TM10076 - John Deere 200D & 200DLC Excavator Technical Manual - Operation and Test

tm10076 - 200D and 200DLC Excavator Technical Manual
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Worksite Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Use Special Care When Lifting Objects

Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9001: Diagnostics

Group 10: Main Controller (MCF) Diagnostic Trouble Codes
Main Controller (MCF) Diagnostic Trouble Codes
11000.02 - Abnormal EEPROM
11001.02 - Abnormal RAM
11002.02 - Abnormal A/D Conversion
11003.03 - Abnormal Sensor Voltage
11004.02 - Abnormal CAN Communication
11100.02 - Abnormal Engine Speed
11101.03 - Engine Control Dial Voltage High
11101.04 - Engine Control Dial Sensor Voltage Low
11200.03 - Pump 1 Delivery Pressure Sensor Voltage High
11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low
11206.03 - Pump 1 Control Pressure Sensor Voltage High
11206.04 - Pump 1 Control Pressure Sensor Voltage Low
11301.03 - Swing Pilot Pressure Sensor Voltage High
11301.04 - Swing Pilot Pressure Sensor Voltage Low
11302.03 - Boom Up Pilot Pressure Sensor Voltage High
11302.04 - Boom Up Pilot Pressure Sensor Voltage Low
11303.03 - Arm In Pilot Pressure Sensor Voltage High
11303.04 - Arm In Pilot Pressure Sensor Voltage Low
11304.03 - Travel Pilot Pressure Sensor Voltage High

11304.04 - Travel Pilot Pressure Sensor Voltage Low
11307.03 - Front Attachment Pilot Pressure Sensor Voltage High
11307.04 - Front Attachment Pilot Pressure Sensor Voltage Low
11400.02 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal
11400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Current Low
11401.02 - Torque Control Solenoid Feedback Current Abnormal
11401.03 - Torque Control Solenoid Feedback Current High
11401.04 - Torque Control Solenoid Feedback Current Low
11402.02 - Dig Regenerative Solenoid Feedback Current Abnormal
11402.03 - Dig Regenerative Solenoid Feedback Current High
11402.04 - Dig Regenerative Solenoid Feedback Current Low
11403.02 - Arm Regenerative Solenoid Feedback Current Abnormal
11403.03 - Arm Regenerative Solenoid Feedback Current High
11403.04 - Arm Regenerative Solenoid Feedback Current Low
11404.02 - Power Dig Solenoid Feedback Current Abnormal
11404.03 - Power Dig Solenoid Feedback Current High
11404.04 - Power Dig Solenoid Feedback Current Low
11405.02 - Travel Speed Solenoid Feedback Current Abnormal
11405.03 - Travel Speed Solenoid Feedback Current High
11405.04 - Travel Speed Solenoid Feedback Current Low
11901.03 - Hydraulic Oil Temperature Sensor Voltage High
11901.04 - Hydraulic Oil Temperature Sensor Voltage Low
11910.02 - Actual Engine Speed Message Error
11911.02 - Security Signal Received from Monitor
11914.02 - Radiator Coolant Temperature Message Error
11918.02 - Work Mode Received Message Error
11920.02 - Fuel Flow Rate Message Error
20100.02 - Engine Coolant Overheat Message
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
171.03 - Intake Air Temperature Sensor Out of Range High
171.04 - Intake Air Temperature Sensor Out of Range Low

647.05 - Proportional Fan Speed Solenoid Driver Open
647.31 - Fan Manual Reverse Mode Input Active Too Long
898.09 - Engine Speed Request Not Received or Timed Out
1638.09 - Hydraulic Oil Temperature Message Not Received or Timed Out
Group 30: Information Controller (ICF) Diagnostic Trouble Codes
Information Controller (ICF) Diagnostic Trouble Codes
14001.02 - ICF: Flash Memory: Read/Write Error
14002.02 - ICF: External RAM: Read/Write Error
14003.02 - ICF: EEPROM: Sum Check Error
14006.02 - ICF: Satellite Communication Terminal: Communication Error
14008.02 - ICF: Abnormal Internal RAM
14100.02 - Satellite Communication Terminal: Abnormal EEPROM
14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue
14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back
14103.02 - Satellite Communication Terminal: The Satellite is not found
14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back
14105.02 - Satellite Communication Terminal: Tail 2 of Remote Loop Back
14106.02 - Satellite Communication Terminal: Sending and Receiving Data are Mismatched
Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
21 - Mix Door Open Circuit
-21 - Mix Door Short Circuit
22 - Mode Encoder Open Circuit
23 - In-Cab Ambient Temperature Sensor Open Circuit
-23 - In-Cab Ambient Temperature Sensor Short Circuit
24 - Outdoor Ambient Temperature Sensor Open Circuit
-24 - Outdoor Ambient Temperature Sensor Short Circuit
25 - Coolant Temperature Sensor Open Circuit
-25 - Coolant Temperature Sensor Short Circuit
26 - Solar Radiation Sensor Open Circuit
-26 - Solar Radiation Sensor Short Circuit

Group 50: Monitor Controller (MON) Diagnostic Trouble Codes
Monitor Controller (MON) Diagnostic Trouble Codes
13303.02 - Abnormal Thermister Temperature
13304.02 - Abnormal REG Input H Level
13310.02 - Shorted Circuit in Coolant Temperature Sensor
13311.03 - Fuel Level Sensor Short Circuit
13311.04 - Fuel Level Sensor Open Circuit
13334.2 - Radiator Coolant Error
20105.2 - Hydraulic Oil Filter Restriction Alarm
20106.2 - Air Cleaner Restriction Alarm
Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure
Operational Checkout
Section 9010: Engine

Group 05: Theory of Operation
Engine Fuel System Component Location
Engine Cooling System Component Location
Cold Weather Starting Aid
Engine Speed Control System Operation
Group 15: Diagnostic Information
PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines
Group 25: Tests
Radiator Temperature Differential Check
Engine Power Test Using Turbocharger Boost Pressure
Section 9015: Electrical System

Group 05: System Information
Electrical Diagram Information
Group 10: System Diagrams
Explanation of Wire Markings
Fuse and Relay Specifications

System Functional Schematic, Component Location, and Wiring Diagram Master Legend
System Functional Schematic
Cab Harness (W1) Component Location
Cab Harness (W1) Wiring Diagram
Machine Harness (W2) Component Location
Machine Harness (W2) Wiring Diagram
Monitor Harness (W3) Component Location
Monitor Harness (W3) Wiring Diagram
Engine Harness (W4) Component Location
Engine Harness (W4) Wiring Diagram
Engine Interface Harness (W5) Component Location
Engine Interface Harness (W5) Wiring Diagram
Right Console Harness (W7) Component Location
Right Console Harness (W7) Wiring Diagram
Pump Harness (W8) Component Location
Pump Harness (W8) Wiring Diagram
Auxiliary Fuse Box Harness (W9) Component Location
Auxiliary Fuse Box Harness (W9) Wiring Diagram
Pilot Shutoff Switch Harness (W11) Component Location
Pilot Shutoff Switch Harness (W11) Wiring Diagram
Air Suspension Seat Harness (W12) Component Location
Air Suspension Seat Harness (W12) Wiring Diagram
Seat Heater Switch Harness (W13) Component Location
Seat Heater Switch Harness (W13) Wiring Diagram
Multi-Function Pilot Control Lever Harness (W14) Component Location
Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram
Travel Alarm Cancel Switch Harness (W15) Component Location
Travel Alarm Cancel Switch Harness (W15) Wiring Diagram
Fan Reversing Switch Harness (W16) Component Location
Fan Reversing Switch Harness (W16) Wiring Diagram
Pilot Shutoff Valve Harness (W17) Component Location
Pilot Shutoff Valve Harness (W17) Wiring Diagram
Attachment Harness (W20) Component Location

Attachment Harness (W20) Wiring Diagram
2-Speed Harness (W21) Component Location
2-Speed Harness (W21) Wiring Diagram
Alternator Harness (W22) Component Location
Alternator Harness (W22) Wiring Diagram
Start Aid Switch Harness (W23) Component Location
Start Aid Switch Harness (W23) Wiring Diagram
Starter Harness (W27) Component Location
Starter Harness (W27) Wiring Diagram
Auxiliary Solenoid Harness (W61) Component Location
Auxiliary Solenoid Harness (W61) Wiring Diagram
JDLink™ System Harnesses Component Location—MIG/GTT
JDLink™ System Harnesses Component Location—MTG/SAT
JDLink™ System Wiring Diagrams—MIG/GTT
JDLink™ System Wiring Diagrams—MTG/SAT
Group 15: Sub-System Diagnostics
Controller Area Network (CAN) Theory of Operation
Starting and Charging Circuit Theory of Operation
Monitor Controller Circuit Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation
Main Controller (MCF) Circuit Theory of Operation
Information Controller (ICF) Circuit Theory of Operation
Travel Alarm Circuit Theory of Operation
Windshield Wiper and Washer Circuit Theory of Operation
Pilot Shutoff Circuit Theory of Operation
Attachment Control Circuit Theory of Operation
JDLink™ Circuit Theory of Operation—If Equipped
Group 16: Monitor Operation
Monitor Menu Operation
Monitor Service Menu Operation
Group 20: References
Monitor Data Items

Reading Diagnostic Trouble Codes With Monitor Display
JDLink™ System Identification
JDLink™ Connection Procedure—If Equipped
Service ADVISOR™ Diagnostic Application
Service ADVISOR™ Connection Procedure
Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application
Fuse Test
Relay Test
Pressure Sensor Test
Solenoid Test
Proportional Solenoid Test
Temperature Sensor Test
Alternator Test
Electrical Component Checks
Battery Remove and Install
Rear Cover Remove and Install
Main Controller (MCF) Remove and Install
Engine Control Unit (ECU) Remove and Install
Information Controller (ICF) Remove and Install
Monitor Controller Remove and Install
Key Switch Remove and Install
Switch Panel Remove and Install
Travel Alarm Remove and Install
Left Console Switch Remove and Install
Disconnect Tab Retainer Connectors
Disconnecting Spring Wire Clip Connectors
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular

Connectors
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors
Replace CINCH CINCH is a trademark of the Cinch Co. Connectors
Install CINCH CINCH is a trademark of the Cinch Co. Contact
Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors
Remove Connector Body from Blade Terminals
Section 9020: Power Train

Track Adjuster and Recoil Spring Operation
Travel Gearbox Operation
Diagnose Undercarriage Components Malfunctions
Measure Swing Bearing Wear
Section 9025: Hydraulic System

Hydraulic System Diagram and Operation
Fan Drive Hydraulic System Operation—If Equipped (Serial No. —511303)
Fan Drive Hydraulic System Operation—If Equipped (Serial No. 511304— )
Pilot System Diagram and Operation
Pilot Pump, Pressure Regulating Valve and Filter Operation
Pilot Shutoff Solenoid Valve Operation
Pilot Control Valve Operation
Travel Pilot Control Valve Operation
Pilot Operation of Control Valve Operation
Pilot Signal Manifold Operation
Pump 1, Pump 2 and Drive Gearbox Operation
Pump 1 and Pump 2 Regulator Operation
Engine Speed Sensing Control Circuit Operation
Control Valve Operation
Control Valve Check Valves Identification and Operation
Main Relief and Power Digging Valve Circuit Operation
Circuit Relief and Anticavitation Valve Operation
Travel Flow Combiner Valve Operation

Boom Lower Meter-In Cut Valve Operation
Boom Regenerative Valve Circuit Operation
Dig Regenerative Valve Circuit Operation
Arm Regenerative Valve Circuit Operation
Bucket Regenerative Valve Circuit Operation
Boom and Arm Reduced Leakage Valves Operation
Arm 1 Flow Rate Control Valve Circuit Operation
Bucket Flow Rate Control Valve Circuit Operation
Boom Flow Rate Control Valve Circuit Operation
Auxiliary Flow Rate Control Valve Circuit Operation
Swing Reduction Gearbox Operation
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation
Swing Motor Dampener Valve Operation
Swing Motor Park Brake Release Circuit Operation
Center Joint Operation
Travel Motor and Park Brake Valve Operation
Travel Motor Speed Circuit Operation
Cylinder Operation
Return Filter Operation
Auxiliary System Operation
Auxiliary Pilot Control Valve Operation
Flow Rate Select Solenoid Valve Operation
Flow Rate Pressure Reducing Valve Operation
Secondary Auxiliary Relief Valve Solenoid Valve Operation
Secondary Auxiliary Relief Control Valve Operation
Secondary Auxiliary Relief Valve Operation
Selector Valve Solenoid Valve Operation
Selector Valve Operation
Auxiliary Flow Combiner Valve Operation
Auxiliary Shuttle Valve Operation
Auxiliary High Flow Line Kit Operation
Two Way Solenoid Kit Operation

Two Pump Combined Flow Kit Operation
Secondary Auxiliary Relief Kit Operation
Low Flow Kit Operation
All Hydraulic Functions Slow
Hydraulic Oil Overheats
No Hydraulic Functions
No Hydraulic Functions—Electrical Checks
Function Does Not Stop When Control Lever Released
Load Drifts Down When Control Lever is in Neutral Position
Load Falls When Control Valve is Actuated To Raise Load
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal
Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal
Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal
Swing Speed Slow During Arm In Function
Boom Cannot Raise Track Off Ground
Swing Function Does Not Operate in Both Directions
Swing Speed Slow in Both Directions
Swing Speed Slow or Does Not Operate in One Direction
Upperstructure Drift With Swing Valve in Neutral
Machine Freewheels Down an Incline
Track Will Not Move in Either Direction
Machine Mistracks
Machine Mistracks Left During Combined Travel and Dig Functions
Machine Will Not Shift Into Fast (Rabbit) Speed
Pump 1, Pump 2, and Pilot Pump Line Identification
Control Valve Line Identification
Swing Motor Line Identification
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern
Pilot Signal Manifold-to-Control Valve Line Connection
Travel System Component Location
Travel Hydraulic System Line Connection

Auxiliary Attachment Schematic
Auxiliary System Line Connections
Hydraulic System Schematic
Hydraulic System Component Location
Hydraulic System Line Connections
Fan Drive Hydraulic System Component Location
Fan Drive Hydraulic System Schematic (S.N. 511304— )
Fan Drive Hydraulic System Schematic (S.N. —511303)
Group 25: Tests
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure/Temperature Analyzer Installation
Hydraulic Oil Cleanup Procedure With Portable Filter Caddy
Hydraulic Oil Warm-Up Procedure
Pilot Pressure Regulating Valve Test and Adjustment
Control Valve Spool Actuating Pilot Pressure Test
Dig Regenerative Solenoid Valve Test and Adjustment
Arm Regenerative Solenoid Valve Test and Adjustment
Power Digging Solenoid Valve Test and Adjustment
Travel Speed Solenoid Valve Test and Adjustment
Pump Control Pilot Pressure Signal Test
Torque Control Solenoid Valve Test and Adjustment
Main Relief and Power Digging Valve Test and Adjustment
Circuit Relief Valve Test and Adjustment
Swing Motor Crossover Relief Valve Test and Adjustment
Travel Motor Crossover Relief Valve Test and Adjustment
Pump Regulator Test and Adjustment—Minimum Flow
Pump Regulator Test and Adjustment—Maximum Flow
Pump Flow Test
Swing Motor Leakage Test
Travel Motor Leakage Test
Cylinder Drift Test—Boom, Arm, and Bucket
Fan Drive Pump Flow Test
Fan Speed Test

Section 9031: Heating and Air Conditioning
Air Conditioning System Cycle of Operation
Diagnose Air Conditioning System Malfunctions
Diagnose Heating System Malfunctions
Heater and Air Conditioner Diagnostic Trouble Code Check
Heater and Air Conditioner Component Location
Group 25: Tests
Refrigerant Cautions and Proper Handling
Heater and Air Conditioner Operational Checks
R134a Air Conditioning System Test
Air Conditioner Compressor Clutch Test
Refrigerant Leak Test
Refrigerant Hoses and Tubing Inspection
Air Conditioner Compressor Belt Check and Adjustment
Operating Pressure Diagnostic Chart
Section 9050: Reference Material

Group 05: Terminology Cross Reference Chart
Terminology Cross Reference Chart
Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools
DFT1218 Split Flange Hose Cap

Foreword
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work
are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented
throughout the text of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the
potential for personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the
components. Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of
each group are summary listings of all applicable essential tools, service equipment and tools, other materials
needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital
information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type of failures and their causes.
DX,TMIFC-19-20140415
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We need your help to continually improve our technical publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
-: Technical Manual Fax
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-19-20010703
15
Table of Contents
Section 9000: General Information

Group 01: Safety
Inspect Machine
Prevent Fires

16
T133555-UN: Safety Alert Symbols
T133588-19: Safety Alert Symbols
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies
the most serious hazards.
On the 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.
Go to Section_9000:Group_01
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T133555-UN: Safety Alert Symbols
T133588-19: Safety Alert Symbols
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies
the most serious hazards.
On the 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.
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T133556-UN: Follow Safety Instructions
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every safety message. Replace operator's manual and safety
labels immediately if missing or damaged.
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Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified
by supervised training and instruction.
Operator should be familiar with the job site and surroundings before operating. Try all controls and machine
functions with the machine in an open area before starting to work.
Know and observe all safety rules that may apply to every work situation and work site.
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TS206-UN: Protective Equipment

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
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.
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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.
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T133733-UN: Cab Guarding
Special work situations or machine attachments may create an environment with falling or flying objects. Working
near an overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for
example, may require added guarding to protect the operator.
FOPS (falling object protective structures) and special screens or guarding should be installed when falling or
flying objects may enter or damage the machine. Contact your authorized dealer for information on devices
intended to provide protection in special work situations.
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Inspect Machine
Inspect Machine
T6607AQ-UN: Inspect Machine
Inspect machine carefully each day by walking around it before starting.
Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 4-1.)
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.
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T133592-UN: Stay Clear Of Moving Parts
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as
service or repair is complete.
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X9811-UN: High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections
before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable
medical source. Such information is available in English from Deere & Company Medical Department in Moline,
Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.
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T133509-UN: Avoid High Pressure Oils
T133840-UN: Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing
serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping
oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
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T133546-UN: Beware Of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove
the exhaust fumes or open doors and windows to bring outside air into the area.
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Prevent Fires
Prevent Fires
T133552-UN: Handle Fuel Safely
T133553-UN: Clean Machine Regularly
T133554-UN: Carry A Fire Extinguisher
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials
inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
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TS204-UN: Battery Explosions
Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
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T133580-UN: Handle Chemical Products Safely
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints
and adhesives used with this machine may be hazardous.
If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and
health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products safely.
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T133567-UN: Dispose Of Waste Properly
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your
authorized dealer for more information.
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TS291-UN: First Aid Kit
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
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T133468-UN: Use Handholds and Steps
Prevent falls by facing the machine when getting 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.
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T133715-UN: Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure 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.
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T133716-19: Use and Maintain Seat Belt
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 webbing is not cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced every 3 years, regardless of appearance.
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T216779-UN: Unintended Machine Movement
Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shutoff lever to
locked position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before
allowing anyone to approach machine.
Always lower work equipment to the ground and pull pilot control shutoff lever to locked position before standing
up or leaving the operator's seat. Stop engine before exiting.
DW90712,00002C0-19-20070103
37
T192984-UN: Contact With Gas Line
T141904-UN: Operate Only On Solid Footing
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before starting work.
Prepare worksite 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 attachment contact with overhead obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments and unsupported
loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.
38
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 your seat belt.
AM40430,0000098-19-20100615
39
T7273AH-UN: Keep Riders Off Machine
Only allow operator on machine.
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by
foreign objects.
Riders may obstruct operator’s view or impair the ability to operate machine safely.
TX03679,0001726-19-20160630
40
T133548-UN: Backover Warning
Before moving machine, be sure all persons are clear of both travel and swing paths. 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 travel 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.
TX03679,00016F3-19-20070103
41
T133716-19: Use Seat Belt
T133545-UN: Unloading Machine
T133803-UN: Do Not Jump
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.
Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these
conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability.
Extending a heavy load or swinging it over side of undercarriage may cause machine to tip.
Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause
42
machine to tip or fall.
TX03679,00016DF-19-20160630
43
T133839-UN: Use Special Care When Lifting Objects
Never use this machine to lift people.
Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free.
Do not leave the seat when there is a raised load.
Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or
swinging over undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good
condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.
TX03679,00016E1-19-20150708
44
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.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and
obstructions, carefully operate attachment to learn its characteristics and range of motion.
TX03679,00016F0-19-20070212
45
T133332-19: Do Not Operate Tag
TS229-UN: Support Machine Properly
Warn others of service work. Always park and prepare your machine for service or repair properly.
Park machine on a level surface and lower equipment and attachments to the ground.
Place pilot shutoff lever in “lock” 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 boom, arm, or other hydraulically actuated attachments.
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.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TX03679,00016E9-19-20070103
46
TS281-UN: Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only
remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure
before removing completely.
TX,SURGE-19-20110119
47
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be
removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent
or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15
minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT-19-20020724
48
T133547-UN: Avoid Heating Near Pressurized Fluid Lines

IMPORTANT:
Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable.
Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
TX03679,00016D5-19-20080425
49
T133738-UN: Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
TX03679,0001745-19-20070103
50
Table of Contents
Section 9001: Diagnostics

Group 10: Main Controller (MCF) Diagnostic Trouble Codes
11001.02 - Abnormal RAM
11002.02 - Abnormal A/D Conversion
11003.03 - Abnormal Sensor Voltage
11100.02 - Abnormal Engine Speed
11101.03 - Engine Control Dial Voltage High
11101.04 - Engine Control Dial Sensor Voltage Low
11301.03 - Swing Pilot Pressure Sensor Voltage High
11301.04 - Swing Pilot Pressure Sensor Voltage Low
11302.03 - Boom Up Pilot Pressure Sensor Voltage High
11302.04 - Boom Up Pilot Pressure Sensor Voltage Low
11303.03 - Arm In Pilot Pressure Sensor Voltage High
11303.04 - Arm In Pilot Pressure Sensor Voltage Low
11304.03 - Travel Pilot Pressure Sensor Voltage High
11304.04 - Travel Pilot Pressure Sensor Voltage Low
11307.03 - Front Attachment Pilot Pressure Sensor Voltage High
11307.04 - Front Attachment Pilot Pressure Sensor Voltage Low
11400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Current Low
11401.02 - Torque Control Solenoid Feedback Current Abnormal

51
Table of Contents
11401.03 - Torque Control Solenoid Feedback Current High
11401.04 - Torque Control Solenoid Feedback Current Low
11402.02 - Dig Regenerative Solenoid Feedback Current Abnormal
11402.03 - Dig Regenerative Solenoid Feedback Current High
11402.04 - Dig Regenerative Solenoid Feedback Current Low
11403.02 - Arm Regenerative Solenoid Feedback Current Abnormal
11403.03 - Arm Regenerative Solenoid Feedback Current High
11403.04 - Arm Regenerative Solenoid Feedback Current Low
11404.02 - Power Dig Solenoid Feedback Current Abnormal
11404.03 - Power Dig Solenoid Feedback Current High
11404.04 - Power Dig Solenoid Feedback Current Low
11405.02 - Travel Speed Solenoid Feedback Current Abnormal
11405.03 - Travel Speed Solenoid Feedback Current High
11405.04 - Travel Speed Solenoid Feedback Current Low
11901.03 - Hydraulic Oil Temperature Sensor Voltage High
11901.04 - Hydraulic Oil Temperature Sensor Voltage Low
11910.02 - Actual Engine Speed Message Error
11911.02 - Security Signal Received from Monitor
11914.02 - Radiator Coolant Temperature Message Error
11918.02 - Work Mode Received Message Error
11920.02 - Fuel Flow Rate Message Error
20100.02 - Engine Coolant Overheat Message
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
171.03 - Intake Air Temperature Sensor Out of Range High
171.04 - Intake Air Temperature Sensor Out of Range Low
647.05 - Proportional Fan Speed Solenoid Driver Open
647.31 - Fan Manual Reverse Mode Input Active Too Long
898.09 - Engine Speed Request Not Received or Timed Out
1638.09 - Hydraulic Oil Temperature Message Not Received or Timed Out
Group 30: Information Controller (ICF) Diagnostic Trouble Codes

52
Table of Contents
14001.02 - ICF: Flash Memory: Read/Write Error
14002.02 - ICF: External RAM: Read/Write Error
14003.02 - ICF: EEPROM: Sum Check Error
14006.02 - ICF: Satellite Communication Terminal: Communication Error
14008.02 - ICF: Abnormal Internal RAM
14100.02 - Satellite Communication Terminal: Abnormal EEPROM
14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue
14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back
14103.02 - Satellite Communication Terminal: The Satellite is not found
14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back
14105.02 - Satellite Communication Terminal: Tail 2 of Remote Loop Back
14106.02 - Satellite Communication Terminal: Sending and Receiving Data are Mismatched
Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes
21 - Mix Door Open Circuit
-21 - Mix Door Short Circuit
22 - Mode Encoder Open Circuit
23 - In-Cab Ambient Temperature Sensor Open Circuit
-23 - In-Cab Ambient Temperature Sensor Short Circuit
24 - Outdoor Ambient Temperature Sensor Open Circuit
-24 - Outdoor Ambient Temperature Sensor Short Circuit
25 - Coolant Temperature Sensor Open Circuit
-25 - Coolant Temperature Sensor Short Circuit
26 - Solar Radiation Sensor Open Circuit
-26 - Solar Radiation Sensor Short Circuit
Group 50: Monitor Controller (MON) Diagnostic Trouble Codes
13303.02 - Abnormal Thermister Temperature
13304.02 - Abnormal REG Input H Level
13310.02 - Shorted Circuit in Coolant Temperature Sensor
13311.03 - Fuel Level Sensor Short Circuit

53
Table of Contents
13311.04 - Fuel Level Sensor Open Circuit
13334.2 - Radiator Coolant Error
20105.2 - Hydraulic Oil Filter Restriction Alarm
20106.2 - Air Cleaner Restriction Alarm
54
For additional information on the main controller circuit. See Main Controller (MCF) Circuit Theory of Operation .
(Group 9015-15.)
Main controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
Advisor, or by connection with WinDr.
See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes With SERVICE ADVISOR™ Diagnostic Application . (Group
9015-20.)
LD30992,000016A-19-20100512
55
For additional information on the main controller circuit. See Main Controller (MCF) Circuit Theory of Operation .
(Group 9015-15.)
Main controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
9015-20.)
LD30992,000016A-19-20100512
56
11000.02 —
Abnormal EEPROM
Controller Hardware Diagnostics

Launch Close Expand List Collapse List
1 Code Check
Action:
Clear and re-check diagnostic trouble codes.
Is DTC 11000.02-Abnormal EEPROM still present?
Record of Actual Results:
Result:
YES:
Code is still present and machine does not operate. Replace main controller (MCF). See Main Controller
(MCF) Remove and Install . (Group 9015-20.)
YES:
Code is still present but machine is still operable. Go to Machine Function Check.
NO:
Main controller (MCF) is OK.
2 Machine Function Check
Action:
Is operation of machine normal? See Operational Checkout . (Group 9005-05.)
Result:
YES:
Machine may be operated but it is recommended that the main controller (MCF) be replaced.
NO:
Main controller (MCF) malfunction. Replace main controller (MCF). See Main Controller (MCF) Remove and
Install . (Group 9015-20.)
LD30992,000016B-19-20070122
57
11001.02 —
Abnormal RAM

1 Code Check
Action:
Is DTC 11001.02-Abnormal RAM still present?
Result:
YES:
YES:
NO:
Action:
Result:
YES:
NO:
LD30992,000016C-19-20070122
58
11002.02 —
Abnormal A/D Conversion

1 Code Check
Action:
Is DTC 11002.02-Abnormal A/D Conversion still present?
Result:
YES:
YES:
NO:
Action:
Result:
YES:
NO:
LD30992,000016D-19-20070122
59
11003.03 —Abnormal Sensor Voltage
11003.03 —
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.
Abnormal Sensor Voltage Diagnostic Procedure

1 Voltage Check
Action:
Turn key switch to OFF position.
Disconnect all 5-volt sensors. See Main Controller (MCF) Circuit Theory of Operation . (Group 9015-15.)
Turn key switch to ON position.
Monitor engine speed dial (R15) voltage while moving the engine speed dial from low idle to high idle. See
Monitor Data Items . (Group 9015-20.)
Does voltage increase steadily as engine speed dial is moved to high idle?
Result:
YES:
Go to Sensor Check.
NO:
Go to Machine Harness Check .
2 Sensor Check
Action:
Perform the following:

Connect one 5-volt sensor at a time.
Monitor engine speed dial (R15) voltage while moving engine speed dial from low idle to high idle.
See Monitor Data Items . (Group 9015-20.)
Does voltage increase steadily as engine speed dial is moved to high idle?
Result:
YES:
Repeat these steps for each remaining sensor.
60
11003.03 —Abnormal Sensor Voltage
NO:
Replace last sensor that was connected.
3 Machine Harness Check

Action:
Disconnect cab harness-to-machine harness 52-pin connector (X3). Turn key switch to ON position and
monitor engine speed dial voltage.
Does voltage reading steadily increase as engine speed dial (R15) is moved from low idle to high idle?
Result:
YES:
Short circuit in machine harness between main controller and one of the 5-volt sensors. Repair or replace
harness. See Machine Harness (W2) Component Location . (Group 9015-10.)
NO:
Go to Cab Harness Check.
4 Cab Harness Check

Action:
Disconnect cab harness-to-machine harness 52-pin connector (X3) and cab harness-to-main controller 16-
pin connector D (X31).
Check for continuity between cab harness-to-main controller 16-pin connector D (X31) pin 1 and ground and
between cab harness-to-main controller 16-pin connector D (X31) pin 6 and ground.
Is continuity indicated?
Result:
YES:
Short to ground in cab harness. Repair or replace harness. See Cab Harness (W1) Component Location .
(Group 9015-10.)
NO:
LD30992,000016E-19-20140724
61
11004.02 —
Abnormal CAN Communication
Controller Area Network (CAN) Diagnostics

1 CAN Harness Check

Action:
Check harness connections to controllers and between harness.
Clear codes and re-check DTCs.
Is DTC 11004.02 still present?
Result:
YES:
Go to Continuity Check MCF and ICF.
NO:
Main controller (MCF) and harness are OK.
2 Continuity Check MCF and ICF

Action:
Check for continuity between main controller (MCF) pin C4 and information controller (ICF) pin C5.
Is there continuity between the connectors?
NOTE:
Key Switch: Off
Result:
YES:
Go to Continuity Check MCF and ECU.
NO:
Open circuit in CAN between main controller (MCF) and information controller (ICF).
Repair or replace harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
3 Continuity Check MCF and ECU
62
Action:
Check for continuity between main controller (MCF) pin C4 and engine control unit (ECU) pin A1 (X15).
Check for continuity between main controller (MCF) pin C15 and engine control unit (ECU) pin B1 (X15).
NOTE:
Key Switch: Off
Result:
YES:
Go to Continuity Check MCF and Monitor Unit.
NO:
Open circuit in CAN between main controller (MCF) and engine control unit (ECU).
Repair or replace harness. See Cab Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring
Diagram , See Monitor Harness (W3) Wiring Diagram , See Engine Harness (W4) Wiring Diagram , and see
Engine Interface Harness (W5) Wiring Diagram . (Group 9015-10.)
4 Continuity Check MCF and Monitor Unit

Action:
Check for continuity between main controller (MCF) pin C4 and monitor controller pin B7.
NOTE:
Key Switch: Off
Result:
YES:
Go to MCF Short to Ground Check.
NO:
Open circuit in CAN between main controller (MCF) and monitor controller.
Repair or replace harnesses. See Cab Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring
63
5 MCF Short to Ground Check
Action:
Disconnect all connectors to main controller (MCF), information controller (ICF), engine control unit (ECU)
and monitor controller.
Check for continuity between main controller (MCF) pin C4 and main controller (MCF) pins A2, A13, B8, and
B18.
Check for continuity between main controller (MCF) pin C15 an main controller (MCF) pins A2, A13, B8, and
B18.
Is there continuity between the CAN circuit and ground circuit?
NOTE:
Key Switch: Off
Result:
YES:
CAN circuit short to ground.
NO:
Go to ECU Short to Ground Check.
6 ECU Short to Ground Check
Action:
Disconnect all connectors to main controller (MCF), information controller (ICF), engine control unit (ECU),
Check for continuity between engine control unit (ECU) pin A1 (X15) and pins L2 (X15), L3 (X15), and M2
(X15).
Check for continuity between engine control unit (ECU) pin B1 (X15) and pins L2 (X15), L3 (X15), and M2
(X15).
Is there continuity between CAN circuit and ground circuit?
64
Result:
YES:
NO:
Go to ICF Short to Ground Check.
7 ICF Short to Ground Check

Action:
Check for continuity between information controller (ICF) pin C5 and pins C14 and C15.
Result:
YES:
NO:
Go to Monitor Controller Short to Ground Check.
8 Monitor Controller Short to Ground Check

Action:
Check for continuity between monitor controller pin B7 and pin B11.
65
Result:
YES:
NO:
Go to MCF Short to Power Check.
9 MCF Short to Power Check
Action:
Check for continuity between main controller (MCF) pin C4 and pins A1, A12, B7, and B17.
Is there continuity between CAN circuit and power circuit?
Result:
YES:
CAN circuit short to power.
NO:
Go to ECU Short to Power Check.
10 ECU Short to Power Check
Action:
Check for continuity between engine control unit (ECU) pin A1 and pins L1 (X15), L4 (X15), M1 (X15), and
M4 (X15).
Check for continuity between engine control unit (ECU) pin B1 and pins L1 (X15), L4 (X15), M1 (X15), and
M4 (X15).
66
Result:
YES:
NO:
Go to ICF Short to Power Check.
11 ICF Short to Power Check
Action:
Result:
YES:
NO:
Go to Monitor Controller Short to Power Check.
12 Monitor Controller Short to Power Check

Action:
Check for continuity between monitor controller pin B7 and A16.
67
Result:
YES:
NO:
Go to MCF Short to Key Switch Signal Check.
13 MCF Short to Key Switch Signal Check
Action:
Check for continuity between main controller (MCF) pin C4 and B16.
Is there continuity between CAN circuit and key switch signal circuit?
NOTE:
Key Switch: Off
Result:
YES:
CAN circuit short to key switch signal.
NO:
Go to ECU Short to Key Switch Signal Check.
14 ECU Short to Key Switch Signal Check

Action:
Check for continuity between engine control unit (ECU) pin A1 (X15) and pin B2 (X15).
68
Check for continuity between engine control unit (ECU) pin B1 (X15) and pin B2 (X15).
NOTE:
Key Switch: Off
Result:
YES:
NO:
Go to ICF Short to Key Switch Signal Check.
15 ICF Short to Key Switch Signal Check
Action:
Check for continuity between information controller (ICF) pin C5 and C7.
NOTE:
Key Switch: Off
Result:
YES:
NO:
Go to Monitor Controller Short to Key Switch Signal Check.
69
16 Monitor Controller Short to Key Switch Signal Check
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Go to MCF CAN High and Low Side Continuity Check.
17 MCF CAN High and Low Side Continuity Check
Action:
Check for continuity between main controller (MCF) pins C4 and C15.
Is there continuity between CAN high and low side wires?
NOTE:
Key Switch: Off
Result:
YES:
70
CAN wires short circuit.
NO:
Go to ECU CAN High and Low Side Continuity Check.
18 ECU CAN High and Low Side Continuity Check
Action:
Check for continuity between engine control unit (ECU) pins A1 (X15) and B1 (X15).
NOTE:
Key Switch: Off
Result:
YES:
NO:
Go to ICF CAN High and Low Side Continuity Check.
19 ICF CAN High and Low Side Continuity Check
Action:
Check for continuity between ICF pins C5 and C11.
NOTE:
Key Switch: Off
71
Result:
YES:
NO:
Go to Monitor Controller CAN High and Low Side Continuity Check.
20 Monitor Controller CAN High and Low Side Continuity Check

Action:
Check for continuity between monitor controller pins B6 and B7.
NOTE:
Key Switch: Off
Result:
YES:
NO:
Go to MCF CAN Resistance Check.
21 MCF CAN Resistance Check

Action:
Connect all connectors except main controller (MCF) connector C (X30).
Check resistance between pin C4 and C15.
Is resistance between 50—70 Ω?
72
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
Go to ICF CAN Resistance Check.
22 DTC Check
Action:
Connect connector to main controller (MCF).
Clear DTC and re-check for DTCs.
Is DTC 11004.02-Abnormal CAN Communication still present?
NOTE:
Key Switch: On
Result:
YES:
Main controller (MCF) malfunction.
Replace main controller. See Main Controller (MCF) Remove and Install . (Group 9015-20.)
NO:
Check harness connection to main controller (MCF).
23 ICF CAN Resistance Check

Action:
Connect all connectors except ICF connector C (X34).
73
Result:
YES:
Go to DTC Check.
NO:
Go to ECU CAN Resistance Check.
24 DTC Check
Action:
Connect connector to information controller (ICF).
NOTE:
Key Switch: On
Result:
YES:
Information controller (ICF) malfunction.
Replace information controller (ICF). See Information Controller (ICF) Remove and Install . (Group 9015-20.)
NO:
Check harness connection to information controller (ICF).
25 ECU CAN Resistance Check
Action:
Connect all connectors except engine control unit (ECU) connector J2 (X15).
Check resistance between pins A1 (X15) and B1 (X15).
NOTE:
Key Switch: Off
74
Result:
YES:
Go to DTC Check.
NO:
Go to Monitor Controller CAN Resistance Check.
26 DTC Check
Action:
Connect connector to engine control unit (ECU).
NOTE:
Key Switch: On
Result:
YES:
Engine control unit (ECU) malfunction.
Replace engine control unit (ECU). See Engine Control Unit (ECU) Remove and Install . (Group 9015-20.)
NO:
Check harness connection to engine control unit (ECU).
27 Monitor Controller CAN Resistance Check
Action:
Connect all connectors except monitor controller connector B (X20).
Check resistance between pins B6 and B7.
Is resistance between 110—130Ω?
NOTE:
Key Switch: Off
Result:
YES:
75
Go to DTC Check.
NO:
Check CAN bus terminator resistor (R10). See CAN Bus Terminator Check . (Group 9015-20.)
28 DTC Check
Action:
Connect connector to monitor controller.
NOTE:
Key Switch: On
Result:
YES:
Monitor controller malfunction.
Replace monitor controller. See Monitor Controller Remove and Install . (Group 9015-20.)
NO:
Check the connection to monitor controller.
LD30992,000016F-19-20100512
76
11100.02 —
Abnormal Engine Speed
Engine Speed Diagnostics
Engine speed is 4000 rpm or faster.
NOTE:
The main controller (MCF) receives engine speed via CAN from the engine control unit (ECU).
1 Engine Speed Check

