to Heater/Evaporator Core Check.
LOOK/FEEL: Is fan securely installed?
NO: Repair or replace components as necessary. TZ24494,0000840 -19-18JUN12-6/9
• 5
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 Cab Air Filter 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. TZ24494,0000840 -19-18JUN12-7/9
• 6
Cab Air Filter Check
Inspect cab air filter.
YES: Go to Cab Door and Windows Check.
LOOK/FEEL: Is cab air filter clean and free of debris? Continued on next page
TM12660 (18APR18)
9031-25-2
NO: Replace cab air filter. TZ24494,0000840 -19-18JUN12-8/9
041818
PN=994
Tests
• 7
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. TZ24494,0000840 -19-18JUN12-9/9
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 (Y11).
4. If clutch solenoid does not engage, replace air conditioner compressor clutch. See Air Conditioner Compressor Remove and Install. (Group 1830.) 5. If clutch solenoid engages but the air conditioning system does not cool, see Air Conditioning System Does Not Operate. (Group 9031-15.)
3. Clutch solenoid will engage and click will be heard. TZ24494,000083E -19-20JAN13-1/1
Refrigerant Leak Test
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.
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. When refrigerant leaks from the system, a small amount of oil is carried out with it. 2. A soap and water solution can be applied on components in the system, this forms bubbles at the source of a leak.
Specification Leak Detector Probe Speed—Speed........................................................... 25 mm per second 1 in. per second
4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection. 5. Repair or replace components as necessary to correct identified leaks. TZ24494,000083A -19-17MAY12-1/1
Refrigerant Hoses and Tubing Inspection IMPORTANT: Prevent refrigerant gas leakage. Do not use hydraulic hoses as replacement hoses in the air conditioning system. Only use certified hoses meeting SAE J2064 Type C requirements. Hoses used for air conditioning systems contain special barriers in their walls to prevent migration of refrigerant gas. When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts.
IMPORTANT: Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. The use of these solvents will cause deterioration of hoses. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. To assist in making leak proof 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.
TZ24494,000083B -19-18JUN12-1/1
TM12660 (18APR18)
9031-25-3
041818
PN=995
Tests
Air Conditioner Compressor Belt Check Inspect condition and tension of air conditioner belt. See Inspect Belts. (Operator's Manual.) TZ24494,000083F -19-29AUG12-1/1
TM12660 (18APR18)
9031-25-4
041818
PN=996
Tests
Air Conditioner High/Low-Pressure Switch Test
Specification Switch Closes—Low Pressure............................................................................ 196—216 kPa 1.96—2.16 bar 28—31 psi
SPECIFICATIONS Switch Closes—Low Pressure
196—216 kPa 1.96—2.16 bar 28—31 psi
Switch Opens—Low Pressure
196—216 kPa 1.96—2.16 bar 28—31 psi
Switch Opens—High Pressure
2550—3140 kPa 25.5—31.4 bar 370—455 psi
Switch Closes—High Pressure
2550—3140 kPa 25.5—31.4 bar 370—455 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............................................................................ 196—216 kPa 1.96—2.16 bar 28—31 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........................................................................ 2550—3140 kPa 25.5—31.4 bar 370—455 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........................................................................ 2550—3140 kPa 25.5—31.4 bar 370—455 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 TX03742,0000127 -19-26MAR18-1/1
TM12660 (18APR18)
9031-25-5
041818
PN=997
Tests
Air Conditioner Freeze Control Switch Test SPECIFICATIONS Air Conditioner Freeze Control Switch Operational Resistance
0.100—115 kΩ
Air Conditioner Freeze Control Switch Resistance (approximate) at 2°C (36°F)
4.2 kΩ
Air Conditioner Freeze Control Switch Resistance (approximate) at 3°C (38°F)
4.5 kΩ
Air Conditioner Freeze Control Switch—Resistance (approximate) at 2°C (36°F).............................................................................................4.2 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—Operational Resistance........................................................................ 0.100—115 kΩ Air Conditioner Freeze Control Switch—Resistance (approximate) at 3°C (38°F).............................................................................................4.5 kΩ
5. Compare resistance readings to specification. If measured resistance is not within specification, replace switch.
Specification Air Conditioner Freeze Control Switch—Operational Resistance........................................................................ 0.100—115 kΩ TX03742,0000128 -19-27MAR18-1/1
TM12660 (18APR18)
9031-25-6
041818
PN=998
Tests
R134a Air Conditioning System Test
NOTE: Follow manufacturer's instructions when operating refrigerant recovery, recycling, and charging station.
SPECIFICATIONS Engine Speed Dial
Fast Idle
Auto-Idle Switch
A/I OFF
Power Mode Button
PWR (power) Mode
5. Connect JT02045 R134a Deluxe Recovery, Recycling, and Charging Station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.)
Temperature Control/Mode Switch Maximum Cooling Blower Motor Speed Switch
High Speed
6. Open both low and high pressure valves on refrigerant recovery, recycling, and charging station.
SERVICE EQUIPMENT AND TOOLS JT02045 R134a Deluxe Recovery/Recycling and Charging Station
7. Open cab door and windows.
JT02167A Prism Pro Refrigerant Identification Instrument
8. Start engine and run at specification.
Thermometer
CAUTION: Avoid personal injury due to exposure to liquid refrigerant. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 9031-25.) IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils to avoid air conditioning system contamination. Identify refrigerant before recovering, recycling, and charging system.
9. Press the blower motor speed switch to turn the air conditioner on. See Cab Heater and Air Conditioner. (Operator's Manual.) 10. Turn the temperature control/mode switch to maximum cooling position. 11. Turn blower motor speed switch to high. 12. Run machine for at least 5 minutes.
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.)
R134a Air Conditioning System Test—Specification Engine Speed Dial—Position............................................................................. Fast Idle Auto-Idle Switch—Position..........................................................................A/I OFF Power Mode Button—Setting.........................................................PWR (power) Mode
13. Measure and record air temperature at condenser air inlet and at air ducts in cab. 14. Observe low side pressure and high side pressure on gauges. 15. Compare pressures and air duct temperature readings to specifications shown.
4. Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument. Ambient Air Temperature
Expected Air Duct Temperature
Low Side Pressure
High Side Pressure
19—21°C 67—70°F
9—13°C 48—56°F
108—131 kPa 1.08—1.31 bar 16—19 psi
1127—1364 kPa 11.27—13.64 bar 163—198 psi
22—24°C 72—76°F
9—13°C 48—55°F
112—135 kPa 1.12—1.35 bar 16—20 psi
1200—1452 kPa 12.00—14.52 bar 174—211 psi
25—26°C 77—79°F
10—14°C 50—57°F
120—146 kPa 1.20—1.46 bar 17—21 psi
1366—1654 kPa 13.66—16.54 bar 198—240 psi
27—29°C 81—85°F
12—16°C 53—60°F
131—159 kPa 1.31—1.59 bar 19—23 psi
1427—1727 kPa 14.27—17.27 bar 207—250 psi
30—32°C 86—90°F
13—17°C 55—63°F
149—181 kPa 1.49—1.81 bar 22—26 psi
1572—1903 kPa 15.72—19.03 bar 228—276 psi
33—35°C 92—95°F
15—19°C 59—67°F
165—200 kPa 1.65—2.00 bar 24—29 psi
1705—2064 kPa 17.05—20.64 bar 247—299 psi
Continued on next page
TM12660 (18APR18)
9031-25-7
TZ24494,000083C -19-29AUG12-1/2
041818
PN=999
Tests Ambient Air Temperature
Expected Air Duct Temperature
Low Side Pressure
High Side Pressure
36—38°C 97—101°F
17—22°C 63—72°F
180—218 kPa 1.80—2.18 bar 17—24 psi
1833—2219 kPa 18.33—22.19 bar 221—324 psi
39—40°C 103—104°F
20—24°C 68—75°F
194—234 kPa 1.94—2.34 bar 28—34 psi
1955—2366 kPa 19.55—23.66 bar 283—343 psi
41—43°C 106—110°F
21—26°C 70—79°F
204—247 kPa 2.04—2.47 bar 30—36 psi
2054—2486 kPa 20.54—24.86 bar 298—360 psi
16. If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart. (Group 9031-25.) TZ24494,000083C -19-29AUG12-2/2
Operating Pressure Diagnostic Chart Condition
Low Side kPa (bar) (psi)
High Side kPa (bar) (psi)
Suction Line
Receiver-Dryer
Liquid Line
Discharge Line Discharge Air
Lack of Refrigerant
Very Low
Very Low
Slightly Cool
Slightly Warm
Slightly Warm
Slightly Warm
Warm
Loss of Refrigerant
Low
Low
Cool
Warm to Hot
Warm
Warm to Hot
Slightly Cool
High Side Restriction
Low
Low
Cool
Cool, Sweating, or Frosting
Cool, Sweating, Hot to Point of or Frosting Restriction
Slightly Cool
Expansion Valve Low Closed
Low
Cold, Sweating, or Frosting Heavily at Valve Outlet
Warm
Warm
Hot
Slightly Cool
Loose Belt or Compressor Malfunction
High
Low
Cool
Warm
Warm
Warm
Slightly Cool
Condenser Malfunction
High
High
Slightly Cool to Warm
Hot
Hot
Hot
Warm
Refrigerant Contaminated and Air in System
High
High
Warm to Hot
Warm
Warm
Hot
Warm
Expansion Valve High Open
High
Cold, Sweating, or Frosting Heavily
Warm
Warm
Hot
Slightly Cool
Plugged Condenser, Overcharge of Refrigerant
Normal
High
Cool
Warm
Warm
Hot
Slightly Cool
Moisture in System
Normal (may drop)
Normal (may drop)
Cool
Warm
Warm
Hot
Cool to Warm
Heater Valve Stuck Open
Normal
Normal
Cool
Warm
Warm
Hot
Warm
Lack of Refrigerant and Air in System
Normal (no drop) Normal
Warm to Hot
Warm
Warm
Warm
Slightly Cool
TZ24494,000083D -19-24APR12-1/1
TM12660 (18APR18)
9031-25-8
041818
PN=1000
Contents
Section 9900 Dealer Fabricated Tools
Page
Group 99—Dealer Fabricated Tools DFT1218 Split Flange Hose Cap............... 9900-99-1
TM12660 (18APR18)
9900-1
041818
PN=1
Contents
TM12660 (18APR18)
9900-2
041818
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
TM12660 (18APR18)
9900-99-1
041818
PN=1003
Dealer Fabricated Tools
TM12660 (18APR18)
9900-99-2
041818
PN=1004
Index Page Page
A Adjustments Engine......................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Air conditioner Freeze control switch test .............................. 9031-25-6 Heater and, component location .................. 9031-15-13 Operating pressure diagnostic chart ............................................................. 9031-25-8 Operational checks ........................................ 9031-25-1 Air conditioner compressor Belt check ...................................................... 9031-25-4 Air conditioner compressor clutch Test ................................................................ 9031-25-3 Air conditioner controller (ACF) Remove and install ...................................... 9015-20-47 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.......................... 9031-25-3 R134a system test ......................................... 9031-25-7 Refrigerant cautions and proper handling........................................................ 9031-25-1 Refrigerant leak test....................................... 9031-25-3 System cycle of operation.............................. 9031-05-1 Alarm setting Setting alarm................................................ 9015-16-15 Alternator Test .............................................................. 9015-20-20 Alternator fuse Check........................................................... 9015-20-30 Ambient air temperature sensor Test .............................................................. 9015-20-19 Anticavitation valve Operation ..................................................... 9025-05-57 Arm 1 flow rate control valve circuit Operation ..................................................... 9025-05-86 Arm 1 flow rate pilot valve Operation ..................................................... 9025-05-14 Arm 2 flow rate control valve circuit Operation ..................................................... 9025-05-90 Arm 3 and boom 3 spool control solenoid valve Operation ..................................................... 9025-05-95 Arm and boom reduced leakage valves Operation ..................................................... 9025-05-84 Arm cylinder Drift test........................................................ 9025-25-55 Operation ................................................... 9025-05-128 Arm regenerative solenoid valve Test and adjustment..................................... 9025-25-16 Arm regenerative valve Operational check ........................................ 9005-10-38
Arm regenerative valve circuit Operation ..................................................... 9025-05-75 Attachemt Control circuit theory of operation ................ 9015-15-60 Attachment harness (W17) Component location ................................... 9015-10-144 Wiring diagram........................................... 9015-10-146 Attachments Adding safely ............................................... 9000-01-12 Operating safely........................................... 9000-01-12 Auto-acceleration System operation ........................................... 9010-05-6 Auto-idle circuit Operational check ........................................ 9005-10-23 Auto-idle control Operation ....................................................... 9010-05-6 Auto-warming up control Operation ....................................................... 9010-05-6 Auxiliary Control circuit theory of operation ................ 9015-15-60 System Operation ...................................... 9025-05-130 Auxiliary 3-button cancel switch harness (W22) Component location ................................... 9015-10-152 Wiring diagram........................................... 9015-10-153 Auxiliary flow combiner valve Operation ..................................................... 9025-05-62 Auxiliary flow rate control valve circuit Operation ..................................................... 9025-05-92 Auxiliary function enable switch harness (W78) Component location ................................... 9015-10-185 Wiring diagram........................................... 9015-10-186 Auxiliary function lever (AFL) grip harness (W77) Component location ................................... 9015-10-185 Wiring diagram........................................... 9015-10-185 Auxiliary function lever (AFL) harness (W75) Component location ................................... 9015-10-178 Wiring diagram........................................... 9015-10-181 Auxiliary function lever (AFL) solenoid harness (W76) Component location ................................... 9015-10-183 Wiring diagram........................................... 9015-10-184 Auxiliary fuse box harness (W13) Component location ................................... 9015-10-124 Wiring diagram........................................... 9015-10-127 Auxiliary High Flow Line Kit Operation ................................................... 9025-05-145 Auxiliary Pilot Control Valve Operation<indxflag/>.................................. 9025-05-130 Auxiliary Shuttle Valve Operation ................................................... 9025-05-144 Auxiliary solenoid harness (W61) Component location ................................... 9015-10-174 Auxiliary System Operation ................................................... 9025-05-130 Continued on next page
TM12660 (18APR18)
Index-1
041818
PN=1
Index
Page
Page
B
C
Backhoe pattern Control lever pattern check .......................... 9005-10-27 Backover Accidents ......................................... 9000-01-10 Barometric pressure sensor Theory of operation...................................... 9015-15-19 Battery Remove and install ...................................... 9015-20-33 Battery fuse Check........................................................... 9015-20-30 Battery relay Check........................................................... 9015-20-29 Battery voltage Check........................................................... 9015-20-29 Belt, air conditioner compressor Check............................................................. 9031-25-4 Bent track shoe Diagnostic procedure ..................................... 9020-15-2 Bleed procedure Adjustable relief ........................................... 9015-20-46 Boom and arm reduced leakage valves Operation ..................................................... 9025-05-84 Boom cylinder Drift test........................................................ 9025-25-55 Operation ................................................... 9025-05-128 Boom down shockless valve Operation ..................................................... 9025-05-14 Boom lower meter-in cut valve Operation ..................................................... 9025-05-65 Boom regenerative valve Operational check ........................................ 9005-10-37 Boom regenerative valve circuit Operation ..................................................... 9025-05-67 Boom up, arm in, and bucket combined function Operational check ........................................ 9005-10-36 Brake valve and travel motor Operation ................................................... 9025-05-112 Bucket cylinder Drift test........................................................ 9025-25-55 Operation ................................................... 9025-05-128 Bucket flow rate pilot valve Operation ..................................................... 9025-05-14 Bucket regenerative valve Operational check ........................................ 9005-10-39 Bucket regenerative valve circuit Operation ..................................................... 9025-05-80 Burn solenoid valves Diesel particulate filter................................ 9025-05-125 Bypass shut-off valve operation ...................................................... 9025-05-62 Bypass valve Return filter, operation................................ 9025-05-129