Action:
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.)
Is engine speed within specification?
Result:
YES:
Check CAN wiring between controllers.
See 11004.02-Abnormal CAN Communication . (Group 9001-10.)
NO:
Verify engine speed using optical tachometer of crankshaft belt pulley.
LD30992,0000170-19-20100512
77
11101.03 —
Engine Control Dial Voltage High
Engine Speed Dial Diagnostics

1 Engine Speed Dial Resistance Check

Action:
Disconnect harness connector from switch panel.
Check resistance between pins 1 and 2.
Is resistance between 4.5—5.5 kΩ?
Result:
YES:
Go to Engine Speed Dial Voltage Diagnostics Check.
NO:
Engine speed dial malfunction.
Replace engine speed dial. See Switch Panel Remove and Install . (Group 9015-20.)
2 Engine Speed Dial Voltage Check

Action:
Connect harness connector to switch panel.
With switch panel connected to harness, measure voltage at pin 3 of connector.
Turn the engine speed dial and note voltage.
Is engine speed dial voltage within specifications?
-: Engine Speed Dial Voltage
Engine Speed Dial Position Voltage
Slow Idle 0.3 to 1.0 Volts
Fast Idle 4.0 to 4.7 Volts
Result:
YES:
Go to Sensor Circuit Voltage Check.
NO:
78
3 Sensor Circuit Voltage Check

Action:
Disconnect connector to switch panel.
Check voltage between terminals 1 and 3 of harness connector.
Is voltage between 4.5—5.5 volts?
NOTE:
Key switch: On
Result:
YES:
Go to Open Circuit Check.
NO:
Go to Harness Voltage Check .
4 Open Circuit Check

Action:
Check continuity between main controller (MCF) connector C (X30) pin C1 and switch panel connector (X27)
pin 2.
Is there continuity between the pins?
Result:
YES:
Go to Short Circuit Check.
NO:
Open circuit in harness.
5 Short Circuit Check
79
Action:
Check continuity between switch panel connector (X27) pin 2 and power and ground.
Is there continuity to power or ground?
Result:
YES:
Short circuit in harness.
NO:
Replace main controller (MCF). See Main Controller (MCF) Remove and Install . (Group 9015-20.)
6 Harness Voltage Check

Action:
NOTE:
Key Switch: On
Check voltage between switch panel connector (X27) pin 1 and machine ground.
Result:
YES:
Open circuit in harness between main controller (MCF) and engine speed dial pin 3.
NO:
LD30992,0000171-19-20100512
80
11101.04 —
Engine Control Dial Sensor Voltage Low
Engine Speed Dial Diagnostics

1 Engine Speed Dial Resistance Check

Action:
Disconnect harness connector from switch panel.
Check resistance between pins 1 and 2.
Is resistance between 4.5—5.5 kΩ?
Result:
YES:
Go to Engine Speed Dial Voltage Diagnostics Check.
NO:
2 Engine Speed Dial Voltage Check

Action:
Connect harness connector to switch panel.
With switch panel connected to harness, measure voltage at pin 3 of connector.
Turn the engine speed dial and note voltage.
Is engine speed dial voltage within specifications?
-: Engine Speed Dial Voltage
Engine Speed Dial Position Voltage
Slow Idle 0.3 to 1.0 Volts
Fast Idle 4.0 to 4.7 Volts
Result:
YES:
Go to Sensor Circuit Voltage Check.
NO:
81
3 Sensor Circuit Voltage Check

Action:
Check voltage between terminals 1 and 3 of harness connector.
NOTE:
Key switch: On
Result:
YES:
NO:

Action:
Check continuity between main controller (MCF) connector C (X30) pin C1 and switch panel connector (X27)
pin 2.
Result:
YES:
NO:
82
Action:
Check continuity between switch panel connector (X27) pin 2 and power and ground.
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Check voltage between switch panel connector (X27) pin 1 and machine ground.
Result:
YES:
NO:
LD30992,0000172-19-20100512
83
11200.03 —
Pump 1 Delivery Pressure Sensor Voltage High
Pump 1 Delivery Pressure Sensor Diagnostics
Pump 1 delivery pressure sensor voltage 4.5 volts or higher.
1 Sensor Check
Action:
Switch pump 1 delivery pressure sensor with pump 2 delivery pressure sensor.
Clear DTCs and re-check DTCs.
Does DTC follow delivery pressure sensor?
Result:
YES:
Faulty pump 1 delivery pressure sensor.
NO:
Go to Sensor Circuit Check.
2 Sensor Circuit Check

Action:
Disconnect connector to pump 1 delivery pressure sensor.
Check voltage between terminals 1 and 3 of harness.
NOTE:
Key Switch: On
Result:
YES:
NO:

84
Action:
Check continuity between main controller (MCF) connector D (X31) pin D10 and pump 1 delivery pressure
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Diagram and See Pump Harness (W8) Wiring Diagram . (Group 9015-10.)
Action:
Disconnect harness from main controller (MCF) and pump 1 delivery pressure sensor.
Check continuity between pump 1 delivery pressure sensor connector pin 2 and power and ground.
Is there continuity between pin 2 and power and ground?
Result:
YES:
NO:
Action:
Disconnect pump 1 delivery pressure sensor from harness.
85
Check voltage between pump 1 delivery pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and pump 1 delivery pressure sensor pin 3. See Cab
Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring Diagram and See Pump Harness (W8)
Wiring Diagram . (Group 9015-10.)
NO:
LD30992,0000173-19-20070122
86
11200.04 —
Pump 1 Delivery Pressure Sensor Voltage Low
Pump 1 delivery pressure sensor voltage 0.5 volts or less.
1 Sensor Check
Action:
Result:
YES:
NO:

Action:
Is voltage between 4.5-5.5 volts?
NOTE:
Key Switch: On
Result:
YES:
NO:

87
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
88
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000174-19-20070122
89
11202.03 —
Pump 2 Delivery Pressure Sensor Voltage High
Pump 2 delivery pressure sensor voltage 4.5 volts or higher.
1 Sensor Check
Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

90
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
91
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000175-19-20070122
92
11202.04 —
Pump 2 Delivery Pressure Sensor Voltage Low
Pump 2 delivery pressure sensor voltage 0.5 volts or less.
1 Sensor Check
Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

93
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
94
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000176-19-20070122
95
11206.03 —
Pump 1 Control Pressure Sensor Voltage High
Pump 1 Control Pressure Sensor Diagnostics
Pump 1 control pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch pump 1 control pressure sensor with pump 2 control pressure sensor.
Does DTC follow control pressure sensor?
Result:
YES:
Faulty pump 1 control pressure sensor.
NO:

Action:
Disconnect connector to pump 1 control pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

96
Action:
Check continuity between main controller (MCF) connector D (X31) pin D11 and pump 1 control pressure
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Disconnect harness from main controller (MCF) and pump 1 control pressure sensor.
Check continuity between pump 1 control pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect pump 1 control pressure sensor from harness.
97
Check voltage between pump 1 control pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and pump 1 control pressure sensor pin 3. See Cab
NO:
LD30992,0000177-19-20070122
98
11206.04 —
Pump 1 Control Pressure Sensor Voltage Low
Pump 1 control pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch pump 1 control pressure sensor with pump 2 control sensor.
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

99
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
100
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000178-19-20070122
101
11208.03 —
Pump 2 Control Pressure Sensor Voltage High
Pump 2 control pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

102
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
103
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000179-19-20070122
104
11208.04 —
Pump 2 Control Pressure Sensor Voltage Low
Pump 2 control pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

105
Action:
sensor pin 2.
Result:
YES:
NO:
Open in harness.
Action:
Result:
YES:
NO:
Action:
106
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,000017A-19-20070122
107
11301.03 —
Swing Pilot Pressure Sensor Voltage High
Swing Pilot Pressure Sensor Diagnostics
Swing pilot pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch swing pilot pressure sensor with another pilot pressure sensor.
Does DTC follow swing pilot pressure sensor?
Result:
YES:
Swing pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of swing pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

108
Action:
Disconnect harness from swing pilot pressure sensor and main controller (MCF).
Check continuity between swing pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C13.
Result:
YES:
NO:
Repair or replace harness. See Cab Harness (W1) Wiring Diagram and See Machine Harness (W2) Wiring
Diagram . (Group 9015-10.)
Action:
Check continuity between swing pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect swing pilot pressure sensor from harness.
109
Check voltage between swing pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and swing pilot pressure sensor pin 3. See Cab
Harness (W1) Wiring Diagram and See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:
LD30992,000017B-19-20070122
110
11301.04 —
Swing Pilot Pressure Sensor Voltage Low
Swing Pilot Pressure Sensor Diagnostics
Swing pilot pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch swing pilot pressure sensor with another pilot pressure sensor.
Does DTC follow swing pilot pressure sensor?
Result:
YES:
Swing pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of swing pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

111
Action:
Check continuity between swing pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C13.
Result:
YES:
NO:
Action:
Check continuity between swing pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect swing pilot pressure sensor from harness.
112
Check voltage between swing pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,000017C-19-20070122
113
11302.03 —
Boom Up Pilot Pressure Sensor Voltage High
Boom Up Pilot Pressure Sensor Diagnostics
Boom up pilot pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch boom up pilot pressure sensor with another pilot pressure sensor.
Does DTC follow boom up pilot pressure sensor?
Result:
YES:
Boom up pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of boom up pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

114
Action:
Disconnect harness from boom up pilot pressure sensor and main controller (MCF).
Check continuity between boom up pilot pressure sensor connector pin 2 and main controller (MCF)
connector D (X31) pin D15.
Result:
YES:
NO:
Action:
Check continuity between boom up pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect boom up pilot pressure sensor from harness.
115
Check voltage between boom up pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and boom up pilot pressure sensor pin 3. See Cab
NO:
LD30992,000017D-19-20070122
116
11302.04 —
Boom Up Pilot Pressure Sensor Voltage Low
Boom Up Pilot Pressure Sensor Diagnostics
Boom up pilot pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch boom up pilot pressure sensor with another pilot pressure sensor.
Does DTC follow boom up pilot pressure sensor?
Result:
YES:
Boom up pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of boom up pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

117
Action:
Check continuity between boom up pilot pressure sensor connector pin 2 and main controller (MCF)
connector D (X31) pin D15.
Result:
YES:
NO:
Action:
Check continuity between boom up pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect boom up pilot pressure sensor from harness.
118
Check voltage between boom up pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,000017E-19-20070122
119
11303.03 —
Arm In Pilot Pressure Sensor Voltage High
Arm In Pilot Pressure Sensor Diagnostics
Arm in pilot pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch arm in pilot pressure sensor with another pilot pressure sensor.
Does DTC follow arm in pilot pressure sensor?
Result:
YES:
Arm in pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of arm in pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

120
Action:
Disconnect harness from arm in pilot pressure sensor and main controller (MCF).
Check continuity between arm in pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C3.
Result:
YES:
NO:
Action:
Check continuity between arm in pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect arm in pilot pressure sensor from harness.
121
Check voltage between arm in pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and arm in pilot pressure sensor pin 3. See Cab
NO:
LD30992,000017F-19-20070122
122
11303.04 —
Arm In Pilot Pressure Sensor Voltage Low
Arm In Pilot Pressure Sensor Diagnostics
Arm in pilot pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch arm in pilot pressure sensor with another pilot pressure sensor.
Does DTC follow arm in pilot pressure sensor?
Result:
YES:
Arm in pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of arm in pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

123
Action:
Check continuity between arm in pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C3.
Result:
YES:
NO:
Action:
Check continuity between arm in pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect arm in pilot pressure sensor from harness.
124
Check voltage between arm in pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000180-19-20070122
125
11304.03 —
Travel Pilot Pressure Sensor Voltage High
Travel Pilot Pressure Sensor Diagnostics
Travel pilot pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch travel pilot pressure sensor with another pilot pressure sensor.
Does DTC follow travel pilot pressure sensor?
Result:
YES:
Travel pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of travel pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

126
Action:
Disconnect harness from travel pilot pressure sensor and main controller (MCF).
Check continuity between travel pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C2.
Result:
YES:
NO:
Action:
Check continuity between travel pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect travel pilot pressure sensor from harness.
127
Check voltage between travel pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and travel pilot pressure sensor pin 3. See Cab
NO:
LD30992,0000181-19-20070122
128
11304.04 —
Travel Pilot Pressure Sensor Voltage Low
Travel Pilot Pressure Sensor Diagnostics
Travel pilot pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch travel pilot pressure sensor with another pilot pressure sensor.
Does DTC follow travel pilot pressure sensor?
Result:
YES:
Travel pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of travel pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

129
Action:
Check continuity between travel pilot pressure sensor connector pin 2 and main controller (MCF) connector
C (X30) pin C2.
Result:
YES:
NO:
Action:
Check continuity between travel pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect travel pilot pressure sensor from harness.
130
Check voltage between travel pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000182-19-20070122
131
11307.03 —
Front Attachment Pilot Pressure Sensor Voltage High
Front Attachment Pilot Pressure Sensor Diagnostics
Front attachment pilot pressure sensor voltage 4.75 volts or higher.
1 Sensor Check
Action:
Switch front attachment pilot pressure sensor with another pilot pressure sensor.
Does DTC follow front attachment pilot pressure sensor?
Result:
YES:
Front attachment pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of front attachment pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

132
Action:
Disconnect harness from front attachment pilot pressure sensor and main controller (MCF).
Check continuity between front attachment pilot pressure sensor connector pin 2 and main controller (MCF)
connector C (X30) pin C12.
Result:
YES:
NO:
Action:
Check continuity between front attachment pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect front attachment pilot pressure sensor from harness.
133
Check voltage between front attachment pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
Open circuit in harness between main controller (MCF) and front attachment pilot pressure sensor pin 3. See
Cab Harness (W1) Wiring Diagram and See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:
LD30992,0000183-19-20070122
134
11307.04 —
Front Attachment Pilot Pressure Sensor Voltage Low
Front Attachment Pilot Pressure Sensor Diagnostics
Front attachment pilot pressure sensor voltage 0.25 volts or less.
1 Sensor Check
Action:
Switch front attachment pilot pressure sensor with another pilot pressure sensor.
Does DTC follow front attachment pilot pressure sensor?
Result:
YES:
Front attachment pilot pressure sensor malfunction. Replace sensor.
NO:

Action:
Disconnect connector of front attachment pilot pressure sensor.
NOTE:
Key Switch: On
Result:
YES:
NO:

135
Action:
Check continuity between front attachment pilot pressure sensor connector pin 2 and main controller (MCF)
connector C (X30) pin C12.
Result:
YES:
NO:
Action:
Check continuity between front attachment pilot pressure sensor connector pin 2 and power and ground.
Result:
YES:
NO:
Action:
Disconnect front attachment pilot pressure sensor from harness.
136
Check voltage between front attachment pilot pressure sensor connector pin 1 and machine ground.
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,0000184-19-20070122
137
11400.02 —
Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal
Pump 2 Flow Rate Limit Solenoid Diagnostics
Pump 2 flow rate limit solenoid current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from pump 2 flow rate limit solenoid and main controller (MCF).
Check continuity between pump 2 flow rate limit solenoid connector pin 1 and main controller (MCF)
connector A (X28) pin A22.
Is there continuity between solenoid and main controller (MCF)?
Result:
YES:
Go to DTC Check.
NO:
Diagram , and See Pump Harness (W8) Wiring Diagram . (Group 9015-10.)
2 DTC Check
Action:
Switch connectors of pump 2 flow rate limit solenoid and torque control solenoid.
Clear DTCs and re-check for DTCs.
Does DTC 11400.02-Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal display for the torque
control solenoid valve?
Result:
YES:
138
NO:
Pump 2 flow rate limit solenoid malfunction.
Replace solenoid.
LD30992,0000185-19-20070122
139
11400.03 —
Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal
Pump 2 Flow rate limit solenoid current 920 mA or higher.
1 Continuity Check
Action:
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Does DTC 11400.03-Flow Rate Limit Solenoid Current Feedback Abnormal display for the torque control
solenoid valve?
Result:
YES:
140
NO:
Replace solenoid.
LD30992,0000186-19-20070122
141
11400.04 —
Pump 2 Flow Rate Limit Solenoid Feedback Current Low
Pump 2 flow rate limit solenoid feedback current below 56 mA.
1 Continuity Check
Action:
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Does DTC 11400.04-Pump 2 Flow Rate Limit Solenoid Feedback Current Low display for the torque control
solenoid valve?
Result:
YES:
142
NO:
Replace solenoid.
LD30992,0000187-19-20070122
143
11401.02 —
Torque Control Solenoid Feedback Current Abnormal
Torque Control Solenoid Diagnostics
Torque control solenoid feedback current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from torque control solenoid and main controller (MCF).
Check continuity between torque control solenoid connector pin 1 and main controller (MCF) connector A
(X28) pin A30.
(X28) pin A19.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of torque control solenoid and pump 2 flow rate limit solenoid.
Does DTC 11401.02-Torque Control Solenoid Feedback Current Abnormal display for pump 2 flow rate limit
solenoid?
Result:
YES:
144
NO:
Torque control solenoid malfunction. Replace solenoid.
LD30992,0000188-19-20070122
145
11401.03 —
Torque Control Solenoid Feedback Current High
Torque control solenoid feedback current 920 mA or higher.
1 Continuity Check
Action:
Disconnect harness from torque control solenoid and main controller (MCF).
(X28) pin A30.
(X28) pin A19.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of torque control solenoid and pump 2 flow rate limit solenoid.
Does DTC 11401.03-Torque control solenoid feedback current high display for pump 2 flow rate limit
solenoid?
Result:
YES:
146
NO:
LD30992,0000189-19-20070122
147
11401.04 —
Torque Control Solenoid Feedback Current Low
Torque control solenoid feedback current below 56 mA.
1 Connector Check
Action:
Check all connections between torque control solenoid (ST) (Y21) and main controller (MCF) (A3).
Are connectors clean and free of debris?
Are pins straight and do they make good contact when connected?
Result:
YES:
Go to Component Check.
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.)
2 Component Check
Action:
NOTE:
Return connectors to appropriate sensors after check is complete.
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 to pump 2 flow rate limit solenoid.
Clear diagnostic trouble codes (DTCs) and operate machine.
Check for DTCs.
Is DTC 11401.04—Torque Control Solenoid Feedback Current Low active?
148
Result:
YES:
Go to Voltage Check.
NO:
3 Voltage Check
Action:
Disconnect torque control solenoid (marked ST) (Y21) connector.
Check for voltage between pins 1 and 2 of torque control solenoid connector.
Is 24 volts present?
Result:
YES:
NO:
Action:
Disconnect machine harness-to-main controller 32-pin connector A (X28).
Check for continuity between:
Pin 1 of torque control solenoid (marked ST) (Y21) connector to machine ground.
Pin 19 of machine harness-to-main controller 32-pin connector A (X28) to machine ground.
Result:
YES:
Short to ground. Repair or replace harness. See appropriate harness.
149
NO:
Go to Solenoid Check.
5 Solenoid Check
Action:
Test torque control solenoid (marked ST) (Y21) and compare to specification. See Proportional Solenoid
Test . (Group 9015-20.)
Is torque control solenoid (marked ST) (Y21) within specification?
Result:
YES:
Checks complete.
NO:
Torque control solenoid (marked ST) (Y21) malfunction. Replace solenoid.
TP97644,00004D4-19-20160720
150
11402.02 —
Dig Regenerative Solenoid Feedback Current Abnormal
Dig Regenerative Solenoid Diagnostics
Dig regenerative solenoid feedback current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from dig regenerative solenoid and main controller (MCF).
Check continuity between dig regenerative solenoid connector pin 1 and main controller (MCF) connector A
(X28) pin A10.
(X28) pin A6.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of dig regenerative solenoid (SF) with another solenoid in manifold.
Clear and re-check DTCs.
Does DTC 11402.02-Dig regenerative solenoid feedback current abnormal still display?
Result:
YES:
151
NO:
Dig regenerative solenoid malfunction. Replace solenoid.
LD30992,000018B-19-20070122
152
11402.03 —
Dig Regenerative Solenoid Feedback Current High
Dig regenerative solenoid feedback current 920 mA or higher.
1 Continuity Check
Action:
(X28) pin A10.
(X28) pin A6.
Result:
YES:
Go to DTC Check.
NO:
Diagram (Group 9015-10).
2 DTC Check
Action:
Does DTC 11402.03-Dig regenerative solenoid feedback current high still display?
Result:
YES:
153
NO:
LD30992,000018C-19-20070122
154
11402.04 —
Dig Regenerative Solenoid Feedback Current Low
Dig regenerative solenoid feedback current below 56 mA.
1 Continuity Check
Action:
(X28) pin A10.
(X28) pin A6.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Does DTC 11402.04-Dig regenerative solenoid feedback current low still display?
Result:
YES:
155
NO:
LD30992,000018D-19-20070122
156
11403.02 —
Arm Regenerative Solenoid Feedback Current Abnormal
Arm Regenerative Solenoid Diagnostics
Arm regenerative solenoid feedback current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from arm regenerative solenoid and main controller (MCF).
Check continuity between arm regenerative solenoid connector pin 1 and main controller (MCF) connector A
(X28) pin 32.
(X28) pin 29.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of arm regenerative solenoid (SC) with another solenoid in solenoid valve manifold.
Does DTC 11403.02-Arm regenerative solenoid current feedback abnormal still display?
Result:
YES:
main controller (MCF) malfunction.
157
NO:
Arm regenerative solenoid malfunction. Replace solenoid.
LD30992,000018E-19-20070122
158
11403.03 —
Arm Regenerative Solenoid Feedback Current High
Arm regenerative solenoid feedback current above 920 mA.
1 Continuity Check
Action:
(X28) pin 32.
(X28) pin 29.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Does DTC 11403.03-Arm regenerative solenoid current feedback current high still display?
Result:
YES:
159
NO:
LD30992,000018F-19-20070122
160
11403.04 —
Arm Regenerative Solenoid Feedback Current Low
Arm regenerative solenoid feedback current below 56 mA.
1 Continuity Check
Action:
(X28) pin 32.
(X28) pin 29.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Does DTC 11403.04-Arm regenerative solenoid feedback current low still display?
Result:
YES:
161
NO:
LD30992,0000190-19-20070122
162
11404.02 —
Power Dig Solenoid Feedback Current Abnormal
Power Dig Solenoid Diagnostics
Power dig solenoid feedback current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from power dig solenoid and main controller (MCF).
Check continuity between power dig solenoid connector pin 1 and main controller (MCF) connector A (X28)
pin A11.
pin A17.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of power dig solenoid (SG) with another solenoid in solenoid valve manifold.
Does DTC 11404.02-Power dig solenoid current feedback abnormal still display?
Result:
YES:
163
NO:
Power dig solenoid malfunction. Replace solenoid.
LD30992,0000191-19-20070122
164
11404.03 —
Power Dig Solenoid Feedback Current High
Power dig solenoid feedback current above 920 mA.
1 Continuity Check
Action:
pin A11.
pin A17.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of power dig solenoid (SC) with another solenoid in solenoid valve manifold.
Does DTC 11404.03-Power dig solenoid current feedback current high still display?
Result:
YES:
165
NO:
LD30992,0000192-19-20070122
166
11404.04 —
Power Dig Solenoid Feedback Current Low
Power dig solenoid feedback current below 56 mA.
1 Continuity Check
Action:
pin A11.
pin A17.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of power dig solenoid (SC) with another solenoid in solenoid valve manifold.
Does DTC 11404.04-Power dig solenoid feedback current low still display?
Result:
YES:
167
NO:
LD30992,0000193-19-20070122
168
11405.02 —
Travel Speed Solenoid Feedback Current Abnormal
Travel speed solenoid feedback current above 920 mA or below 60 mA.
1 Continuity Check
Action:
Disconnect harness from travel speed solenoid and main controller (MCF).
Check continuity between travel speed solenoid connector pin 1 and main controller (MCF) connector A
(X28) pin A31.
(X28) pin A5.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of travel speed (SI) solenoid with another solenoid in solenoid valve manifold.
Does DTC 11405.02-Travel speed solenoid current feedback abnormal still display?
Result:
YES:
main controller (MCF) malfunction.
169
NO:
Travel speed solenoid malfunction. Replace solenoid.
LD30992,0000194-19-20070122
170
11405.03 —
Travel Speed Solenoid Feedback Current High
Travel Speed Solenoid Diagnostics
Travel speed solenoid feedback current above 920 mA.
1 Continuity Check
Action:
(X28) pin A31.
(X28) pin A5.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of travel speed solenoid (SC) with another solenoid in solenoid valve manifold.
Does DTC 11405.03-Travel speed solenoid feedback current high still display?
Result:
YES:
171
NO:
LD30992,0000195-19-20070122
172
11405.04 —
Travel Speed Solenoid Feedback Current Low
Travel Speed Solenoid Diagnostics
Travel speed solenoid feedback current below 56 mA.
1 Continuity Check
Action:
(X28) pin A31.
(X28) pin A5.
Result:
YES:
Go to DTC Check.
NO:
2 DTC Check
Action:
Switch connectors of travel speed solenoid (SI) with another solenoid in solenoid valve manifold.
Does DTC 11405.04-Travel speed solenoid feedback current low still display?
Result:
YES:
173
NO:
LD30992,0000196-19-20070122
174
11901.03 —
Hydraulic Oil Temperature Sensor Voltage High
Hydraulic Oil Temperature Sensor Diagnostics
Hydraulic oil temperature sensor 4.52 volts or higher.
1 Connector Check
Action:
Check harness connections to hydraulic oil temperature sensor, main controller (MCF) and between
harness.
Are connectors clean and free from debris?
Are pins straight and make a good connection?
Result:
YES:
Go to Hydraulic Oil Temperature Sensor Check.
NO:
Repair or replace connector.
2 Hydraulic Oil Temperature Sensor Check

Action:
Disconnect hydraulic oil temperature sensor from harness.
Check resistance of sensor. See Temperature Sensor Test . (Group 9015-20.)
Is sensor within specifications?
Result:
YES:
Go to Continuity Check.
NO:
Hydraulic oil temperature sensor malfunction. Replace sensor.
3 Continuity Check
Action:
Connect pin 1 and pin 2 of hydraulic oil temperature sensor harness connector.
175
Check continuity between main controller (MCF) connector D (X31) pin 2 and pin 6.
Is there continuity between main controller (MCF) connector D (X31) pin 2 and pin 6?
Result:
YES:
NO:
Open in harness.
Action:
Connect main controller (MCF) connector D (X31) pin 6 to machine ground.
Check continuity between hydraulic oil temperature sensor harness connector pin 2 and ground.
Is there continuity between main controller (MCF) connector and hydraulic oil temperature sensor
connector?
Result:
YES:
Open circuit in harness between main controller (MCF) connector D (X31) pin 2 and hydraulic oil
temperature sensor connector pin 1.
NO:
LD30992,000019A-19-20070122
176
11901.04 —
Hydraulic Oil Temperature Sensor Voltage Low
Hydraulic Oil Temperature Sensor Diagnostics
Hydraulic oil temperature sensor 0.23 volts or less.
1 Connector Check
Action:
Check harness connections to hydraulic oil temperature sensor, main controller (MCF) and between
harness.
Are connectors clean and free from debris?
Are pins straight and make a good connection?
Result:
YES:
Go to Hydraulic Oil Temperature Sensor Check.
NO:
Repair or replace connector.
2 Hydraulic Oil Temperature Sensor Check

Action:
Disconnect hydraulic oil temperature sensor from harness.
Check resistance of sensor. See Temperature Sensor Test . (Group 9015-20.)
Is sensor within specifications?
Result:
YES:
NO:
Hydraulic oil temperature sensor malfunction. Replace sensor.
3 Continuity Check
Action:
Connect pin 1 and pin 2 of hydraulic oil temperature sensor harness connector.
177
Check continuity between main controller (MCF) connector D (X31) pin 2 and pin 6.
Is there continuity between main controller (MCF) connector D (X31) pin 2 and pin 6?
Result:
YES:
NO:
Open in harness.
Action:
Connect main controller (MCF) connector D (X31) pin 6 to machine ground.
Check continuity between hydraulic oil temperature sensor harness connector pin 2 and ground.
Is there continuity between main controller (MCF) connector and hydraulic oil temperature sensor
connector?
Result:
YES:
NO:
LD30992,000019B-19-20070122
178
11910.02 —
Actual Engine Speed Message Error
NOTE:
Engine speed is determined by the engine control unit (ECU) and sent over CAN.

1 CAN Voltage and Resistance Check

Action:
Access the Service ADVISOR™ diagnostic connector (X1).
Switched power ON.
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.
Using a multimeter, measure voltage from Service ADVISOR™ diagnostic connector (X1) pins C and D to
battery ground.
Is the combined voltage on the two wires approximately 5.0 volts?
Result:
YES:
Go to next step in this check.
NO:
Go to CAN Terminating Resistor Check .
Action:
Switched power OFF.
Measure the resistance between Service ADVISOR™ diagnostic connector (X1) pins C and D.
Is the CAN circuit resistance within specification?
Item Measurement Specification

CAN Circuit Resistance 55—65 Ω
Result:
YES:
Go to Controller Power Check.
179
NO:
2 Controller Power Check

Action:
Check schematics and wiring diagrams in this section to determine where power and ground is supplied to
the controller that is not communicating. Check the appropriate pins for unswitched power, switched power,
and ground.
Is power and ground indicated in the correct locations?
Result:
YES:
Controller malfunction. Replace controller that is not communicating.
NO:
Repair or replace harness.
3 CAN Terminating Resistor Check
Action:
Switched power OFF.
Remove and measure the resistance of the serviceable CAN terminating resistor. See Controller Area
Network (CAN) Theory of Operation . (Group 9015-15.)
Is the resistance within specification?

CAN Terminating Resistor Resistance 110—130 Ω
Result:
YES:
Install resistor and go to Controller Check.
NO:
Replace resistor.
4 Controller Check
Action:
Switched power OFF.
IMPORTANT:
180
Avoid possible controller and circuit damage. Never disconnect or connect a controller with key switch ON.
NOTE:
Only one controller at a time should be disconnected to perform this check. The controller
should be reconnected after this check has been completed.
Disconnect one of the controllers on the CAN circuit. See Controller Area Network (CAN) Theory of
Operation . (Group 9015-15.)
Switched power ON.
IMPORTANT:
Using a multimeter, measure the voltage from Service ADVISOR™ diagnostic connector (X1) pins C and D
to battery ground.
Switched power OFF.
NOTE:
If the disconnected controller contains one of the terminating resistors, resistance in the
CAN circuit should be within the specification for 1 terminating resistor.
Is the combined voltage on the two wires approximately 5.0 volts and is the circuit resistance within
specification?

CAN Circuit Resistance (1 terminating resistor) 110—130 Ω
Resistance (2 terminating resistors) 55—65 Ω
Result:
YES:
Disconnected controller has malfunctioned. Replace controller.
NO:
Reconnect the controller and repeat this check with a different controller disconnected. If this check has
been completed for each controller, repair or replace harness.
LD30992,0000324-19-20161209
181
11911.02 —
Security Signal Received from Monitor
NOTE:
Security signal is sent from the monitor to the main controller (MCF) via CAN.

1 CAN Harness Check

Action:
Is DTC 11911.02-Security Signal Received from Monitor still present?
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
182
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
183
Action:
B18.
B18.
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
(X15).
(X15).
184
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
185
Result:
YES:
NO:
Action:
Result:
YES:
NO:
Action:
M4 (X15).
M4 (X15).
186
Result:
YES:
NO:

Action:
Check for continuity between information contCheck for continuity between information controller (ICF) pin
C11 and pins C1 and C2.roller (ICF) pin C11 and pins C1 and C2.
Result:
YES:
NO:

Action:

187
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
188
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
189
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
190
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
191
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
192
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
22 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
193
Result:
YES:
Go to DTC Check.
NO:
24 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
194
Result:
YES:
Go to DTC Check.
NO:
26 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
195
Result:
YES:
Go to DTC Check.
NO:
28 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,000019D-19-20100805
196
11914.02 —
Radiator Coolant Temperature Message Error
NOTE:
Radiator coolant temperature is determined by the engine control unit (ECU) and sent over CAN.


Action:
Switched power ON.
IMPORTANT:
battery ground.
Result:
YES:
NO:
Action:
Switched power OFF.

Result:
YES:
197
NO:

Action:
and ground.
Result:
YES:
NO:
Action:
Switched power OFF.

Result:
YES:
NO:
Replace resistor.
4 Controller Check
Action:
Switched power OFF.
IMPORTANT:
198
NOTE:
Switched power ON.
IMPORTANT:
to battery ground.
Switched power OFF.
NOTE:
specification?

Result:
YES:
NO:
LD30992,0000326-19-20161209
199
11918.02 —
Work Mode Received Message Error
NOTE:
Work mode is selected in monitor controller and sent over CAN.

1 CAN Harness Check

Action:
Is DTC 11918.02-Work Mode Received Message Error still present?
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
200
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
201
Action:
B18.
B18.
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
(X15).
(X15).
202
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
203
Result:
YES:
NO:
Action:
Result:
YES:
NO:
Action:
M4 (X15).
M4 (X15).
204
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
205
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
206
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
207
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
208
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
209
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
210
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
22 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
211
Result:
YES:
Go to DTC Check.
NO:
24 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
212
Result:
YES:
Go to DTC Check.
NO:
26 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
213
Result:
YES:
Go to DTC Check.
NO:
28 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,000019F-19-20100805
214
11920.02 —
Fuel Flow Rate Message Error


Action:
Switched power ON.
IMPORTANT:
battery ground.
Result:
YES:
NO:
Action:
Switched power OFF.

Result:
YES:
NO:

215
Action:
and ground.
Result:
YES:
NO:

Action:
Switched power OFF.

Result:
YES:
NO:
Replace resistor.
4 Controller Check
Action:
Switched power OFF.
IMPORTANT:
NOTE:
216
Switched power ON.
IMPORTANT:
to battery ground.
Switched power OFF.
NOTE:
specification?

Result:
YES:
NO:
LD30992,0000328-19-20161209
217
20100.02 —Engine Coolant Overheat Message
20100.02 —
Engine Coolant Overheat Message
Engine coolant temperature is at least 105°C (221°F).
NOTE:
If any engine coolant-related engine control unit (ECU) codes are active, they should be
diagnosed along with this code.
MB00333,000035E-19-20161216
218
Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-
20.)
See Trouble Code Diagnostics and Tests for engine diagnostic trouble code information. (CTM502.)
LD30992,00001A2-19-20100512
219
Engine control unit diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
20.)
See Trouble Code Diagnostics and Tests for engine diagnostic trouble code information. (CTM502.)
LD30992,00001A2-19-20100512
220
171.03 —
Intake Air Temperature Sensor Out of Range High
Intake air temperature sensor open circuit.
Intake Air Temperature Sensor Diagnostics

1 Connector Check
Action:
Check harness connection to intake air temperature sensor, engine control unit and between harnesses.
Are connectors clean and free from debris? Are pins straight and do they make a good connection?
Result:
YES:
Go to Temperature Sensor Check.
NO:
Repair or replace connector or pins.
2 Temperature Sensor Check
Action:
Disconnect harness from intake air temperature sensor. Check sensor to specification. See Temperature
Sensor Test . (Group 9015-20.)
Is intake air temperature sensor within specification?
Result:
YES:
NO:
Intake air temperature sensor malfunction. Replace sensor.

Action:
Disconnect harness from intake air temperature sensor and engine control unit. Check continuity between
intake air temperature sensor pin A and engine control unit connector X15 (J2) pin G4. Check continuity
between intake air temperature sensor pin B and engine control unit connector X14 (J1) pin D2.
Is there continuity between the appropriate pin between intake air temperature sensor and engine control
unit?
221
Result:
YES:
Engine control unit malfunction. Reprogram engine control unit.
NO:
Open circuit in harness. Repair or replace harness. See Engine Harness (W4) Wiring Diagram and see
LD30992,00002EE-19-20070122
222
171.04 —
Intake Air Temperature Sensor Out of Range Low
Intake air temperature sensor signal short to ground.
Intake Air Temperature Sensor Diagnostics

1 Connector Check
Action:
Result:
YES:
Go to Temperature Sensor Check.
NO:
2 Temperature Sensor Check
Action:
Disconnect harness from intake air temperature sensor. Check sensor to specification. See Temperature
Sensor Test . (Group 9015-20.)
Result:
YES:
NO:
Intake air temperature sensor malfunction. Replace sensor.

Action:
Disconnect harness from intake air temperature sensor and engine control unit. Check for continuity
between intake air temperature sensor pin A and machine ground.
Is there continuity between intake air temperature sensor pin A and machine ground?
223
Result:
YES:
Short circuit in harness. Repair or replace harness. See Engine Harness (W4) Wiring Diagram and see
NO:
LD30992,00002EF-19-20070122
224
647.05 —
Proportional Fan Speed Solenoid Driver Open
Proportional Fan Speed Solenoid Diagnostics

1 Connector Check
Action:
Result:
YES:
NO:
2 Solenoid Check
Action:
Disconnect harness from fan speed solenoid. See Proportional Solenoid Test . (Group 9015-20.)
Is fan speed solenoid within specification.
Result:
YES:
Go to Harness Check.
NO:
Solenoid malfunction. Replace solenoid.
3 Harness Check
Action:
Disconnect harness from fan speed solenoid and engine control unit. Check continuity between solenoid
connector pin 1 and engine control unit connector X15 (J2) pin J4.
Is there continuity between fan speed solenoid and engine control unit?
225
Result:
YES:
NO:
Open circuit in harness. Repair or replace harness. See Engine Harness (W4) Wiring Diagram and see
LD30992,00002F0-19-20070122
226
647.31 —
Fan Manual Reverse Mode Input Active Too Long
Fan reversing switch held in manual mode for 160 seconds or more or input short to power.
Fan Manual Reverse Mode Input Diagnostics

1 Connector Check
Action:
Result:
YES:
Go to Short to Power Check.
NO:
2 Short to Power Check
Action:
Remove 12 volt power outlet 10 A fuse (F6). Clear and recheck diagnostic trouble codes.
Is diagnostic trouble code 647.31 still present?
Result:
YES:
Harness shorted to power. Repair or replace harness. See Cab Harness (W1) Wiring Diagram , see Machine
Harness (W2) Wiring Diagram , see Engine Harness (W4) Wiring Diagram , see Engine Interface Harness
(W5) Wiring Diagram , and see Fan Reversing Switch Harness (W16) Wiring Diagram . (Group 9015-10)
NO:
Fan reversing switch malfunction. Replace fan reversing switch.
LD30992,00002F1-19-20070123
227
898.09 —
Engine Speed Request Not Received or Timed Out
Engine speed request from main controller to engine control unit is missing or timed out. Engine speed request
from main controller to engine control unit is communicated via controller area network.

1 CAN Harness Check

Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
228
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
229

Action:
B18.
B18.
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
(X15).
(X15).
230
Result:
YES:
NO:
Action:
Result:
YES:
NO:
Action:
231
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
M4 (X15).
M4 (X15).
232
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
233
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
234
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
235
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
236
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
237
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
238
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
22 DTC Check
Action:
Is DTC 898.09-engine speed request not received or timed out still present?
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
239
Result:
YES:
Go to DTC Check.
NO:
24 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
240
Result:
YES:
Go to DTC Check.
NO:
26 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
241
Result:
YES:
Go to DTC Check.
NO:
28 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,00002F2-19-20100512
242
1638.09 —
Hydraulic Oil Temperature Message Not Received or Timed Out
Hydraulic oil temperature sensor message from main controller to engine control unit not received or timed out.
Hydraulic oil temperature message is communicated from the main controller to engine control unit via controller
area network.

1 CAN Harness Check
Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
243

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
244
Action:
B18.
B18.
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
(X15).
(X15).
245
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
246
Result:
YES:
NO:
Action:
Result:
YES:
NO:
Action:
M4 (X15).
M4 (X15).
247
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
248
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
249
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
250
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
251
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
252
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
253
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
22 DTC Check
Action:
Is DTC 1638.09-hydraulic oil temperature message not received or timed out still present?
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
254
Result:
YES:
Go to DTC Check.
NO:
24 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
255
Result:
YES:
Go to DTC Check.
NO:
26 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
256
Result:
YES:
Go to DTC Check.
NO:
28 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,00002F3-19-20100512
257
For additional information on the information controller circuit. See Information Controller (ICF) Circuit Theory of
Information controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
ADVISOR, or by connection with WinDr.
9015-20.)
LD30992,00001A3-19-20100512
258
For additional information on the information controller circuit. See Information Controller (ICF) Circuit Theory of
Information controller diagnostic trouble codes (DTCs) can be displayed on the monitor, connection with Service
ADVISOR, or by connection with WinDr.
9015-20.)
LD30992,00001A3-19-20100512
259
14000.02 —

1 CAN Harness Check

Action:
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
260
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
261
Action:
B18.
B18.
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
(X15).
(X15).
262
Result:
YES:
NO:

Action:
Result:
YES:
NO:

Action:
263
Result:
YES:
NO:
Action:
Result:
YES:
NO:
Action:
M4 (X15).
M4 (X15).
264
Result:
YES:
NO:
Action:
Result:
YES:
NO:

Action:
265
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
266
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
267
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
268
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
269
Result:
YES:
NO:

Action:
NOTE:
Key Switch: Off
Result:
YES:
NO:

Action:
270
NOTE:
Key Switch: Off
Result:
YES:
Go to DTC Check.
NO:
22 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:

Action:
271
Result:
YES:
Go to DTC Check.
NO:
24 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
272
Result:
YES:
Go to DTC Check.
NO:
26 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
Action:
NOTE:
Key Switch: Off
Result:
YES:
273
Go to DTC Check.
NO:
28 DTC Check
Action:
NOTE:
Key Switch: On
Result:
YES:
NO:
LD30992,00001A4-19-20060914
274
14001.02 —
ICF: Flash Memory: Read/Write Error

1 Code Check
Action:
Is DTC 14001.02—ICF: Flash Memory: Read / Write Error still present?
Result:
YES:
Code is still present go to Initialize Information Controller (ICF) Check.
NO:
Information controller (ICF) is OK.
2 Initialize Information Controller (ICF) Check
Action:
Initialize information controller (ICF) using procedure in Hitachi Technical Manual—Troubleshooting. See
Troubleshooting/ ICF and perform 1.1 Select Information Controller procedure.
Is DTC 14001.02—ICF: Flash Memory: Read / Write Error still present?
Result:
YES:
Code is still present and machine does not operate. Replace information controller (ICF). See Information
Controller (ICF) Remove and Install . (Group 9015-20.)
YES:
Code is still present but machine is still operable, go to Machine Function Check.
NO:

Action:
275
Result:
YES:
Machine may be operated but it is recommended that the information controller (ICF) be replaced.
NO:
Information controller (ICF) malfunction. Replace information controller (ICF). See Information Controller
(ICF) Remove and Install . (Group 9015-20.)
LD30992,00001A5-19-20130909
276
14002.02 —
ICF: External RAM: Read/Write Error

1 Code Check
Action:
Is DTC 14002.02—External RAM: Read - Write Error still present?
Result:
YES:
NO:
Action:
Is DTC 14002.02—External RAM: Read - Write Error still present?
Result:
YES:
YES:
NO:

Action:
277
Result:
YES:
NO:
LD30992,00001A6-19-20130909
278
14003.02 —
ICF: EEPROM: Sum Check Error

1 Code Check
Action:
Is DTC 14003.02—EEPROM: Sum Check Error still present?
Result:
YES:
NO:
Action:
Is DTC 14003.02—EEPROM: Sum Check Error still present?
Result:
YES:
YES:
NO:

Action:
279
Result:
YES:
NO:
LD30992,00001A7-19-20130909
280
14006.02 —ICF: Satellite Communication Terminal: Communication Error
14006.02 —
ICF: Satellite Communication Terminal: Communication Error
NOT APPLICABLE TO THIS MACHINE
LD30992,00001A8-19-20060914
281
14008.02 —
ICF: Abnormal Internal RAM

1 Code Check
Action:
Is DTC 14008.02—Abnormal Internal RAM still present?
Result:
YES:
NO:
Action:
Is DTC 14008.02—Abnormal Internal RAM still present?
Result:
YES:
YES:
NO:

Action:
282
Result:
YES:
NO:
LD30992,00001A9-19-20130909
283
14100.02 —Satellite Communication Terminal: Abnormal EEPROM
14100.02 —
Satellite Communication Terminal: Abnormal EEPROM
LD30992,00001AA-19-20060914
284
14101.02 —Satellite Communication Terminal: Abnormal IB/OB Queue
14101.02 —
Satellite Communication Terminal: Abnormal IB/OB Queue
LD30992,00001AB-19-20060914
285
14102.02 —Satellite Communication Terminal: Abnormal Local Loop Back
14102.02 —
Satellite Communication Terminal: Abnormal Local Loop Back
LD30992,00001AC-19-20060914
286
14103.02 —Satellite Communication Terminal: The Satellite is not found
14103.02 —
Satellite Communication Terminal: The Satellite is not found
LD30992,00001AD-19-20060914
287
14104.02 —Satellite Communication Terminal: Fail 1 of Remote Loop Back
14104.02 —
Satellite Communication Terminal: Fail 1 of Remote Loop Back
LD30992,00001AE-19-20060914
288
14105.02 —Satellite Communication Terminal: Tail 2 of Remote Loop Back
14105.02 —
Satellite Communication Terminal: Tail 2 of Remote Loop Back
LD30992,00001AF-19-20060914
289
14106.02 —Satellite Communication Terminal: Sending and Receiving Data are Mismatched
14106.02 —
Satellite Communication Terminal: Sending and Receiving Data are Mismatched
LD30992,00001B0-19-20060914
290
Air conditioner controller (ACF) diagnostic trouble codes are read by accessing the diagnostic menu in the
controller. See Heater and Air Conditioner Diagnostic Trouble Code Check to access codes. (Group 9031-15.)
LD30992,00001B1-19-20060914
291
Air conditioner controller (ACF) diagnostic trouble codes are read by accessing the diagnostic menu in the
controller. See Heater and Air Conditioner Diagnostic Trouble Code Check to access codes. (Group 9031-15.)
LD30992,00001B1-19-20060914
292
21 —Mix Door Open Circuit
21 —
Mix Door Open Circuit
Wiring to heater and air conditioner mixer servomotor has an open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to heater and air conditioner mixer servomotor and heater and air conditioner
controller.
Result:
YES:
NO:

Action:
Disconnect harness from heater and air conditioner mixer servomotor and heater and air conditioner
controller.
Check continuity between pins on controller and servomotor connector. See Right Console Harness (W7)
Is there continuity on the appropriate pins?
IMPORTANT:
Some wires between air conditioner controller and air conditioner servomotor are spliced with other control,
power, and ground circuits. Use caution when checking and testing wires.
Result:
YES:
Air conditioner heater servomotor malfunction. Replace servomotor.
NO:
Repair or replace wiring harness.
293
21 —Mix Door Open Circuit
LD30992,00001B2-19-20070122
294
-21 —Mix Door Short Circuit
-21 —
Mix Door Short Circuit
Wiring to heater and air conditioner mixer servomotor has a short circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to heater and air conditioner mixer servomotor and heater and air conditioner
controller.
Result:
YES:
NO:

Action:
Disconnect harness from heater and air conditioner mixer servomotor and heater and air conditioner
controller.
Connect to appropriate pin from air conditioner controller to machine ground and check continuity. See Right
Console Harness (W7) Wiring Diagram . (Group 9015-10.)
IMPORTANT:
Result:
YES:
Harness has a short to ground. Repair or replace harness.
NO:
Air conditioner heater and heater mixer servomotor malfunction. Replace servomotor.
295
-21 —Mix Door Short Circuit
LD30992,00001B3-19-20070122
296
22 —Mode Encoder Open Circuit
22 —
Mode Encoder Open Circuit
Air conditioner heater blower port change servomotor has an open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to air conditioner heater blower port change servomotor and heater and air
conditioner controller.
Are Connections clean and free of debris? Are pins straight and do they make a good connection?
Result:
YES:
NO:

Action:
Disconnect harness from air conditioner heater blower port change servomotor and heater and air
Check continuity between pins on controller and servomotor connector. See Right Console Harness (W7)
IMPORTANT:
Result:
YES:
NO:
3 Continuity Check
297
22 —Mode Encoder Open Circuit
Action:
Disconnect harness from heater and air conditioner blower port change servomotor and heater and air
Check for continuity between pins on harness connectors and machine ground. See Right Console Harness
(W7) Wiring Diagram . (Group 9015-10.)
Is there continuity on any of the pins?
IMPORTANT:
Result:
YES:
Harness has a short. Repair or replace harness.
NO:
Air conditioner heater blower port change servomotor malfunction. Replace servomotor.
LD30992,00001B4-19-20070122
298
23 —In-Cab Ambient Temperature Sensor Open Circuit
23 —
In-Cab Ambient Temperature Sensor Open Circuit
Cab air temperature sensor has an open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to cab air temperature sensor and air conditioner heater controller.
Are connectors clean and free of debris? Are pins straight and do they make a good connection?
Result:
YES:
NO:

Action:
Disconnect harness from cab air temperature sensor and heater and air conditioner controller.
Check for continuity between pins on controller and temperature sensor connector. See Right Console
Harness (W7) Wiring Diagram . (Group 9015-10.)
Result:
YES:
Cab air temperature sensor malfunction. Replace sensor.
NO:
LD30992,00001B5-19-20070122
299
-23 —In-Cab Ambient Temperature Sensor Short Circuit
-23 —
In-Cab Ambient Temperature Sensor Short Circuit
Cab air temperature sensor has a short circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to cab air temperature sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from cab air temperature sensor and heater and air conditioner controller.
Check wires between controller and cab air temperature sensor connector for continuity to ground. See Right
Is there continuity on any of the wires?
Result:
YES:
NO:
Cab air temperature sensor malfunction. Replace sensor.
LD30992,00001B6-19-20070122
300
24 —Outdoor Ambient Temperature Sensor Open Circuit
24 —
Outdoor Ambient Temperature Sensor Open Circuit
Ambient air temperature sensor has an open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to ambient air temperature sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from ambient air temperature sensor and heater and air conditioner controller.
Check for continuity between pins on controller and ambient air temperature sensor connector. See Cab
Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring Diagram and See Right Console
Result:
YES:
Ambient air temperature sensor malfunction. Replace sensor.
NO:
LD30992,00001B7-19-20070122
301
-24 —Outdoor Ambient Temperature Sensor Short Circuit
-24 —
Outdoor Ambient Temperature Sensor Short Circuit
Ambient air temperature sensor has a short circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to ambient temperature sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from ambient air temperature sensor and heater and air conditioner controller.
Check wires between controller and ambient air temperature sensor connector for continuity to ground. See
Cab Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring Diagram and See Right Console
Is there continuity on any of the wires?
Result:
YES:
NO:
Ambient temperature sensor malfunction. Replace sensor.
LD30992,00001B8-19-20070122
302
25 —Coolant Temperature Sensor Open Circuit
25 —
Coolant Temperature Sensor Open Circuit
Coolant temperature sensor has an open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to coolant temperature sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from coolant temperature sensor and heater and air conditioner controller.
Check for continuity between pins on controller and coolant temperature sensor connector. See Right
Result:
YES:
Coolant temperature sensor malfunction. Replace sensor.
NO:
LD30992,00001B9-19-20070122
303
-25 —Coolant Temperature Sensor Short Circuit
-25 —
Coolant Temperature Sensor Short Circuit
Coolant temperature sensor has a short circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to coolant temperature sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from coolant temperature sensor and heater and air conditioner controller.
Check wires between controller and coolant temperature sensor connector for continuity to ground. See
Right Console Harness (W7) Wiring Diagram . (Group 9015-10.)
Result:
YES:
NO:
Coolant temperature sensor malfunction. Replace sensor.
LD30992,00001BA-19-20070122
304
26 —Solar Radiation Sensor Open Circuit
26 —
Solar Radiation Sensor Open Circuit
Solar sensor has an open circuit.
NOTE:
When solar radiation is shaded, the solar radiation sensor indicates the fault code of open circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to solar sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from heater and air conditioner controller and solar sensor.
Check for continuity between pins on controller and solar radiation sensor connector. See Cab Harness
(W1) Wiring Diagram , See Monitor Harness (W3) Wiring Diagram , and See Right Console Harness (W7)
Result:
YES:
Solar sensor malfunction. Replace sensor.
NO:
305
26 —Solar Radiation Sensor Open Circuit
LD30992,00001BB-19-20070122
306
-26 —Solar Radiation Sensor Short Circuit
-26 —
Solar Radiation Sensor Short Circuit
Solar sensor has a short circuit.
Harness Diagnostics
1 Connector Check
Action:
Check harness connection to solar sensor and heater and air conditioner controller.
Result:
YES:
NO:

Action:
Disconnect harness from heater and air conditioner controller and solar sensor.
Check wires between controller and solar radiation sensor connector for continuity to ground. See Cab
Harness (W1) Wiring Diagram , See Monitor Harness (W3) Wiring Diagram , and See Right Console
Result:
YES:
NO:
Solar sensor malfunction. Replace sensor.
LD30992,00001BC-19-20070122
307
The monitor controller (MON) diagnostic trouble codes may be viewed on the monitor, by using WinDr., or by
using SERVICE ADVISOR™ . See the following procedures for viewing the information controller diagnostic
trouble codes.
20.)
LD30992,00001BD-19-20060914
308
The monitor controller (MON) diagnostic trouble codes may be viewed on the monitor, by using WinDr., or by
using SERVICE ADVISOR™ . See the following procedures for viewing the information controller diagnostic
trouble codes.
20.)
LD30992,00001BD-19-20060914
309
13303.02 —
Abnormal Thermister Temperature
Monitor Temperature Diagnostics
Temperature in or around monitor controller is above 85°C (185°F).
1 Temperature Check
Action:
Check temperature around monitor controller.
Is temperature high?
Result:
YES:
Go to Screen Check.
NO:
2 Screen Check
Action:
Cool monitor controller and observe monitor screen.
Does monitor screen return to normal as monitor is cooled?
Result:
YES:
Monitor and monitor controller are OK.
NO:
LD30992,00001BE-19-20070122
310
13304.02 —
Abnormal REG Input H Level
Alternator Output Diagnostics
Alternator output above 33.5 volts.
1 Alternator Output Check

Action:
Measure alternator output. See Alternator Test . (Group 9015-20.)
Is voltage below 33.5 volts?
Result:
YES:
NO:
Alternator malfunction.
Repair or replace alternator.
2 Harness Check
Action:
Disconnect monitor controller connector C (X21) and check voltage on pin 7.
Is voltage below 33.5 volts?
NOTE:
Engine: Running
Result:
YES:
NO:
Open circuit in harness between alternator and monitor controller.
311
Diagram , and See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)
LD30992,00001BF-19-20070122
312
13306.02 —
Abnormal EEPROM
Information Controller Diagnostics
Abnormal EEPROM in monitor controller.
1 Diagnostic Trouble Code Re-check

Action:
Clear codes and check for code again.
Is diagnostic trouble code (DTC) 13306.02-Abnormal EEPROM still present?
Result:
YES:
NO:
Monitor controller is OK.
LD30992,00001C0-19-20060914
313
13308.02 —
Controller Area Network Diagnostics
Controller Area Network (CAN) communication error.
1 Diagnostic Trouble Code Re-check

Action:
Clear codes and check for code again.
Is diagnostic trouble code (DTC) 13308.02-Abnormal CAN communication error still present?
Result:
YES:
Go to Harness Connector Check.
NO:
Harness and monitor controller are OK.
2 Harness Connector Check
Action:
Check harness connection to monitor controller, information controller (ICF) and between cab harness and
monitor harness. See Cab Harness (W1) Wiring Diagram and See Monitor Harness (W3) Wiring Diagram .
(Group 9015-10.)
Are harness connections clean? Are pins straight and make a good connection?
Result:
YES:
NO:
Repair or replace damaged connector or pins.
3 Harness Check
Action:
Check CAN wires between monitor controller and information controller (ICF).
See Cab Harness (W1) Wiring Diagram and See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)
Is there continuity on wires between controllers? Is the circuit either open, shorted to power, or shorted to
314
ground?
Result:
YES:
Repair or replace damaged harness.
NO:
LD30992,00001C1-19-20070122
315
13310.02 —Shorted Circuit in Coolant Temperature Sensor
13310.02 —
Shorted Circuit in Coolant Temperature Sensor
LD30992,00001C2-19-20060914
316
13311.03 —
Fuel Level Sensor Short Circuit
Fuel Level Sensor Diagnostics
Fuel level sensor shorted to ground.
1 Resistance Check
Action:
Disconnect fuel level sensor and check sensor resistance.
Is sensor resistance within specifications?
-: Fuel Level Sensor Specifications
Fuel Level Sensor
Float Position Resistance (Ohms)
Upper Limit (FULL) 6-10
3/4 26
1/2 33-43
1/4 53
Alarm Level 82-88
Lower Limit (EMPTY) 90-100
Result:
YES:
NO:
Fuel level sensor malfunction. Replace sensor.
2 Continuity Check
Action:
Disconnect fuel level sensor from harness and check for continuity between monitor pin C2 and machine
ground.
Is there continuity between monitor and machine ground?
Result:
317
YES:
Short circuit in harness between monitor controller and sensor.
Check wiring. See Cab Harness (W1) Wiring Diagram , See Machine Harness (W2) Wiring Diagram , and
See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:
Replace monitor. See Monitor Controller Remove and Install . (Group 9015-20.)
LD30992,00001C3-19-20070122
318
13311.04 —
Fuel Level Sensor Open Circuit
Fuel Level Sensor Diagnostics
Fuel level sensor open circuit
1 Resistance Check
Action:
Disconnect fuel level sensor and check sensor resistance.
Is sensor resistance within specifications?
-: Fuel Level Sensor Specifications
Fuel Level Sensor
Float Position Resistance (Ohms)
Upper Limit (FULL) 6-10
3/4 26
1/2 33-43
1/4 53
Alarm Level 82-88
Lower Limit (EMPTY) 90-100
Result:
YES:
NO:
Fuel level sensor malfunction. Replace sensor.
2 Continuity Check
Action:
Disconnect fuel level sensor from harness. Connect pin 1 of fuel level sensor harness connector to ground.
Check for continuity between monitor controller pin C2 and machine ground.
Is there continuity between monitor and machine ground?
Result:
319
YES:
Monitor controller malfunction. Replace monitor. See Monitor Controller Remove and Install . (Group 9015-
20.)
NO:
Open circuit in harness between monitor controller and sensor. Check wires. See Short circuit in harness
between monitor controller and sensor. Check wiring. See Cab Harness (W1) Wiring Diagram , See Machine
Harness (W2) Wiring Diagram , and See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)
LD30992,00001C4-19-20070122
320
13334.2 —
Radiator Coolant Error
Diagnose the diagnostic trouble codes (DTC) in the engine control unit (ECU), then clear codes and re-check
DTCs.
See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
See 13308.02 - Abnormal CAN Communication . (Group 9001-50.)
MB00333,0000251-19-20150114
321
20105.2 —
Hydraulic Oil Filter Restriction Alarm
Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure

1 Filter Check
Action:
Replace hydraulic oil filter. See Replace Hydraulic Oil Tank Filter . (Operator’s Manual.)
Result:
YES:
Go to Hydraulic Oil Filter Restriction Switch Check.
NO:
Checks complete.
2 Hydraulic Oil Filter Restriction Switch Check
Action:
Disconnect hydraulic oil filter restriction switch (B27). See Machine Harness (W2) Component Location .
(Group 9015-10.)
Check for continuity between terminals of hydraulic oil filter restriction switch.
Result:
YES:
Hydraulic oil filter restriction switch malfunction. Replace switch.
NO:
Go to Circuit Check.
3 Circuit Check
Action:
Disconnect monitor controller 20-pin connector B (X20) and hydraulic oil filter restriction switch (B27).
322
Check for continuity between pin 15 on monitor controller 20-pin connector B (X20) and machine ground.
Result:
YES:
Short to ground. Repair or replace harness. See appropriate harness.
NO:
Monitor controller malfunction. Replace monitor controller. See Monitor Controller Remove and Install .
(Group 9015-20.)
MB00333,00001A4-19-20130709
323
20106.2 —
Air Cleaner Restriction Alarm
Air Cleaner Restriction Alarm Diagnostics

1 Sensor Check
Action:
Disconnect air filter restriction switch (B16).
See Machine Harness (W2) Component Location . (Group 9015-10.)
Connect Service ADVISOR™ .
See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
Is diagnostic trouble code (DTC) 20106.2 still present?
Result:
YES:
Go to Circuit Check.
NO:
Replace air filter restriction switch (B16).
2 Circuit Check
Action:
Disconnect monitor controller (A4) connector X20 and air filter restriction switch (B16).
See Monitor Harness (W3) Component Location and see Machine Harness (W2) Component Location .
(Group 9015-10.)
Check for continuity between connector X20 pin 4 and ground.
Is continuity present?
Result:
YES:
Short to ground. Repair or replace harness.
See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
See Monitor Harness (W3) Wiring Diagram . (Group 9015-10.)
324
NO:
Monitor controller (A4) malfunction. Replace monitor controller.
MB00333,00001BD-19-20130820
325
Table of Contents
Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure
326
This procedure is used to check operation of the 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 the machine, diagnostic information in this checkout will help determine 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 the checks. No tools are needed to
perform the checkout.
Complete the usual necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage,
wiring) prior to doing the checkout. The machine must be at operating temperature for many of the checks.
Read each check completely before performing. If no problem is found, you will be instructed to go to the next
check. If a problem is indicated, you will be referred to a procedure for adjustment, repair, or replacement.
The monitor can be used to perform diagnostic and operational checks. The monitor can display engine speed,
pressures, and Diagnostic Trouble Codes (DTCs).
Diagnostic Trouble Codes Check

1 Display and Clear Diagnostic Trouble Codes
Action:
Always check for diagnostic trouble codes and correct them before performing the operational checkout.
Diagnostic trouble codes can be displayed by using several methods:
Monitor Controller
With Service Advisor
With WinDr
LOOK: Are diagnostic trouble codes present?
Result:
YES:
Correct all diagnostic trouble codes before proceeding.
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
NO:
Proceed with operational checkout.
Operational Checks—Key Switch Off, Engine Off Checks

327
1 Horn Circuit Check
Action:
TX1093717-UN: Horn Button

LEGEND:
1 - Horn Button
Key switch OFF.
Push horn button (1) on top of left pilot control lever.
LISTEN: Does horn sound?
Result:
YES:
Go to next check.
NO:
Check horn 10 A fuse (F17) (Marked HORN). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check horn wiring harness. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) and see Machine
2 Hour Meter and Fuel Gauge Check
Action:
328
TX1005661-UN: Monitor, Hour Meter and Fuel Gauge

LEGEND:
1 - Hour Meter
14 - Hour Meter Button
Press and hold hour meter button (14) until default screen appears.
LOOK: Does hour meter (1) display machine hours?
LOOK: Does fuel gauge display a fuel level?
Result:
YES:
Go to next check.
NO:
Check controller key signal switch 5 A fuse (F16) (Marked POW ON). See Fuse and Relay Specifications .
(Group 9015-10.)
NO:
Check wiring See Cab Harness (W1) Wiring Diagram (Group 9015-10.) or see Monitor Harness (W3) Wiring
Operational Checks—Key Switch On, Engine Off Checks

1 Monitor Start Up Check
Action:
329
TX1005660-UN: Monitor, System Starting Screen
TX1005657-UN: Monitor, System Default Screen

LEGEND:
1 - Alternator Alarm Indicator
LOOK: Does monitor display system starting screen?
LOOK: Does default screen with hour meter appear after system starting screen disappears?
LOOK: Does alternator alarm indicator (1) appear on default screen?
330
Result:
YES:
Go to next check.
NO:
(Group 9015-10.)
2 Monitor, Gauges, and Battery Relay Checks

Action:
TX1005659-UN: Monitor, Gauges

LEGEND:
1 - Work Mode Indicator
2 - Auto-Idle Indicator
3 - Engine Coolant Temperature Gauge
4 - F1 Function Button Indicator
5 - Fuel Gauge
6 - Hour Meter
7 - Alarm Indicator Light
NOTE:
If engine coolant temperature is below 30°C (86°F) engine temperature gauge needle may
not move.
Turn key switch to ON.
LISTEN: Does battery relay click?
331
LOOK: Does auto-idle indicator (2), when turned on, display flash then remain on?
LOOK: Does alarm indicator light (7) come on?
LOOK: Does alternator alarm indicator (8) come on?
LOOK: Does engine coolant temperature gauge (3) display an engine coolant temperature?
LOOK: Does fuel gauge (5) display a fuel level?
LOOK: Does work mode indicator (1) display (dig or attachment) work mode?
Result:
YES:
Go to next check.
NO:
Monitor does not come ON. Check monitor controller key switch signal 5 A fuse (F16) (Marked POW ON).
See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check wiring. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) or see Monitor Harness (W3) Wiring
NO:
Check key switch. See Key Switch Check . (Group 9015-20.)
Check battery relay. See Battery Relay Check . (Group 9015-20.)
Check wiring. See Machine Harness (W2) Wiring Diagram (Group 9015-10.) and see Cab Harness (W1)
NO:
Neither engine coolant temperature gauge nor fuel gauge moves. Check gauge sensor and wiring. See
Machine Harness (W2) Wiring Diagram (Group 9015-10.) and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)
NO:
Other than normal indicator lights remain on. Check diagnostic trouble codes. See Reading Diagnostic
Trouble Codes With Monitor Display (Group 9015-20.) or see Reading Diagnostic Trouble Codes With
Service ADVISOR™ Diagnostic Application (Group 9015-20.)
3 Travel Lever and Pedal Neutral Checks
Action:
332
TX1093760-UN: Travel Levers and Pedals

LEGEND:
1 - Forward
2 - Rearward
Push both travel levers and pedals forward (1), then release.
Pull both travel levers and pedals rearward (2), then release.
FEEL: Do levers and pedals require equal effort to operate in forward and reverse?
LOOK: Do levers and pedals return to neutral at the same time when released?
Result:
YES:
Go to next check.
NO:
Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Remove and Install . (Group 3360.)
4 Light Circuit Checks
333
Action:
TX1095488-UN: Switch Panel

LEGEND:
5 - Work Light Switch
6 - Windshield Wiper and Washer Switch
Turn work light switch (5) to first position.
LOOK: Are monitor panel back lights and drive lights on?
Turn light switch to second position.
LOOK: Do monitor panel back lights and drive lights remain on and boom work lights come on?
Result:
YES:
Go to next check.
NO:
Check work and drive lights 20 A fuse (F1) (Marked LAMP) and controller key switch signal 5 A fuse (F16)
(Marked POW ON). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check wiring harness. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) and see System Functional
Schematic . (Group 9015-10.)
5 Windshield Wiper Controls Check

Action:
334
LEGEND:
NOTE:
Front window must be fully closed and latched for this check.
Turn wiper switch (6) to first INT position.
LOOK: Does wiper operate intermittently?
Turn wiper switch to second INT position.
LOOK: Does wiper operate intermittently, but faster than when in first position?
Turn wiper switch to third INT position.
LOOK: Does wiper operate intermittently, but faster than when in second position?
Turn wiper switch to ON position.
LOOK: Does wiper operate continuously?
Move wiper switch to OFF position.
LOOK: Does wiper arm stop in park position at left side of windshield?
Result:
YES:
Go to next check.
NO:
Check that front window is fully latched and switch contacts make good connection.
NO:
Check windshield wiper and washer 10 A fuse (F2) (Marked WIPER). See Fuse and Relay Specifications .
(Group 9015-10.)
NO:
Check Wiring See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) for additional information
6 Windshield Washer and Wiper Circuit Check
Action:
IMPORTANT:
Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually operated
with no fluid in the washer fluid tank.
NOTE:
335
The washer can operate with the upper front window open. The wiper cannot operate with
the upper front window open. When closing window, check that window upper left corner
makes good contact with the cab.

LEGEND:
NOTE:
Front window should be fully closed and latched for this check.
Push washer switch (6).
LOOK: Is washer fluid supplied to windshield?
Turn windshield wiper (6) ON.
LISTEN: Does wiper circuit click?
LOOK: Does windshield wiper operate?
Result:
YES:
Go to next check.
NO:
Check washer fluid level. See Check Windshield Washer Fluid . (Operator's Manual.)
NO:
Check that the window upper left corner is making good contact with the cab.
NO:
(Group 9015-10.)
NO:
Check wiring harness. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)
336
Operational Checks—Key Switch On, Engine On Checks

1 Monitor and Gauge Circuit Checks

Action:

LEGEND:
2 - Hour Meter
4 - Fuel Gauge
5 - Alarm Indicator
6 - Alarm Indicator
IMPORTANT:
Stop the engine immediately if alarm Indicator light (7) or any alarm indicators come on after engine starts.
Start engine.
LOOK: Do all alarm indicators go off and remain off after engine starts?
Result:
YES:
Go to next check.
337
NO:
Other alarms are seen on display. See Alarm Occurrence Screen . (Operator's Manual.)
2 Pilot Control Shutoff Circuit Check

Action:
TX1093762-UN: Engine Speed Dial
TX1093763-UN: Locked
LEGEND:
1 - Engine Speed Dial
CAUTION:
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.
Pull pilot shutoff lever into LOCKED (rearward) position.
Slowly actuate dig and travel functions.
LOOK: Do dig and travel functions operate?
Result:
YES:
338
Check wiring. See Pilot Shutoff Switch Harness (W11) Wiring Diagram (Group 9015-10.) and See Cab
YES:
See Diagnose Pilot Circuit Malfunctions . (Group 9025-15.)
YES:
see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) for additional information.
NO:
Continue check.
Action:
TX1093764-UN: Unlocked
Push pilot shutoff lever into UNLOCKED (forward) position.
Result:
YES:
Go to next check.
NO:
Check wiring. See Pilot Shutoff Switch Harness (W11) Wiring Diagram (Group 9015-10.) and see Cab
Harness (W1) Wiring Diagram . (Group 9015-10.) or see Diagnose Pilot Circuit Malfunctions (Group 9025-
15.)
NO:
See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) for additional information.
3 Fan Reversing System—If Equipped

Action:
339
TX1005672-UN: Left Console Switch Location

LEGEND:
1 - Travel Alarm and Travel Alarm Cancel Switch
2 - Not Used
3 - Not Used
4 - Not Used
5 - Not Used
6 - Right Enable Switch (Optional)
7 - Not Used
8 - Not Used
9 - Reversing Cooling Fan Switch (Optional)
TX1015264A-UN: Fan Reversing Switch

LEGEND:
9 - Fan Reversing Switch
Turn engine speed dial (1) to H (fast-idle).

340
Turn (auto-idle) A/I OFF.
Push air conditioner switch OFF.
Press reversing cooling fan switch to MANUAL position.
LISTEN: Does fan speed slow down?
LOOK/LISTEN: After approximately 20 seconds, does the fan speed increase and rotate in reverse direction
for approximately one minute?
LISTEN/LOOK: Does the fan speed slow for approximately 20 seconds? Does fan direction return to normal?
LISTEN: Does fan speed increase?
Result:
YES:
Go to next check.
NO:
See Fan Reversing Switch Harness (W16) Wiring Diagram (Group 9015-10.) and see Fan Reversing Switch
Harness (W16) Component Location (Group 9015-10.) and see Cab Harness (W1) Wiring Diagram . (Group
9015-10.)
4 Engine Speed Dial Check

Action:
341
LEGEND:
2 - Auto-Idle Switch
3 - Power Mode Switch
Turn (auto-idle) switch (2) to A/I OFF.
Turn engine speed dial (1) to H (fast idle).
LISTEN: Does engine speed increase?
Turn engine speed dial (1) to L (slow idle).
LISTEN: Does engine speed decrease?
Result:
YES:
Go to next check.
NO:
(Group 9015-10.)
IF OK:
Check engine speed dial on monitor display. See Monitor Service Menu Operation . (Group 9015-16.) See
Monitor Controller Circuit Theory of Operation for additional information. (Group 9015-15.)
IF OK:
5 E (Economy) Mode and P (Power) Mode Check

Action:
342

LEGEND:
4 - Travel Speed Switch
Turn power mode switch (3) to P (power) mode.
Turn engine speed dial (1) to H (fast idle) position.
Turn power mode switch (3) to E (economy) mode.
LOOK/LISTEN: Does engine speed decrease?
LOOK/LISTEN: Does engine speed increase?
Result:
YES:
Go to next check.
NO:
See Engine Speed Control System Operation . (Group 9010-05.) for additional information on engine speed
343
and power mode
6 HP (High Power) Mode Check

Action:

LEGEND:
Turn power mode switch (3) to HP (high power) mode.
Actuate arm in function over relief.
LOOK/LISTEN: Does engine speed increase as function goes over relief?
Result:
YES:
344
Go to next check.
NO:
Check controller key signal switch 5 A fuse (F16) (Marked POW ON). See Fuse and Relay Specifications
(Group 9015-10.) and see Engine Speed Control System Operation . (Group 9010-05.)
NO:
Check wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
See Diagnose Dig Circuit Malfunctions . (Group 9025-15.)
7 Auto-Idle Circuit Check

Action:

LEGEND:
TX1005666-UN: Monitor, Auto Idle Indicator

LEGEND:
345
5 - Fuel Gauge
6 - Hour Meter
Turn (auto-idle) switch (2) to A/I ON.
LOOK/LISTEN: Does (auto-idle) indicator (2) illuminate?
Does engine speed decrease after 4—6 seconds?
Slowly actuate dig function.
LOOK/LISTEN: Does engine speed return to fast idle?
Result:
YES:
Go to next check.
NO:
Check solenoid 10 A fuse (F4) (Marked SOLENOID). See Fuse and Relay Specifications (Group 9015-10.)
and see Cab Harness (W1) Wiring Diagram . (9015-10.)
8 Travel Alarm Check

Action:
346
TX1095490-UN: Operator's Station

LEGEND:
1 - Forward
2 - Rearward
3 - Pilot Shutoff Lever
CAUTION:
Machine will move during this check. Make sure area is clear and large enough to
operate the machine.
Push pilot shutoff lever (3) into UNLOCKED (forward) position.
Slowly push travel pedals or levers forward (1).
LISTEN: Does travel alarm sound?
Slowly pull travel levers and pedals rearward (2).
347
Result:
YES:
Go to next check.
NO:
Check travel alarm 5 A fuse (F5) (Marked OPT. 1). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check wiring. See Travel Alarm Circuit Theory of Operation . (Group 9015-15.)
9 Travel Alarm Cancel Switch Circuit Check

Action:
TX1095494-UN: Travel Alarm Cancel Switch

LEGEND:
1 - Travel Alarm Cancel Switch
CAUTION:
NOTE:
348
Travel alarm must operate for this check.
Push travel pedals or levers forward and allow travel alarm to operate for a minimum of 12 seconds.
While continuing travel, push travel alarm cancel switch (1).
LISTEN: Does travel alarm stop sounding?
Pull travel pedals or levers rearward.
LISTEN: Does travel alarm start sounding again?
Result:
YES:
Go to next check.
NO:
Check travel alarm 5 A fuse (F5) (Marked OPT. 1). See Fuse and Relay Specifications (Group 9015-20.)
NO:
10 Hydraulic Oil Tank Pressurization Check
Action:
TX1093766-UN: Hydraulic Oil Tank Cover

LEGEND:
1 - Hydraulic Oil Tank Pressure Release Button
2 - Hydraulic Oil Tank Cover
Raise boom to full height, then lower boom to ground.
Slowly depress pressure release button on hydraulic oil tank cover.
LISTEN: Is air heard escaping from the pressure release button on hydraulic oil tank cover?
IMPORTANT:
349
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.
Result:
YES:
Go to next check.
NO:
Replace hydraulic oil tank cover.
11 Swing Dynamic Braking Check

Action:
TX1095482-UN: Swing Dynamic Braking

LEGEND:
CAUTION:
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.
350
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.
Fully actuate swing function. Swing right 90 degrees and then release lever.
LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever?
Fully actuate swing function. Swing left 90 degrees and then release lever.
Result:
YES:
Go to next check.
NO:
Perform Swing Motor Leakage Test (Group 9025-25.) and perform Swing Motor Crossover Relief Valve Test
and Adjustment . (Group 9025-25.)
NO:
Check swing valve spool and spring. See Control Valve Remove and Install . (Group 3360.)
12 Swing Park Brake and Circuit Drift Check

Action:
TX1093770-UN: Machine Position
351

LEGEND:
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.
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 left and repeat procedure.
352
Result:
YES:
Go to next check.
NO:
Upperstructure moves when all functions are in neutral and park brake is engaged. Check for pilot oil
pressure to swing park brake. See Upperstructure Drift With Swing Valve In Neutral . (Group 9025-15.)
NO:
Upperstructure movement is excessive when park brake is disengaged. See Swing Motor Leakage Test .
(Group 9025-25.)
NO:
Check swing spool in the control valve. See Control Valve Remove and Install . (Group 3360.)
13 Swing Power Check
Action:

LEGEND:
Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-
353
to-frame pivot pin.
Swing upperstructure right so it is 90 degrees to the slope.
Turn power mode switch (3) to HP (high power) mode
Actuate the swing function to swing uphill.
LOOK: Does upperstructure swing uphill?
Power mode switch (3) in HP (high power) mode.
Result:
YES:
Go to next check.
NO:
See Swing Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
NO:
Check swing motor leakage. See Swing Motor Leakage Test . (Group 9025-25.)
NO:
See Diagnose Swing Circuit Malfunctions . (Group 9025-15.)
NO:
Check swing spool in control valve. See Control Valve Remove and Install . (Group 3360.)
14 Dig Function Drift Check

Action:
354
TX1095487-UN: Dig Function Drift
Position bucket at maximum reach with bucket pivot pin at the same height as boom pivot pin.
Retract arm cylinder, then extend about 2 inches
Extend bucket cylinder, then retract about 2 inches.
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
Boom Cylinder Drift 5 mm
0.2 in.
Arm Cylinder Drift 10 mm
0.4 in.
Bucket Cylinder Drift 15 mm
0.6 in.
Bottom Of Bucket-To-Ground Drift 100 mm
3.94 in.
LOOK: Is cylinder drift within specification?
Result:
355
YES:
Go to next check.
NO:
See Diagnose Dig Circuit Malfunctions (Group 9025-15.) and see Cylinder Drift Test—Boom, Arm, and
Bucket . (Group 9025-25.)
15 Swing Priority Circuit Check
Action:
CAUTION:
Perform check in an open area away from other machinery or personnel.
T6290AF-UN: Swing Priority Check

LEGEND:
Position machine as shown.
Operate swing function and record time required for three complete revolutions.
Divide that time by three to get an average time for one revolution.
356

Swing Function Time—One Revolution 4.17—4.83 seconds
IMPORTANT:
Position machine as shown. Operate swing and arm in slowly a few times before attempting to perform
check to ensure bucket does not contact machine or ground.
Position machine as shown, arm extended, bucket curled, and upper structure 90 degrees to tracks.
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 one complete revolution.
NOTE:
Swing speed should not slow when actuating arm in.
LOOK: Does swing speed remain unchanged when actuating arm in?
Result:
YES:
Go to next check.
NO:
Check arm 1 flow rate pilot valve. See Diagnose Swing Circuit Malfunctions (Group 9025-15.) and see Pilot
Signal Manifold Operation (Group 9025-05.) and see Arm 1 Flow Rate Control Valve Circuit Operation .
(Group 9025-05.)
16 Control Valve Lift Check Test

Action:
T6292AZ-UN: Control Valve Lift
357

LEGEND:
Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).
LOOK: Do functions move in opposite direction as pilot control levers are first moved, then change direction
as levers are moved farther?
Result:
YES:
See Load Falls When Control Valve Is Actuated To Raise Load With Engine Running At Slow Idle . (Group
9025-15.)
NO:
Go to next check.
17 Boom Up, Arm In, and Bucket Combined Function Operation Check
Action:

LEGEND:
358
Actuate boom up function, arm in function, and then bucket function in combination.
LOOK: Does boom continue to move at approximately the same speed after bucket function is actuated?
Result:
YES:
Go to next check.
NO:
If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve Remove and
Install . (Group 3360.)
18 Boom Regenerative Valve Operation Check
Action:

LEGEND:
Raise boom and extend the arm to full extension.
Actuate the boom down, then arm in and boom up functions in combined operation.
LOOK: Does the boom move smoothly through the complete cycle down and up and not hesitate when it
goes past the vertical position?
359
Result:
YES:
Go to next check.
NO:
Check pump 1 and pump 2 delivery pressure sensors (B35 and B37) and boom up pressure sensor (B30).
See Pressure Sensor Test . (Group 9015-20.)
NO:
Check boom regenerative valve. See Boom Regenerative Valve Circuit Operation (Group 9025-05.) and see
Control Valve Remove and Install (Group 3360.) and see Control Valve (5-Spool) Disassemble and
Assemble . (Group 3360.)
19 Arm Regenerative Valve Operation Check

Action:

LEGEND:
Extend the arm to full extension and then lower boom so bucket is on the ground.
Actuate the boom up and arm in functions in combined operation.
LOOK: Does the arm move smoothly through the complete cycle and not hesitate when it goes through the
vertical position?
Result:
YES:
Go to next check.
NO:
Check pump 1 and pump 2 delivery pressure sensors (B35 and B37), arm in pressure sensor (B31), and
boom up pressure sensor (B30). See Pressure Sensor Test . (Group 9015-20.)
NO:
360
Check arm regenerative solenoid valve. See Arm Regenerative Valve Circuit Operation . (Group 9025-05.)
IF OK:
Check arm regenerative valve. See Control Valve Remove and Install . (Group 3360.)
20 Bucket Regenerative Valve Operation Check

Action:

LEGEND:
Actuate boom up, arm out and bucket dump functions.
Actuate boom down function, arm in function, and then the bucket curl function.
LOOK: Does the bucket move smoothly through the complete cycle and not hesitate when it goes to the curl
position?
Result:
YES:
Go to next check.
NO:
Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation . (Group 9025-05.)
21 Travel Speed Selection Check

Action:
361

LEGEND:
Turn travel speed switch (4) to slow speed (turtle) mode.
Actuate travel function to full speed.
Turn travel speed switch (4) 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?
LOOK: Does machine travel speed decrease?
Result:
362
YES:
Go to next check.
NO:
Check travel pressure sensor (B34) and travel speed switch (S11). See Pressure Sensor Test (Group 9015-
20.) and see Travel Motor Speed Circuit Operation . (Group 9025-05.)
22 Travel System Tracking Check

Action:
CAUTION:
Prevent possible injury from unexpected machine movement. Clear all persons from
the area before operating machine.
Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-Up Procedure . (Group
9025-25.)