Cab harness (W1) Component location ..................................... 9015-10-51 Wiring diagram............................................. 9015-10-55 Calibration Exhaust differential pressure sensor ........................................................ 9015-20-42 Camshaft position sensor Theory of operation...................................... 9015-15-19 CAN bus terminator Check.......................................9015-20-32, 9015-20-33 CAN circuit Test .............................................................. 9015-20-23 Center joint Operation ....................................................9025-05-111 Charging Theory of operation........................................ 9015-15-5 Check valve Control valve, identification and operation .................................................... 9025-05-49 Travel motor, operation .............................. 9025-05-112 Chipped link rails Diagnostic procedure ..................................... 9020-15-4 Cinch connector Install contact ...........................9015-20-63, 9015-20-64 Cinch connector (32 and 48 Way) Repair .......................................................... 9015-20-64 Cinch connectors Replace Connector ...................................... 9015-20-61 Circuit Lighting, theory of operation ........................ 9015-15-53 Machine controller (BCZ), theory of operation .................................................... 9015-15-47 Pilot shutoff, theory of operation .................. 9015-15-57 Windshield wiper and washer, theory of operation .................................................... 9015-15-49 Circuit relief valve Operation ..................................................... 9025-05-57 Test and adjustment..................................... 9025-25-33 Cleanup Hydraulic oil ................................................... 9025-25-6 Cleanup procedure General hydraulic oil ...................................... 9025-25-2 Hydraulic component failure .......................... 9025-25-4 Cold Start Theory of Operation ....................................... 9010-05-5 Cold weather Starting aid..................................................... 9010-05-5 Component failure Hydraulic, cleanup procedure ........................ 9025-25-4 Component location 9-Pin sevice advisor connector harness (W20) ....................................................... 9015-10-149 Attachment harness (W17) ........................ 9015-10-144 Auxiliary 3-button cancel switch harness (W22) ....................................................... 9015-10-152 Continued on next page
TM12660 (18APR18)
Index-2
041818
PN=2
Index
Page
Page
Auxiliary function enable switch harness (W78) ....................................................... 9015-10-185 Auxiliary function lever (AFL) grip harness (W77) ....................................................... 9015-10-185 Auxiliary function lever (AFL) harness (W75) ....................................................... 9015-10-178 Auxiliary function lever (AFL) solenoid harness (W76).......................................... 9015-10-183 Auxiliary fuse box harness (W13) .............. 9015-10-124 Auxiliary solenoid harness (W61) .............. 9015-10-174 Cab harness (W1)........................................ 9015-10-51 Engine cooling system ................................... 9010-05-4 Engine fuel system......................................... 9010-05-2 Engine harness (W4) ................................... 9015-10-95 Exhaust filter parked cleaning switch harness (W9)............................................ 9015-10-119 Heated air seat harness (W14) .................. 9015-10-130 Heater and air conditioner............................ 9031-15-13 Heater and air conditioner harness (W41) ....................................................... 9015-10-167 Hydraulic system.......................................... 9025-15-70 Information ..................................................... 9015-05-1 JDLink harness .......................................... 9015-10-188 Machine harness.......................................... 9015-10-73 Monitor harness (W3) .................................. 9015-10-90 Multi-function pilot control lever harness (W15) ....................................................... 9015-10-132 Pilot shutoff switch harness (W11)............. 9015-10-120 Pilot shutoff valve harness (W21) .............. 9015-10-151 Pump harness (W8) ................................... 9015-10-114 Rear camera harness (W19)...................... 9015-10-148 Satellite (SAT) harness .............................. 9015-10-186 Seat heater switch harness (W24)............. 9015-10-153 Side camera harness (W5) ........................ 9015-10-106 Side monitor harness (W6) ........................ 9015-10-108 Spool Control Harness............................... 9015-10-171 Starter switch harness (W29)..................... 9015-10-158 Travel alarm cancel switch harness (W16) ....................................................... 9015-10-143 Travel alarm harness (W26) ...................... 9015-10-155 Travel sub harness .................................... 9015-10-156 Travel system............................................... 9025-15-46 Component Location 2-speed harness ........................................ 9015-10-165 Data Converter Harness (W30) ................. 9015-10-160 Data Converter Interface Harness (W31) ....................................................... 9015-10-163 Compressor clutch Air conditioner, test ........................................ 9031-25-3 Compressor, air conditioner Belt check ...................................................... 9031-25-4 Control lever pattern check - backhoe pattern Operational check ........................................ 9005-10-27 Control lever pattern check - excavator pattern Operational check ........................................ 9005-10-26 Control pattern................................................... 9000-01-3
Control valve Arm 1 flow rate, circuit operation ................. 9025-05-86 Arm 2 flow rate, circuit operation ................. 9025-05-90 Auxiliary flow rate, circuit operation ............. 9025-05-92 Check valves identification and operation .................................................... 9025-05-49 Circuit relief and anticavitation valve operation .................................................... 9025-05-57 Line identification, 4-spool ........................... 9025-15-30 Line identification, 5-spool ........................... 9025-15-30 Line identification, front ................................ 9025-15-30 Operation ..................................................... 9025-05-35 Pilot operation .............................................. 9025-05-11 Schematic .................................................... 9025-15-53 Spool, actuating pilot pressure test.............. 9025-25-12 Control valve lift check valve Operational check ........................................ 9005-10-35 Controller area network (CAN) Circuit test .................................................... 9015-20-23 Theory of operation........................................ 9015-15-1 Controller version Monitor operation ........................................... 9015-16-6 Counterbalance valve Travel motor, operation .............................. 9025-05-112 Cracked track link Diagnostic procedure ..................................... 9020-15-3 Crankshaft position sensor Theory of operation...................................... 9015-15-19 Crossover relief valve Operation ..................................................... 9025-05-99 Swing motor, test and adjustment................ 9025-25-36 Travel motor, operation .............................. 9025-05-112 Travel motor, test and adjustment................ 9025-25-38 Cycle times check Operational check ........................................ 9005-10-45 Cylinder Boom, arm, and bucket, operation............. 9025-05-128 Cylinder drift Boom, arm, and bucket................................ 9025-25-55
D Damper valve Swing motor, operation .............................. 9025-05-102 Data converter Remove and install ...................................... 9015-20-45 Data Converter Harness (W30) Component Location.................................. 9015-10-160 Wiring Diagram .......................................... 9015-10-162 Data Converter Interface Harness (W31) Component Location.................................. 9015-10-163 Wiring Diagram .......................................... 9015-10-164 Diagnostic connection MPDr. ........................................................... 9015-20-11 Service ADVISOR™ ...................................... 9015-20-2 Diagnostic information .................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Continued on next page
TM12660 (18APR18)
Index-3
041818
PN=3
Index
Page
Page