LEGEND:
9 - Bucket Height
Fully extend arm cylinder and bucket cylinder.
Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.
363

LEGEND:
Turn auto-idle switch (2) to A/I OFF position.
Turn power mode switch (3) to P (standard) mode.
364
TX1120481-UN: Tracking Check

LEGEND:
5 - Distance of Mistrack
6 - Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)
7 - Test Line (distance): 20 m (66 ft.)
8 - Track Print
Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.).
NOTE:
When machine mistracks right, hydraulic pump 1 circuit oil flow may be less than
specification. When machine mistracks left, hydraulic pump 2 circuit oil flow may be less
than specification.
Observe direction of mistrack.
Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).
Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.
Repeat procedure in reverse travel.
LOOK: Does machine mistrack less than 200 mm (7.87 in.)?
365
Result:
YES:
Go to next check.
NO:
Check track sag. See Check and Adjust Track Sag . (Operator’s Manual.)
NO:
Perform Travel Motor Leakage Test or perform Pump Flow Test . (Group 9025-25.)
23 Travel System Tracking Checks While Operating a Dig Function
Action:

LEGEND:
NOTE:
Machine will slow down during this test.
366
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.
LOOK: Does machine mistrack excessively when the arm is extended?
Result:
YES:
See Diagnose Dig Circuit Malfunctions (Group 9025-15.) and see Diagnose Travel Circuit Malfunctions .
(Group 9025-15.)
NO:
Go to next check.
24 Travel System Maneuverability Check

Action:

LEGEND:
367
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 (4) in fast speed (rabbit) mode.
Drive machine at full speed in reverse down a slope.
Result:
YES:
Go to next check.
NO:
See Diagnose Travel Circuit Malfunctions . (Group 9025-15.)
25 Cycle Times Check
Action:
CAUTION:
NOTE:
Warm hydraulic oil to operating temperature for this check.
368

LEGEND:
TX1095475-UN: Boom
TX1095499-UN: Arm, Bucket, Swing

Move machine to position shown for each test.
Record cycle time for each function.
369

Boom Raise (Cylinder Extend) Cycle Time 2.8—3.4 sec.
Boom Lower (Cylinder Retract) Cycle Time 1.9—2.5 sec.
Arm In (Cylinder Extend) Cycle Time 2.9—3.5 sec.
Arm Out (Cylinder Retract) Cycle Time 2.2—2.8 sec.
Bucket Load (Cylinder Extend) Cycle Time 2.7—3.3 sec.
Bucket Dump (Cylinder Retract) Cycle Time 1.7—2.3 sec.
Swing Left or Right, 3 Revolutions From a Running Start Cycle Time 12.5—14.5
sec.
Drive 20 m (65 ft) From A Running Start (Check In Forward And Reverse Cycle Time 12.6—13.8
With Travel Speed Switch In FAST Position) sec.
With Travel Speed Switch In SLOW Position) sec.
Track Raised For 3 Revolutions From A Running Start (Check In Forward Cycle Time 16.2—18.2
And Reverse With Travel Mode Switch In FAST Position) (200 D) sec.
Cycle Time 17.3—19.3
(200 DLC) sec.
And Reverse With Travel Mode Switch In SLOW Position) (200 D) sec.
(200 DLC) sec.
LOOK: Does machine perform within specifications?
Result:
YES:
Go to next check.
NO:
See Diagnose Hydraulic System Malfunctions . (Group 9025-15.)
26 Heater And Air Conditioner Circuit Check And Controls Check (Automatic Temperature Control)
Action:
370
TX1095437-UN: Heater and Air Conditioner Controls

LEGEND:
1 - Fan Speed Switches
2 - Monitor Display
3 - Air Conditioner ON and OFF Switch (A/C)
4 - Automatic Operation Switch (AUTO)
5 - Heater and Air Conditioner OFF Switch (OFF)
6 - Temperature Control Switches (TEMP)
7 - Recirculating Air Switch
8 - Fresh Air Switch
9 - Front, Rear, and Defroster Vent Control Switch (Mode)
NOTE:
The air conditioner and heater controller automatically adjusts vent position, fan speed, and
intake air source to achieve any temperature set by the operator.
Key ON, press OFF switch (1).
Start engine.
Run engine until normal operating temperature is reached.
Start engine and warm to normal operating temperature.
Press temperature control switch to maximum heat position.
FEEL: Does warm air come from the vents?
Press temperature control switch to maximum cold position.
LISTEN: Does air conditioner compressor clutch solenoid “click”?
FEEL: Does cool air come from the vents?
Press AUTO switch (4).
371
LOOK: Does indicator light above A/C and AUTO switches illuminate?
LOOK: Does monitor display illuminate and display vent position, fan speed, and temperature setting?
FEEL/LISTEN: Does vent position change?
LOOK: Does fan speed change to maximum and temperature setting increase?
LOOK: Does full heat (FH) appear in the temperature setting area?
LOOK: Does fan speed change to maximum and temperature setting decrease?
LOOK: Does full cool (FC) appear in the temperature setting area?
Press A/C switch.
LISTEN: Does air conditioner compressor clutch solenoid “click”? (Heater is ON in manual mode.)
LOOK: Do indicator lights above A/C and AUTO switches go OFF?
Press A/C switch.
LISTEN: Does air conditioner compressor clutch solenoid “click”? (Air conditioner and heater are ON in
manual mode.)
Press OFF switch.
LOOK: Are air conditioner and heater OFF? (Push AUTO to start A/C and heater).
372
Result:
YES:
Check complete.
NO:
Heater fan does not blow air. Check air conditioner and heater 20 A fuse (F3) (Marked HEATER). See Fuse
and Relay Specifications . (Group 9015-10.)
NO:
Check system operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)
NO:
JD29379,000003D-19-20121119
373
This procedure is used to check operation of the 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 the machine, diagnostic information in this checkout will help determine 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 the checks. No tools are needed to
perform the checkout.
Complete the usual necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage,
wiring) prior to doing the checkout. The machine must be at operating temperature for many of the checks.
Read each check completely before performing. If no problem is found, you will be instructed to go to the next
check. If a problem is indicated, you will be referred to a procedure for adjustment, repair, or replacement.
The monitor can be used to perform diagnostic and operational checks. The monitor can display engine speed,
pressures, and Diagnostic Trouble Codes (DTCs).
Diagnostic Trouble Codes Check

1 Display and Clear Diagnostic Trouble Codes
Action:
Always check for diagnostic trouble codes and correct them before performing the operational checkout.
Diagnostic trouble codes can be displayed by using several methods:
Monitor Controller
With Service Advisor
With WinDr
LOOK: Are diagnostic trouble codes present?
Result:
YES:
Correct all diagnostic trouble codes before proceeding.
See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
NO:
Proceed with operational checkout.
Operational Checks—Key Switch Off, Engine Off Checks

374
1 Horn Circuit Check
Action:
TX1093717-UN: Horn Button

LEGEND:
1 - Horn Button
Key switch OFF.
Push horn button (1) on top of left pilot control lever.
LISTEN: Does horn sound?
Result:
YES:
Go to next check.
NO:
Check horn 10 A fuse (F17) (Marked HORN). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check horn wiring harness. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) and see Machine
2 Hour Meter and Fuel Gauge Check
Action:
375
TX1005661-UN: Monitor, Hour Meter and Fuel Gauge

LEGEND:
1 - Hour Meter
14 - Hour Meter Button
Press and hold hour meter button (14) until default screen appears.
LOOK: Does fuel gauge display a fuel level?
Result:
YES:
Go to next check.
NO:
(Group 9015-10.)
NO:
Check wiring See Cab Harness (W1) Wiring Diagram (Group 9015-10.) or see Monitor Harness (W3) Wiring
Operational Checks—Key Switch On, Engine Off Checks

1 Monitor Start Up Check
Action:
376
TX1005660-UN: Monitor, System Starting Screen
TX1005657-UN: Monitor, System Default Screen

LEGEND:
LOOK: Does monitor display system starting screen?
LOOK: Does default screen with hour meter appear after system starting screen disappears?
LOOK: Does alternator alarm indicator (1) appear on default screen?
377
Result:
YES:
Go to next check.
NO:
(Group 9015-10.)
2 Monitor, Gauges, and Battery Relay Checks

Action:

LEGEND:
5 - Fuel Gauge
6 - Hour Meter
NOTE:
If engine coolant temperature is below 30°C (86°F) engine temperature gauge needle may
not move.
Turn key switch to ON.
LISTEN: Does battery relay click?
378
LOOK: Does auto-idle indicator (2), when turned on, display flash then remain on?
LOOK: Does alarm indicator light (7) come on?
LOOK: Does alternator alarm indicator (8) come on?
LOOK: Does work mode indicator (1) display (dig or attachment) work mode?
Result:
YES:
Go to next check.
NO:
Monitor does not come ON. Check monitor controller key switch signal 5 A fuse (F16) (Marked POW ON).
See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check wiring. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) or see Monitor Harness (W3) Wiring
NO:
Check key switch. See Key Switch Check . (Group 9015-20.)
Check battery relay. See Battery Relay Check . (Group 9015-20.)
Check wiring. See Machine Harness (W2) Wiring Diagram (Group 9015-10.) and see Cab Harness (W1)
NO:
Neither engine coolant temperature gauge nor fuel gauge moves. Check gauge sensor and wiring. See
Machine Harness (W2) Wiring Diagram (Group 9015-10.) and see Cab Harness (W1) Wiring Diagram .
(Group 9015-10.)
NO:
Other than normal indicator lights remain on. Check diagnostic trouble codes. See Reading Diagnostic
Trouble Codes With Monitor Display (Group 9015-20.) or see Reading Diagnostic Trouble Codes With
Service ADVISOR™ Diagnostic Application (Group 9015-20.)
3 Travel Lever and Pedal Neutral Checks
Action:
379
TX1093760-UN: Travel Levers and Pedals

LEGEND:
1 - Forward
2 - Rearward
Push both travel levers and pedals forward (1), then release.
Pull both travel levers and pedals rearward (2), then release.
FEEL: Do levers and pedals require equal effort to operate in forward and reverse?
LOOK: Do levers and pedals return to neutral at the same time when released?
Result:
YES:
Go to next check.
NO:
Inspect, repair or replace travel pilot control valve. See Travel Pilot Valve Remove and Install . (Group 3360.)
4 Light Circuit Checks
380
Action:

LEGEND:
Turn work light switch (5) to first position.
LOOK: Are monitor panel back lights and drive lights on?
Turn light switch to second position.
LOOK: Do monitor panel back lights and drive lights remain on and boom work lights come on?
Result:
YES:
Go to next check.
NO:
Check work and drive lights 20 A fuse (F1) (Marked LAMP) and controller key switch signal 5 A fuse (F16)
(Marked POW ON). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Check wiring harness. See Cab Harness (W1) Wiring Diagram (Group 9015-10.) and see System Functional
Schematic . (Group 9015-10.)
5 Windshield Wiper Controls Check

Action:
381
LEGEND:
NOTE:
Front window must be fully closed and latched for this check.
Turn wiper switch (6) to first INT position.
LOOK: Does wiper operate intermittently?
Turn wiper switch to second INT position.
LOOK: Does wiper operate intermittently, but faster than when in first position?
Turn wiper switch to third INT position.
LOOK: Does wiper operate intermittently, but faster than when in second position?
Turn wiper switch to ON position.
LOOK: Does wiper operate continuously?
Move wiper switch to OFF position.
LOOK: Does wiper arm stop in park position at left side of windshield?
Result:
YES:
Go to next check.
NO:
Check that front window is fully latched and switch contacts make good connection.
NO:
(Group 9015-10.)
NO:
Check Wiring See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.) for additional information
6 Windshield Washer and Wiper Circuit Check
Action:
IMPORTANT:
Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually operated
with no fluid in the washer fluid tank.
NOTE:
382
The washer can operate with the upper front window open. The wiper cannot operate with
the upper front window open. When closing window, check that window upper left corner
makes good contact with the cab.

LEGEND:
NOTE:
Front window should be fully closed and latched for this check.
Push washer switch (6).
LOOK: Is washer fluid supplied to windshield?
Turn windshield wiper (6) ON.
LISTEN: Does wiper circuit click?
LOOK: Does windshield wiper operate?
Result:
YES:
Go to next check.
NO:
Check washer fluid level. See Check Windshield Washer Fluid . (Operator's Manual.)
NO:
Check that the window upper left corner is making good contact with the cab.
NO:
(Group 9015-10.)
NO:
NO:
Check washer pump. See Windshield Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)
383
Operational Checks—Key Switch On, Engine On Checks

1 Monitor and Gauge Circuit Checks

Action:

LEGEND:
2 - Hour Meter
4 - Fuel Gauge
5 - Alarm Indicator
6 - Alarm Indicator
IMPORTANT:
Stop the engine immediately if alarm Indicator light (7) or any alarm indicators come on after engine starts.
Start engine.
LOOK: Do all alarm indicators go off and remain off after engine starts?
Result:
YES:
Go to next check.
384
NO:
Other alarms are seen on display. See Alarm Occurrence Screen . (Operator's Manual.)
2 Pilot Control Shutoff Circuit Check

Action:
TX1093763-UN: Locked
LEGEND:
CAUTION:
Machine may move during this check. Make sure area is clear and large enough to
operate all machine functions.
Result:
YES:
385
Check wiring. See Pilot Shutoff Switch Harness (W11) Wiring Diagram (Group 9015-10.) and See Cab
YES:
See Diagnose Pilot Circuit Malfunctions . (Group 9025-15.)
YES:
see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) for additional information.
NO:
Continue check.
Action:
TX1093764-UN: Unlocked
Result:
YES:
Go to next check.
NO:
Check wiring. See Pilot Shutoff Switch Harness (W11) Wiring Diagram (Group 9015-10.) and see Cab
Harness (W1) Wiring Diagram . (Group 9015-10.) or see Diagnose Pilot Circuit Malfunctions (Group 9025-
15.)
NO:
See Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.) for additional information.
3 Fan Reversing System—If Equipped

Action:
386
TX1005672-UN: Left Console Switch Location

LEGEND:
1 - Travel Alarm and Travel Alarm Cancel Switch
2 - Not Used
3 - Not Used
4 - Not Used
5 - Not Used
6 - Right Enable Switch (Optional)
7 - Not Used
8 - Not Used
9 - Reversing Cooling Fan Switch (Optional)
TX1015264A-UN: Fan Reversing Switch

LEGEND:
9 - Fan Reversing Switch
Turn engine speed dial (1) to H (fast-idle).

387
Turn (auto-idle) A/I OFF.
Push air conditioner switch OFF.
Press reversing cooling fan switch to MANUAL position.
LISTEN: Does fan speed slow down?
LOOK/LISTEN: After approximately 20 seconds, does the fan speed increase and rotate in reverse direction
for approximately one minute?
LISTEN/LOOK: Does the fan speed slow for approximately 20 seconds? Does fan direction return to normal?
LISTEN: Does fan speed increase?
Result:
YES:
Go to next check.
NO:
See Fan Reversing Switch Harness (W16) Wiring Diagram (Group 9015-10.) and see Fan Reversing Switch
Harness (W16) Component Location (Group 9015-10.) and see Cab Harness (W1) Wiring Diagram . (Group
9015-10.)
4 Engine Speed Dial Check

Action:
388
LEGEND:
Turn engine speed dial (1) to H (fast idle).
LISTEN: Does engine speed increase?
Turn engine speed dial (1) to L (slow idle).
LISTEN: Does engine speed decrease?
Result:
YES:
Go to next check.
NO:
(Group 9015-10.)
IF OK:
Check engine speed dial on monitor display. See Monitor Service Menu Operation . (Group 9015-16.) See
Monitor Controller Circuit Theory of Operation for additional information. (Group 9015-15.)
IF OK:
5 E (Economy) Mode and P (Power) Mode Check

Action:
389

LEGEND:
Turn power mode switch (3) to E (economy) mode.
LOOK/LISTEN: Does engine speed decrease?
LOOK/LISTEN: Does engine speed increase?
Result:
YES:
Go to next check.
NO:
See Engine Speed Control System Operation . (Group 9010-05.) for additional information on engine speed
390
and power mode
6 HP (High Power) Mode Check

Action:

LEGEND:
Actuate arm in function over relief.
LOOK/LISTEN: Does engine speed increase as function goes over relief?
Result:
YES:
391
Go to next check.
NO:
Check controller key signal switch 5 A fuse (F16) (Marked POW ON). See Fuse and Relay Specifications
(Group 9015-10.) and see Engine Speed Control System Operation . (Group 9010-05.)
NO:
Check wiring. See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
See Diagnose Dig Circuit Malfunctions . (Group 9025-15.)
7 Auto-Idle Circuit Check

Action:

LEGEND:
TX1005666-UN: Monitor, Auto Idle Indicator

LEGEND:
392
5 - Fuel Gauge
6 - Hour Meter
Turn (auto-idle) switch (2) to A/I ON.
LOOK/LISTEN: Does (auto-idle) indicator (2) illuminate?
Does engine speed decrease after 4—6 seconds?
Slowly actuate dig function.
LOOK/LISTEN: Does engine speed return to fast idle?
Result:
YES:
Go to next check.
NO:
Check solenoid 10 A fuse (F4) (Marked SOLENOID). See Fuse and Relay Specifications (Group 9015-10.)
and see Cab Harness (W1) Wiring Diagram . (9015-10.)
8 Travel Alarm Check

Action:
393
TX1095490-UN: Operator's Station

LEGEND:
1 - Forward
2 - Rearward
3 - Pilot Shutoff Lever
CAUTION:
Slowly push travel pedals or levers forward (1).
Slowly pull travel levers and pedals rearward (2).
394
Result:
YES:
Go to next check.
NO:
Check travel alarm 5 A fuse (F5) (Marked OPT. 1). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
9 Travel Alarm Cancel Switch Circuit Check

Action:

LEGEND:
1 - Travel Alarm Cancel Switch
CAUTION:
NOTE:
395
Travel alarm must operate for this check.
Push travel pedals or levers forward and allow travel alarm to operate for a minimum of 12 seconds.
While continuing travel, push travel alarm cancel switch (1).
LISTEN: Does travel alarm stop sounding?
Pull travel pedals or levers rearward.
LISTEN: Does travel alarm start sounding again?
Result:
YES:
Go to next check.
NO:
Check travel alarm 5 A fuse (F5) (Marked OPT. 1). See Fuse and Relay Specifications (Group 9015-20.)
NO:
10 Hydraulic Oil Tank Pressurization Check
Action:
TX1093766-UN: Hydraulic Oil Tank Cover

LEGEND:
1 - Hydraulic Oil Tank Pressure Release Button
2 - Hydraulic Oil Tank Cover
Raise boom to full height, then lower boom to ground.
Slowly depress pressure release button on hydraulic oil tank cover.
LISTEN: Is air heard escaping from the pressure release button on hydraulic oil tank cover?
IMPORTANT:
396
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.
Result:
YES:
Go to next check.
NO:
Replace hydraulic oil tank cover.
11 Swing Dynamic Braking Check

Action:
TX1095482-UN: Swing Dynamic Braking

LEGEND:
CAUTION:
Make sure area is clear and large enough to swing extended arm and bucket. Machine
must be on level ground.
397
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.
Fully actuate swing function. Swing right 90 degrees and then release lever.
Fully actuate swing function. Swing left 90 degrees and then release lever.
Result:
YES:
Go to next check.
NO:
Perform Swing Motor Leakage Test (Group 9025-25.) and perform Swing Motor Crossover Relief Valve Test
NO:
Check swing valve spool and spring. See Control Valve Remove and Install . (Group 3360.)
12 Swing Park Brake and Circuit Drift Check

Action:
398

LEGEND:
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.
NOTE:
Function does not need to be fully actuated to disengage the swing park brake.
399
Result:
YES:
Go to next check.
NO:
Upperstructure moves when all functions are in neutral and park brake is engaged. Check for pilot oil
pressure to swing park brake. See Upperstructure Drift With Swing Valve In Neutral . (Group 9025-15.)
NO:
Upperstructure movement is excessive when park brake is disengaged. See Swing Motor Leakage Test .
(Group 9025-25.)
NO:
Check swing spool in the control valve. See Control Valve Remove and Install . (Group 3360.)
13 Swing Power Check
Action:

LEGEND:
Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is the same height as boom-
400
to-frame pivot pin.
Swing upperstructure right so it is 90 degrees to the slope.
Turn power mode switch (3) to HP (high power) mode
Power mode switch (3) in HP (high power) mode.
Result:
YES:
Go to next check.
NO:
NO:
Check swing motor leakage. See Swing Motor Leakage Test . (Group 9025-25.)
NO:
See Diagnose Swing Circuit Malfunctions . (Group 9025-15.)
NO:
Check swing spool in control valve. See Control Valve Remove and Install . (Group 3360.)
14 Dig Function Drift Check

Action:
401
TX1095487-UN: Dig Function Drift
Position bucket at maximum reach with bucket pivot pin at the same height as boom pivot pin.
Retract arm cylinder, then extend about 2 inches
Extend bucket cylinder, then retract about 2 inches.
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
Boom Cylinder Drift 5 mm
0.2 in.
Arm Cylinder Drift 10 mm
0.4 in.
Bucket Cylinder Drift 15 mm
0.6 in.
Bottom Of Bucket-To-Ground Drift 100 mm
3.94 in.
LOOK: Is cylinder drift within specification?
Result:
402
YES:
Go to next check.
NO:
See Diagnose Dig Circuit Malfunctions (Group 9025-15.) and see Cylinder Drift Test—Boom, Arm, and
Bucket . (Group 9025-25.)
15 Swing Priority Circuit Check
Action:
CAUTION:
Perform check in an open area away from other machinery or personnel.
T6290AF-UN: Swing Priority Check

LEGEND:
Operate swing function and record time required for three complete revolutions.
Divide that time by three to get an average time for one revolution.
403

Swing Function Time—One Revolution 4.17—4.83 seconds
IMPORTANT:
Position machine as shown. Operate swing and arm in slowly a few times before attempting to perform
check to ensure bucket does not contact machine or ground.
Position machine as shown, arm extended, bucket curled, and upper structure 90 degrees to tracks.
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 one complete revolution.
NOTE:
Swing speed should not slow when actuating arm in.
LOOK: Does swing speed remain unchanged when actuating arm in?
Result:
YES:
Go to next check.
NO:
Check arm 1 flow rate pilot valve. See Diagnose Swing Circuit Malfunctions (Group 9025-15.) and see Pilot
Signal Manifold Operation (Group 9025-05.) and see Arm 1 Flow Rate Control Valve Circuit Operation .
(Group 9025-05.)
16 Control Valve Lift Check Test

Action:
T6292AZ-UN: Control Valve Lift
404

LEGEND:
Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder).
LOOK: Do functions move in opposite direction as pilot control levers are first moved, then change direction
as levers are moved farther?
Result:
YES:
See Load Falls When Control Valve Is Actuated To Raise Load With Engine Running At Slow Idle . (Group
9025-15.)
NO:
Go to next check.
17 Boom Up, Arm In, and Bucket Combined Function Operation Check
Action:

LEGEND:
405
Actuate boom up function, arm in function, and then bucket function in combination.
LOOK: Does boom continue to move at approximately the same speed after bucket function is actuated?
Result:
YES:
Go to next check.
NO:
If boom speed slows excessively, inspect bucket flow rate control valve. See Control Valve Remove and
18 Boom Regenerative Valve Operation Check
Action:

LEGEND:
Raise boom and extend the arm to full extension.
Actuate the boom down, then arm in and boom up functions in combined operation.
LOOK: Does the boom move smoothly through the complete cycle down and up and not hesitate when it
goes past the vertical position?
406
Result:
YES:
Go to next check.
NO:
Check pump 1 and pump 2 delivery pressure sensors (B35 and B37) and boom up pressure sensor (B30).
See Pressure Sensor Test . (Group 9015-20.)
NO:
Check boom regenerative valve. See Boom Regenerative Valve Circuit Operation (Group 9025-05.) and see
Control Valve Remove and Install (Group 3360.) and see Control Valve (5-Spool) Disassemble and
19 Arm Regenerative Valve Operation Check

Action:

LEGEND:
Extend the arm to full extension and then lower boom so bucket is on the ground.
Actuate the boom up and arm in functions in combined operation.
LOOK: Does the arm move smoothly through the complete cycle and not hesitate when it goes through the
vertical position?
Result:
YES:
Go to next check.
NO:
Check pump 1 and pump 2 delivery pressure sensors (B35 and B37), arm in pressure sensor (B31), and
boom up pressure sensor (B30). See Pressure Sensor Test . (Group 9015-20.)
NO:
407
Check arm regenerative solenoid valve. See Arm Regenerative Valve Circuit Operation . (Group 9025-05.)
IF OK:
Check arm regenerative valve. See Control Valve Remove and Install . (Group 3360.)
20 Bucket Regenerative Valve Operation Check

Action:

LEGEND:
Actuate boom up, arm out and bucket dump functions.
Actuate boom down function, arm in function, and then the bucket curl function.
LOOK: Does the bucket move smoothly through the complete cycle and not hesitate when it goes to the curl
position?
Result:
YES:
Go to next check.
NO:
Check bucket regenerative valve. See Bucket Regenerative Valve Circuit Operation . (Group 9025-05.)
21 Travel Speed Selection Check

Action:
408

LEGEND:
Actuate travel function to full speed.
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?
LOOK: Does machine travel speed decrease?
Result:
409
YES:
Go to next check.
NO:
Check travel pressure sensor (B34) and travel speed switch (S11). See Pressure Sensor Test (Group 9015-
20.) and see Travel Motor Speed Circuit Operation . (Group 9025-05.)
22 Travel System Tracking Check

Action:
CAUTION:
Warm hydraulic oil to operating temperature for this check. See Hydraulic Oil Warm-Up Procedure . (Group
9025-25.)

LEGEND:
9 - Bucket Height
Fully extend arm cylinder and bucket cylinder.
Position boom so bucket height (9) is approximately 400 mm (16 in.) above ground.
410

LEGEND:
Turn auto-idle switch (2) to A/I OFF position.
Turn power mode switch (3) to P (standard) mode.
411
TX1120481-UN: Tracking Check

LEGEND:
5 - Distance of Mistrack
6 - Acceleration and Deceleration Zone (approximate): 3—5 m (10—16 ft.)
7 - Test Line (distance): 20 m (66 ft.)
8 - Track Print
Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.).
NOTE:
When machine mistracks right, hydraulic pump 1 circuit oil flow may be less than
specification. When machine mistracks left, hydraulic pump 2 circuit oil flow may be less
than specification.
Observe direction of mistrack.
Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).
Measure and record greatest distance of mistrack (5) between inside edge of track print and test line.
Repeat procedure in reverse travel.
LOOK: Does machine mistrack less than 200 mm (7.87 in.)?
412
Result:
YES:
Go to next check.
NO:
Check track sag. See Check and Adjust Track Sag . (Operator’s Manual.)
NO:
Perform Travel Motor Leakage Test or perform Pump Flow Test . (Group 9025-25.)
23 Travel System Tracking Checks While Operating a Dig Function
Action:

LEGEND:
NOTE:
Machine will slow down during this test.
413
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.
LOOK: Does machine mistrack excessively when the arm is extended?
Result:
YES:
See Diagnose Dig Circuit Malfunctions (Group 9025-15.) and see Diagnose Travel Circuit Malfunctions .
(Group 9025-15.)
NO:
Go to next check.
24 Travel System Maneuverability Check

Action:

LEGEND:
414
Drive machine at full speed forward down a slope.
Repeat the procedure in reverse travel.
Turn travel speed switch (4) in fast speed (rabbit) mode.
Drive machine at full speed in reverse down a slope.
Result:
YES:
Go to next check.
NO:
See Diagnose Travel Circuit Malfunctions . (Group 9025-15.)
25 Cycle Times Check
Action:
CAUTION:
NOTE:
Warm hydraulic oil to operating temperature for this check.
415

LEGEND:
TX1095475-UN: Boom
TX1095499-UN: Arm, Bucket, Swing

Move machine to position shown for each test.
Record cycle time for each function.
416

Boom Raise (Cylinder Extend) Cycle Time 2.8—3.4 sec.
Boom Lower (Cylinder Retract) Cycle Time 1.9—2.5 sec.
Arm In (Cylinder Extend) Cycle Time 2.9—3.5 sec.
Arm Out (Cylinder Retract) Cycle Time 2.2—2.8 sec.
Bucket Load (Cylinder Extend) Cycle Time 2.7—3.3 sec.
Bucket Dump (Cylinder Retract) Cycle Time 1.7—2.3 sec.
Swing Left or Right, 3 Revolutions From a Running Start Cycle Time 12.5—14.5
sec.
With Travel Speed Switch In FAST Position) sec.
With Travel Speed Switch In SLOW Position) sec.
And Reverse With Travel Mode Switch In FAST Position) (200 D) sec.
(200 DLC) sec.
And Reverse With Travel Mode Switch In SLOW Position) (200 D) sec.
(200 DLC) sec.
LOOK: Does machine perform within specifications?
Result:
YES:
Go to next check.
NO:
See Diagnose Hydraulic System Malfunctions . (Group 9025-15.)
26 Heater And Air Conditioner Circuit Check And Controls Check (Automatic Temperature Control)
Action:
417
TX1095437-UN: Heater and Air Conditioner Controls

LEGEND:
1 - Fan Speed Switches
2 - Monitor Display
3 - Air Conditioner ON and OFF Switch (A/C)
4 - Automatic Operation Switch (AUTO)
5 - Heater and Air Conditioner OFF Switch (OFF)
6 - Temperature Control Switches (TEMP)
7 - Recirculating Air Switch
8 - Fresh Air Switch
9 - Front, Rear, and Defroster Vent Control Switch (Mode)
NOTE:
The air conditioner and heater controller automatically adjusts vent position, fan speed, and
intake air source to achieve any temperature set by the operator.
Key ON, press OFF switch (1).
Start engine.
Run engine until normal operating temperature is reached.
Start engine and warm to normal operating temperature.
418
LOOK: Does indicator light above A/C and AUTO switches illuminate?
LOOK: Does monitor display illuminate and display vent position, fan speed, and temperature setting?
Press A/C switch.
LISTEN: Does air conditioner compressor clutch solenoid “click”? (Heater is ON in manual mode.)
LOOK: Do indicator lights above A/C and AUTO switches go OFF?
Press A/C switch.
LISTEN: Does air conditioner compressor clutch solenoid “click”? (Air conditioner and heater are ON in
manual mode.)
Press OFF switch.
LOOK: Are air conditioner and heater OFF? (Push AUTO to start A/C and heater).
419
Result:
YES:
Check complete.
NO:
Heater fan does not blow air. Check air conditioner and heater 20 A fuse (F3) (Marked HEATER). See Fuse
and Relay Specifications . (Group 9015-10.)
NO:
Check system operation. See Heater and Air Conditioner Operational Checks . (Group 9031-25.)
NO:
JD29379,000003D-19-20121119
420
Table of Contents
Section 9010: Engine

Group 25: Tests
421
TX1015728-UN: Fuel System Component Location—Left Side of Engine

LEGEND:
1 - High Pressure Fuel Pump
2 - High Pressure Fuel Pump-to-Fuel Cooler Return Line
3 - Secondary Fuel Filter-to-High Pressure Fuel Pump Supply Line
4 - High Pressure Common Rail
5 - Fuel Cooler
6 - Fuel Cooler-to-Fuel Tank Return Line
8 - Secondary Fuel Filter
9 - Primary Fuel Filter
10 - Fuel Transfer Pump-to-Secondary Fuel Filter Supply Line
12 - Primary Fuel Filter-to-Fuel Transfer Pump Supply Line
13 - Fuel Tank-to-Primary Fuel Filter Supply Line
14 - Fuel Tank
15 - Fuel Transfer Pump
16 - Fuel Injection Nozzle
17 - High Pressure Fuel Line
422
TX1015727-UN: Fuel System Component Location—Right Side of Engine

LEGEND:
5 - Fuel Cooler
14 - Fuel Tank
GD61784,0000083-19-20061127
423
TX1015728-UN: Fuel System Component Location—Left Side of Engine

LEGEND:
5 - Fuel Cooler
14 - Fuel Tank
424
TX1015727-UN: Fuel System Component Location—Right Side of Engine

LEGEND:
5 - Fuel Cooler
14 - Fuel Tank
GD61784,0000083-19-20061127
425
TX1015097-UN: Engine Left Side

LEGEND:
1 - Radiator
2 - Upper Radiator Hose
3 - Coolant Pump
4 - Thermostat Housing
5 - Cylinder Head
6 - Cylinder Block
7 - Lower Radiator Hose
TX1015096-UN: Engine Right Side

LEGEND:
426
2 - Upper Radiator Hose
7 - Lower Radiator Hose
8 - Surge Tank
9 - Radiator Housing
10 - Cooling Fan Shroud
11 - Cooling Fan
12 - Supply Heater Coolant Hose
13 - Return Heater Coolant Hose
LD30992,000052F-19-20061114
427
TX1015170-UN: Cold Weather Starting Aid

IMPORTANT:
Excess starting fluid could damage engine; push ether start aid switch only when engine is cold and cranking.
Starting aid fluid is being injected into engine as long as you push and hold switch.
Start aid switch (S17) is momentary switch that energizes start aid relay (K15). Start aid relay then energizes start
aid solenoid (Y19) to spray starting fluid into engine intake manifold. Releasing start aid switch will stop flow of
starting fluid.
If engine is operated without starting fluid canister, the dust seal must be properly installed to prevent engine
damage.
GD61784,000005D-19-20061214
428
Engine Speed Specifications

Engine Speeds
Slow Idle Speed 750—850 rpm
Fast Idle—HP Mode (arm in over relief) Speed 1950—2050 rpm
Fast Idle—P Mode Speed 1750—1850 rpm
Fast Idle—E Mode (no load) Speed 1600—1700 rpm
Travel HP Speed 1950—2050 rpm
Auto-Idle Speed 1150—1250 rpm
Fast Idle Speed Heater Control Speed 1950—2050 rpm
Auto-Warming Up Control Speed 1300—1500 rpm
Idle Speed-Up Speed 850—950 rpm

LEGEND:
R15 - Engine Speed Dial
S8 - Auto-Idle Switch
S9 - Windshield Wiper and Washer Switch
S10 - Work Light Switch
S11 - Travel Speed Switch
429
S12 - Power Mode Switch
The engine speed is controlled by the following items:

Engine Speed Dial (R15)
Auto-Idle Control (S8)
Power Mode Switch (S12)
HP (high power) Mode
P (standard) Mode
E (economy) Mode
Engine Speed Dial

The purpose of the engine speed dial is to control the engine rpm via operator input.
The main controller (MCF) uses these input signals to determine appropriate engine speed:

Auto-Idle Switch (S8)
Boom Up Pressure Sensor (B30)
Arm In Pressure Sensor (B31)
Swing Pressure Sensor (B33)
Travel Pressure Sensor (B34)
Front Attachment Pressure Sensor (B32)
The MCF then sends a signal via controller area network (CAN) to the engine control module (ECM), and the
ECM then sets engine rpm.
HP (high power) Mode

1950—2050 rpm
The purpose of the HP mode is to increase engine speed while performing certain dig functions.
The MCF sends a signal to the engine control module ECM via CAN communication to raise engine rpm when the
following conditions are met:
Power mode switch is turned to the HP mode position.