Diagnostic trouble code check Operational check .......................................... 9005-10-1 Diagnostic trouble codes Information controller (ICZ) ............................ 9001-40-1 MPDr............................................................ 9015-20-10 Reading, monitor display ............................... 9015-20-1 Reading, Service ADVISOR .......................... 9015-20-5 Reading, Service ADVISOR™....................... 9015-20-3 Diagnostic Trouble Codes Service ADVISOR™ ...................................... 9015-20-1 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 Diesel particulate filter (DPF) Burn solenoid valves.................................. 9025-05-125 Dig function drift Operational check ....................9005-10-32, 9005-10-33 Dig regenerative Solenoid valve test and adjustment ............. 9025-25-14 Valve operation ............................................ 9025-05-69 Digital thermometer installation ......................... 9025-25-1 Diode Check........................................................... 9015-20-30 Display and clear trouble codes Operational check .......................................... 9005-10-1 Drive gear case, pump 1, pump 2, and pump 3 Operation ..................................................... 9025-05-24
Electronic injector 1 Theory of operation...................................... 9015-15-19 Electronic injector 2 Theory of operation...................................... 9015-15-19 Electronic injector 3 Theory of operation...................................... 9015-15-19 Electronic injector 4 Theory of operation...................................... 9015-15-19 Engine Cooling system, component location......................................................... 9010-05-4 Fuel system, component location .................. 9010-05-2 Tests.........................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Theory of operation..................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine adjustments .....................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine control unit (ECU) Remove and install ...................................... 9015-20-40 Theory of operation...................................... 9015-15-19 Engine control unit (ECU) diagnostics trouble codes Diagnostic trouble codes engine control unit (ECU) .................................................... 9001-20-1 Engine coolant temperature sensor Theory of operation...................................... 9015-15-19 Engine harness (W4) Component location ..................................... 9015-10-95 Wiring diagram........................................... 9015-10-103 Engine oil pressure sensor Theory of operation...................................... 9015-15-19 Engine setting Monitor operation ......................................... 9015-16-15 Engine speed Specifications................................................. 9010-05-6 Engine speed control Heater control ................................................ 9010-05-6 System operation ........................................... 9010-05-6 Engine speed dial Operation ....................................................... 9010-05-6 Operational check ........................................ 9005-10-20 Engine speed sensing control circuit Operation ..................................................... 9025-05-33 Excavator pattern Control lever pattern check .......................... 9005-10-26 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 Differential pressure sensor zero point calibration................................................... 9015-20-42 Exhaust aftertreatment circuit Theory of operation...................................... 9015-15-28
E E (economy) mode Operational check ........................................ 9005-10-21 Economy mode Operation ....................................................... 9010-05-6 Electrical Fuse and relay specifications......................... 9015-10-2 Schematic, wiring diagram, and component location information ................... 9015-05-1 Spring wire retainer connector ..................... 9015-20-54 Tab retainer connector ................................. 9015-20-54 Electrical component check............................. 9015-20-27 Electrical diagnostic procedures Key switch check ......................................... 9015-20-27
Continued on next page
TM12660 (18APR18)
Index-4
041818
PN=4
Index
Page
Page
Exhaust differential pressure sensor Theory of operation...................................... 9015-15-28 Zero point calibration ................................... 9015-20-42 Exhaust filter...................................................... 9000-01-7 Monitor operation ......................................... 9015-16-15 Exhaust filter parked cleaning switch Theory of operation...................................... 9015-15-19 Exhaust filter parked cleaning switch harness (W9) Component location ................................... 9015-10-119 Wiring diagram........................................... 9015-10-119 Exhaust Filter, Safety Safety, Exhaust Filter ................................... 9000-01-15 Exhaust gas recirculation (EGR) valve acutator Theory of operation...................................... 9015-15-19 Exhaust gas recirculation (EGR) valve sensor Theory of operation...................................... 9015-15-19 Exhaust temperature sensor 1 (DPF) Theory of operation...................................... 9015-15-28 Exhaust temperature sensor 2 (DOC) Theory of operation...................................... 9015-15-28
F Filter Pilot, operation ............................................... 9025-05-2 Return, operation ....................................... 9025-05-129 Fire prevention................................................... 9000-01-5 Flow rate control valve Arm 1, circuit operation ................................ 9025-05-86 Arm 2, circuit operation ................................ 9025-05-90 Auxiliary, circuit operation ............................ 9025-05-92 Flow Rate Pressure Reducing Valve Operation ................................................... 9025-05-141 Flow rate select solenoid valve Operation ................................................... 9025-05-140 Flow test Pump............................................................ 9025-25-45 Frequent track chain sag adjustment Diagnostic procedure ..................................... 9020-15-2 Fuel filter restriction sensor Theory of operation...................................... 9015-15-19 Fuel gauge Operational check .......................................... 9005-10-3 Fuel rail pressure sensor Theory of operation...................................... 9015-15-19 Fuel temperature sensor Theory of operation...................................... 9015-15-19 Fuse Specification................................................... 9015-10-2 Fuse test.......................................................... 9015-20-12
G Gear case Pump 1, pump 2, pump 3, and drive, operation .................................................... 9025-05-24 Swing reduction, operation .......................... 9025-05-98 Travel operation ............................................. 9020-05-2 General hydraulic oil Cleanup procedure ........................................ 9025-25-2 Glow Plug Test Relay............................................................ 9015-20-15
H Hazards Avoiding ......................................................... 9000-01-9 Heated air seat harness (W14) Component location ................................... 9015-10-130 Wiring diagram........................................... 9015-10-131 Heater Operational checks ........................................ 9031-25-1 Heater and air conditioner Component location ..................................... 9031-15-13 Heater and air conditioner controls check Operational check ........................................ 9005-10-48 Heater and air conditioner harness (W41) Component location ................................... 9015-10-167 Wiring diagram........................................... 9015-10-169 Heater and air conditioning circuit check Operational check ........................................ 9005-10-47 Heater control Disable and enable ...................................... 9015-20-54 High power mode Operation ....................................................... 9010-05-6 High/low-pressure switch Test ................................................................ 9031-25-5 Horn circuit Operational check .......................................... 9005-10-2 Hoses and tubing inspection Air conditioning .............................................. 9031-25-3 Hour meter Operational check .......................................... 9005-10-3 HP (high power) mode Operational check ........................................ 9005-10-22 Hydraulic Component faliure cleanup procedure ..................................................... 9025-25-4 Hydraulic oil Cleanup procedure ........................................ 9025-25-6 Warm-up procedure ....................................... 9025-25-8 Hydraulic Oil General, cleanup procedure .......................... 9025-25-2 Hydraulic oil tank Pressure release procedure........................... 9025-25-7 Hydraulic oil tank pressurization Operational check ........................................ 9005-10-26 Continued on next page
TM12660 (18APR18)
Index-5
041818
PN=5
Index
Page
Page
Hydraulic oil temperature sensor Test .............................................................. 9015-20-19 Hydraulic pump Regulator minimum flow test........................ 9025-25-41 Regulator operation ..................................... 9025-05-27 Hydraulic system Component location ..................................... 9025-15-70 Diagram and operation .................................. 9025-05-1 Line connections .......................................... 9025-15-73 Oil cleanup procedure.................................... 9025-25-6 Schematic .................................................... 9025-15-53