Engine speed dial set at fast idle.
Arm in, boom up, or a combination of both functions actuated.
Pump delivery pressure high.
P (standard) Mode
1750—1850 rpm
The function of P mode is to control the engine speed from slow idle to fast idle in response to the position of the
engine speed dial.
E (economy) Mode (no load)

1600—1700 rpm
The purpose of E mode is to lower engine speed to reduce fuel consumption and noise level.
In E mode the engine will run at programmed engine speed. The MCF looks at the hydraulic pump control
pressure and average pump delivery pressure to determine if engine speed must be increased. The engine speed
will increase back to P mode speed only when the control pressure is high and the average pump delivery
pressure is low. The MCF sends a signal to the ECM via CAN communication to reduce engine rpm when the
following conditions are met:
Engine speed is 1650 rpm or higher.

Power mode switch in E mode.
430
Travel HP (high power) Mode Control
1950—2050 rpm
The purpose of Travel HP mode is to increase engine speed for faster travel.
The MCF uses these input signals from the travel right, travel left pressure sensors, and engine speed dial to
determine appropriate engine speed. The MCF then sends a signal via CAN communication to the ECM to
increase engine speed when the following conditions are met:
Engine speed dial set at fast idle.

Travel function is operated.
Auto-Idle Control
1150—1250 rpm
The purpose of auto-idle control is to lower engine speed to reduce fuel consumption and noise levels while
engine is running and no hydraulic function actuated.
The MCF uses these input signals to determine appropriate engine speed:

Auto-Idle Switch (S8)
Travel Left Pressure Sensor (B34)
Auto-idle is activated when the following conditions are met:
Auto-idle switch is on.

No functions activated for approximately 4 seconds.
Engine speed is above 1200 rpm.
Auto-idle control is deactivated when the following conditions are met:
Auto-idle control switch turned to OFF.

A hydraulic function is actuated.
Power mode switch is turned from E to P or P to E.
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-Warming Up Control
1300—1500 rpm
The purpose of Auto-Warming Up Control is to increase engine speed is to warm the hydraulic system faster.
For 12 minutes after the engine starts or when the hydraulic oil is below 0°C (32°F). The MCF then sends a signal
via CAN communication to the ECM to command target engine speed to be higher for warming of the hydraulic
system.
Fast Idle Speed Heater Control

1950—2050 rpm
The purpose of Fast Idle Speed Heater Control is to increase temperature of the engine coolant at a faster rate by
rasing engine speed.
Engine Coolant temperature less than 5°C (41°F).

Pumps 1 and 2 control pressure 0.5 MPa (500 kPa), (5 bar), (73 psi).
431
Idle Speed Up Control
850—950 rpm
The purpose of Idle Speed Up Control is to prevent the engine from hunting when running at slow speed.
When travel or front attachment is operated while the engine is running at a speed between slow idle and idle
speed up. The ECM then commands engine speed to be raised to idle speed up speed.
GD61784,000005B-19-20080626
432
For more information on John Deere engines and components, see the following Component Technical Manuals:
PowerTech Plus 4.5 L and 6.8 L Diesel Engines Base Engine . (CTM104.)
PowerTech Plus 6.8 L Diesel Engines Level 16 Electronic Fuel System With Denso HPCR . (CTM502.)
GD61784,0000059-19-20061130
433
For more information on John Deere engines and components, see the following Component Technical Manuals:
PowerTech Plus 4.5 L and 6.8 L Diesel Engines Base Engine . (CTM104.)
PowerTech Plus 6.8 L Diesel Engines Level 16 Electronic Fuel System With Denso HPCR . (CTM502.)
GD61784,0000059-19-20061130
434
-: Specifications
SPECIFICATIONS
Engine Coolant Temperature (at full load) 94°C

200°F
Hydraulic Oil Temperature 45—55°C

110—130°F
Engine Speed Dial Position Fast Idle
Work Mode Switch Position Dig Mode
Power Mode Switch Position HP (high power)
Auto-Idle Switch Position Off
Top to Bottom of Radiator Temperature Differential (typical at 1950 rpm fan speed) 4.4—6.7°C
8—12°F
-: Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
JT107253 Noncontact Temperature Measuring Gun
JT05800 Digital Thermometer
NOTE:
Test will be more accurate at higher ambient temperatures.
1. Before performing this test, check the following to determine these are not the cause of the overheating:
Correct coolant is in engine and at the proper level.

Radiator and any screens are clean of any dirt or debris.
Fan blades not damaged and fan is installed correctly.
Make sure proportional fan speed solenoid is functioning properly.
All shields, guards, shrouds, baffles, and hoods are in place and properly fastened.
Check all foam baffles and seals. Make sure they are in place and in good condition.
2. NOTE:
Engine must be warmed to specification and readings must be taken when engine is
under full load to allow thermostats to open fully. Allow heat to transfer throughout
engine components.
Warm engine coolant and hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group
9025-25.)
435

200°F
110—130°F
3. Run machine at specifications.

4. Hold arm-in function at relief to keep a full load on engine. Temperature readings must be taken with full
load on engine.
5. NOTE:
Coolant enters radiator through upper radiator hose, travels through the radiator, then
exits radiator through lower radiator hose.
NOTE:
If using JT05800 Digital Thermometer, place electrodes on metal surface of inlet and
outlet of radiator.
TX1014925A-UN: Radiator Top Test Position
436
TX1014926A-UN: Radiator Bottom Test Position

LEGEND:
1 - Top Test Position
2 - Bottom Test Position
Measure the temperature differential between the top and bottom of radiator using JT107253 Noncontact
Temperature Measuring Gun or JT05800 Digital Thermometer. Repeat test three times. See Engine
Cooling System Component Location . (Group 9010-05.)
See JT05800 Digital Thermometer Installation . (Group 9025-25.)
6. Average readings and compare to specification.

Top to Bottom of Radiator Temperature Differential (typical at 1950 rpm fan speed 4.4—6.7°C
8—12°F
7. A higher temperature differential than specification indicates low coolant flow.
A lower temperature differential than specification indicates low air flow.
See 4.5L/6.8L - C1 - Engine Coolant Temperature Above Normal (CTM104) for diagnosing problems.
GD61784,000005A-19-20120809
437
-: Specifications
SPECIFICATIONS

200°F

110—130°F
Top to Bottom of Radiator Temperature Differential (typical at 1950 rpm fan speed) 4.4—6.7°C
8—12°F
JT107253 Noncontact Temperature Measuring Gun
NOTE:
Test will be more accurate at higher ambient temperatures.
1. Before performing this test, check the following to determine these are not the cause of the overheating:
Correct coolant is in engine and at the proper level.

Radiator and any screens are clean of any dirt or debris.
Fan blades not damaged and fan is installed correctly.
Make sure proportional fan speed solenoid is functioning properly.
All shields, guards, shrouds, baffles, and hoods are in place and properly fastened.
Check all foam baffles and seals. Make sure they are in place and in good condition.
2. NOTE:
Engine must be warmed to specification and readings must be taken when engine is
under full load to allow thermostats to open fully. Allow heat to transfer throughout
engine components.
Warm engine coolant and hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group
9025-25.)
438

200°F
110—130°F

4. Hold arm-in function at relief to keep a full load on engine. Temperature readings must be taken with full
load on engine.
5. NOTE:
Coolant enters radiator through upper radiator hose, travels through the radiator, then
exits radiator through lower radiator hose.
NOTE:
If using JT05800 Digital Thermometer, place electrodes on metal surface of inlet and
outlet of radiator.
TX1014925A-UN: Radiator Top Test Position
439
TX1014926A-UN: Radiator Bottom Test Position

LEGEND:
1 - Top Test Position
2 - Bottom Test Position
Measure the temperature differential between the top and bottom of radiator using JT107253 Noncontact
Temperature Measuring Gun or JT05800 Digital Thermometer. Repeat test three times. See Engine
Cooling System Component Location . (Group 9010-05.)
See JT05800 Digital Thermometer Installation . (Group 9025-25.)
6. Average readings and compare to specification.

Top to Bottom of Radiator Temperature Differential (typical at 1950 rpm fan speed 4.4—6.7°C
8—12°F
7. A higher temperature differential than specification indicates low coolant flow.
A lower temperature differential than specification indicates low air flow.
See 4.5L/6.8L - C1 - Engine Coolant Temperature Above Normal (CTM104) for diagnosing problems.
GD61784,000005A-19-20120809
440
-: Specifications
SPECIFICATIONS

200°F

110—130°F
Turbocharger Boost Pressure 90—117 kPa

0.9—1.2 bar
13—17 psi
JT07248 Turbo Boost Test Kit
-: Other Material
242 LOCTITE® Thread Lock and Sealer (medium strength)
NOTE:
This procedure must only be used as a guide to determine engine condition. One technician can
perform this test if the JT07248 Turbo Boost Test Kit is used.
1.
TX1016087A-UN: Turbocharger Boost Pressure

LEGEND:
1 - Pressure Gauge
2 - Hose
3 - Adapter
Remove hose and install barbed fitting.
2. Install hose (2), adapter (3), and pressure gauge (1) from JT07248 Turbo Boost Test Kit.
441
3. Warm engine and hydraulic oil to normal operating temperature. See Hydraulic Oil Warm-Up Procedure
. (Group 9025-25.)

200°F
110—130°F
4. Turn engine rpm dial to fast idle.
5. Turn work mode switch to HP position.

6. NOTE:
Diagnostic display unit for engine throttle percent must be at 100% to obtain accurate
turbo boost pressure reading. Engine throttle will only go to 100% when the work mode
switch is in HP mode and the hydraulic oil is at operating temperature.
Slowly actuate arm in function over relief and hold until engine rpm stabilizes at highest reading. Repeat
this step at least six times.
7. NOTE:
If using the JT07248 Turbo Boost Kit, a check valve at the pressure gauge inlet traps the
highest reading for boost pressure and does not decrease as the pressure decreases.
Record the highest pressure reading.
8. Compare highest reading to specifications.

Turbocharger Boost Pressure 90—117 kPa
0.9—1.2 bar
13—17 psi
9. IMPORTANT:
Pressure gauge accuracy is very critical for this test. Do not make adjustments to injection pump fuel
delivery on the machine to raise or lower boost pressure.
New engine may not develop specified boost pressure. Check after 50 hours of operation.
If turbocharger boost pressure is low, check the following:
Wrong fuel.
Restricted air filter elements. See Air Cleaner Remove and Install . (Group 0520.)
Restricted fuel filter elements. See Final Fuel Filter Remove and Install . (Group 0560.)
Restricted muffler. Remove muffler and repeat test.
Exhaust manifold leaks.
442
Intake manifold leaks.
Faulty fuel pump. See Remove and Install High Pressure Fuel Pump . (CTM502.)
Low compression pressure. See Test Engine Compression Pressure . (CTM104.)
Cam lobe wear (valve clearance). See Check and Adjust Valve Clearance . (CTM104.)
Faulty fuel injectors. See Engine Test Instructions - Cylinder Cutout Test . (CTM502.)
Carbon build up in turbocharger.
Turbocharger compressor or turbine wheel rubbing housing.
10. Remove gauge and fittings.
11. Apply PM37418 Thread Lock and Sealer (medium strength) to plug. Tighten plug.
GD61784,000008A-19-20120828
443
Table of Contents
Section 9015: Electrical System

Group 05: System Information
Group 10: System Diagrams

444
Table of Contents
Group 15: Sub-System Diagnostics

445
Table of Contents
Group 16: Monitor Operation
Group 20: References
Monitor Data Items
Fuse Test
Relay Test
Solenoid Test
Alternator Test
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular

446
Table of Contents
Connectors
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
Replace CINCH CINCH is a trademark of the Cinch Co. Connectors
Install CINCH CINCH is a trademark of the Cinch Co. Contact
Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors
447
NOTE:
All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key
switch in the OFF position.
System Functional Schematic Diagram
TX1077066-UN: System Functional Schematic Example

LEGEND:
448
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
G2 - Battery
K14 - Battery Relay
S1 - Key Switch
W5 - Battery To Frame Ground
W6 - Engine To Frame Ground
The System Functional Schematic is made up of equal sections to simplify searching the schematic. Each section
of the System Functional Schematic is assigned a number (7). The System Functional Schematic is formatted
with power supply wires (2) shown near the top of the drawing and ground wires (5) near the bottom. The
schematic may contain some harness or connector information.
When connector information is shown, it will be displayed as a double chevron (12) with a component
identification number (11) corresponding to the connector identification number. Connector pin information (13)
will be displayed in a text size smaller than that of the connector identification number.
Each electrical component is shown by a schematic symbol (10), the component name (8), and a component
identification number (9). A component identification number and name will remain the same throughout the
Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings
(Schematics, Wiring Diagrams, and Component Location).
Routing location information (3) is presented to let the reader know when a wire is connected to a component in
another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a
different location. The section and component identification number are given in the first line of information and
any pin information for the component is given in parenthesis in the second line. In this example, power is going
TO section 23, component B14 on pin C4.
Wiring Diagram
449
TX1001167-UN: Wiring Diagram Example

LEGEND:
1 - Wire Number
2 - Wire Color
3 - Wire End #1 Termination Location
5 - Wiring Diagram Wire Legend
7 - Connector End View
8 - Wire Number
9 - Connector Pin Number
450
11 - Wire Number
12 - Wire Color
13 - Wire Termination Location
14 - Wire Harness
Each harness on the machine is drawn showing components, connectors, and wires. Harnesses are identified by
a “W” component identification number and description (W6 ENGINE HARNESS, Etc.).
A component or connector identification number (6) identifies each component on the harness. Each harness
branch (14) is terminated by an end view of the connector (7). The connector end view show pin (9) and wire
number (8) information which corresponds to the component or connector wire table.
The wire table displays the component or connector pin number (10), the wire number (11), the wire color (12),
and the location where the wire terminates (13).
A wire legend (5) is provided for each harness. All wires in the harness are listed in the wire legend. The wire
legend contains a wire number (1), End #1 (2), wire color (3), and End #2 (4) information for each wire. The wire
number and color are unique to each harness and may not match other wire numbers and colors on other
harnesses. The component identification numbers or wire numbers listed in the End #1 and End #2 columns
indicate where the wire terminates within the harness.
Wiring Diagram
451
T195714-UN: Wiring Diagram Example

LEGEND:
2 - Connector
4 - Wire Harness
5 - Wire Number
6 - Wire Splice
8 - Wire Number
9 - Wire Color
452
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification
number identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and
branches.
A component identification or connector number (1) identifies each component. The harness branch (4) is
terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness
side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is
supplied to the connector, the wire number (5) is indicated.
An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and
side B wires to differentiate the side of the harness that the wires come from.
A wire legend is provided for each harness. A component identification number is listed in the “END #1” column
(7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9)
are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire.
Component Location Diagram
The Component Location Diagram is a pictorial view by harness showing location of all electrical components,
connectors, harness main ground locations and harness band and clamp location. Each component will be
identified by the same identification letter/number and description used in the System Functional Schematic
Diagram.
Connector End View Diagram
The Connector End View Diagram is a pictorial end view of the component connectors showing the number of
pins in the connector and the wire color and identifier of the wire in every connector. Each component will be
Diagram.
Electrical Schematic Symbols
T143000-UN: Electrical Schematic Symbols

LEGEND:
1 - Battery
2 - Wire Splice
3 - Fuse
4 - Circuit Breaker
5 - Fusible Link
6 - Power Outlet
453
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
454
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
LD30992,0000534-19-20070202
455
NOTE:
All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key
switch in the OFF position.
System Functional Schematic Diagram
TX1077066-UN: System Functional Schematic Example

LEGEND:
456
1 - Continuity Chart
2 - Power Wires
3 - Routing Location Information
4 - Wire Identification
5 - Ground Wires
7 - Section Number
8 - Component Name
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
G2 - Battery
K14 - Battery Relay
S1 - Key Switch
W5 - Battery To Frame Ground
W6 - Engine To Frame Ground
The System Functional Schematic is made up of equal sections to simplify searching the schematic. Each section
of the System Functional Schematic is assigned a number (7). The System Functional Schematic is formatted
with power supply wires (2) shown near the top of the drawing and ground wires (5) near the bottom. The
schematic may contain some harness or connector information.
When connector information is shown, it will be displayed as a double chevron (12) with a component
identification number (11) corresponding to the connector identification number. Connector pin information (13)
will be displayed in a text size smaller than that of the connector identification number.
Each electrical component is shown by a schematic symbol (10), the component name (8), and a component
identification number (9). A component identification number and name will remain the same throughout the
Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings
(Schematics, Wiring Diagrams, and Component Location).
Routing location information (3) is presented to let the reader know when a wire is connected to a component in
another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a
different location. The section and component identification number are given in the first line of information and
any pin information for the component is given in parenthesis in the second line. In this example, power is going
TO section 23, component B14 on pin C4.
Wiring Diagram
457
TX1001167-UN: Wiring Diagram Example

LEGEND:
1 - Wire Number
2 - Wire Color
5 - Wiring Diagram Wire Legend
8 - Wire Number
458
11 - Wire Number
12 - Wire Color
13 - Wire Termination Location
14 - Wire Harness
Each harness on the machine is drawn showing components, connectors, and wires. Harnesses are identified by
a “W” component identification number and description (W6 ENGINE HARNESS, Etc.).
A component or connector identification number (6) identifies each component on the harness. Each harness
branch (14) is terminated by an end view of the connector (7). The connector end view show pin (9) and wire
number (8) information which corresponds to the component or connector wire table.
The wire table displays the component or connector pin number (10), the wire number (11), the wire color (12),
and the location where the wire terminates (13).
A wire legend (5) is provided for each harness. All wires in the harness are listed in the wire legend. The wire
legend contains a wire number (1), End #1 (2), wire color (3), and End #2 (4) information for each wire. The wire
number and color are unique to each harness and may not match other wire numbers and colors on other
harnesses. The component identification numbers or wire numbers listed in the End #1 and End #2 columns
indicate where the wire terminates within the harness.
Wiring Diagram
459
T195714-UN: Wiring Diagram Example

LEGEND:
2 - Connector
4 - Wire Harness
5 - Wire Number
6 - Wire Splice
8 - Wire Number
9 - Wire Color
460
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification
number identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and
branches.
A component identification or connector number (1) identifies each component. The harness branch (4) is
terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness
side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is
supplied to the connector, the wire number (5) is indicated.
An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and
side B wires to differentiate the side of the harness that the wires come from.
A wire legend is provided for each harness. A component identification number is listed in the “END #1” column
(7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9)
are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire.
Component Location Diagram
The Component Location Diagram is a pictorial view by harness showing location of all electrical components,
connectors, harness main ground locations and harness band and clamp location. Each component will be
Diagram.
Connector End View Diagram
The Connector End View Diagram is a pictorial end view of the component connectors showing the number of
pins in the connector and the wire color and identifier of the wire in every connector. Each component will be
Diagram.
Electrical Schematic Symbols
T143000-UN: Electrical Schematic Symbols

LEGEND:
1 - Battery
2 - Wire Splice
3 - Fuse
4 - Circuit Breaker
5 - Fusible Link
6 - Power Outlet
461
7 - Alternator
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
462
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
LD30992,0000534-19-20070202
463
Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on
some connector drawings simply as reference numbers, useful in tracing wires through the harness.
Some wires are solid wire colors. These would be identified by one color name such as RED or BLK or GRN.
Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a
wire identified as RED/WHT would be a primarily RED wire, with a WHT stripe. A wire identified as WHT/RED
would be a primarily WHT wire with a RED stripe.
Following is a listing of wire color abbreviations used on drawings.
BLK—Black
BLU—Blue
BRN—Brown
GRN—Green
GRY—Grey
LTGRN—Light Green
ORG—Orange
PNK—Pink
PUR—Purple
RED—Red
VLT—Violet
WHT—White
YEL—Yellow
Not all wire colors are not available at time of first production. In those cases the wire is identified by a number
only. Wire color will be added as soon as it is available.
LD30992,0000535-19-20060922
464
Electrical harness wires are identified by color, with no number stamped on wire. Wire numbers are used on
some connector drawings simply as reference numbers, useful in tracing wires through the harness.
Some wires are solid wire colors. These would be identified by one color name such as RED or BLK or GRN.
Other wire colors are identified with two color names. These are solid wires with a narrow stripe. For example, a
wire identified as RED/WHT would be a primarily RED wire, with a WHT stripe. A wire identified as WHT/RED
would be a primarily WHT wire with a RED stripe.
Following is a listing of wire color abbreviations used on drawings.
BLK—Black
BLU—Blue
BRN—Brown
GRN—Green
GRY—Grey
LTGRN—Light Green
ORG—Orange
PNK—Pink
PUR—Purple
RED—Red
VLT—Violet
WHT—White
YEL—Yellow
Not all wire colors are not available at time of first production. In those cases the wire is identified by a number
only. Wire color will be added as soon as it is available.
LD30992,0000535-19-20060922
465
TX1001022-UN: Relay and Fuse Block Component Location

LEGEND:
1 - Relay Block
2 - Fuse Block 1
3 - Fuse Block 2
Relay block (1), fuse block 1 (2) and fuse block 2 (3) are located behind the seat.
Fuse Block 1
TX1000782-UN: Fuse Block 1

LEGEND:
466
F1 - Work and Drive Lights 20 A Fuse (marked LAMP)
F2 - Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F3 - Heater and Air Conditioner 20 A Fuse (marked HEATER)
F4 - Solenoid 10 A Fuse (marked SOLENOID)
F5 - Travel Alarm 5 A Fuse (marked OPT. 1 [ALT])
F6 - 12 Volt Power Outlet 10 A Fuse (marked OPT. 2 [ALT])
F7 - Start Aid 20 A Fuse (marked START AID) (not used) (field option)
F8 - Engine Control Unit (ECU) 20 A Fuse (marked ECM)
F9 - Radio Backup 10 A Fuse (marked BACK UP)
F10 - Information Controller and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
F11 - Radio and Dome Light 5 A Fuse (marked RADIO)
F12 - Lighter 10 A Fuse (marked LIGHTER)
F13 - Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX.)
F14 - Not Used
F15 - Heater and Air Conditioner 5 A Fuse (marked AIRCON)
F16 - Controller Key Switch Signal 5 A Fuse (marked POWER ON)
F17 - Horn 10 A Fuse (marked HORN)
F18 - Service Advisor Diagnostic Connector Power 5 A Fuse (marked DIAG)
F19 - Controller 5 A Fuse (marked SW. BOX)
F20 - Optional Equipment 5 A Fuse (marked OPT. 3 [BATT])
Fuse Block 2
TX1000660-UN: Fuse Block 2

LEGEND:
F21 - Air Suspension Seat 10 A Fuse (marked SEAT HEATER)
F22 - Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 - Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 - 12 Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 - IMOBI 5 A Fuse (marked IMOBI)
F26 - Quick Hitch 5 A Fuse (marked QUICK HITCH)
F27 - Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3)
467
F28 - Not Used
F29 - Not Used
F30 - Not Used
F31 - Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 - Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT +2)
F33 - Warning Lamp 10 A Fuse (marked WARNING LAMP)
F35 - Not Used
F36 - Not Used
F37 - Not Used
F38 - Not Used
F39 - Not Used
F40 - Not Used
Additional fuses located under cover behind radiator door:
F40— JDLink™ Unswitched Power 7 A Fuse (if equipped)

F41—JDLink™ Switched Power 3 A Fuse (if equipped)
F42—JDLink™ Run Signal 3 A Fuse (if equipped)
F43—JDLink™ Ground 7.5 A Fuse (if equipped)
F60—Fusible Link 65 A
F61—Fusible Link 45 A
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)
Relay Block
TX1001020-UN: Relay Block

LEGEND:
K1 - Load Dump Relay
K2 - Pilot Shutoff Solenoid Relay
K3 - Security Alarm Relay
468
K4 - Starter Relay
K5 - Security Relay
K6 - Windshield Wiper Relay
K7 - Drive Light Relay
K8 - Boom Work Light Relay
K9 - Windshield Washer Relay
K10 - Horn Relay
K11 - Air Conditioner Compressor Clutch Relay
K12 - Blower Motor (low speed) and Main Power Relay
K13 - Blower Motor (high speed) Relay
K14 - Alternator Relay
Battery Relay (K19) is located under cover behind radiator door.
Additional relays located under the rear cover:
K15—Start Aid Relay (if equipped)

K20—Seat Heater Relay (if equipped)
K30—Right Solenoid Relay A (if equipped)
K31—Right Solenoid Relay B (if equipped)
K32—Left Solenoid Relay A (if equipped)
K33—Left Solenoid Relay B (if equipped)
LD30992,0000536-19-20110720
469
A1—Engine Control Unit (ECU) ( SE10 , SE11 , SE12 , SE13 ) ( W4 )

A3—Main Controller (MCF) ( SE8 , SE9 ) ( W1 )
A4—Monitor Controller ( SE5 , SE6 ) ( W3 )
A5—Information Controller (ICF) ( SE4 ) ( W1 )
A6—Radio ( SE17 ) ( W7 )
A7—Air Conditioner and Heater Controller (ACF) ( SE20 , SE23 ) ( W7 )
A8—12-Volt Power Converter ( SE15 ) ( W1 )
A9—Switch Panel ( SE7 )
A10—Machine Information Gateway (MIG) Controller (if equipped) ( SE26 ) ( W50 )
A11— GlobalTRACS® Terminal (GTT) Controller (if equipped) ( SE26 ) ( W51 )
A6000—Modular Telematics Gateway (MTG) (if equipped) ( SE13 ) ( W6002 )
A6001—GPS and Cellular Antenna (if equipped) ( SE13 ) ( W6002 )
A6002—Satellite (SAT) Module (if equipped)
A6003—Satellite Antenna (if equipped)
B1—Crankshaft Position Sensor ( SE10 ) ( W4 )
B2—Camshaft Position Sensor ( SE10 ) ( W4 )
B4—Engine Coolant Temperature Sensor ( SE11 ) ( W4 )
B5—Fuel Temperature Sensor ( SE11 ) ( W4 )
B7—Intake Air Temperature Sensor ( SE11 ) ( W5 )
B9—Manifold Air Temperature Sensor ( SE11 ) ( W4 )
B11—Engine Oil Pressure Sensor ( SE10 ) ( W4 )
B12—Fuel Rail Pressure Sensor ( SE10 ) ( W4 )
B13—Fuel Transfer Pump Pressure Sensor ( SE10 ) ( W5 )
B16—Air Filter Restriction Switch ( SE6 ) ( W2 )
B17—Water-in-Fuel Sensor ( SE11 ) ( W5 )
B18—Fuel Level Sensor ( SE5 ) ( W2
B20—Air Conditioner High/Low-Pressure Switch ( SE19 , SE22 ) ( W2 )
B21—Solar Sensor ( SE21 , SE24 ) ( W3 )
B22—Ambient Air Temperature Sensor ( SE21 , SE24 ) ( W2 )
B23—High Note Horn ( SE19 ) ( W2 )
B24—Low Note Horn ( SE19 ) ( W2 )
B25—Right Speaker ( SE17 ) ( W1 )
B26—Left Speaker ( SE17 ) ( W1 )
B27—Hydraulic Oil Filter Restriction Switch (if equipped) ( SE5 ) ( W2 )
B30—Boom Up Pressure Sensor ( SE8 ) ( W2 )
B31—Arm In Pressure Sensor ( SE8 ) ( W2 )
B32—Front Attachment Pressure Sensor ( SE8 ) ( W2 )
B33—Swing Pressure Sensor ( SE8 ) ( W2 )
B34—Travel Pressure Sensor ( SE8 ) ( W2 )
B35—Pump 1 Delivery Pressure Sensor ( SE8 ) ( W8 )
B36—Pump 1 Control Pressure Sensor ( SE9 ) ( W8 )
B37—Pump 2 Delivery Pressure Sensor ( SE9 ) ( W8 )
B38—Pump 2 Control Pressure Sensor ( SE9 ) ( W8 )
B40—Hydraulic Oil Temperature Sensor ( SE9 ) ( W2 )
B41—Air Conditioner Freeze Control Switch ( SE19 ) ( W7 )
B42—Cab Air Temperature Sensor ( SE21 , SE24 ) ( W7 )
B43—Coolant Temperature Sensor ( SE21 , SE24 ) ( W7 )
B45—Attachment Pressure Sensor ( SE9 ) ( W20 )
B46—Arm Out Pressure Sensor ( SE9 ) ( W21 )
B47—Air Conditioner Freeze Control Sensor ( SE24 ) ( W7 )
B80—Seat Temperature Switch 1 ( SE18 )
B81—Seat Temperature Switch 2 ( SE18 )
E1—Drive Light ( SE14 ) ( W2 )
E2—Boom Work Light ( SE15 ) ( W2 )
470
E3—Cab Dome Light ( SE17 ) ( W1 )
E5—Switch Panel Back Light ( SE7 )
F1—Work and Drive Lights 20 A Fuse (marked LAMP) ( SE14 ) ( W1 )
F2—Windshield Wiper and Washer 10 A Fuse (marked WIPER) ( SE14 ) ( W1 )
F3—Heater and Air Conditioner 20 A Fuse (marked HEATER) ( SE19 , SE22 ) ( W1 )
F4—Solenoid 10 A Fuse (marked SOLENOID) ( SE8 ) ( W1 )
F5—Travel Alarm 5 A Fuse (marked OPT. 1 [ALT]) ( SE10 ) ( W1 )
F6—12-Volt Power Outlet 10 A Fuse (marked OPT. 2 [ALT]) ( SE15 ) ( W1 )
F7—Start Aid 20 A Fuse (marked START AID) (not used) (field option) ( SE1 ) ( W1 )
F8—Engine Control Unit (ECU) 20 A Fuse (marked ECM) ( SE12 ) ( W1 )
F9—Radio Backup 10 A Fuse (marked BACK UP) ( SE6 ) ( W1 )
F10—Information Controller and Main Controller Battery Power 5 A Fuse (marked CONTROLLER) (
SE4 ) ( W1 )
F11—Radio and Dome Light 5 A Fuse (marked RADIO) ( SE17 ) ( W1 )
F12—Lighter 10 A Fuse (marked LIGHTER) ( SE19 ) ( W1 )
F13—Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX.) ( SE17 ) ( W1 )
F14—Not Used
F15—Heater and Air Conditioner 5 A Fuse (marked AIRCON) ( SE19 , SE22 ) ( W1 )
F16—Controller Key Switch Signal 5 A Fuse (marked POWER ON) ( SE3 ) ( W1 )
F17—Horn 10 A Fuse (marked HORN) ( SE19 ) ( W1 )
F18— Service ADVISOR™ Diagnostic Connector Power 5 A Fuse (marked DIAG) ( SE13 ) ( W1 )
F19—Controller 5 A Fuse (marked SW. BOX) ( SE5 ) ( W1 )
F20—Optional Equipment 5 A Fuse (marked OPT. 3 [BATT]) ( SE15 ) ( W1 )
F21—Air Suspension Seat 10 A Fuse (marked SEAT HEATER) ( SE18 ) ( W9 )
F22—Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT) ( SE18 ) ( W9 )
F23—Rear Cab Light 10 A Fuse (marked CAB LAMP REAR) ( SE17 ) ( W9 )
F24—12-Volt Power Unit 10 A Fuse (marked 12V UNIT) ( SE17 ) ( W9 )
F25—IMOBI 5 A Fuse (marked IMOBI) ( SE17 ) ( W9 )
F26—Quick Hitch 5 A Fuse (marked QUICK HITCH) ( SE17 ) ( W9 )
F27—Cab Auxiliary Power Connector 3 5 A Fuse (marked AUX. 3) ( W9 )
F31—Seat Compressor 10 A Fuse (marked SEAT COMPR) ( SE18 ) ( W9 )
F32—Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT+2) ( SE18 ) ( W9 )
F33—Warning Lamp 10 A Fuse (marked WARNING LAMP) ( SE18 ) ( W9 )
F34—Cab Auxiliary Power Connector 2 10 A Fuse (marked AUX. 2) ( SE18 ) ( W9 )
F40—JDLink™ Unswitched Power 7 Amp Fuse (if equipped) ( SE25 ) ( W53 )
F41—JDLink™ Switched Power 3 Amp Fuse (if equipped) ( SE25 ) ( W53 )
F42—JDLink™ Alternator Run Signal 3 Amp Fuse (if equipped) ( SE25 ) ( W53 )
F43—JDLink™ Ground 7.5 Amp Fuse (if equipped) ( SE25 ) ( W53 )
F6000— JDLink™ Unswitched Power 7.5 A Fuse (if equipped) ( SE13 ) ( W6002 )
F6001—JDLink™ Ground 7.5 A Fuse (if equipped) ( SE13 ) ( W6002 )
F6002—JDLink™ Switched Power 7.5 A Fuse (if equipped) ( SE13 ) ( W6002 )
F45—Starter In-Line 30 A Fuse ( SE2 ) ( W27 )
F60—Fusible Link 65 A ( SE1 ) ( W2 )
F61—Fusible Link 45 A ( SE1 ) ( W2 )
F62—Wiper Motor Assembly Circuit Breaker ( SE13 )
G1—Battery ( SE1 )
G2—Battery ( SE1 )
G3—Alternator ( SE3 ) ( W2 )
G5—12-Volt Power Outlet ( SE15 ) ( W1 )
H2—Security Alarm ( SE6 ) ( W1 )
H3—Monitor Warning Alarm ( SE5 ) ( W1 )
H4—Travel Alarm ( SE10 ) ( W2
K1—Load Dump Relay ( SE3 ) ( W1 )
K2—Pilot Shutoff Solenoid Relay ( SE2 ) ( W1
K3—Security Alarm Relay ( SE6 ) ( W1 )
K4—Starter Relay (S.N. —511090) ( SE1 ) ( W1 )
471
K4—Starter Cut Relay (S.N. 511091— ) ( SE2 ) ( W1 )
K5—Security Relay ( SE2 ) ( W1 )
K6—Windshield Wiper Relay ( SE14 ) ( W1 )
K7—Drive Light Relay ( SE14 ) ( W1 )
K8—Boom Work Light Relay ( SE15 ) ( W1 )
K9—Windshield Washer Relay ( SE14 ) ( W1 )
K10—Horn Relay ( SE19 ) ( W1 )
K11—Air Conditioner Compressor Clutch Relay ( SE19 , SE22 ) ( W1 )
K12—Blower Motor (low speed) and Main Power Relay ( SE20 , SE23 ) ( W1 )
K13—Blower Motor (high speed) Relay ( SE20 , SE23 ) ( W1 )
K14—Alternator Relay ( SE3 ) ( W1 )
K15—Start Aid Relay ( SE1 ) ( W1 )
K19—Battery Relay ( SE1 ) ( W2 )
K20—Seat Heater Relay ( SE18 ) ( W12 )
K30—Right Solenoid Relay B ( SE16 ) ( W14 )
K31—Right Solenoid Relay A ( SE16 ) ( W14 )
K32—Left Solenoid Relay B ( SE16 ) ( W14 )
K33—Left Solenoid Relay A ( SE16 ) ( W14 )
K34—Starter Relay (S.N. 511091— )( SE2 ) ( W27 )
K35—Starter Protection Relay (S.N. 511091— )( SE2 ) ( W2 )
M1—Starter Motor (S.N. —511090) ( SE1 ) ( W2 )
M1—Starter Motor (S.N. 511091— ) ( SE2 ) ( W2 )
M5—Windshield Wiper Motor ( SE14 ) ( W1 )
M6—Windshield Washer Motor ( SE14 ) ( W2 )
M7—Air Conditioner and Heater Blower Motor ( SE20 , SE23 ) ( W7 )
M9—Air Conditioner and Heater Internal and External Servomotor ( SE21 , SE24 ) ( W7 )
M10—Air Conditioner and Heater Blower Port Change Servomotor ( SE21 , SE24 ) ( W7 )
M11—Air Conditioner and Heater Mixer Servomotor ( SE21 , SE24 ) ( W7 )
M12—Seat Air Compressor Motor ( SE18 ) ( W12 )
R9—Lighter ( SE19 ) ( W1 )
R10—CAN Termination Resistor 1 ( SE13 ) ( W4 )
R12—JDLink™ CAN Termination Resistor 3-Pin Connector (if equipped) ( SE25 ) ( W52 )
R15—Engine Speed Dial ( SE7 ) ( W1 )
R16—Blower Motor Resistor and Thermofuse ( SE20 , SE23 ) ( W7 )
R17—Blower Motor Resistor (low speed) ( SE20 , SE23 ) ( W7 )
R18—Seat Heater ( SE18 ) ( W12 )
S1—Key Switch ( SE1 ) ( W7 )
S2—Cab Dome Light Switch ( SE17 ) ( W1 )
S3—Pilot Shutoff Switch 1 ( SE3 ) ( W11 )
S4—Pilot Shutoff Switch 2 ( SE3 ) ( W11 )
S5—Horn Switch ( SE19 ) ( W1 )
S7—Power Dig Switch ( SE9 ) ( W7 )
S8—Auto-Idle Switch ( SE7 ) ( W1 )
S9—Windshield Wiper and Washer Switch ( SE7 ) ( W1 )
S10—Work Light Switch ( SE7 ) ( W1 )
S11—Travel Speed Switch ( SE7 ) ( W1 )
S12—Power Mode Switch ( SE7 ) ( W1 )
S13—Travel Alarm Cancel Switch ( SE10 ) ( W15 )
S15—Fan Reversing Switch ( SE12 ) ( W16 )
S17—Start Aid Switch ( SE1 )
S23—Seat Heater Switch ( SE18 ) ( W13 )
S24—Seat Compressor Switch ( SE18 ) ( W13 )
S30—Right Pilot Control Lever Switch B ( SE16 ) ( W14 )
S31—Right Pilot Control Lever Switch A ( SE16 ) ( W14 )
S32—Left Pilot Control Lever Switch B ( SE16 ) ( W14 )
S33—Left Pilot Control Lever Switch A ( SE16 ) ( W14 )
472
S34—Right Enable Switch ( SE16 ) ( W14 )
S35—Left Enable Switch ( SE16 ) ( W14 )
S40—Hydraulic Oil Temperature Switch (if equipped) ( SE5 ) ( W2 )
V1—Battery Relay Diode ( SE1 ) ( W1 )
V2—Alternator Excitation Diode ( SE3 ) ( W1 )
V3—Load Dump Relay Diode ( SE3 ) ( W1 )
V4—Security Relay Diode ( SE2 ) ( W1 )
V5—Starter Relay Diode ( SE3 ) ( W1 )
V6—Auxiliary Power Connector Diode ( SE16 ) ( W1 )
V7—Start Aid Diode( W1 )
V8—Pilot Shutoff Diode ( SE3 ) ( W11 )
V30—Right Solenoid Diode B ( SE16 ) ( W61 )
V31—Right Solenoid Diode A ( SE16 ) ( W61 )
V32—Left Solenoid Diode B ( SE16 ) ( W61 )
V33—Left Solenoid Diode A ( SE16 ) ( W61 )
V40—Selector Valve Solenoid Valve Diode ( SE9 ) ( W20 )
V41—Secondary Relief Solenoid Valve Diode ( SE9 ) ( W20 )
V42—Accumulator Solenoid Valve Diode ( SE9 ) ( W20 )
V43—2-Speed Activation Solenoid Valve Diode ( SE9 ) ( W21 )
V44—Starter Relay Diode (S.N. 511091— )( SE2 ) ( W27 )
W1—Cab Harness ( W1 )
W2—Machine Harness ( W2 )
W3—Monitor Harness ( W3 )
W4—Engine Harness ( W4 )
W5—Engine Interface Harness ( W5 )
W7—Right Console Harness ( W7 )
W8—Pump Harness ( W8 )
W9—Auxiliary Fuse Box Harness ( W9 )
W11—Pilot Shutoff Switch Harness ( W11 )
W12—Air Suspension Seat Harness ( W12 )
W13—Seat Heater Switch Harness ( W13 )
W14—Multi-Function Pilot Control Lever Harness ( W14 )
W15—Travel Alarm Cancel Switch Harness ( W15 )
W16—Fan Reversing Switch Harness ( W16 )
W17—Pilot Shutoff Valve Harness ( W17 )
W20—Attachment Harness ( W20 )
W21—2-Speed Harness ( W21 )
W22—Alternator Harness ( W22 )
W23—Start Aid Switch Harness ( W23 )
W27—Starter Harness ( W27 )
W29—Radio Antenna ( SE17 )
W30—Engine Harness Ground ( SE12 ) ( W4 )
W34—Air Conditioner Harness Ground ( W7 )
W35—Cab Harness Ground 1 ( W1 )
W36—Cab Harness Ground 2 ( SE4 ) ( W1 )
W37—Cab Harness Ground 3 ( SE1 ) ( W1 )
W38—Cab Harness Ground 4 ( SE10 , SE17 ) ( W1 )
W40—Alternator Ground ( SE3 ) ( W2 )
W41—Battery-to-Frame Ground ( SE13 ) ( W52 )
W50—Machine Information Gateway (MIG) Harness (if equipped) ( W50 )
W51—GlobalTRACS® Terminal (GTT) Harness (if equipped) ( W51 )
W52—JDLink™ CAN Harness (if equipped) ( W52 )
W53—JDLink™ Power Harness (if equipped) ( W53 )
W54—JDLink™ Jumper Harness (if equipped) ( W54 )
W55—GlobalTRACS® Terminal (GTT) Controller Ground (if equipped) ( SE26 ) ( W51 ), ( W53 )
W56—JDLink™ Power Harness Ground (if equipped) ( SE25 ) ( W53 )
473
W57—GlobalTRACS® Terminal (GTT) Antenna (if equipped) ( SE26 ) ( W51 )
W61—Auxiliary Solenoid Harness ( W61 )
W6002—Modular Telematics Gateway (MTG) Harness (if equipped) ( W6002 )
X1—Service ADVISOR™ Diagnostic Connector ( SE13 ) ( W2 )
X2—Dr. ZX 6-Pin Connector ( SE4 ) ( W1 )
X3—Cab Harness-to-Machine Harness 52-Pin Connector ( W1 ), ( W2 )
X4—Cab Harness-to-Machine Harness 32-Pin Connector ( W1 ), ( W2 )
X5—Engine Harness-to-Engine Interface Harness 8-Pin Connector A (black) ( W4 ), ( W5 )
X6—Engine Harness-to-Engine Interface Harness 8-Pin Connector B (gray) ( W4 ), ( W5 )
X7—Engine Interface Harness-to-Machine Harness 8-Pin Connector ( W2 ), ( W5 )
X8—Engine Interface Harness-to-Machine Harness 1-Pin Connector ( W2 ), ( W5 )
X11—Cab Harness-to-Pilot Shutoff Solenoid Valve Harness Connector ( W1 ), ( W17 )
X12—Cab Harness-to-Fan Reversing Switch Harness Connector ( W1 ), ( W16 )
X14—Engine Control Unit (ECU)-to-Engine Harness Connector 1 (J1) ( W4 )
X15—Engine Control Unit (ECU)-to-Engine Interface Harness Connector 2 (J2) ( W4 )
X17—Engine Harness-to-Injector Harness Connector ( W4 )
X18—Cab Harness-to-Monitor Harness 4-Pin Connector (not used) ( W3 )
X19—Monitor 16-Pin Connector A ( W3 )
X20—Monitor 20-Pin Connector B ( W3 )
X21—Monitor 12-Pin Connector C ( W3 )
X22—Cab Harness-to-Monitor Harness Connector A (white) ( W1 ), ( W3 )
X23—Cab Harness-to-Monitor Harness Connector B (black) ( W1 ), ( W3 )
X24—Cab Harness-to-Monitor Harness Connector C (brown) ( W1 ), ( W3 )
X25—Cab Harness Auxiliary Power Connector 1 ( SE17 ) ( W1 )
X26—Optional Connector ( SE15 ) ( W1 ), ( W14 )
X27—Cab Harness-to-Switch Panel Connector ( SE7 ) ( W1 )
X28—Cab Harness-to-Main Controller 32-Pin Connector A ( W1 )
X29—Cab Harness-to-Main Controller 25-Pin Connector B ( W1 )
X30—Cab Harness-to-Main Controller 31-Pin Connector C ( W1 )
X31—Cab Harness-to-Main Controller 16-Pin Connector D ( W1 )
X32—Cab Harness-to-Information Controller 31-Pin Connector A ( W1 )
X34—Cab Harness-to-Information Controller 17-Pin Connector C ( W1 )
X36—Machine Information Center 20-Pin Connector (not used) ( SE4 ) ( W1 )
X37—Machine Information Center 16-Pin Connector (not used) ( SE4 ) ( W1 )
X38—Cab Harness-to-Right Console Harness 16-Pin Connector ( SE19 , SE20 , SE21 , SE22 , SE23 ,
SE24 ) ( W1 ), ( W7 )
X39—Cab Harness-to-Right Console Harness 4-Pin Connector ( SE20 , SE23 ) ( W1 ), ( W7 )
X40—Pump Harness-to-Machine Harness Connector ( W2 ), ( W8 )
X41—Cab Harness-to-Machine Harness 2-Pin Connector 1 ( W1 ), ( W2 )
X42—Cab Harness-to-Machine Harness 2-Pin Connector 2 ( W1 ), ( W2 )
X43—Auxiliary Fuse Box Connector ( W1 ), ( W9 )
X44—Optional Light Connector ( SE18 ) ( W1 ), ( W9 )
X45—Option 2 12-Pin Connector (not used) ( W1 )
X46—Attachment Connector (not used) ( W2 ), ( W20 )
X47—Cab Harness-to-Right Console Harness 6-Pin Connector ( W1 ), ( W7 )
X48—Right Console Harness-to-Air Conditioner and Heater Controller 20-Pin Connector (ACF) ( SE20 ,
SE23 ) ( W7 )
X49—Right Console Harness-to-Air Conditioner and Heater Controller 16-Pin Connector (ACF) ( SE20 ,
SE23 ) ( W7 )
X50—Cab Harness-to-Travel Alarm Cancel Switch ( W1 ), ( W15 )
X51—Cab Harness 3-Pin Connector (not used)
X52—Monitor Harness Connector (not used) ( W3 )
X60—Air Suspension Seat Harness-to-Auxiliary Fuse Box Harness 3-Pin Connector ( SE18 ) ( W9 ), (
W12 )
X61—Rear Cab Light Connector ( SE17 ) ( W9 )
X62—12-Volt Power Unit Connector ( SE17 ) ( W9 )
474
X63—IMOBI Connector ( SE17 ) ( W9 )
X64—Quick Hitch Connector ( SE17 ) ( W9 )
X65—Cab Auxiliary Power Connector 3 ( SE17 ) ( W9 )
X66—Front Cab Light 2 Connector ( SE18 ) ( W9 )
X67—Warning Lamp Connector ( SE18 ) ( W9 )
X68—Cab Auxiliary Power Connector 2 ( SE18 ) ( W9 )
X69—Front Cab Light 1 Connector ( SE18 ) ( W9 )
X70—Cab Harness-to-Start Aid Switch Harness Connector ( W1 )
X72—Cab Harness-to-Pilot Shutoff Switch Harness Connector ( W1 ), ( W11 )
X76—Air Suspension Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector ( W12 ), ( W13 )
X79—Machine Harness Auxiliary Power Connector ( W2 )
X80—Machine Harness-to-Start Aid Solenoid Connector ( W2 )
X87—Attachment Harness-to-2-Speed Harness Connector ( W20 ), ( W21 )
X90—Machine Harness-to-Hydraulic Oil Temperature Switch Connector ( SE5 ) ( W2 )
X100—Cab Ground Splice Connector ( W1 )
X101—Machine Harness Splice Connector ( W2 )
X102—Pump Harness Splice Connector ( W8 )
X103 —SHLD BLK Splice ( W4 )
X104—G01 BLK Splice ( W4 )
X105—P01 RED Splice ( W4 )
X111—R99 BLK Splice ( W4 )
X116—M12 YEL Splice ( W4 )
X117—M13 LT GRN Splice ( W4 )
X127—Machine Harness-to-Starter Harness Connector ( W2 ), ( W27 )
X128—Engine Harness-to-Starter Harness Connector ( W4 ), ( W27 )
X135—Pilot Shutoff Harness Splice 1 ( W11 )
X138—Machine Harness-to-Alternator Harness Connector ( W2 ), ( W22 )
X140—Machine Information Gateway (MIG) Harness-to-JDLink™ Power Harness 4-Pin Connector (if
equipped) ( SE25 ) ( W50 )
X141—Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 10-
Pin Connector (if equipped) ( SE26 ) ( W50 ), ( W51 )
X142—Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 4-Pin
Connector (if equipped) ( SE25 ) ( W50 ), ( W51 )
X143—Machine Information Gateway (MIG) Harness-to-JDLink™ CAN Harness 8-Pin Connector (if
equipped) ( SE25 ) ( W50 )
X144—Machine Information Gateway (MIG) 30-Pin (L1-Y3) Connector (if equipped) ( SE26 ) ( W50 )
X145—Machine Information Gateway (MIG) 30-Pin (A1-K3) Connector (if equipped) ( SE26 ) ( W50 )
X146—Machine Information Gateway (MIG) Ethernet Diagnostic 4-Pin Connector (if equipped) ( SE25 )
( W50 )
X147—2-Pin Connector (not used) (if equipped) ( SE26 ) ( W50 )
X148—GlobalTRACS® Terminal (GTT) 70-Pin Connector (if equipped) ( SE26 ) ( W51 )
X149—JDLink™ Jumper Harness-to-JDLink™ Power Harness Connector (if equipped) ( W54 )
X150— GT Config Tool Adapter 6-Pin Connector (if equipped) ( SE25 ) ( W51 )
X151—JDLink™ Jumper Harness-to-Alternator Connector (if equipped) ( W54 )
X152—JDLink™ Jumper Harness-to-Machine Harness Connector (if equipped) ( W54 )
X160—GlobalTRACS® Terminal (GTT) Shield Splice ( W51 )
X161—Machine Harness-to-JDLink™ CAN Harness 3-Pin Connector (if equipped) ( SE25 ) ( W52 )
X164—M16 PUR Splice ( W54 )
X165—M09 YEL Splice ( W52 )
475
X166—M10 GRN Splice ( W52 )
X199—Machine Harness-to-Engine Interface Harness 1-Pin Connector ( W2 ) ( W5 ) (S.N. XXXXXX— )
X200—Engine Harness-to-Engine Interface Harness 1-Pin Connector ( W4 ) ( W5 ) (S.N. XXXXXX— )
X316—E03 WHT Splice ( W27 )
X534—Right Auxiliary Solenoid Connector (marked SR/H) ( SE16 ) ( W14 ), ( W61 )
X535—Left Auxiliary Solenoid Connector (marked SL/H) ( SE16 ) ( W14 ), ( W61 )
X5000—Splice G01 BLK ( W6002 )
X5001—Splice M12 YEL ( W6002 )
X5002—Splice M13 LT GRN ( W6002 )
X5003—Splice P01 RED ( W6002 )
X6001—GPS Antenna RED Connector
X6002—Cellular Antenna BLK Connector
X6005—Satellite Antenna Connector
X6007—Modular Telematics Gateway (MTG) Frame Ground Connector ( W6002 )
X6008—JDLink™ Switched Power Connector ( W6002 )
X6011—JDLink™ Ground Connector ( W6002 )
X6012—JDLink™ Unswitched Power Connector ( W6002 )
X6014—Modular Telematics Gateway (MTG) Connector ( W6002 )
X6015—Satellite (SAT) Module Connector ( W6002 )
X6016—JDLink™ Modular Telematics Gateway (MTG) Harness-to-Satellite Harness 6-Pin Connector (
W6002 )
Y1—Electronic Injector #1 ( SE11 )
Y7—Fuel Pump Control Valve Solenoid ( SE10 ) ( W4 )
Y8—Proportional Fan Speed Solenoid ( SE12 ) ( W5 )
Y9—Fan Reversing Solenoid ( SE12 ) ( W5 )
Y10—Pilot Shutoff Solenoid ( SE2 ) ( W17 )
Y11—Air Conditioner Compressor Clutch ( SE19 , SE22 ) ( W2 )
Y19—Start Aid Solenoid ( SE1 )
Y20—Pump 2 Flow Rate Limit Solenoid (SB) ( SE8 ) ( W8 )
Y21—Torque Control Solenoid (ST) ( SE8 ) ( W8 )
Y22—Dig Regenerative Solenoid (SF) ( SE8 ) ( W2 )
Y23—Arm Regenerative Solenoid (SC) ( SE8 ) ( W2 )
Y24—Power Dig Solenoid (SG) ( SE9 ) ( W2 )
Y25—Travel Speed Solenoid (SI) ( SE9 ) ( W2 )
Y34—Right Solenoid ( SE16 ) ( W61 )
Y35—Left Solenoid ( SE16 ) ( W61 )
Y40—Selector Valve Solenoid Valve ( SE9 ) ( W20 )
Y41—Secondary Relief Solenoid Valve ( SE9 ) ( W20 )
Y42—Accumulator Solenoid Valve ( SE9 ) ( W20 )
Y43—2-Speed Activation Solenoid Valve ( SE9 ) ( W21 )
Y44—Flow Rate Adjustment Solenoid Valve (not used) ( SE9 ) ( W21 )
LD30992,0000537-19-20170223
476
TX1234593-UN: System Functional Schematic (SE1—SE3) (1 of 9)

LEGEND:
F7 - Start Aid 20 A Fuse (marked START AID) (not used, field option)
F16 - Controller Key Switch Signal 5 A Fuse (marked POWER ON)
F45 - Starter In-Line 30 A Fuse
F60 - Fusible Link 65A
G1 - Battery
G2 - Battery
G3 - Alternator
K4 - Starter Relay (S.N. —511090)
K4 - Starter Cut Relay (S.N. 511091—)
K5 - Security Relay
K15 - Start Aid Relay
K19 - Battery Relay
K34 - Starter Relay (S.N. 511091—)
K35 - Starter Protection Relay (S.N. 511091—511868)
K35 - Starter Protection Relay (S.N. 511869—)
M1 - Starter Motor (S.N. —511090)
M1 - Starter Motor (S.N. 511091—)
S1 - Key Switch
S3 - Pilot Shutoff Switch 1
S17 - Start Aid Switch
V1 - Battery Relay Diode
V2 - Alternator Excitation Diode
V3 - Load Dump Relay Diode
V4 - Security Relay Diode
V5 - Starter Relay Diode
V7 - Start Aid Diode
V8 - Pilot Shutoff Diode
477
V44 - Starter Relay Diode (S.N. 511091—)
W37 - Cab Harness Ground 3
W40 - Alternator Ground
Y10 - Pilot Shutoff Solenoid
Y19 - Start Aid Solenoid

LEGEND:
A4 - Monitor Controller
A5 - Information Controller (ICF)
B16 - Air Filter Restriction Switch
B18 - Fuel Level Sensor
B27 - Hydraulic Oil Filter Restriction Switch (if equipped)
F9 - Radio Backup 10 A Fuse (marked BACK UP)
F10 - Information Controller and Main Controller Battery Power 5 A Fuse (marked CONTROLLER)
H2 - Security Alarm
H3 - Monitor Warning Alarm
S40 - Hydraulic Oil Temperature Switch (if equipped)
X2 - Dr. ZX 6-Pin Connector
X3 - Cab Harness-to-Machine Harness 52-Pin Connector
X24 - Cab Harness-to-Monitor Harness Connector C (brown)
X36 - Machine Information Center 20-Pin Connector (not used)
X90 - Machine Harness-to-Hydraulic Oil Temperature Switch Connector
478

LEGEND:
A3 - Main Controller (MCF)
A9 - Switch Panel
B30 - Boom Up Pressure Sensor
B31 - Arm In Pressure Sensor
B32 - Front Attachment Pressure Sensor
B33 - Swing Pressure Sensor
B34 - Travel Pressure Sensor
B35 - Pump 1 Delivery Pressure Sensor
B36 - Pump 1 Control Pressure Sensor
B40 - Hydraulic Oil Temperature Sensor
B45 - Attachment Pressure Sensor
B46 - Arm Out Pressure Sensor
E5 - Switch Panel Back Light
S7 - Power Dig Switch
V40 - Selector Valve Solenoid Valve Diode
V41 - Secondary Relief Solenoid Valve Diode
V42 - Accumulator Solenoid Valve Diode
V43 - 2-Speed Activation Solenoid Valve Diode
X27 - Cab Harness-to-Switch Panel Connector
Y20 - Pump 2 Flow Rate Limit Solenoid (SB)
Y21 - Torque Control Solenoid (ST)
Y22 - Dig Regenerative Solenoid (SF)
479
Y23 - Arm Regenerative Solenoid (SC)
Y24 - Power Dig Solenoid (SG)
Y25 - Travel Speed Solenoid (SI)
Y40 - Selector Valve Solenoid Valve
Y41 - Secondary Relief Solenoid Valve
Y42 - Accumulator Solenoid Valve
Y43 - 2-Speed Activation Solenoid Valve
Y44 - Flow Rate Adjustment Solenoid Valve (not used)

LEGEND:
A1 - Engine Control Unit (ECU)
B1 - Crankshaft Position Sensor
B2 - Camshaft Position Sensor
B4 - Engine Coolant Temperature Sensor
B5 - Fuel Temperature Sensor
B7 - Intake Air Temperature Sensor
B9 - Manifold Air Temperature Sensor
B11 - Engine Oil Pressure Sensor
B12 - Fuel Rail Pressure Sensor
B13 - Fuel Transfer Pump Pressure Sensor
B17 - Water In Fuel Sensor
F5 - Travel Alarm 5 A Fuse (marked OPT. 1 [ALT])
F8 - Engine Control Unit (ECU) 20 A Fuse (marked ECM)
F18 - Service ADVISOR™ Diagnostic Connector Power 5 A Fuse (marked DIAG)
H4 - Travel Alarm
S13 - Travel Alarm Cancel Switch
S15 - Fan Reversing Switch
W30 - Engine Harness Ground
X1 - Service ADVISOR™ Diagnostic Connector
X14 - Engine Control Unit (ECU)-to-Engine Harness Connector 1
X15 - Engine Control Unit (ECU)-to-Engine Harness Connector 2
Y1 - Electronic Injector #1
480
Y7 - Fuel Pump Control Valve Solenoid
Y8 - Proportional Fan Speed Solenoid
Y9 - Fan Reversing Solenoid

LEGEND:
A6000 - Modular Telematics Gateway (MTG)
A6001 - GPS and Cellular Antenna
A8 - 12-Volt Power Converter
E1 - Drive Light
E2 - Boom Work Light
F1 - Work and Drive Lights 20 A Fuse (marked LAMP)
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)
F2 - Windshield Wiper and Washer 10 A Fuse (marked WIPER)
F6 - 12-Volt Power Outlet 10 A Fuse (marked OPT. 2 [ALT])
F20 - Optional Equipment 5 A Fuse (marked (OPT. 3 [BATT])
F62 - Wiper Motor Assembly Circuit Breaker
G5 - 12-Volt Power Outlet
M5 - Windshield Wiper Motor
M6 - Windshield Washer Motor
R10 - CAN Termination Resistor 1
R12 - JDLink™ CAN Termination Resistor 3-Pin Connector
W41 - Battery-to-Frame Ground
481
X26A - Optional Connector
X26B - Optional Connector
X161 - Machine Harness-to-JDLink™ CAN Harness 3-Pin Connector (if equipped)
X6001 - GPS Antenna RED Connector
X6002 - Cellular Antenna BLK Connector
X6014 - Modular Telematics Gateway (MTG) Connector
X6016 - JDLink™ Modular Telematics Gateway (MTG) Harness-to-Satellite Harness 6-Pin Connector

LEGEND:
A6 - Radio
B25 - Right Speaker
B26 - Left Speaker
B80 - Seat Temperature Switch 1
B81 - Seat Temperature Switch 2
E3 - Cab Dome Light
F11 - Radio and Dome Light 5 A Fuse (marked RADIO)
F13 - Cab Auxiliary Power Connector 1 10 A Fuse (marked AUX.)
F21 - Air Suspension Seat 10 A Fuse (marked SEAT HEATER)
F22 - Front Cab Light 1 10 A Fuse (marked CAB LAMP FRONT)
F23 - Rear Cab Light 10 A Fuse (marked CAB LAMP REAR)
F24 - 12-Volt Power Unit 10 A Fuse (marked 12V UNIT)
F25 - IMOBI 5 A Fuse (marked IMOBI)
F26 - Quick Hitch 5 A Fuse (marked QUICK HITCH)
F31 - Seat Compressor 10 A Fuse (marked SEAT COMPR)
F32 - Front Cab Light 2 10 A Fuse (marked CAB LAMP FRONT+2)
F33 - Warning Lamp 10 A Fuse (marked WARNING LAMP)
K20 - Seat Heater Relay
K30 - Right Solenoid Relay B
K31 - Right Solenoid Relay A
K32 - Left Solenoid Relay B
K33 - Left Solenoid Relay A
M12 - Seat Air Compressor Motor
R18 - Seat Heater
482
S2 - Cab Dome Light Switch
S23 - Seat Heater Switch
S24 - Seat Compressor Switch
S30 - Right Pilot Control Lever Switch B
S31 - Right Pilot Control Lever Switch A
S32 - Left Pilot Control Lever Switch B
S33 - Left Pilot Control Lever Switch A
S34 - Right Enable Switch
S35 - Left Enable Switch
V6 - Auxiliary Power Connector Diode
V30 - Right Solenoid Diode B
V31 - Right Solenoid Diode A
V32 - Left Solenoid Diode B
V33 - Left Solenoid Diode A
W29 - Radio Antenna
X25 - Cab Harness Auxiliary Power Connector 1
X44 - Optional Light Connector
X60 - Air Suspension Seat Harness-to-Auxiliary Fuse Box Harness 3-Pin Connector
X61 - Rear Cab Light Connector
X62 - 12-Volt Power Unit Connector
X63 - IMOBI Connector
X64 - Quick Hitch Connector
X65 - Cab Auxiliary Power Connector 3
X66 - Front Cab Light 2 Connector
X67 - Warning Lamp Connector
X534 - Right Auxiliary Solenoid Connector (marked SR/H)
X535 - Left Auxiliary Solenoid Connector (marked SL/H)
Y34 - Right Solenoid (marked SR/H)
Y35 - Left Solenoid (marked SL/H)
TX1233858-UN: System Functional Schematic (early design) (SE19—SE21) (7 of 9)

LEGEND:
A7 - Air Conditioner and Heater Controller (ACF)
483
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
B42 - Cab Air Temperature Sensor
B43 - Coolant Temperature Sensor
F12 - Lighter 10 A Fuse (marked LIGHTER)
F17 - Horn 10 A Fuse (marked HORN)
K10 - Horn Relay
M7 - Air Conditioner and Heater Blower Motor
M9 - Air Conditioner and Heater Internal and External Servomotor
M10 - Air Conditioner and Heater Blower Port Change Servomotor
M11 - Air Conditioner and Heater Mixer Servomotor
R9 - Lighter
R16 - Blower Motor Resistor and Thermofuse
R17 - Blower Motor Resistor (low speed)
S5 - Horn Switch
X38 - Cab Harness-to-Right Console Harness 16-Pin Connector
X48 - Right Console Harness-to-Air Conditioner and Heater Controller (ACF) 20-Pin Connector
Y11 - Air Conditioner Compressor Clutch
TX1233860-UN: System Functional Schematic (late design) (SE22—SE24) (8 of 9)

LEGEND:
B20 - Air Conditioner High/Low-Pressure Switch
B21 - Solar Sensor
484
B47 - Air Conditioner Freeze Control Sensor

LEGEND:
A10 - Machine Information Gateway (MIG) Controller (if equipped)
A11 - GlobalTRACS® Terminal (GTT) Controller (if equipped)
F40 - JDLink™ Unswitched Power 7 A Fuse (if equipped)
F41 - JDLink™ Switched Power 3 A Fuse (if equipped)
F42 - JDLink™ Alternator Run Signal 3 A Fuse (if equipped)
F43 - JDLink™ Ground 7.5 A Fuse (if equipped)
R12 - JDLink™ CAN Termination Resistor (if equipped)
W55 - GlobalTRACS® Terminal (GTT) Controller Ground (if equipped)
W56 - JDLink™ Power Harness Ground (if equipped)
W57 - GlobalTRACS® Terminal (GTT) Antenna (if equipped)
X140 - Machine Information Gateway (MIG) Harness-to-JDLink™ Power Harness 4-Pin Connector (if equipped)
X141 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 10-Pin Connector (if
equipped)
X142 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 4-Pin Connector (if
485
equipped)
X143 - Machine Information Gateway (MIG) Harness-to-JDLink™ CAN Harness 8-Pin Connector (if equipped)
X144 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector (if equipped)
X145 - Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector (if equipped)
X146 - Machine Information Gateway (MIG) Ethernet Diagnostic 4-Pin Connector (if equipped)
X147 - 2-Pin Connector (if equipped, not used)
X148 - GlobalTRACS® Terminal (GTT) 70-Pin Connector (if equipped)
X150 - GlobalTRACS® Configuration Tool Adapter 6-Pin Connector (if equipped)
X161 - Machine Harness-to-JDLink™ CAN Harness 3-Pin Connector (if equipped)
LD30992,0000538-19-20170227
486
TX1076041-UN: Cab Harness (W1) Component Location

LEGEND:
A8 - 12 Volt Power Converter
A9 - Switch Panel
B25 - Right Speaker
B26 - Left Speaker
E3 - Cab Dome Light
F - Auxiliary Fuse Box
G5 - 12 Volt Power Outlet
H2 - Security Alarm
K - Relay Block
R9 - Lighter
S5 - Horn Switch
487
W15 - Travel Alarm Cancel Switch Harness
W16 - Fan Reversing Switch Harness
W17 - Pilot Shutoff Valve Harness
W23 - Start Aid Switch Harness
X11 - Cab Harness-to-Pilot Shutoff Solenoid Valve Harness Connector
X12 - Cab Harness-to-Fan Reversing Switch Harness Connector
X22 - Cab Harness-to-Monitor Harness Connector A (White)
X23 - Cab Harness-to-Monitor Harness Connector B (Black)
X24 - Cab Harness-to-Monitor Harness Connector C (Brown)
X26 - Optional Connector
X28 - Cab Harness-to-Main Controller 32-Pin Connector A
X29 - Cab Harness-to-Main Controller 25-Pin Connector B
X30 - Cab Harness-to-Main Controller 31-Pin Connector C
X31 - Cab Harness-to-Main Controller 16-Pin Connector D
X32 - Cab Harness-to-Information Controller 31-Pin Connector A
X34 - Cab Harness-to-Information Controller 17-Pin Connector C
X36 - Machine Information Center 20-Pin Connector (Not Used)
X41 - Cab Harness-to-Machine Harness 2-Pin Connector 1
X43 - Auxiliary Fuse Box Connector
X45 - Option 2 12-Pin Connector (Not Used)
X50 - Cab Harness-to-Travel Alarm Cancel Switch
X72 - Cab Harness-to-Pilot Shutoff Switch Harness Connector
X100 - Cab Ground Splice Connector
LD30992,0000539-19-20061107
488
(S.N. —512063)
TX1076045-UN: Cab Harness (W1) Wiring Diagram (1 of 3) (S.N. —512063)

LEGEND:
B25 - Right Speaker
B26 - Left Speaker
H2 - Security Alarm
K4 - Starter Relay
K5 - Security Relay
K10 - Horn Relay
489
X22 - Cab Harness-to-Monitor Harness Connector A (white)
X23 - Cab Harness-to-Monitor Harness Connector B (black)

LEGEND:
E3 - Cab Dome Light
R9 - Lighter
S5 - Horn Switch
490
X32 - Cab Harness-to-Machine Information Center 31-Pin Connector A
X34 - Cab Harness-to-Machine Information Center 17-Pin Connector C
X43 - Optional Fuse Connector
X45 - Option 2 12-Pin Connector (not used)
X70 - Cab Harness-to-Start Aid Switch Harness Connector
(S.N 512064— )
TX1076042-UN: Cab Harness (W1) Wiring Diagram (1 of 3) (S.N. 512064— )
491
LEGEND:
B25 - Right Speaker
B26 - Left Speaker
H2 - Security Alarm
K4 - Starter Relay
K5 - Security Relay
K10 - Horn Relay
X22 - Cab Harness-to-Monitor Harness Connector A (white)
X23 - Cab Harness-to-Monitor Harness Connector B (black)
492

LEGEND:
E3 - Cab Dome Light
R9 - Lighter
S5 - Horn Switch
X32 - Cab Harness-to-Machine Information Center 31-Pin Connector A
X45 - Option 2 12-Pin Connector (not used)
LD30992,000053A-19-20130820
493
(S.N. —511090)
TX1137496-UN: Machine Harness (W2) Component Location (S.N. —511090)

LEGEND:
B20 - Air Conditioner High/Low Pressure Switch
B24 - Low Note Horn
E1 - Drive Light
F60 - Fusible Link 65 A
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
M1 - Starter Motor
W22 - Alternator Harness
X1 - Service Advisor Diagnostic Connector
494
X7 - Engine Interface Harness-to-Machine Harness 8-Pin Connector
X40 - Pump Harness-to-Machine Harness Connector
X46 - Attachment Connector (not used)
X79 - Machine Harness Auxiliary Power Connector
X80 - Machine Harness-to-Start Aid Solenoid Connector
X101 - Machine Harness Splice Connector
X138 - Machine Harness-to-Alternator Harness Connector
(S.N. 511091—511846)
TX1137490-UN: Machine Harness (W2) Component Location (S.N. 511091—511846)

LEGEND:
B24 - Low Note Horn
495
E1 - Drive Light
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
X127 - Machine Harness-to-Starter Harness Connector
(S.N. 511847—)
496
TX1137492-UN: Machine Harness (W2) Component Location (S.N. 511847— )

LEGEND:
B24 - Low Note Horn
E1 - Drive Light
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
497

X199 - Machine Harness-to-Engine Interface Harness Connector
LD30992,000053B-19-20130621
498
(S.N. —511090)
TX1139752-UN: Machine Harness (W2) Wiring Diagram (1 of 2) (S.N. —511090)

LEGEND:
TX1138155-UN: Machine Harness (W2) Wiring Diagram (2 of 2) (S.N. —511090)

LEGEND:
499
B24 - Low Note Horn
E1 - Drive Light
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
M1 - Starter
(S.N. 511091—511846)
500
TX1140015-UN: Machine Harness (W2) Wiring Diagram (1 of 2) (S.N. 511091—511846)

LEGEND:
TX1138157-UN: Machine Harness (W2) Wiring Diagram (2 of 2) (S.N. 511091— 511846)

LEGEND:
501
B24 - Low Note Horn
E1 - Drive Light
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
(S.N. 511847—)
502
TX1140023-UN: Machine Harness (W2) Wiring Diagram (1 of 2) (S.N. 511847— )

LEGEND:
TX1138158-UN: Machine Harness (W2) Wiring Diagram (2 of 2) (S.N. 511847— )

LEGEND:
503
B24 - Low Note Horn
E1 - Drive Light
G3 - Alternator
H4 - Travel Alarm
K19 - Battery Relay
LD30992,000053C-19-20140917
504
TX1014379-UN: Monitor Harness (W3) Component Location

LEGEND:
B21 - Solar Sensor
X18 - Cab Harness-to-Monitor Harness 4-Pin Connector (Not Used)
X19 - Monitor 16-Pin Connector A
X20 - Monitor 20-Pin Connector B
X21 - Monitor 12-Pin Connector C
X52 - Monitor Harness Connector (Not Used)
LD30992,000053D-19-20061102
505
(S.N. —511900)
TX1138933-UN: Monitor Harness (W3) Wiring Diagram (S.N. —511900)

LEGEND:
B21 - Solar Sensor
X18 - Cab Harness-to-Monitor Harness 4-Pin Connector
(S.N. 511901—)
506
TX1076051-UN: Monitor Harness (W3) Wiring Diagram (S.N. 511901—)

LEGEND:
B21 - Solar Sensor
W3 - Monitor Harness
X51 - Monitor Harness 4-Pin Connector (Not Used)
LD30992,000053E-19-20130620
507
(S.N. —511090)
TX1076056-UN: Engine Harness (W4) Component Location (right side) (S.N. —511090)
LEGEND:
R10 - CAN Termination Resistor 1 (machines without JDLink™ only)
X5 - Engine Harness-to-Engine Interface Harness 8-Pin Connector A (black)
X6 - Engine Harness-to-Engine Interface Harness 8-Pin Connector B (gray)
X14 - Engine Control Unit (ECU)-to-Engine Harness Connector 1 (J1)
508
X15 - Engine Control Unit (ECU)-to-Engine Interface Harness Connector 2 (J2)
X17 - Engine Harness-to-Injector Harness Connector
TX1015336-UN: Engine Harness (W4) Component Location (left side) (S.N. —511090)
LEGEND:
(S.N. 511091—511791)
509
(S.N. 511091—511791)
TX1076057-UN: Engine Harness (W4) Component Location (right side) (S.N. 511091—511791)
LEGEND:
X128 - Engine Harness-to-Starter Harness Connector
510
TX1015336-UN: Engine Harness (W4) Component Location (left side) (S.N. 511091—511791)
LEGEND:
(S.N. 511792—)
511
TX1076058-UN: Engine Harness (W4) Component Location (right side) (S.N. 511792—)
LEGEND:
512
X200 - Engine Harness-to-Engine Interface Harness Connector
TX1015336-UN: Engine Harness (W4) Component Location (left side) (S.N. 511792—)
LEGEND:
513
MB00333,0000100-19-20121015
514
(S.N. —511090)
TX1076055-UN: Engine Harness (W4) Wiring Diagram (S.N. —511090)

LEGEND:
X103 - SHLD BLK Splice
X104 - G01 BLK Splice
X105 - P01 RED Splice
X111 - R99 BLK Splice
X116 - M12 YEL Splice
X117 - M13 LT GRN Splice
(S.N. 511091—511791)
515
TX1076040-UN: Engine Harness (W4) Wiring Diagram (S.N. 511091—511791)

LEGEND:
(S.N. 511792—511868)
516
TX1076225-UN: Engine Harness (W4) Wiring Diagram (S.N. 511792—511868)

LEGEND:
X200 - Engine Harness-to-Engine Interface Connector
(S.N. 511869—)
517
TX1076226-UN: Engine Harness (W4) Wiring Diagram (S.N. 511869—)

LEGEND:
X200 - Engine Harness-to-Engine Interface Connector
MB00333,0000101-19-20121015
518
(S.N. —511868)
TX1015323-UN: Engine Interface Harness (W5) Component Location (S.N. —511868)

LEGEND:
X5 - Engine Harness-to-Engine Interface Harness 8-Pin Connector A (Black)
X6 - Engine Harness-to-Engine Interface Harness 8-Pin Connector B (Gray)
(S.N. 511869—)
519
TX1076059-UN: Engine Interface Harness (W5) Component Location (S.N. 511869—)

LEGEND:
LD30992,000020F-19-20100513
520
(S.N. —511868)
TX1076053-UN: Engine Interface Harness (W5) Wiring Diagram (S.N. —511868)

LEGEND:
521
(S.N. 511869—)
TX1076054-UN: Engine Interface Harness (W5) Wiring Diagram (S.N. 511869—)

LEGEND:
522
LD30992,0000210-19-20100513
523
Early Design
TX1234001-UN: Right Console Harness (W7) Component Location (early design)

LEGEND:
A6 - Radio
S1 - Key Switch
524
Late Design
TX1234002-UN: Right Console Harness (W7) Component Location (late design)

LEGEND:
A6 - Radio
525
S1 - Key Switch
TX17984,000014E-19-20170220
526
Early Design
TX1225736-UN: Right Console Harness (W7) Wiring Diagram (early design)

LEGEND:
A6 - Radio
S1 - Key Switch
Late Design
527
TX1226173-UN: Right Console Harness (W7) Wiring Diagram (late design)

LEGEND:
A6 - Radio
S1 - Key Switch
TX17984,000014F-19-20170220
528
TX1014375-UN: Pump Harness (W8) Component Location

LEGEND:
X102 - Pump Harness Splice Connector
LD30992,0000543-19-20061031
529
TX1076052-UN: Pump Harness (W8) Wiring Diagram

LEGEND:
X102 - Pump Harness Splice Connector
LD30992,0000544-19-20061005
530
TX1014454-UN: Auxiliary Fuse Box Harness (W9) Component Location

LEGEND:
X43 - Auxiliary Fuse Box Connector
X62 - 12 Volt Power Unit Connector
531
TX17984,0000150-19-20061120
532
TX1137138-UN: Auxiliary Fuse Box Harness (W9) Wiring Diagram