I Idle speed up control Operation ....................................................... 9010-05-6 Individual undercarriage component wear Diagnsotic Procedure..................................... 9020-15-5 Information controller (ICZ) Diagnostic trouble codes................................ 9001-40-1 Intake air temperature sensor Theory of operation...................................... 9015-15-19 Intake air throttle Theory of operation...................................... 9015-15-19 Intake air throttle valve position sensor Theory of operation...................................... 9015-15-19 Issued warning record Monitor operation ........................................... 9015-16-7
J JDLink harness Component location ................................... 9015-10-188 Wiring diagram........................................... 9015-10-191 JT02156A digital pressure and temperature analyzer Installation...................................................... 9025-25-1 JT05800 digital thermometer installation........................................................ 9025-25-1
K Key switch Check........................................................... 9015-20-27 Remove and install ...................................... 9015-20-49 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 ........................................ 9005-10-16 Kit Auxiliary High Flow .................................... 9025-05-145
L Leakage test Swing motor ................................................. 9025-25-52 Travel motor................................................. 9025-25-53 Leakage valves Boom and arm reduced, operation .............. 9025-05-84 Left switch console Remove and install ...................................... 9015-20-52 Legend System functional schematic, wiring diagram, and component location ................ 9015-10-6 Lifting objects Special care ................................................. 9000-01-11 Light circuit Operational check ........................................ 9005-10-11 Lighting Circuit theory of operation............................ 9015-15-53 Line connection Pilot signal manifold to control valve........................................................... 9025-15-42 Travel system............................................... 9025-15-49 Line connections Hydraulic system.......................................... 9025-15-73 Line identification Pump 1, pump 2, pump 3, and pilot pump .......................................................... 9025-15-29 Swing motor ................................................. 9025-15-33 Low Flow Kit Operation ................................................... 9025-05-163
M Machine controller (BCZ) circuit Theory of operation...................................... 9015-15-47 Machine harness Component location ..................................... 9015-10-73 Wiring diagram............................................. 9015-10-77 Machine modifications Avoid .............................................................. 9000-01-2 Machine movement Unintended..................................................... 9000-01-9 Machine setting Monitor operation ........................................... 9015-16-8 Machine tip over Avoiding ....................................................... 9000-01-11 Machine,inspect................................................. 9000-01-3 Main controller Remove and install ..................9015-20-37, 9015-20-39 Main controller (MCZ) Theory of operation...................................... 9015-15-31 Main controller (MCZ) diagnostics trouble codes Diagnostic trouble codes main controller (MCZ) ........................................................... 9001-10-1 Main relief Circuit operation........................................... 9025-05-53 Continued on next page
TM12660 (18APR18)
Index-6
041818
PN=6
Index
Page
Page
Main relief valve Test and adjustment..................................... 9025-25-29 Main Relief Valve Circuit Operation .......................................... 9025-05-53 Make-up check valve Operation ..................................................... 9025-05-99 Manifold Pilot signal, operation................................... 9025-05-14 Manifold air temperature sensor Theory of operation...................................... 9015-15-19 Manual boom lower screw Operation ..................................................... 9025-05-84 Mass air flow sensor Theory of operation...................................... 9015-15-19 Monitor Reading diagnostic trouble codes.................. 9015-20-1 Side, operation............................................... 9015-16-7 Monitor and gauge circuit Operational check ........................................ 9005-10-17 Monitor controller Remove and install ...................................... 9015-20-47 Monitor controller (DSZ) circuit Theory of operation...................................... 9015-15-11 Monitor controller (DSZ) diagnostics trouble codes Diagnostic trouble codes monitor controller (DSZ)............................................ 9001-30-1 Monitor harness (W3) Component location ..................................... 9015-10-90 Wiring diagram............................................. 9015-10-92 Monitor setting Monitor operation ......................................... 9015-16-13 Monitor start-up Operational check .......................................... 9005-10-5 Monitor warning alarm Check........................................................... 9015-20-31 Monitor, gauges and battery relay Operational check .......................................... 9005-10-6 Monitoring Monitor operation ........................................... 9015-16-2 Motor Swing crossover relief valve test and adjustment.................................................. 9025-25-36 Swing, leakage test...................................... 9025-25-52 Swing, operation .......................................... 9025-05-99 Travel, leakage test...................................... 9025-25-53 Travel, operation ........................................ 9025-05-112 Travel, speed circuit operation................... 9025-05-121 MPDr Overview ...................................................... 9015-20-10 MPDr. Connection procedure.................................. 9015-20-11 Multi-function pilot control lever harness (W15) Component location ................................... 9015-10-132 Wiring diagram.....................9015-10-137, 9015-10-176
N Noisy or loose track chain Diagnostic procedure ..................................... 9020-15-1
O Oil tank, hydraulic Pressure release procedure........................... 9025-25-7 Operating pressure diagnostic chart Air conditioner ................................................ 9031-25-8 Operation Auxiliary High Flow Line Kit ....................... 9025-05-145 Auxiliary Pilot Control Valve ....................... 9025-05-130 Auxiliary Shuttle Valve ............................... 9025-05-144 Auxiliary System ........................................ 9025-05-130 Flow rate select solenoid valve .................. 9025-05-140 Low Flow Kit............................................... 9025-05-163 Monitor operation ........................................... 9015-16-7 Secondary Auxiliary Relief Valve ............... 9025-05-142 Secondary Pilot Relief Pressure Control Solenoid Valve ......................................... 9025-05-141 Selector Valve ............................................ 9025-05-143 Selector Valve Solenoid Valve ................... 9025-05-143 Side monitor................................................... 9015-16-7 Operation qualification....................................... 9000-01-1 Operational check Arm regenerative valve ................................ 9005-10-38 Auto-idle circuit ............................................ 9005-10-23 Boom regenerative valve ............................. 9005-10-37 Boom up, arm in, and bucket combined function....................................................... 9005-10-36 Bucket regenerative valve............................ 9005-10-39 Control lever pattern check - backhoe pattern ........................................................ 9005-10-27 Control lever pattern check - excavator pattern ........................................................ 9005-10-26 Control valve lift check valve........................ 9005-10-35 Cycle times check ........................................ 9005-10-45 Diagnostic trouble code check ....................... 9005-10-1 Dig function drift .......................9005-10-32, 9005-10-33 Display and clear trouble codes..................... 9005-10-1 E (economy) mode....................................... 9005-10-21 Engine speed dial ........................................ 9005-10-20 Fuel gauge ..................................................... 9005-10-3 Heater and air conditioner controls check.......................................................... 9005-10-48 Heater and air conditioning circuit check.......................................................... 9005-10-47 Horn circuit..................................................... 9005-10-2 Hour meter ..................................................... 9005-10-3 HP (high power) mode ................................. 9005-10-22 Hydraulic oil tank pressurization .................. 9005-10-26 Key switch off, engine off ............................... 9005-10-1 Key switch on, engine off ............................... 9005-10-4 Key switch on, engine on ............................. 9005-10-16 Light circuit................................................... 9005-10-11 Continued on next page
TM12660 (18APR18)
Index-7
041818
PN=7
Index
Page
Page
Monitor and gauge circuit............................. 9005-10-17 Monitor start-up.............................................. 9005-10-5 Monitor, gauges and battery relay.................. 9005-10-6 Pilot shutoff circuit........................................ 9005-10-18 PWR (standard) mode ................................. 9005-10-21 Rear camera .................................................. 9005-10-8 Swing dynamic braking ................................ 9005-10-28 Swing park brake and circuit drift................. 9005-10-30 Swing power check ...................................... 9005-10-31 Swing priority circuit ..................................... 9005-10-34 Travel alarm ................................................. 9005-10-24 Travel alarm cancel switch circuit ................ 9005-10-25 Travel lever and pedal ................................. 9005-10-10 Travel speed selection ................................. 9005-10-40 Travel system maneuverability .................... 9005-10-44 Travel system tracking ................................. 9005-10-41 Travel system tracking while operating a dig function................................................. 9005-10-43 Windshield washer circuit ............................ 9005-10-16 Windshield washer control ........................... 9005-10-13 Windshield wiper circuit ............................... 9005-10-14 Windshield wiper controls ............................ 9005-10-12
Pilot shutoff valve harness (W21) Component location ................................... 9015-10-151 Wiring diagram........................................... 9015-10-152 Pilot signal manifold Operation ..................................................... 9025-05-14 Port identification ......................................... 9025-05-14 Schematic .................................................... 9025-15-53 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 Diagram and operation .................................. 9025-05-1 Pins, metal Drive safely .................................................. 9000-01-14 "Popping" of track Diagnostic procedure ..................................... 9020-15-3 Power digging Valve test and adjustment............................ 9025-25-29 Power digging solenoid valve Test and adjustment..................................... 9025-25-18 Pressure Reducing Valve Operation Flow Rate................................................... 9025-05-141 Pressure release procedure Hydraulic oil tank............................................ 9025-25-7 Pressure sensor Test .............................................................. 9015-20-16 Proportional Solenoid test ................................................ 9015-20-18 Pump Flow test....................................................... 9025-25-45 Hydraulic, regulator minimum flow test ............................................................. 9025-25-41 Hydraulic, regulator operation...................... 9025-05-27 Pilot, operation ............................................... 9025-05-2 Regulator test, maximum flow...................... 9025-25-43 Pump 1, pump 2, pump 3, and drive gear case Operation ..................................................... 9025-05-24 Pump 1, pump 2, pump 3, and pilot pump Line identification ......................................... 9025-15-29 Pump and regulator Schematic .................................................... 9025-15-53 Pump control pilot pressure Signal test .................................................... 9025-25-27 Pump flow rate pilot valve Operation ..................................................... 9025-05-14 Pump harness (W8) Component location ................................... 9015-10-114 Wiring diagram........................................... 9015-10-117 Pump regulator Test maximum flow ...................................... 9025-25-43 PWR (standard) mode Operational check ........................................ 9005-10-21
P Park brake Swing motor, release circuit operation .................................................. 9025-05-110 Parts, moving Stay clear ....................................................... 9000-01-3 Pilot control valve Operation ....................................................... 9025-05-6 Schematic .................................................... 9025-15-53 Travel operation ............................................. 9025-05-8 Pilot control valve-to-pilot signal mainifold component location Backhoe pattern........................................... 9025-15-39 Pilot control valve-to-pilot signal mainifold component location Excavator pattern......................................... 9025-15-35 Pilot filter Operation ....................................................... 9025-05-2 Pilot pressure regulating valve Operation ....................................................... 9025-05-2 Test and adjustment..................................... 9025-25-10 Pilot pump Operation ....................................................... 9025-05-2 Pilot shutoff Circuit theory of operation............................ 9015-15-57 Pilot shutoff circuit Operational check ........................................ 9005-10-18 Pilot shutoff lever ............................................... 9000-01-9 Pilot shutoff solenoid valve Operation ....................................................... 9025-05-3 Pilot shutoff switch harness (W11) Component location ................................... 9015-10-120 Wiring diagram........................................... 9015-10-121
Continued on next page
TM12660 (18APR18)
Index-8
041818
PN=8
Index
Page
Page
R R134a air conditioning System test .................................................... 9031-25-7 Reading diagnostic trouble codes Service ADVISOR.......................................... 9015-20-5 Service ADVISOR™ ...................................... 9015-20-3 Rear camera Operational check .......................................... 9005-10-8 Rear camera harness (W19) Component location ................................... 9015-10-148 Wiring diagram........................................... 9015-10-149 Rear cover Remove and install ...................................... 9015-20-36 Recognize Safety, information ......................................... 9000-01-1 Refrigerant cautions and proper handling Air conditioning .............................................. 9031-25-1 Refrigerant leak Test ................................................................ 9031-25-3 Regulator Hydraulic pump, operation ........................... 9025-05-27 Minimum flow test, hydraulic pump.............. 9025-25-41 Pump, test maximum flow............................ 9025-25-43 Relay Battery, check .............................................. 9015-20-29 Specification................................................... 9015-10-2 Test .............................................................. 9015-20-15 Relief Bleed procedure........................................... 9015-20-46 Relief valve Circuit, test and adjustment ......................... 9025-25-33 Return filter Operation ................................................... 9025-05-129 Riding machine................................................ 9000-01-10 Right switch console Remove and install ...................................... 9015-20-50 ROPS Inspect ......................................................... 9000-01-10 Maintain ....................................................... 9000-01-10
S Safety Add cab guarding for special uses............................................9000-01-1, 9000-01-3 Clean debris from machine ............................ 9000-01-8 Operator's seat .............................................. 9000-01-8 Protective equipment ..................................... 9000-01-2 Safety, Avoid High-Pressure Fluids Avoid High-Pressure Fluids ........................... 9000-01-4 Safety, information Recognize ...................................................... 9000-01-1 Satellite (SAT) harness Component location ................................... 9015-10-186 Wiring diagram........................................... 9015-10-187
Schematic Information ..................................................... 9015-05-1 System functional......................................... 9015-10-13 Seat heater switch harness (W24) Component location ................................... 9015-10-153 Wiring diagram........................................... 9015-10-154 Secondary Auxiliary Relief Valve Operation ................................................... 9025-05-142 Secondary Pilot Relief Pressure Control Valve Operation ............. 9025-05-142 Secondary Pilot Relief Pressure Control Solenoid Valve Operation ................................................... 9025-05-141 Secondary Pilot Relief Pressure Control Valve Operation ................................................... 9025-05-142 Selector Valve Operation ................................................... 9025-05-143 Selector Valve Solenoid Valve Operation ................................................... 9025-05-143 Sensor test Ambient air temperature sensor................... 9015-20-19 Hydraulic oil temperature sensor ................. 9015-20-19 Pressure....................................................... 9015-20-16 Service ADVISOR Reading diagnostic trouble codes..........................................9015-20-3, 9015-20-5 Service ADVISOR™ Connection procedure.................................... 9015-20-2 Overview ........................................................ 9015-20-1 Service menu Monitor operation ........................................... 9015-16-1 Shuttle valve Pilot signal manifold operation ..................... 9025-05-14 Side camera harness (W5) Component location ................................... 9015-10-106 Wiring diagram........................................... 9015-10-107 Side monitor harness (W6) Component location ................................... 9015-10-108 Wiring diagram............................................9015-10-111 Slow speed sensing Operation ..................................................... 9025-05-33 Solenoid Pilot shutoff valve, operation.......................... 9025-05-3 Proportional, test.......................................... 9015-20-18 Solenoid valve Arm 3 and boom 3 spool control, operation .................................................... 9025-05-95 Arm regenerative, test and adjustment.................................................. 9025-25-16 Dig regenerative, test and adjustment ........................................................... 9025-25-14 Engine speed sensing control circuit.......................................................... 9025-05-33 Power digging, test and adjustment ........................................................... 9025-25-18 Torque control, test ..................9025-25-22, 9025-25-25