LEGEND:
F21 - Air Suspension Seat 10 A Fuse (Marked SEAT HEATER)
F22 - Front Cab Light 1 10 A Fuse (Marked CAB LAMP FRONT)
F23 - Rear Cab Light 10 A Fuse (Marked CAB LAMP REAR)
F24 - 12 Volt Power Unit 10 A Fuse (Marked 12V UNIT)
F25 - IMOBI 5 A Fuse (Marked IMOBI)
F26 - Quick Hitch 5 A Fuse (Marked QUICK HITCH)
F27 - Cab Auxiliary Power Connector 3 5 A Fuse (Marked AUX. 3)
F31 - Seat Compressor 10 A Fuse (Marked SEAT COMPR)
F32 - Front Cab Light 2 10 A Fuse (Marked CAB LAMP FRONT + 2)
F33 - Warning Lamp 10 A Fuse (Marked WARNING LAMP)
X60 - Air Suspension Seat Harness Power Connector
X62 - 12 Volt Power Unit Connector
CW08338,0000F12-19-20130529
533
534
TX1006061-UN: Pilot Shutoff Switch Harness (W11) Component Location

LEGEND:
TX17984,0000152-19-20061101
535
TX1012126-UN: Pilot Shutoff Switch Harness (W11) Wiring Diagram

LEGEND:
X135 - Pilot Shutoff Harness Splice 1
TX17984,0000153-19-20061005
536
TX1014468-UN: Air Suspension Seat Harness (W12) Component Location

LEGEND:
M12 - Seat Air Compressor motor
R18 - Seat Heater
W12 - Air Suspension Seat Harness
W13 - Seat Heater Switch Harness
537
X76 - Air Suspension Seat Harness-to-Heated Seat Switch Harness 3-Pin Connector
TX17984,0000154-19-20061101
538
TX1012129-UN: Air Suspension Seat Harness (W12) Wiring Diagram

LEGEND:
M12 - Seat Air Compressor motor
R18 - Seat Heater
X60 - Air Suspension Seat Harness Power Connector
TX17984,0000155-19-20061005
539
For Seat Heater Switch Harness (W13) Component Location, See Air Suspension Seat Harness (W12)
Component Location . (Group 9015-10.)
TX17984,0000156-19-20070118
540
TX1012137-UN: Seat Heater Switch Harness (W13) Wiring Diagram

LEGEND:
TX17984,0000157-19-20061005
541
TX1144637-UN: Multi-Function Pilot Control Lever Harness (W14) Component Location

LEGEND:
542
TP97644,000052D-19-20131004
543
TX1144638-UN: Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram

LEGEND:
X26A - Optional Connector A
X26B - Optional Connector B
AS79221,0000014-19-20131004
544
For Travel Alarm Cancel Switch Harness (W15) Component Location, See Cab Harness (W1) Component
Location . (Group 9015-10.)
LD30992,0000211-19-20061101
545
TX1073350-UN: Travel Alarm Cancel Switch Harness (W15) Wiring Diagram

LEGEND:
LD30992,0000212-19-20071213
546
For Fan Reversing Switch Harness (W16) Component Location, See Cab Harness (W1) Component Location .
(Group 9015-10.)
TX17984,000015A-19-20061101
547
TX1012132-UN: Fan Reversing Switch Harness (W16) Wiring Diagram

LEGEND:
TX17984,000015B-19-20061005
548
For Pilot Shutoff Valve Harness (W17) Component Location, See Cab Harness (W1) Component Location .
(Group 9015-10.)
TX17984,000015C-19-20061101
549
TX1014020-UN: Pilot Shutoff Valve Harness (W17) Wiring Diagram

LEGEND:
TX17984,000015D-19-20061102
550
TX1017056-UN: Attachment Harness (W20) Component Location

LEGEND:
W21 - 2-Speed Harness
X46 - Attachment Connector
X87 - Attachment Harness-to-Two Speed Harness Connector
Y44 - Flow Rate Adjustment Solenoid Valve (Not Used)
MT89988,0000062-19-20070202
551
TX1016209-UN: Attachment Harness (W20) Wiring Diagram

LEGEND:
X46 - Attachment Connector
MT89988,0000063-19-20070111
552
For 2-Speed Harness (W21) Component Location, See Attachment Harness (W20) Component Location . (Group
9015-10.)
MT89988,000007E-19-20070118
553
TX1017517-UN: 2-Speed Harness (W21) Wiring Diagram

LEGEND:
Y44 - Flow Rate Adjustment Solenoid Valve (Not Used)
MT89988,000007F-19-20070122
554
For Alternator Harness (W22) Component Location, See Machine Harness (W2) Component Location . (Group
9015-10.)
LD30992,000019A-19-20100512
555
TX1076970-UN: Alternator Harness (W22) Wiring Diagram

LEGEND:
G3 - Alternator
LD30992,000019B-19-20100427
556
For Start Aid Switch Harness (W23) Component Location, See Cab Harness (W1) Component Location . (Group
9015-10.)
LD30992,0000196-19-20100412
557
TX1076224-UN: Start Aid Switch Harness (W23) Wiring Diagram

LEGEND:
LD30992,0000197-19-20100412
558
(S.N. 511091—)
TX1035020-UN: Starter Harness (W27) Component Location (S.N. 511091— )

LEGEND:
F45 - Starter In-line 30 A Fuse
K34 - Starter Relay
K35 - Starter Protection Relay
M1 - Starter Motor
559
TF44157,00003AC-19-20100513
560
(S.N. 511091—511868)
TX1033014-UN: Starter Harness (W27) Wiring Diagram (S.N. 511091—511868 )

LEGEND:
K34 - Starter Relay
M1 - Starter Motor
X316 - E03 WHT Splice
(S.N. 511869—)
561
TX1061358-UN: Starter Harness (W27) Wiring Diagram (S.N. 511869— )

LEGEND:
K34 - Starter Relay
M1 - Starter Motor
TF44157,00003AD-19-20100513
562
TX1198181-UN: Auxiliary Solenoid Harness (W61) Component Location

LEGEND:
V33 - Left Solenoid Diode A
W15 - Multi-Function Pilot Control Lever Harness
W61 - Auxiliary Solenoid Harness
W75 - Auxiliary Function Lever (AFL) Harness
Y34 - Right Solenoid (marked SR/H)
Y34A - Right Solenoid Connector A (marked SR/H)
Y34B - Right Solenoid Connector B (marked SR/H)
Y35 - Left Solenoid (marked SR/H)
Y35A - Left Solenoid Connector A (marked SR/H)
563
Y35B - Left Solenoid Connector B (marked SR/H)
TZ24494,000115C-19-20150722
564
TX1144334-UN: Auxiliary Solenoid Harness (W61) Wiring Diagram

LEGEND:
V33 - Leftt Solenoid Diode A
X450 - GO5 BLK Splice
X451 - HO1 GRN Splice
X452 - HO2 GRN Splice
565
Y34A - Right Solenoid Connector A (marked SR/H)
Y34B - Right Solenoid Connector B (marked SR/H)
Y35A - Left Solenoid Connector A (marked SR/H)
Y35B - Left Solenoid Connector B (marked SR/H)
TZ24494,000115D-19-20140620
566
Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)
JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component Location—If
Equipped
TX1148663-UN: JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component Location
LEGEND:
A10 - Machine Information Gateway (MIG) Controller
A11 - GlobalTRACS® Terminal (GTT) Controller
F40 - JDLink™ Unswitched Power 7 Amp Fuse
F41 - JDLink™ Switched Power 3 Amp Fuse
F42 - JDLink™ Alternator Run Signal 3 Amp Fuse
F43 - JDLink™ Ground 7.5 Amp Fuse
G3 - Alternator
K19 - Battery Relay
R12 - JDLink™ CAN Termination Resistor
W50 - Machine Information Gateway (MIG) Harness
W51 - GlobalTRACS® Terminal (GTT) Harness
W52 - JDLink™ CAN Harness
W53 - JDLink™ Power Harness
W54 - JDLink™ Jumper Harness
W57 - GlobalTRACS® Terminal (GTT) Antenna
X140 - Machine Information Gateway (MIG) Harness-to-JDLink™ Power Harness 4-Pin Connector
X141 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 10-Pin Connector
X143 - Machine Information Gateway (MIG) Harness-to-JDLink™ CAN Harness 8-Pin Connector
X144 - Machine Information Gateway (MIG) 30-Pin (L1-Y3) Connector
X145 - Machine Information Gateway (MIG) 30-Pin (A1-K3) Connector
567
X146 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X147 - 2-Pin Connector (not used)
X148 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X149 - JDLink™ Power Harness-to-JDLink™ Jumper Harness Connector
X150 - GT Config Tool Adapter 6-Pin Connector (RS-232)
X152 - JDLink™ Jumper Harness-to-Machine Harness Connector
X161 - Machine Harness-to-JDLink™ CAN Harness 3-Pin Connector
DP27668,00007BE-19-20131203
568
(Group 9015-20.)
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Component Location—If

Equipped
TX1148671-UN: JDLink™ Modular Telematics Gateway (MTG) Harness Component Location

LEGEND:
F6000 - JDLink™ Unswitched Power 7.5 A Fuse
F6001 - JDLink™ Ground 7.5 A Fuse
F6002 - JDLink™ Switched Power 7.5 A Fuse
K19 - Battery Relay
R12 - JDLink™ Harness Controller Area Network (CAN) Termination Resistor
W6002 - Modular Telematics Gateway (MTG) Harness
X161 - Engine Harness-to-JDLink™ Harness Controller Area Network (CAN) Connector
X6007 - Modular Telematics Gateway (MTG) Frame Ground Connector
569
X6008 - JDLink™ Switched Power Connector
X6011 - JDLink™ Ground Connector
X6012 - JDLink™ Unswitched Power Connector
DP27668,00007BF-19-20131203
570
(Group 9015-20.)
Machine Information Gateway (MIG) Harness (W50) Wiring Diagram—If Equipped
TX1026496-UN: Machine Information Gateway (MIG) Harness (W50) Wiring Diagram

LEGEND:
X140 - Machine Information Gateway (MIG) Harness-to- JDLink™ Power Harness 4-Pin Connector
X141 - Machine Information Gateway (MIG) Harness-to- GlobalTRACS® Terminal (GTT) Harness 10-Pin Connector
X144 - Machine Information Gateway (MIG) 30-Pin (L1-Y3) Connector
X145 - Machine Information Gateway (MIG) 30-Pin (A1-K3) Connector
X146 - Machine Information Gateway (MIG) Ethernet Diagnostic 4-Pin Connector
X147 - 2-Pin Connector (not used)
X161 - Machine Information Gateway (MIG) Shield Splice
GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram—If Equipped
571
TX1026500-UN: GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram

LEGEND:
W55 - GlobalTRACS® Terminal (GTT) Controller Ground
X141 - GlobalTRACS® Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness10-Pin Connector
X142 - GlobalTRACS® Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector
X148 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X150 - 6-Pin GT config Tool Adapter Connector
X160 - GlobalTRACS® Terminal (GTT) Shield Splice
JDLink™ CAN Harness (W52) Wiring Diagram—If Equipped
572
TX1026491-UN: JDLink™ CAN Harness (W52) Wiring Diagram

LEGEND:
R12 - JDLink™ CAN Termination resistor 3-Pin Connector
X161 - Machine Harness-to-JDLink™ CAN Harness 3-Pin Connector
X166 - M10 GRN Splice
JDLink™ Power Harness (W53) Wiring Diagram—If Equipped
573
TX1026494-UN: JDLink™ Power Harness (W53) Wiring Diagram

LEGEND:
F40 - JDLink™ Unswitched Power 7 Amp Fuse
F41 - JDLink™ Switched Power 3 Amp Fuse
F42 - JDLink™ Alternator Run Signal 3 Amp Fuse
K19 - Battery Relay
W56 - JDLink™ Power Harness Ground
X140 - Power Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector
X149 - Power Harness-to-JDLink™ Jumper Harness Connector
JDLink™ Jumper Harness (W54) Wiring Diagram—If Equipped
574
TX1026493-UN: JDLink™ Jumper Harness (W54) Wiring Diagram

LEGEND:
X149 - JDLink™ Jumper Harness-to-JDLink™ Power Harness Connector
X151 - JDLink™ Jumper Harness-to-Alternator Connector
X152 - JDLink™ Jumper Harness-to-Machine Harness Connector
X164 - M16 PUR Splice
DP27668,00007C0-19-20131203
575
(Group 9015-20.)
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If

Equipped
TX1088965-UN: JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
LEGEND:
F6000 - JDLink™ Unswitched Power 7.5 Amp Fuse
F6002 - JDLink™ Switched Power 7.5 Amp Fuse
R12 - JDLink™ Harness Controller Area Network (CAN) Termination Resistor
X5000 - Splice G01 BLK
X5001 - Splice M12 YEL
X5002 - Splice M13 LT GRN
X5003 - Splice P01 RED
X6007 - Modular Telematics Gateway (MTG) Control Unit Frame Ground Connector
X6008 - JDLink™ Switched Power Connector
X6011 - JDLink™ Ground Connector
X6012 - JDLink™ Unswitched Power Connector
DP27668,00007C1-19-20131203
576
TX1129021-UN: Controller Area Network (CAN) Circuit

LEGEND:
A4 - Monitor Controller (MON)
577
X6 - Engine Harness-to-Engine Interface Harness 8-Pin Connector B
X144 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector
Controller Area Network (CAN) Overview— The CAN data line provides a standardized means for electronic
controllers and other devices to communicate with each other.
The CAN consists of two 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, along with a ground
wire, are woven together, forming what is called a twisted triple. The twisted triple provides an additional method
of reducing interference and thus helps the devices communicate with minimal errors.
To help prevent signal errors, the CAN data line uses two 120-ohm termination resistors. One of these resistors is
located inside the monitor and is not serviceable. If JDLink™ is not installed, CAN termination resistor 1 (R10) is
installed in the engine harness-to-JDLink™ harness controller area network (CAN) connector (X161). When
JDLink™ is installed, CAN termination resistor 1 (R10) is replaced by JDLink™ CAN termination resistor (R12),
which is installed in the JDLink™ harness. See JDLink™ Modular Telematics Gateway (MTG) Harness (W6002)
Wiring Diagram—If Equipped . (Group 9015-10.)
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 data line is idle before it transmits a signal. Whichever
device gets on the data line first is able to transmit its signal.
When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the
highest priority has access to the bus. The device that loses arbitration immediately retransmits its signal when
the device with the higher priority has completed its transmission.
Each controller has the ability to generate a diagnostic trouble code (DTC) if CAN communication is lost. Refer to
DTC diagnostics of specific controller in Section 9001.
The engine control unit (ECU), monitor controller (MON), information controller (ICF), main controller (MCF), and
a JDLink™ controller (modular telematics gateway or machine information gateway) are all connected to the
CAN. Operations and functions of these individual devices are covered separately.
See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
See Monitor Controller Circuit Theory of Operation . (Group 9015-15.)
See Information Controller (ICF) Circuit Theory of Operation . (Group 9015-15.)
See Main Controller (MCF) Circuit Theory of Operation . (Group 9015-15.)
See JDLink™ Circuit Theory of Operation—If Equipped . (Group 9015-15.)
The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as
a laptop. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
578
TZ24494,0000AAF-19-20160628
579
TX1129021-UN: Controller Area Network (CAN) Circuit

LEGEND:
580
X144 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector
Controller Area Network (CAN) Overview— The CAN data line provides a standardized means for electronic
controllers and other devices to communicate with each other.
The CAN consists of two 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, along with a ground
wire, are woven together, forming what is called a twisted triple. The twisted triple provides an additional method
of reducing interference and thus helps the devices communicate with minimal errors.
To help prevent signal errors, the CAN data line uses two 120-ohm termination resistors. One of these resistors is
located inside the monitor and is not serviceable. If JDLink™ is not installed, CAN termination resistor 1 (R10) is
installed in the engine harness-to-JDLink™ harness controller area network (CAN) connector (X161). When
JDLink™ is installed, CAN termination resistor 1 (R10) is replaced by JDLink™ CAN termination resistor (R12),
which is installed in the JDLink™ harness. See JDLink™ Modular Telematics Gateway (MTG) Harness (W6002)
Wiring Diagram—If Equipped . (Group 9015-10.)
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 data line is idle before it transmits a signal. Whichever
device gets on the data line first is able to transmit its signal.
When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the
highest priority has access to the bus. The device that loses arbitration immediately retransmits its signal when
the device with the higher priority has completed its transmission.
Each controller has the ability to generate a diagnostic trouble code (DTC) if CAN communication is lost. Refer to
DTC diagnostics of specific controller in Section 9001.
The engine control unit (ECU), monitor controller (MON), information controller (ICF), main controller (MCF), and
a JDLink™ controller (modular telematics gateway or machine information gateway) are all connected to the
CAN. Operations and functions of these individual devices are covered separately.
See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
See Monitor Controller Circuit Theory of Operation . (Group 9015-15.)
See Information Controller (ICF) Circuit Theory of Operation . (Group 9015-15.)
See Main Controller (MCF) Circuit Theory of Operation . (Group 9015-15.)
See JDLink™ Circuit Theory of Operation—If Equipped . (Group 9015-15.)
The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as
a laptop. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
581
TZ24494,0000AAF-19-20160628
582
TX1076343-UN: Starting and Charging Circuit

LEGEND:
F16 - Controller Key Switch Signal 5 A Fuse (Marked POW ON)
G3 - Alternator
S1 - Key Switch
V4 - Security Diode
V5 - Start Relay Diode
Starting Circuit (S.N. —511090)
The starting circuit consists of:
Monitor controller (A4)

Batteries (G1 and G2)
583
Starter relay (K4)
Security relay (K5)
Battery relay (K19)
Starter (M1)
Key switch (S1)
Pilot shutoff switches (S3 and S4)
Security diode (V4)
Starter relay diode (V5)
Pilot shutoff diode (V8)
When key switch (S1) is moved to the START position, power is applied from key switch terminal ST to terminals
1 and 3 of starter relay (K4). Key switch terminal M also receives power, energizing battery relay (K19). Energized
battery relay (K19) supplies power to starter motor (M1) terminal B through terminals A and B on battery relay
(K19). De-energized starter relay (K4) terminal 4 supplies power to starter motor (M1) terminal C, cranking the
engine.
When a warning alarm or security code error is detected, the monitor controller (A4) pin A4 is connected to
ground, energizing starter relay (K4) and security relay (K5) through security diode (V4), removing power from
starter motor (M1) terminal C, preventing engine from starting. When pilot shutoff switches 1 and 2 (S3) and (S4)
are closed, pilot control lever in down (unlocked) position, starter relay (K4) terminal 2 is connected to ground,
energizing starter relay (K4) removing power from starter motor (M1) terminal C. This prevents the activation of
starter motor when pilot control lever is in the down (unlocked) position.
Security diode (V4), starter relay diode (V5), and pilot shutoff diode (V8) work as logic gates to allow more than
one device to control one circuit without backfeeding other circuits.
Starting Circuit (S.N. 511091—511868)
Engine control unit (ECU) (A1)

Starter cut relay (K4)
Security relay (K5)
Battery relay (K19)
Starter relay (K34)
Starter protection relay (K35)
Starter (M1)
Key switch (S1)
Security diode (V4)
Starter cut relay diode (V5)
1 and 3 of starter cut relay (K4). Key switch terminal M also receives power, energizing battery relay (K19).
Energized battery relay (K19) supplies power to starter motor (M1) terminal B.
Starter cut relay (K4) utilizes the normally closed contacts of the relay to continue the start signal to the starter
protection relay (K35) pin 87A. Starter cut relay is energized when there is power from key switch on relay pin 1
and ground on relay pin 2. The ground on pin 2 can come from the monitor controller (A4) through security diode
(V4) or from pilot shutoff switches (S3 and S4) through starter cut relay diode (V5). A ground from the monitor
controller (A4) is the result of a security code violation or machine warning alarm. A ground from pilot shutoff
switches (S3 and S4) is the result of the pilot shutoff lever in the down (Unlocked) position or an error in the pilot
shutoff circuit.
584
Starter protection relay (K35) also utilizes the normally closed contacts of the relay to supply power to starter
relay (K34) pin 2. Starter protection relay receives power from starter in-line 30 A fuse (F45) on relay pin 86 and
ground from engine control unit (ECU) (A1) connector X15 pin E2 on relay pin 85. The engine control unit (A1)
activates the starter protection relay (K35) based on the engine run status. If the engine is running, the engine
control unit will ground starter protection relay (K35) pin 85. This opens the normally closed contacts of the starter
protection relay and prevents power from going to the starter relay (K34) pin 2. If the engine is not running, the
engine control unit will not ground starter protection relay (K35) pin 85. This leaves the normally closed contacts
of the starter protection relay to stay closed and supply power to the starter relay (K34) pin 2. Engine control unit
(A1) control of the starter protection relay prevents the starter from engaging the engine while the engine is
running.
Starter relay (K34) is a normally open relay which closes when ground is present on relay pin 1 and power is
present on relay pin 2. Energized starter relay (K34) provides power from starter in-line 30 A fuse (F45) to starter
motor (M1) terminal C. When power is present on starter motor terminal C, the starter rotates thus cranking the
engine. When starter relay (K34) is de-energized, starter relay contacts are opened, removing power from starter
terminal C, stopping the starter motor from turning.
ground, energizing starter cut relay (K4) and security relay (K5) through security diode (V4), removing the start
signal from starter protection relay (K35) and starter relay (K34). With no start signal at starter relay (K34), the
relay remains de-energized, removing power from starter motor (M1) terminal C, preventing engine from starting.
When pilot shutoff switches 1 and 2 (S3) and (S4) are closed, pilot control lever in down (unlocked) position,
starter cut relay (K4) terminal 2 is connected to ground through starter cut relay diode (V5), removing the start
relay remains de-energized, removing power from starter motor (M1) terminal C. This prevents the activation of
Starting Circuit (S.N. 511869—)
Engine control unit (ECU) (A1)

Starter cut relay (K4)
Security relay (K5)
Battery relay (K19)
Starter relay (K34)
Starter protection relay (K35)
Starter (M1)
Key switch (S1)
Security diode (V4)
Starter cut relay diode (V5)
1 and 3 of starter cut relay (K4). Key switch terminal M also receives power, energizing battery relay (K19).
Energized battery relay (K19) supplies power to starter motor (M1) terminal B.
Starter cut relay (K4) utilizes the normally closed contacts of the relay to continue the start signal to the starter
protection relay (K35) pin 87A. Starter cut relay is energized when there is power from key switch on relay pin 1
and ground on relay pin 2. The ground on pin 2 can come from the monitor controller (A4) through security diode
585
(V4) or from pilot shutoff switches (S3 and S4) through starter cut relay diode (V5). A ground from the monitor
controller (A4) is the result of a security code violation or machine warning alarm. A ground from pilot shutoff
switches (S3 and S4) is the result of the pilot shutoff lever in the down (Unlocked) position or an error in the pilot
shutoff circuit.
Starter protection relay (K35) also utilizes the normally closed contacts of the relay to supply power to starter
relay (K34) pin 2. Starter protection relay receives power from engine control unit (ECU) (A1) connector X15 pin
M3 on relay pin 86 and ground on relay pin 85. The engine control unit (A1) activates the starter protection relay
(K35) based on the engine run status. If the engine is running, the engine control unit will power starter protection
relay (K35) pin 86. This opens the normally closed contacts of the starter protection relay and prevents power
from going to the starter relay (K34) pin 2. If the engine is not running, the engine control unit will not power starter
protection relay (K35) pin 86. This leaves the normally closed contacts of the starter protection relay to stay
closed and supply power to the starter relay (K34) pin 2. Engine control unit (A1) control of the starter protection
relay prevents the starter from engaging the engine while the engine is running.
Starter relay (K34) is a normally open relay which closes when ground is present on relay pin 1 and power is
present on relay pin 2. Energized starter relay (K34) provides power from starter in-line 30 A fuse (F45) to starter
motor (M1) terminal C. When power is present on starter motor terminal C, the starter rotates thus cranking the
engine. When starter relay (K34) is de-energized, starter relay contacts are opened, removing power from starter
terminal C, stopping the starter motor from turning.
ground, energizing starter cut relay (K4) and security relay (K5) through security diode (V4), removing the start
relay remains de-energized, removing power from starter motor (M1) terminal C, preventing engine from starting.
When pilot shutoff switches 1 and 2 (S3) and (S4) are closed, pilot control lever in down (unlocked) position,
starter cut relay (K4) terminal 2 is connected to ground through starter cut relay diode (V5), removing the start
relay remains de-energized, removing power from starter motor (M1) terminal C. This prevents the activation of
Charging Circuit
The charging circuit consists of batteries (G1) and (G2), key switch (S1), alternator (G3), alternator relay (K14),
load dump relay (K1), load dump relay diode (V3), and monitor controller (A4).
With key switch (S1) ON, battery power is applied through fusible link (F16) and excites alternator through
terminal 15. The terminal B2+ of alternator (G3) charges the batteries (G1) and (G2).
When alternator terminal L produces output voltage, alternator relay (K14) will energize, routing power from key
switch terminal M, to the monitor controller (A4) pin C7, turning off the alternator indicator light and the monitor
warning alarm (H3). If voltage at alternator terminal L drops below operating voltage, alternator relay will de-
energize, removing power to monitor controller pin C7. With battery voltage removed from monitor controller pin
C7, alternator voltage indicator will illuminate and monitor warning alarm (H3) will sound.
System voltage must be present at alternator terminal S (battery sense) for the alternator to produce a signal at
the L terminal.
When battery voltage is present at monitor controller pin C7, load dump relay (K1) is energized by a ground from
the monitor controller pin A12. With load dump relay energized, battery power is supplied to battery relay (K19)
pin S. This keeps the battery relay energized to ensure that excitation power to alternator is maintained as long
as the engine is running, even if the key switch is turned to the OFF or ACC position momentarily.
586
Load Dump Circuit
The load dump circuit consists of load dump relay (K1) and load dump diode (V3).
When the alternator (G3) is generating electricity, the alternator relay (K14) is energized, sending voltage to
monitor controller (A4) pin C7. This causes monitor to put pin A12 to ground, energizing load dump relay (K1).
With load dump relay (K1) energized, battery power is applied through terminals 3 and 5 to battery relay (K19).
Monitor controller (A4) terminal A12 retains a ground path for load dump relay (K1) until alternator (G3) stops
producing output voltage, keeping the battery relay (K19) energized, providing a path to the batteries (G1) and
(G2) for any power produced by the alternator (G3) as the engine slows to a stop. Then the ground path is
removed from load dump relay, and battery relay (K19) is de-energized.
Load dump relay diode (V3) isolates battery power at terminal 5 of load dump relay (K1) from key switch ON
power circuits.
LD30992,0000214-19-20100423
587
TX1217896-UN: Monitor Controller Circuit (1 of 2)

LEGEND:
F16 - Controller Key Switch Signal 10 A Fuse (marked POW ON)
G1 - Battery
G2 - Battery
K2 - Pilot Shutoff Relay
K5 - Security Relay
K19 - Battery Relay
S1 - Key Switch
V4 - Security Diode
V5 - Starter Cut Relay Diode
588
TX1138138-UN: Monitor Controller Circuit (2 of 2)

LEGEND:
A9 - Switch Panel
B16 - Air Filter Restriction Switch (if installed)
F9 - Radio Back-Up 10A Fuse (marked BACK UP)
H2 - Security Alarm
S8 - Auto Idle Switch
X27 - Cab Harness-to-Switch Panel 16-Pin Connector
The monitor controller (A4) contains gauges and indicators, sensor inputs, and switches. The gauges and
indicators display the status of machine systems and control switches. The sensor inputs are used by the monitor
controller to monitor the status of the machine systems, and the switches are used to control or select machine
functions by providing control signal outputs to other machine systems. The illumination of the indicators and the
status of control signal outputs are controlled by logic circuits in the monitor controller in response to the sensor
inputs and control switch settings.
Operating power to the monitor controller is applied from controller power fuse (F19) to pin A16. Frame ground is
applied to pin B11. Switched power comes from controller key switch signal 10 Amp fuse (F16) to pin A7 of
monitor controller (A4).
589
Hour Meter And Gauges— The hour meter monitors battery voltage at monitor controller pin C7. When the
engine is running and battery voltage is present at pin C7, the hour meter records hours of operation.
The engine coolant temperature and fuel level gauges are controlled by engine coolant temperature sensor (B4)
and fuel level sensor (B18). Fuel level sensor (B18) provides a variable resistance to ground on pin C2 to indicate
fuel level and engine coolant temperature is provided by the ECU via CAN.
Air Filter Restriction Indicator Light— The air filter restriction switch (B16) puts monitor controller pin B4 to
ground when a plugged filter is sensed with the engine running, causing the air filter restriction indicator to
illuminate.
Fuel Level Indicator Light— 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 monitor controller (A4) pin C2, the
fuel level indicator light will illuminate indicating a low level of fuel.

Fuel Level Indicator Light Resistance Illuminates Above 82—88 ohms
Hydraulic Oil Filter Restriction Indicator— Ground is passed to pin B15 of monitor controller (MON) 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, hydraulic oil filter restriction indicator will illuminate.
Engine Coolant Temperature Indicator Light— The engine coolant temperature indicator light will illuminate
when the ECU (A1) senses engine coolant temperature above 110°C (230°F) from the engine coolant
temperature sensor (B4). The monitor controller (A4) receives engine coolant temperature signal from ECU
through control area network (CAN) and illuminates the engine coolant temperature light.
Engine Coolant Temperature Gauge— Engine coolant temperature sensor (B4) provides a variable resistance
to the ECU (A1) as the engine temperature changes. The ECU sends a signal to the monitor controller (A4) over
CAN, and the monitor controller displays the temperature on the temperature gauge.
Alternator Voltage Indicator— The alternator alarm indicator is controlled by alternator relay (K14) and
monitored by the monitor controller (A4) at pin C7. When the alternator voltage is below charging level, the
alternator relay is de-energized . This removes system voltage from monitor controller pin C7 and illuminates the
alternator warning indicator.
Monitor Display Alarm— The monitor warning alarm (H3) sounds when certain diagnostic trouble codes or
machine conditions exist which could damage the machine. The alarm notifies the operator of the condition. The
alarm receives power from controller 5 Amp fuse (F19).
Water-in-Fuel Indicator (S.N. 512064—)— The water-in-fuel indicator will illuminate when water is present in the
fuel. The engine control unit (ECU) monitors the water-in-fuel sensor for indication of water in the fuel. When
water is present, the engine control unit grounds an output on connector X15 pin E2. The grounded output on the
engine control unit grounds monitor controller (A4) pin C12. This displays the water-in-fuel alarm on the monitor.
Check Engine Indicator Light— The check engine indicator light will come ON if there is an engine problem.
The engine may run at a reduced power to protect the engine but still allow the machine to be moved. For more
information on the engine control unit (ECU) (A1) and sensors, see Engine Control Unit (ECU) Circuit Theory of
Operation . (Group 9015-15.) For instructions on reading engine diagnostic trouble codes, see Reading
Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) and see Reading
Diagnostic Trouble Codes With Monitor Display . (Group 9015-20.)
CONTROL SWITCHES AND INDICATORS
590
Windshield Wiper and Washer Switch (S9)— Windshield wiper and washer switch (S9) is used to select
intermittent or continuous windshield wiper operation and to activate the windshield washer motor. The monitor
controller supplies a 5-volt reference voltage terminal (C6) and a ground terminal (C9) to the windshield wiper and
washer switch. The monitor controller determines the position of the windshield wiper and washer switch from
signals received at terminal C3. When the windshield wiper and washer switch is turned to the ON or one of the
INT positions, the monitor controller momentarily connects terminals A2 and A11 to ground, energizing windshield
wiper relay (K6).
When the windshield wiper and washer switch is pressed, terminal B3 on the monitor controller is connected to
ground. This causes the monitor controller to connect terminal A10 to ground, energizing windshield washer relay
(K9).
For more information on the windshield wiper and washer circuit, See Windshield Wiper and Washer Circuit
Theory of Operation . (Group 9015-15.)
Work Light Switch (S10)— The work light switch (S10) provides a signal to the monitor controller, which sends
ground to boom work light relay (K8) and drive light relay (K7). When the switch is moved to position 1, monitor
controller (A4) pin B20 is grounded, which grounds pin A1 of monitor controller and energizes drive light relay
(K7). When the switch is moved to position 2, monitor controller (A4) pin A6 is grounded, which grounds pin A5
and pin A1 of monitor controller, energizing boom work light relay (K8) and drive light relay (K7). In position 2,
both drive lights and boom work lights are on.
Auto-Idle Switch (S8)— When the auto-idle switch (S8) is turned to AI position, the auto-idle switch applies a
ground to monitor controller (A4) pin B18 and main controller (MCF) (A3) pin B6. This causes auto-idle mode to
be selected, and the auto-idle indicator light illuminates.
For more information on auto-idle, see Main Controller (MCF) Circuit Theory of Operation . (Group 9015-15.)
Engine Speed Dial (R15)— The engine speed dial has a 5-volt reference voltage provided by main controller
(MCF) (A3) terminal D1 and a ground reference shared with MCF terminal D6 and monitor controller (A4) terminal
C10. The engine speed dial applies a varied voltage level to MCF terminal C1 and monitor controller terminal C4.
The main controller uses this input to set an appropriate engine speed for the machine. For more information on
engine speeds, see Engine Speed Control System Operation . (Group 9010-05.)
Power Mode Switch (S12)— When the power mode switch is turned to E (Economy) position, a ground is
applied to main controller (MCF) (A3) terminal B13, causing the economy mode to be selected.
When the power mode switch is turned to P (Standard) position, ground is removed from MCF (A3) terminal B13
and B21, causing the standard mode to be selected.
When the power mode switch is turned to HP (High Power) position, ground is applied to MCF (A3) terminal B21,
causing the high power mode to be selected.
For more information on machine power modes, see Engine Speed Control System Operation . (Group 9010-05.)
LD30992,0000215-19-20160624
591
TX1229711-UN: Engine Control Unit (ECU) Circuit (1 of 2)

LEGEND:
G1 - Battery
G2 - Battery
K19 - Battery Relay
S1 - Key Switch
Y9 - Reversing Fan Solenoid
592
TX1078565-UN: Engine Control Unit (ECU) Circuit (2 of 2)

LEGEND:
F6 - 12 Volt Power Outlet 10 A Fuse (Marked OPT. 2)
F8 - Engine Control Unit (ECU) 20 A Fuse (Marked ECM)
F18 - Service Advisor Diagnostic Connector Power 5 A Fuse (Marked DIAG)
S15 - Reversing Fan Switch
Engine Control Unit
The engine control unit (ECU) (A1) manages the engine with input from main controller (MCF) (A3) and sensors
located on the engine. The ECU is supplied with unswitched power through connector X15 and engine control unit
20 Amp fuse (F8). The ECU is turned on by a key switch signal from the controller 5 Amp fuse (F16) through pin
B2 of connector X15. The ECU communicates with the main controller (A3) through a CAN (Controller Area
Network). CAN connects to ECU through pins A1, B1, and K2 of connector X15. If there is a malfunction with the
ECU or one of the sensor circuits it is connected to, it will illuminate an indicator on the monitor controller (A4) to
notify the operator of the problem. See Reading Diagnostic Trouble Codes With Monitor Display . (Group 9015-
20.) See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.)
593
Engine Speed Control
The engine speed dial (R15) allows for manual adjustment of the engine speed through the main controller (MCF)
(A3) to the engine control unit (ECU) (A1). A variable voltage of 0 to 5 volts is sent from the engine speed dial to
the MCF. The MCF uses this information along with the status of the power mode switch (S12), the auto idle
switch (S8) and information from the pressure sensors to create an engine speed output signal. The engine
speed output signal from the MCF is used by the ECU to set the engine speed. The engine speed dial uses
terminals 1, 2, and 3 in connector X27. Terminal 1 in connector X27 is the power wire which goes to MCF
connector X31 pin D1. Terminal 2 in connector X27 is a signal wire which goes to MCF connector X30 pin C1,
and to monitor controller connector X21 pin C4. Terminal 3 in connector X27 is a ground wire which goes to MCF
connector X31 pin D6, and monitor controller (A4) connector X21 pin C10. For information on auto idle and power
modes E, P, and HP, See Engine Speed Control System Operation . (9010-05.)
Power Limiting
The engine control unit (ECU) (A1) has a built-in engine protection program. The ECU will derate the amount of
fuel that is delivered to the engine when sensor inputs exceed normal operating ranges. For a list of these fault
codes and derate percentages, See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
Variable Speed Fan
The variable speed fan cools the machine's systems by a hydraulic pump and motor controlled by a proportional
solenoid. This provides machine efficiency and reduced fan noise levels by only operating the fan at the minimum
speed necessary to cool the machine systems. The engine control unit (ECU) uses inputs from the engine coolant
temperature sensor (B4) at terminal C4 (X14) of the engine control unit, intake air temperature sensor (B7)
terminals D2 and G4 (X15), and hydraulic oil temperature sensor (B40) via controller area network (CAN) to
determine the proper fan speed. The input that requires the most cooling takes precedence over the other inputs
and the fan is run at a speed sufficient to cool the warmest input. If any of the three temperature sensor inputs are
invalid, the fan will run at maximum speed to ensure proper cooling. Temperature thresholds and proportional
solenoid duty cycles (fan speeds) are preprogrammed into the ECU and cannot be changed. The proportional fan
solenoid is driven from engine control unit (ECU) terminals C1, D2, and J4 of connector X15.
-: Fan Speed Temperature Thresholds
Engine Control Unit (ECU) Sensor Input Temperature
Coolant Temperature 90°C (194°F)
Hydraulic Oil Temperature 80°C (176°F)
Intake Air Temperature 52°C at 25°C ambient (126°F at 77°F ambient)*
*The engine control unit measures the intake air temperature and adds a constant value to it at ambient
temperatures above 25°C (77°F). In this application, the constant value is 27 degrees Celsius (49 degrees
Fahrenheit) above ambient air temperature when ambient air temperature is above 25°C (77°F). At
temperatures below 25°C (77°F), the engine control unit uses the constant of 52°C (126°F) for the fan speed
calculations. For example:
at 26°C (79°F) ambient temperature, the ECU calculated temperature would be 53°C (128°F)
Variable Speed Fan Reversing Function (if equipped)
The variable speed fan reversing option switches the direction of the cooling fan to help clear the cooling package
of debris buildup. A complete reversing cycle takes approximately 2 minutes with the fan running for 60 seconds
at full speed in reverse during that time.
594
The variable speed fan reversing operation can be activated in two ways, manual or automatic mode. The fan
reversing switch (S15) applies power from power outlet 10 amp fuse (F6) to engine control unit (ECU) terminal F2
of connector X15 for manual mode or engine control unit (ECU) terminal E1 of connector X15 for automatic mode.
The manual mode position on the switch is a momentary position and the automatic position on the switch is a
detent position. The reversing fan solenoid (Y9) is powered by engine control unit (ECU) terminal K4 on
connector X15.
In manual mode, the fan may be reversed by pressing the fan reversing switch (S15) momentarily to the manual
position. If the engine is running and hydraulic oil temperature is above 12°C (53°F), the fan will reverse.
In automatic reverse mode, the fan will reverse every 60 minutes when the fan reversing switch (S15) is in the
automatic position, hydraulic oil temperature is above 12°C (53°F), and the engine speed is greater than 1000
rpm for 60 minutes.
Once a reversing cycle has been started, it cannot be stopped unless the engine control unit (ECU) is powered
down. After a reversing cycle completes, the ECU prevents reactivation of the reversing circuit for 1 minute and
the automatic reversing mode timer is reset to 60 minutes. If the fan reversing switch (S15) is held in the manual
position for 160 seconds or more, a diagnostic trouble code (DTC) will occur and the manual reversing mode is
deactivated. Continuously holding the fan reversing switch in the manual position will not trigger a second cycle.
The switch must be cycled to trigger a new reverse cycle.
Starter Protection (S.N. 511091—512063)
The engine control unit (ECU) (A1) monitors the engine run status by checking engine speed from crankshaft
position sensor (B1) or camshaft position sensor (B2). When engine speed is above 600 rpm, the engine control
unit will prevent the starter from engaging the flywheel even if the operator moves the key switch to the START
position. See Starting and Charging Circuit Theory of Operation for more information. (Group 9015-15.)
Water-In-Fuel Alarm (S.N. 512064—)
The engine control unit (ECU) (A1) monitors the water in fuel sensor (B17) for water in the fuel. When water is
present, the engine control unit will ground connector X15 pin C2, grounding monitor controller (A4) pin C12.
When monitor controller (A4) pin C12 is grounded, the monitor will display the water-in-fuel indicator to notify the
operator of the water-in-fuel condition.
LD30992,0000552-19-20170119
595
TX1074501-UN: Main Controller (MCF) Circuit (1 of 2)