Continued on next page
TM12660 (18APR18)
Index-9
041818
PN=9
Index
Page
Page
Specification Fuse ............................................................... 9015-10-2 Relay.............................................................. 9015-10-2 Spool Valve, actuating pilot pressure test .............. 9025-25-12 Spool control harness Component location ................................... 9015-10-171 Wiring diagram........................................... 9015-10-172 Standard mode Operation ....................................................... 9010-05-6 Start Aid Theory of operation........................................ 9010-05-5 Starter switch harness (W29) Component location ................................... 9015-10-158 Wiring diagram........................................... 9015-10-158 Starting and charging circuit Theory of operation........................................ 9015-15-5 Steps Use correctly Handholds .................................................. 9000-01-8 Suction control valve Theory of operation...................................... 9015-15-19 Swing bearing Measure wear ................................................ 9020-15-6 Swing dynamic braking Operational check ........................................ 9005-10-28 Swing motor Crossover relief valve test and adjustment.................................................. 9025-25-36 Damper valve operation............................. 9025-05-102 Leakage test ................................................ 9025-25-52 Line identification ......................................... 9025-15-33 Operation ..................................................... 9025-05-99 Schematic .................................................... 9025-15-53 Swing motor park brake release circuit Operation ................................................... 9025-05-110 Swing park brake and circuit drift Operational check ........................................ 9005-10-30 Swing park brake release pilot valve Operation ..................................................... 9025-05-14 Swing power check Operational check ........................................ 9005-10-31 Swing priority circuit Operational check ........................................ 9005-10-34 Swing reduction gear case Operation ..................................................... 9025-05-98 Switch Binary pressure, test ...................................... 9031-25-5 System Functional schematic ................................... 9015-10-13 System cycle of operation Air conditioning .............................................. 9031-05-1 System functional schematic Information ..................................................... 9015-05-1 System functional schematic, wiring diagram, and component location legend .............................................................. 9015-10-6
T Temperature sensor test.................................. 9015-20-19 Test Alternator ..................................................... 9015-20-20 Binary pressure switch................................... 9031-25-5 Fuse ............................................................. 9015-20-12 Glow Plug Relay .......................................... 9015-20-15 Relay............................................................ 9015-20-15 Temperature sensor ..................................... 9015-20-19 Tests Engine......................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Theory of operation Barometric pressure sensor......................... 9015-15-19 Camshaft position sensor ............................ 9015-15-19 Controller area network (CAN)....................... 9015-15-1 Crankshaft position sensor .......................... 9015-15-19 Electronic injector 1...................................... 9015-15-19 Electronic injector 2...................................... 9015-15-19 Electronic injector 3...................................... 9015-15-19 Electronic injector 4...................................... 9015-15-19 Engine......................................9010-05-1, 9010-15-1, 9010-20-1, 9010-25-1 Engine control unit (ECU) ............................ 9015-15-19 Engine coolant temperature sensor ........................................................ 9015-15-19 Engine oil pressure sensor .......................... 9015-15-19 Exhaust aftertreatment circuit ...................... 9015-15-28 Exhaust differential pressure sensor ........................................................ 9015-15-28 Exhaust filter parked cleaning switch ......................................................... 9015-15-19 Exhaust gas recirculation (EGR) valve acutator ...................................................... 9015-15-19 Exhaust gas recirculation (EGR) valve sensor ........................................................ 9015-15-19 Exhaust temperature sensor 1 (DPF).......................................................... 9015-15-28 Exhaust temperature sensor 2 (DOC)......................................................... 9015-15-28 Fuel filter restriction sensor.......................... 9015-15-19 Fuel rail pressure sensor ............................. 9015-15-19 Fuel temperature sensor.............................. 9015-15-19 Intake air temperature sensor ...................... 9015-15-19 Intake air throttle .......................................... 9015-15-19 Intake air throttle valve position sensor ........................................................ 9015-15-19 Lighting circuit .............................................. 9015-15-53 Machine controller (BCZ) circuit................... 9015-15-47 Main controller (MCZ) .................................. 9015-15-31 Manifold air temperature sensor .................. 9015-15-19 Mass air flow sensor .................................... 9015-15-19 Monitor controller (DSZ) cirucit .................... 9015-15-11 Pilot shutoff circuit........................................ 9015-15-57 Starting and charging circuit .......................... 9015-15-5 Suction control valve.................................... 9015-15-19 Continued on next page
TM12660 (18APR18)
Index-10
041818
PN=10
Index
Page
Page
Travel alarm circuit....................................... 9015-15-46 Turbocharger actuator ................................. 9015-15-19 Turbocharger boost pressure sensor ........................................................ 9015-15-19 Turbocharger boost temperature sensor ........................................................ 9015-15-19 Turbocharger position sensor ...................... 9015-15-19 Variable geometry turbocharger (VGT) ......................................................... 9015-15-19 Windshield wiper and washer circuit.......................................................... 9015-15-49 Theory of Operation Cold Start ....................................................... 9010-05-5 Start Aid ......................................................... 9010-05-5 Thermometer installation, digital........................ 9025-25-1 Tight track chain Diagnostic procedure ..................................... 9020-15-1 Tip over Avoiding ....................................................... 9000-01-11 Torque control solenoid valve Control circuit operation ............................... 9025-05-33 Test and adjustment.................9025-25-22, 9025-25-25 Track Adjuster and recoil spring operation ............................................................... 9020-05-1 Track adjuster and recoil spring Operation ....................................................... 9020-05-1 Travel alarm Check........................................................... 9015-20-31 Operational check ........................................ 9005-10-24 Remove and install ...................................... 9015-20-53 Travel alarm cancel switch circuit Operational check ........................................ 9005-10-25 Travel alarm cancel switch harness (W16) Component location ................................... 9015-10-143 Wiring diagram........................................... 9015-10-143 Travel alarm circuit Theory of operation...................................... 9015-15-46 Travel alarm harness (W26) Component location ................................... 9015-10-155 Wiring diagram........................................... 9015-10-156 Travel flow combiner pilot valve Operation ..................................................... 9025-05-14 Travel flow combiner valve Operation ..................................................... 9025-05-58 Travel gear case Operation ....................................................... 9020-05-2 Travel high power mode Operation ....................................................... 9010-05-6 Travel lever and pedal Operational check ........................................ 9005-10-10 Travel motor Check valve operation ............................... 9025-05-112 Counterbalance valve operation ................ 9025-05-112 Crossover relief valve operation ................ 9025-05-112 Crossover relief valve test and adjustment.................................................. 9025-25-38 Leakage test ................................................ 9025-25-53
Schematic .................................................... 9025-15-53 Travel motor and brake valve Operation ................................................... 9025-05-112 Travel motor speed circuit Operation ................................................... 9025-05-121 Travel pilot control valve Operation ....................................................... 9025-05-8 Travel speed selection Operational check ........................................ 9005-10-40 Travel sub harness Component location ................................... 9015-10-156 Wiring diagram........................................... 9015-10-157 Travel system Component location ..................................... 9025-15-46 Line connection............................................ 9025-15-49 Travel system maneuverability Operational check ........................................ 9005-10-44 Travel system tracking Operational check ........................................ 9005-10-41 Travel system tracking while operating a dig function Operational check ........................................ 9005-10-43 Travel torque-up control Operation ..................................................... 9025-05-33 Troubleshooting Monitor operation ........................................... 9015-16-1 Turbocharger actuator Theory of operation...................................... 9015-15-19 Turbocharger boost pressure sensor Theory of operation...................................... 9015-15-19 Turbocharger boost temperature sensor Theory of operation...................................... 9015-15-19 Turbocharger position sensor Theory of operation...................................... 9015-15-19 Two pump combined flow Kit............................................................... 9025-05-153 Kit operation............................................... 9025-05-153 Two pump combined flow kit Operation ................................................... 9025-05-153 Two way solenoid Operation ................................................... 9025-05-149 Two way solenoid kit Operation ................................................... 9025-05-149
V Valve Arm 1 flow rate control, circuit operation .................................................... 9025-05-86 Arm 1 flow rate pilot, operation .................... 9025-05-14 Arm 2 flow rate control, circuit operation .................................................... 9025-05-90 Arm regenerative solenoid test and adjustment.................................................. 9025-25-16 Arm regenerative, circuit operation .............. 9025-05-75 Auxiliary flow combiner, operation ............... 9025-05-62 Auxiliary flow rate control, circuit operation .................................................... 9025-05-92 Continued on next page
TM12660 (18APR18)
Index-11
041818
PN=11
Index
Page
Page
Boom and arm reduced leakage, operation .................................................... 9025-05-84 Boom down shockless, operation ................ 9025-05-14 Boom lower meter-in cut, operation ............................................................. 9025-05-65 Boom regenerative, circuit operation ............................................................. 9025-05-67 Bucket flow rate pilot, operation................... 9025-05-14 Bucket regenerative, circuit operation .................................................... 9025-05-80 Bypass shut-off, operation ........................... 9025-05-62 Circuit relief and anticavitation, operation .................................................... 9025-05-57 Circuit relief, test and adjustment................. 9025-25-33 Control, check valves identification and operation .................................................... 9025-05-49 Control, operation ........................................ 9025-05-35 Crossover relief, operation........................... 9025-05-99 Dig regenerative operation........................... 9025-05-69 Dig regenerative solenoid test and adjustment.................................................. 9025-25-14 Main relief , circuit operation ........................ 9025-05-53 Main relief and power digging, test and adjustment.................................................. 9025-25-29 Make-up check, operation............................ 9025-05-99 Pilot control, operation ................................... 9025-05-6 Pilot operation of control .............................. 9025-05-11 Pilot pressure regulating, operation ............................................................... 9025-05-2 Pilot pressure regulating, test and adjustment.................................................. 9025-25-10 Pilot shutoff solenoid, operation..................... 9025-05-3 Power digging solenoid test and adjustment.................................................. 9025-25-18 Pump flow rate pilot, operation .................... 9025-05-14 Return filter bypass, operation ................... 9025-05-129 Shuttle, pilot signal manifold operation .................................................... 9025-05-14 Swing motor crossover relief, test and adjustment.................................................. 9025-25-36 Swing motor damper, operation ................. 9025-05-102 Swing park brake release pilot, operation .................................................... 9025-05-14 Torque control solenoid, test ..9025-25-22, 9025-25-25 Travel flow combiner pilot, operation ............................................................. 9025-05-14 Travel flow combiner, operation ................... 9025-05-58 Travel motor and park brake, operation .................................................. 9025-05-112 Travel motor check, operation ................... 9025-05-112 Travel motor counterbalance, operation .................................................. 9025-05-112 Travel motor crossover relief, operation .................................................. 9025-05-112 Travel motor crossover relief, test and adjustment.................................................. 9025-25-38 Travel pilot control, operation......................... 9025-05-8
Valve spool Actuating pilot pressure test......................... 9025-25-12 Variable geometry turbocharger (VGT) Theory of operation...................................... 9015-15-19 Voltage Battery, check .............................................. 9015-20-29
W Warm-up procedure Hydraulic oil ................................................... 9025-25-8 Welding repairs................................................ 9000-01-14 Windshield washer circuit Operational check ........................................ 9005-10-16 Windshield washer control Operational check ........................................ 9005-10-13 Windshield wiper and washer circuit Theory of operation...................................... 9015-15-49 Windshield wiper circuit Operational check ........................................ 9005-10-14 Windshield wiper controls Operational check ........................................ 9005-10-12 Wiring diagram 2-speed harness ........................................ 9015-10-166 9-Pin sevice ADVISOR connector harness (W20) ....................................................... 9015-10-150 Attachment harness (W17) ........................ 9015-10-146 Auxiliary 3-button cancel switch harness (W22) ....................................................... 9015-10-153 Auxiliary function enable switch harness (W78) ....................................................... 9015-10-186 Auxiliary function lever (AFL) grip harness (W77) ....................................................... 9015-10-185 Auxiliary function lever (AFL) harness (W75) ....................................................... 9015-10-181 Auxiliary function lever (AFL) solenoid harness (W76).......................................... 9015-10-184 Auxiliary fuse box harness (W13) .............. 9015-10-127 Cab harness (W1)........................................ 9015-10-55 Engine harness (W4) ................................. 9015-10-103 Exhaust filter parked cleaning switch harness (W9)............................................ 9015-10-119 Heated air seat harness (W14) .................. 9015-10-131 Heater and air conditioner harness (W41) ....................................................... 9015-10-169 Information ..................................................... 9015-05-1 JDLink harness .......................................... 9015-10-191 Machine harness.......................................... 9015-10-77 Monitor harness (W3) .................................. 9015-10-92 Multi-function pilot control lever harness (W15) .................................9015-10-137, 9015-10-176 Pilot shutoff switch harness (W11)............. 9015-10-121 Pilot shutoff valve harness (W21) .............. 9015-10-152 Pump harness (W8) ................................... 9015-10-117 Rear camera harness (W19)...................... 9015-10-149 Satellite (SAT) harness .............................. 9015-10-187 Seat heater switch harness (W24)............. 9015-10-154 Side monitor harness (W5) ........................ 9015-10-107 Continued on next page
TM12660 (18APR18)
Index-12
041818
PN=12
Index
Page
Page
Side monitor harness (W6) .........................9015-10-111 Starter switch harness (W29)..................... 9015-10-158 System functional schematic ....................... 9015-10-13 Travel alarm cancel switch harness (W16) ....................................................... 9015-10-143 Travel alarm harness (W26) ...................... 9015-10-156 Travel sub harness .................................... 9015-10-157
Wiring Diagram Data Converter Harness (W30) ................. 9015-10-162 Data Converter Interface Harness (W31) ....................................................... 9015-10-164 Spool control harness ................................ 9015-10-172 Work site hazards Avoid .............................................................. 9000-01-9
TM12660 (18APR18)
Index-13
041818
PN=13
Index
TM12660 (18APR18)
Index-14
041818
PN=14