LEGEND:
A9 - Switch Panel
F10 - Information Controller and Monitor Controller Battery Power 5 A Fuse (marked C/U)
F16 - Controller Key Switch Signal 5 A Fuse (marked POW ON)
G1 - Battery
G2 - Battery
K19 - Battery Relay
S1 - Key Switch
S8 - Auto Idle Switch
596
TX1074502-UN: Main Controller (MCF) Circuit (2 of 2)

LEGEND:
H4 - Travel Alarm
NOTE:
For information on diagnosing main controller (MCF) circuit malfunctions, see Main Controller
(MCF) Diagnostic Trouble Codes . (Group 9001-10.)
Main Controller (MCF) (A3)

597
The main controller (MCF) uses inputs from the following sensors on the machine:
Boom Up Pressure Sensor (B30)

Arm In Pressure Sensor (B31)
Travel Pressure Sensor (B34)
Pump 1 Delivery Pressure Sensor (B35)
Pump 1 Control Pressure Sensor (B36)
Pump 2 Delivery Pressure Sensor (B37)
Pump 2 Control Pressure Sensor (B38)
Hydraulic Oil Temperature Sensor (B40)
The Main controller (MCF) controls the following solenoids:
Pump 2 flow rate limit solenoid (SB) (Y20)

Torque control solenoid (ST) (Y21)
Dig regenerative solenoid (SF) (Y22)
Arm regenerative solenoid (SC) (Y23)
Power dig solenoid (SG) (Y24)
Travel speed solenoid (SI) (Y25)
The main controller varies the engine speed signal to the engine based on the engine speed dial (R15), the power
mode selected, and the hydraulic function being actuated. Economy (E) mode limits engine speed to reduce
pump control and pump delivery pressure to save fuel over standard (P) mode. High power (HP) mode delivers
more power to boom up and arm in functions when hydraulic pump delivery pressure is high. The main controller
sends an engine speed request to the engine control unit (ECU) (A1) 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 main controller. See Engine Speed Control System Operation for more information. (Group
9010-05.)
Pump displacement is hydraulically controlled by regulators located on the pumps. As the pilot control valves are
operated, the increase in pilot pressure causes the regulators to put the pumps into stroke. When the load
increases, high pressure from within the pumps is sensed by the regulators and they begin to reduce pump stroke
to maintain engine speed. The main controller sets the target engine speed based on the position of the engine
speed dial (R15), power mode switch (S12), auto-idle switch (S8), and input from the pressure sensors. Target
engine speed is the same as actual engine speed. Actual engine speed is determined by the engine control unit
and sent via the controller area network to the main controller.
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 from the switch
panel (A9) to the monitor controller (A4) and to the main controller (MCF). The ground to the monitor controller
illuminates the auto-idle indicator. When the engine speed dial is set to an engine speed above auto-idle speed,
the main controller will reduce the engine speed to auto-idle speed if hydraulic functions are not operated for more
that 4 seconds. If engine speed dial is set to an engine speed below auto-idle speed, the engine speed will not
increase or decrease after 4 seconds. The main controller receives the pressure signal from the front attachment
pressure sensor (B32) in the swing park brake circuit or the travel pressure sensor (B34) to sense if a hydraulic
function has been operated.
Hydraulic Oil Warm-Up Circuit
When hydraulic oil temperature is below 0°C (32°F), the main controller (MCF) activates a warm-up circuit, which
raises the engine speed a little above slow idle to help warm up the oil. The main controller receives oil
temperature from the hydraulic oil temperature sensor (B40), located in the hydraulic oil tank. The main controller
will activate the warm-up circuit for 12 minutes or until the hydraulic oil temperature rises above 2°C (36°F). See
598
Engine Speed Control System Operation for more information. (Group 9010-05.)
Travel Speed Solenoid (SI) (Y25)
When the travel speed switch (S11) is set to fast travel speed, the switch grounds the main controller (MCF) at
terminal B14. The main controller then activates the travel speed solenoid valve (SI) (Y25), depending on the
status of the travel pressure sensor (B34), the front attachment pressure sensor (B32), the pump control pressure
sensors (B36 and B38), and the pump delivery pressure sensors (B35 and B37). The travel speed solenoid (Y25)
is a proportional solenoid that is controlled by a pulse width modulated signal from terminals A5 and A31 of the
main controller (MCF).
The travel speed solenoid valve is activated when:
Travel pressure sensor sensing pressure (travel function actuated)

Front attachment pressure sensor not sensing pressure (no swing or dig functions actuated)
Either pump 1 or pump 2 delivery pressure low
Either pump 1 or pump 2 control pressure high
Activation of the travel speed solenoid valve 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 slow in travel speed as
hydraulic oil is routed to other functions. See Travel Motor Speed Circuit Operation for more information. (Group
9025-05.)
Dig Regenerative Solenoid (SF) (Y22)
The dig regenerative solenoid valve (SF) (Y22) redirects oil from the boom cylinder rod end to the arm cylinder
head end during a boom up and arm in function. This helps improve arm control and prevents arm cylinder
cavitation during the combined function. The dig regenerative solenoid (Y22) is a proportional solenoid that is
controlled by a pulse width modulated signal from terminals A6 and A10 of the main controller (MCF).
The main controller activates the dig regenerative solenoid valve (SF) when the following conditions have been
met:
Pump 1 and pump 2 delivery pressure high

Arm in pressure sensor sensing high pressure (arm in function fully actuated)
When the dig regenerative solenoid valve is activated, pilot oil from the dig regenerative solenoid valve shifts the
dig regenerative valve in the control valve. This allows oil from the boom cylinder rod end to combine with oil in
the arm cylinder head end. See Dig Regenerative Valve Circuit Operation for more information. (Group 9025-05.)
Arm Regenerative Solenoid (SC) (Y23)
The arm regenerative solenoid valve (SC) (Y23) combines the return oil from the arm cylinder rod end with the
supply oil to the arm cylinder head end. This helps prevent arm hesitation or cavitation in the arm in circuit during
a combined arm in and swing or boom up function. The arm regenerative solenoid is a proportional solenoid that
is controlled by a pulse width modulated signal from terminals A29 and A32 of the main controller (MCF).
The main controller activates the arm regenerative solenoid valve (SC) when the following conditions have been
met:
Either pump 1 or pump 2 delivery pressure low

Arm in pressure sensor sensing high pressure (arm in function fully actuated)
Swing or boom up pressure sensor sensing pressure (swing or boom up function actuated)
599
When the arm regenerative solenoid valve is activated, pilot oil from the arm regenerative solenoid valve shifts the
arm regenerative valve in the control valve. This blocks the return oil from the arm cylinder rod end from returning
to the hydraulic oil tank and combines it with the oil to the arm cylinder head end. Pilot oil from the arm
regenerative solenoid valve also shifts the arm flow control valve, limiting the oil to the second arm spool to
preserve oil flow to other functions in the control valve. See Arm Regenerative Valve Circuit Operation for more
information. (Group 9025-05.)
Power Dig Solenoid (SG) (Y24)
The power dig solenoid valve (SG) (Y24) temporarily raises the main system relief pressure therefore temporarily
increasing digging power. The main controller activates the power dig solenoid valve when the operator presses
the power dig switch (S7) on the pilot control lever. When the power dig switch (S7) is pressed, a ground is
applied to main controller (MCF) terminal B4. The power dig solenoid (Y24) is a proportional solenoid and is
controlled by a pulse width modulated signal from terminals A11 and A17 of the main controller (MCF).
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. See Main Relief and Power Digging Valve Circuit Operation for more information. (Group 9025-05.)
Torque Control Solenoid (ST) (Y21)
The torque control solenoid valve (ST) (Y21) helps control pump displacement in response to changes in engine
load. As engine load increases, the torque control solenoid valve is deactivated reducing the pump displacement
and therefore reducing engine load and prevents engine stall. As engine load decreases, the torque control
solenoid is activated increasing pump displacement therefore increasing the efficiency of the machine. The main
controller monitors the difference between target engine speed as set by the main controller and the actual engine
speed as read by the engine control unit (ECU) and communicated to the main controller over controller area
network (CAN). As engine speed varies above or below target speed, the main controller adjusts the signal to the
torque control solenoid valve to change the pump displacement to utilize the maximum efficiency of the engine
without allowing the engine to stall.
The torque control solenoid (Y21) is a proportional solenoid and is controlled by a pulse width modulated signal
from terminals A19 and A30 of the main controller (MCF). Under most conditions, the torque control solenoid is
activated to some degree. See Engine Speed Sensing Control Circuit Operation for more information. (Group
9025-05.)
Travel Torque Up
The torque control solenoid valve may also be activated during a travel function. At slow engine speeds, the
torque control solenoid valve is activated and both pumps are moved to maximum displacement. This reduces the
oil flow difference between the two hydraulic pumps and therefore reduces machine mistracking at low engine
speeds. At fast engine speeds, the torque control solenoid may also be activated to slightly increase pump oil
flow to improve the travel function. The torque control solenoid (Y21) is a proportional solenoid and is controlled
by a pulse width modulated signal from terminals A19 and A30 of the main controller (MCF).
Pump 2 Flow Rate Limit Solenoid (SB) (Y20)
The pump 2 flow rate limit solenoid valve (SB) (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 controlled and is
controlled by a pulse width modulated signal from terminals A16 and A22 of the main controller (MCF). The main
controller 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 WinDr.
Fine adjustments to the pump 2 flow rate can be made through the monitor.
600
NOTE:
Flow rates and adjustments in WinDr. and the monitor are approximate. Actual flow rates may
vary.
The auxiliary flow combiner may greatly affect WinDr. flow adjustments if activated.
Work Modes
Work modes are selected in the monitor controller and communicated by CAN to the main controller. The main
controller 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 WinDr..
MB00333,00000FE-19-20121015
601
TX1074509-UN: Information Controller (ICF) Circuit

LEGEND:
F10 - Information Controller and Monitor Controller Battery Power 5 A Fuse (Marked C/U)
G1 - Battery
G2 - Battery
K19 - Battery Relay
S1 - Key Switch
The information controller (ICF) stores information on machine activity. The information is obtained from various
sensors and switches on the machine. The information is transferred to ICF through control area network (CAN)
communication. See Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)
The ICF records data related to machine use, operating hours, alarm lists, and failure lists.
602
LD30992,0000217-19-20061108
603
TX1074508-UN: Travel Alarm Circuit

LEGEND:
F5 - Travel Alarm 5 A Fuse (marked OPT. 1)
H4 - Travel Alarm
The travel alarm circuit consists of a travel pressure sensor (B34), main controller (A3), travel alarm (H4), and a
travel alarm cancel switch (S13).
604
The circuit is designed to warn bystanders of machine movement by signaling with an audible alarm any time the
travel levers are moved.
Power to the travel alarm pin 1 comes from travel alarm 5 A fuse (F5). When the travel levers are moved, travel
pressure sensor (B34) senses pilot pressure and sends a signal to the main controller (A3) terminal C2. When
signal is received from travel pressure sensor, the main controller provides access to ground at terminal A28 to
the travel alarm (H4) pin 2, activating the alarm.
When pressed, the travel alarm cancel switch (S13) applies ground to pin 4 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. The travel alarm (H4) is reset when
the control levers are returned to the neutral position. The travel alarm cancel switch (S13) must be pressed and
released again to cancel the alarm.
LD30992,0000218-19-20121126
605
TX1074507-UN: Windshield Wiper and Washer Circuit Schematic

LEGEND:
A9 - Switch Panel
F2 - Windshield Wiper and Washer 10 A Fuse (Marked WIPER)
F62 - Wiper Motor Assembly Circuit Breaker
G1 - Battery
G2 - Battery
K19 - Battery Relay
S1 - Key Switch
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 monitor controller and the
state of the wiper motor internal position status switch.
Windshield Wiper Continuous Operation— When windshield wiper and washer switch (S9) is placed in the ON
position, windshield wiper relay (K6) is energized by ground at terminal A2 and A11 of monitor controller (A4).
Power for windshield wiper motor (M5) is supplied from windshield wiper and washer 10 amp fuse (F2). When
ground for windshield wiper motor is supplied through terminals 3 and 5 of energized windshield wiper relay (K6),
the wiper motor will run. The wiper motor drives a pitman arm assembly which moves the wiper blade back and
606
forth across the windshield.
Windshield wiper operates at a constant speed.
Windshield Wiper Intermittent Operation— When windshield wiper and washer switch (S9) is placed in INT
position, monitor controller and display (A4) intermittently grounds terminal A2 and A11. The monitor controller
controls wiper delay time.
Windshield Wiper Park Operation— When windshield wiper and washer switch (S9) is turned to the OFF,
windshield wiper motor continues to run until a cam driven switch inside the wiper assembly opens and removes
power from the motor. The cam driven switch applies ground to the windshield wiper motor (M5) terminal 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 wiper motor reaches the park position, ground is removed from motor
terminal S by the internal switch, and the wiper motor stops.
Windshield Washer Operation— When windshield wiper and washer switch (S9) is pressed, windshield washer
relay (K9) is energized by ground at terminal A10 of monitor controller and display (A4). Power is applied to
windshield washer motor (M6) from windshield wiper and washer 10 amp fuse (F2) through terminals 3 and 5 of
energized relay (K9). The windshield washer pump 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 terminal A10 of monitor controller, and the washer motor stops.
LD30992,0000219-19-20100422
607
TX1076337-UN: Pilot Shutoff Circuit

LEGEND:
F4 - Solenoid 10 A Fuse (Marked SOLENOID)
G1 - Battery
G2 - Battery
K2 - Pilot Shutoff Relay
K5 - Security Relay
S1 - Key Switch
V4 - Security Diode
V5 - Start Relay Diode
The pilot shutoff circuit enables or disables (unlocks or locks) the pilot oil thus enabling or disabling the machine
hydraulics. The pilot shutoff circuit consists of the pilot shutoff switches 1 and 2 (S3 and S4), pilot shutoff diode
(V8), pilot shutoff solenoid (Y10), pilot shutoff solenoid relay (K2), security relay (K5), monitor controller (A4),
security diode (V4), and start relay diode (V5).
When the pilot shutoff lever is in the rearward (locked) position, the monitor pin (B19) detects a ground through
608
pilot shutoff diode (V8) indicating that both switches are in the same position. This allows the monitor to diagnose
if there is a malfunction with one of the switches. With the pilot shutoff lever in the rearward position, ground is not
detected through start relay diode (V5) to monitor pin (B12). With no ground signal at monitor pin (B12), the pilot
shutoff solenoid relay (K2) is not energized, which keeps the pilot shutoff solenoid (Y10) de-energized and the
pilot hydraulics disabled (locked).
When the pilot shutoff lever is moved to the forward (unlocked) position, the monitor pin (B19) detects a ground
though pilot shutoff diode (V8) 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. With the pilot shutoff lever in the forward
(unlocked) position, ground passes through the pilot shut off switches and through start relay diode to monitor
controller pin (B12). With a ground signal at monitor controller pin (B12), the monitor controller applies ground to
pin (B2) to ground pilot shutoff solenoid relay pin (2). This energizes the pilot shutoff solenoid relay which then
applies ground from de-energized security relay (K5) to pilot shutoff solenoid. This activates the pilot shutoff
solenoid, enabling (unlocking) the pilot hydraulics.
When the monitor security is active, the monitor controller pin (A4) is grounded, energizing the starter relay (K4)
and security relay (K5) through security diode (V4). Energized security relay (K5) removes ground to pilot shutoff
solenoid relay. If pilot shutoff lever is in the forward (unlocked) position (pilot shutoff solenoid relay energized), the
ground path to the pilot shutoff solenoid is broken, preventing the pilot hydraulics from being enabled (unlocked).
This keeps the machine from being operated when the security system is active.
NOTE:
When security signal is present and monitor controller pin (A4) is grounded, starter relay (K4) is
also energized, which prevents the machine from being started. See Starting and Charging Circuit
LD30992,000021A-19-20100426
609
TX1074510-UN: Attachment Control Circuit

LEGEND:
F5 - Travel Alarm 5 A Fuse (Marked OPT. 1)
V41 - Secondary Relief Solenoid Vlave Diode
610
V43 - 2-Speed Activation Solenoid Diode
Y43 - 2-Speed Activation Solenoid
The main controller (MCF) and monitor allow for the selection of up to five 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 WinDr. to return the machine to the
attachment that was last selected when the machine was powered down. Each attachment selection (1 through 5)
can be customized using WinDr. and the monitor.
WinDr. can adjust:
Attachment name
Attachment number
Pump flow
Engine speed
Secondary relief selection
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, or 5)
Pump flow
Engine speed
Secondary relief selection (ON or OFF)
Return oil flow selection (O/T or C/V)
2-Speed selection (ON or OFF)
Accumulator selection (ON or OFF)
611
TX1074619-UN: Work Mode Screen
TX1074620-UN: Attachment Specification Screen

LEGEND:
1 - Dig Mode
612
2 - ATT1 (Attachment 1)
6 - ATT5 (Attachment 5) (Turned OFF)
10 - Attachment Name
11 - Attachment Number
12 - Maximum Pump Flow Rate
13 - Maximum Engine Speed
14 - Valve Selector
15 - 2-Speed Selector
16 - Accumulator
17 - Secondary Hydraulic Relief Selector
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.
Attachment Number— Each attachment can be assigned a number from 1 through 5. Each attachment has a
static number that refers to the position of the attachment icon on the monitor. For example, ATT1 (attachment 1)
is always in the farthest left position next to dig mode on the monitor and ATT5 (attachment 5) is always in the
farthest right position on the monitor work mode selection screen.
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).
613
TX1074621-UN: Attachment Adjustment—Pump Flow Rate
TX1074622-UN: Attachment Adjustment—Priority Level

LEGEND:
20 - Pump 2 Flow Rate Adjustment
614
21 - Priority Level Adjustment
Maximum Pump Flow— The maximum pump flow can be adjusted using WinDr. Adjustments made to pump
flow in WinDr. are only approximate values. The machine is not designed to measure pump flow and therefore the
values in WinDr. and the monitor are calculated approximations. Actual flow must be measured using a flow meter
to accurately adjust pump flow. See Pump Flow Test . (Group 9025-25.)
In WinDr. pump 1 and pump 2 flow rates can be adjusted individually. If 2-speed is not selected (OFF), only pump
2 is used to run the attachment. In this mode, only adjustments to pump 2 will affect the flow to the attachment.
Pump 2 flow rate adjustments are controlled by the main controller (MCF) with the pump 2 flow rate limit solenoid.
See Main Controller (MCF) Circuit Theory of Operation for more information. (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 Monitor
Menu Operation . (Group 9015-16.)
NOTE:
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 flow meter to accurately set pump flow. If 2-speed is
selected (ON), small adjustments can be made to the priority of oil flow. The priority can be adjusted to favor the
attachment or the boom-up, arm-out, swing and travel functions. Adjustments are only approximate and relative to
the overall selected flow. Actual flow must be measured using a flow meter to accurately set pump flow. See
Pump Flow Test (Group 9025-25.) and see Monitor Menu Operation . (Group 9015-16.)
Maximum Engine Speed— The maximum engine speed for an attachment may be adjusted using WinDr. 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.
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 (MCF) on pin A26. When the monitor displays “C/V,” the return oil from the attachment
flows through the control valve before it returns to the hydraulic oil tank. When the monitor displays “O/T,” 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 WinDr. The valve selector will default to “C/V” or
control valve in dig mode (no attachment selected).
NOTE:
Selector valve control will not work properly unless appropriate kits are installed on machine.
Accumulator— The accumulator icon on the monitor controls the accumulator solenoid valve (Y42). The
accumulator solenoid valve is powered by the travel alarm 5 A fuse (F5) and grounded by the main controller on
pin B25. When the accumulator is “ON,” the accumulator solenoid valve is activated, pilot oil is sent to the
accumulator control valve. The accumulator shutoff valve shifts, connecting the accumulators to the supply and
return lines of the attachment hydraulic circuit. The accumulators help reduce the shock of oil pressure and
buffers vibrations when certain types of attachments are used, such as breakers. When the accumulator is “OFF,”
the accumulator solenoid valve is deactivated and the accumulators are isolated from the attachment hydraulic oil
circuit. The accumulator status for each attachment can be adjusted using WinDr.
The accumulator solenoid valve diode (V42) suppresses voltage spikes created when the solenoid valve is
615
activated or deactivated.
NOTE:
Accumulator control will not work properly unless appropriate kits are installed on machine.
2-Speed Selector— The 2-Speed selector icon on the monitor controls the 2-speed activation solenoid valve
(Y43) and the flow rate adjustment solenoid valve (Y44). The 2-speed activation solenoid valve is powered by
travel alarm 5 A fuse (F5) and grounded by the main controller (MCF) pin B23. The flow rate adjustment solenoid
valve is powered by main controller (MCF) pin A7 and grounded on pin A23. 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
(MCF) can vary the signal to the flow rate adjustment solenoid valve to vary the pilot oil pressure at the auxiliary
flow rate control valve. This allows for adjustment of the priority of the attachment function over arm-out, boom-
up, swing and travel. The 2-speed selector status can be adjusted for each attachment using WinDr. Adjustments
to the priority level can be made in the monitor in the attachment adjustment menu. See Monitor Menu Operation .
(Group 9015-16.)
The 2-speed activation solenoid valve diode (V43) suppresses voltage spikes created when the solenoid valve is
energized and de-energized.
NOTE:
2-Speed control will not work properly unless appropriate kits are installed on machine.
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 (MCF) pin A27. 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 WinDr.
The secondary relief solenoid valve diode (V41) suppresses voltage spikes created when the solenoid valve is
energized and de-energized.
LD30992,000036A-19-20070125
616
JDLink™ With GlobalTRACS® Terminal (GTT) Controller
NOTE:
For electrical schematic information, refer to the system functional schematic (SE22—SE24). See
System Functional Schematic . (Group 9015-10.)
The JDLink™ is a system used to communicate machine information and GPS location to an internet website
using GPS and cellular connections provided by GlobalTRACS® terminal (GTT) controller (A11).
For more information on the JDLink™ system, see General Information . (CTM114519.)
JDLink™ With Modular Telematics Gateway (MTG)
TX1089680-UN: JDLink™ Circuit Schematic

LEGEND:
A6002 - Satellite (SAT) Module
A6003 - Satellite Antenna
F6000 - JDLink™ Unswitched Power 7.5 A Fuse
F6001 - JDLink™ Ground 7.5 A Fuse
F6002 - JDLink™ Switched Power 7.5 A Fuse
G1 - Battery
G2 - Battery
K19 - Battery Relay
R12 - JDLink™ Harness CAN Termination Resistor
S1 - Key Switch
617
W41 - Battery-to-Frame Ground
X34 - Cab Harness-to-Information Controller 17-Pin Connector C
X6001 - GPS Antenna RED Connector
X6002 - Cellular Antenna BLK Connector
X6005 - Satellite Antenna Connector
X6015 - Satellite (SAT) Module Connector
The JDLink™ is a system used to communicate machine information and GPS location to an internet website
using GPS and cellular connections provided by the modular telematics gateway (MTG) (A6000).
The optional satellite (SAT) module (A6002) allows wireless data transfer in remote areas where a cellular signal
is not consistently available.
For more information on the JDLink system, see System Overview . (TM114519.)
MTG and SAT Power-Up (Power and Ground)— The MTG and SAT receive unswitched battery power from
fuse (F6000) at terminal M2 on MTG connector (X6014) and SAT connector (X6015).
Ground is provided to the MTG and SAT at terminal M1 on MTG connector (X6014) and SAT connector (X6015)
through fuse (F6001).
Ground is also provided to the MTG at terminal F3 on MTG connector (X6014) from the cab harness ground 1
(W35).
When key switch (S1) is turned to the ON or START position, current flows to the coil of battery relay (K19),
energizing the relay.
With the battery relay energized, current flows through fuse (F6002) to terminal L1 on MTG connector (X6014),
powering up the controller.
JDLink CAN Communication— The MTG communicates across the CAN data line with the following controllers:
Engine Control Unit (ECU) (A1)

Main Controller (MCF) (A3)
Monitor Controller (MON) (A4)
Information Controller (ICF) (A5)
For more information on the CAN data line, see Controller Area Network (CAN) Theory of Operation . (Group
9015-15.)
The MTG stores the information collected from the machine controllers and transmits the information to the
618
JDLink servers.
Service ADVISOR™ diagnostic connector (X1) is used to interface to the MTG. See Service ADVISOR™
Connection Procedure . (Group 9015-20.)
CS33148,0004020-19-20170315
619
For monitor operation, See Monitor . (Owner's Manual).
LD30992,0000558-19-20070112
620
For monitor operation, See Monitor . (Owner's Manual).
LD30992,0000558-19-20070112
621
TX1077067-UN: Default Screen

LEGEND:
11 - Menu Button
12 - Return Button
1. Press button (12), then turn ignition key to the ON position. Once the default screen appears, let go of
the button.
2. Press button (11) for the menu.
3.
TX1077068-UN: Main Menu Screen

LEGEND:
1 - Down Arrow Button
622
2 - Up Arrow Button
11 - Menu Button
12 - Return Button
13 - Select Button
Use button (1) or (2) to scroll to the Service Menu.
4. Press button (13) to enter the Service Menu.

LEGEND:
2 - Up Arrow Button
11 - Menu Button
12 - Return Button
13 - Select Button
From this screen there are three menus to choose from:
Troubleshooting menu
Monitoring menu
Controller menu
Use buttons (1) or (2) to highlight the desired menu. Press button (13) to select the highlighted menu option or
press button (12) to return to the previous screen.
Troubleshooting Menu
623

LEGEND:
2 - Up Arrow Button
11 - Menu Button
12 - Return Button
13 - Select Button
The troubleshooting menu displays fault codes (diagnostic trouble codes (DTCs)) by the controller they originated
from. Controllers listed are:
Main Controller (MCF)

Engine Governor Controller (also known as Engine Control Unit (ECU))
Monitor Controller
Information Controller (ICF)
1. From the service menu screen, select Troubleshooting, then press button (13).
2. If a diagnostic trouble codes is present, press button (13) to view more information on the code. If more
than one controller displays diagnostic trouble codes, use buttons (1) or (2) to scroll to the desired
controller.
624
TX1077069-UN: Fault Code List

LEGEND:
2 - Up Arrow Button
12 - Return Button
From the main fault code screen, use buttons (1) or (2) to scroll to the desired to code to be viewed and press
button (12).
Monitoring
TX1077071-UN: Monitoring Screen

LEGEND:
2 - Up Arrow Button
3 - Hold Button
4 - Reset Button
12 - Return Button
625
13 - Select Button
The monitoring menu displays temperature and pressure data received from each controller.
Use buttons (1) or (2) to scroll through the list of items.
NOTE:
Only four items may be displayed at one time.
Press the select button (13) to move the highlighted item to the top of the list.
Press the hold button (3) to freeze the current readings. Press the hold button again to unfreeze the readings.
Press the reset button (4) to reset the monitoring data item list to the default order.
Press the return button (12) to return to the previous screen.
TX1077072-UN: Monitoring Reset Screen

LEGEND:
12 - Select Button
13 - Return Button
Press button (13) to reset the monitoring data item list or press button (12) to return to the previous screen.
Controller Version
626
TX1077073-UN: Controller Version Screen

LEGEND:
12 - Return Button
The controller version screen displays the version of each controller.
Press button (12) to return to the previous screen.
LD30992,0000559-19-20100312
627
Monitor Data Items
Monitor Data Items
Monitor Data Items List can be rearranged. See Monitor Service Menu Operation for instructions to access and
rearrange monitor data items. (Group 9015-16.)
-: Monitor Data Items
Items Units Comment
Engine Torque % N/A
Coolant Temperature (E) °C Reading From Engine Coolant Temperature Sensor B4
Fuel Temperature °C Reading From Fuel Temperature Sensor B5
Engine Oil Pressure kPa Reading From Engine Oil Pressure Sensor B11
Atmospheric Pressure kPa N/A
Intake Air Temperature °C N/A
Boost Pressure kPa N/A
Boost Temperature °C Reading From Manifold Air Temperature Sensor B9
Coolant Temperature (M) °C Reading From Engine Coolant Temperature Sensor B4
Target Engine Speed min1 Reading From Main Controller (MCF) A3
Actual Engine Speed min1 Reading From Engine Control Unit (ECU) A1
Pump 1 Delivery Pressure MPa Reading From Pump 1 Delivery Pressure Sensor B35
Pump 1 Pump Control Pressure MPa Reading From Pump 1 Control Pressure Sensor B36
Pump 1 Target Flow Rate L/min Calculated From Main Controller (MCF) A3
Pump 2 Target Flow Rate L/min Calculated From Main Controller A3
Front Attachment Control Pilot Pressure MPa Reading From Front Attachment Pressure Sensor B32
Boom Raise Control Pilot Pressure MPa Reading From Boom Up Pressure Sensor B30
Arm Roll-In Pilot Pressure MPa Reading From Arm In Pressure Sensor B31
Swing Control Pilot Pressure MPa Reading From Swing Pressure Sensor B33
Travel Control Pilot Pressure MPa Reading From Travel Pressure Sensor B34
Attachment Control Pilot Pressure MPa Main Controller A3 Calculated For Y20
EC Dial Angle V Reading From Engine Speed Dial R15
Hydraulic Oil Temperature °C Reading From Hydraulic Oil Temperature Sensor B40
Pump Torque Proportional Valve MPa Main Controller A3 Calculated For Y21
Digging Regeneration Valve MPa Main Controller A3 Calculated For Y22
Arm Regeneration Valve MPa Main Controller A3 Calculated For Y23
Travel Mode Control Pressure MPa Main Controller A3 Calculated For Y25
Power Digging Control Pressure MPa Main Controller A3 Calculated For Y24
628
Monitor Data Items
Power Mode - Reading From Power Mode Switch S12
Travel Mode Switch - Reading From Travel Speed Switch S11
Power Digging Switch - Reading From Power Dig Switch S7
Radio Signal Strength - N/A
LD30992,00001C5-19-20061109
629
Monitor Data Items
Monitor Data Items
Monitor Data Items List can be rearranged. See Monitor Service Menu Operation for instructions to access and
rearrange monitor data items. (Group 9015-16.)
-: Monitor Data Items
Items Units Comment
Engine Torque % N/A
Coolant Temperature (E) °C Reading From Engine Coolant Temperature Sensor B4
Fuel Temperature °C Reading From Fuel Temperature Sensor B5
Engine Oil Pressure kPa Reading From Engine Oil Pressure Sensor B11
Atmospheric Pressure kPa N/A
Intake Air Temperature °C N/A
Boost Pressure kPa N/A
Boost Temperature °C Reading From Manifold Air Temperature Sensor B9
Coolant Temperature (M) °C Reading From Engine Coolant Temperature Sensor B4
Target Engine Speed min1 Reading From Main Controller (MCF) A3
Actual Engine Speed min1 Reading From Engine Control Unit (ECU) A1
Pump 1 Target Flow Rate L/min Calculated From Main Controller (MCF) A3
Pump 2 Target Flow Rate L/min Calculated From Main Controller A3
Front Attachment Control Pilot Pressure MPa Reading From Front Attachment Pressure Sensor B32
Boom Raise Control Pilot Pressure MPa Reading From Boom Up Pressure Sensor B30
Arm Roll-In Pilot Pressure MPa Reading From Arm In Pressure Sensor B31
Swing Control Pilot Pressure MPa Reading From Swing Pressure Sensor B33
Travel Control Pilot Pressure MPa Reading From Travel Pressure Sensor B34
Attachment Control Pilot Pressure MPa Main Controller A3 Calculated For Y20
EC Dial Angle V Reading From Engine Speed Dial R15
Hydraulic Oil Temperature °C Reading From Hydraulic Oil Temperature Sensor B40
Pump Torque Proportional Valve MPa Main Controller A3 Calculated For Y21
Digging Regeneration Valve MPa Main Controller A3 Calculated For Y22
Arm Regeneration Valve MPa Main Controller A3 Calculated For Y23
Travel Mode Control Pressure MPa Main Controller A3 Calculated For Y25
Power Digging Control Pressure MPa Main Controller A3 Calculated For Y24
630
Monitor Data Items
Power Mode - Reading From Power Mode Switch S12
Travel Mode Switch - Reading From Travel Speed Switch S11
Power Digging Switch - Reading From Power Dig Switch S7
Radio Signal Strength - N/A
LD30992,00001C5-19-20061109
631
1.
TX1002673-UN: Default Screen

LEGEND:
12 - Back Button
13 - Menu Button
Press and hold the back button (12) and turn key switch to the ON position. This step adds the service
menu option to the main menu.
2. After the default screen displays, push the menu button (13) to display the main menu.
3.
TX1077074-UN: Main Menu

LEGEND:
1 - Button 1
632
2 - Button 2
11 - Select Button
Select Service Menu from the main menu using buttons (1) and (2), then push the select button (11) to
display the service menu.
4.

LEGEND:
1 - Button 1
2 - Button 2
11 - Select Button
Select Troubleshooting from the service menu using buttons (1) and (2), then push the select button (11)
to display the Troubleshooting screen.
5. The Troubleshooting screen displays the current code status for the four main machine controllers:
Main Controller (MCF)

Engine Governor Controller (also known as engine control unit [ECU])
Monitor Controller
Information Controller (ICF)
633
6.

LEGEND:
1 - Button 1
2 - Button 2
11 - Select Button
Any controllers listed as abnormal have diagnostic trouble codes associated with them. Select the
appropriate controller name using buttons (1) and (2), then push the select button (11) to display the
Main Fault Code screen.
7. NOTE:
The monitor can display up to 20 diagnostic trouble codes for each controller. The Main
Fault Code screen can display 10 diagnostic trouble codes at one time. If the Main Fault
Code screen displays 10 codes, use the buttons (1) and (2) to view any additional codes
on the next screen.
634
TX1077069-UN: Main Fault Code Screen
LEGEND:
1 - Button 1
2 - Button 2
6 - Return to Default Screen Button
12 - Back Button
View the diagnostic trouble codes for the selected controller.
See Main Controller (MCF) Diagnostic Trouble Codes . (Group 9001-10.)
See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
See Information Controller (ICF) Diagnostic Trouble Codes . (Group 9001-30.)
See Monitor Controller (MON) Diagnostic Trouble Codes . (Group 9001-50.)
8. Press the back button (12) to return to the Troubleshooting screen and select another controller, or push
the Return to Default Screen button (6) to display the default screen.
LD30992,00001C6-19-20061213
635
Use the following information to identify which JDLink™ system is equipped. One of the following systems may be
equipped:
GlobalTRACS® Terminal (GTT) and Machine Information Gateway (MIG) JDLink™ System
Modular Telematics Gateway (MTG) and Satellite (SAT) JDLink™ System
NOTE:
If JDLink™ system contains two control units, control units may be installed side by side or
stacked on top of each other.
Locate JDLink™ system. The following are typical system locations according to machine family. JDLink™
system may not be installed at suggested location due to specific machine options or configuration. If necessary,
refer to JDLink™ component location in Electrical—System Diagrams (Group 9015-10.)
-: JDLink™ System Locations
JDLink™ System Locations
Machine Family Location
Loader Backhoe Inside battery box.
Crawler Mounted to bottom of operator station floor or floor plate.
High Speed Dozer Inside load center (outer access door on right side of cab).
4WD Loader Inside load center (outer access door at right rear of cab).
Inside compartment on left side of machine, directly behind cab.

Excavator
Mounted to sheet metal near swing motor.
Articulated Dump Truck (ADT) Inside cab, behind front lower left panel (under load center).
Below main frame sheet metal panel (directly in front of cab).

Motor Grader
Behind rear panel in cab (panel behind seat)
Skidder Below right rear cab console.
Wheeled Feller Inside load center (outer access door on right side of cab).
Buncher/Harvester
Track Feller Below seat in cab.

Buncher/Harvester Mounted to inside of engine enclosure door.
Mounted to bottom of plate covering heating and air conditioning system behind
Knuckleboom Loader
seat in cab.
Forestry Swing Machines Left inner side of boom pivot pin/mounting frame.
GTT and MIG System
636
TX1143631A-UN: GTT (older)
TX1143632A-UN: MIG (if equipped)
TX1143633A-UN: GTT (newer) and MIG (stacked installation)

LEGEND:
1 - GTT (newer)
2 - MIG (if equipped)
GTT is main control unit. MIG control unit is optional.
Key distinguishing characteristics of GTT/MIG:
Single large 70-pin connector on face of control unit, along with antenna connectors.
GTT is black, MIG is silver.
MTG and SAT System
637
MTG is main control unit. SAT control unit is optional.
Key distinguishing characteristics of MTG/SAT:
TX1143680A-UN: MTG
TX1143681A-UN: SAT (if equipped)
Three smaller connectors on side of control unit. All connectors are located on sides of control unit.
Both control units are silver.
Both control units are very similar (SAT has less connectors on one side).
AA95137,00000DA-19-20131108
638
JDLink™ Connection Procedure—With GlobalTRACS® Terminal (GTT) Controller
TX1089059A-UN: GT Config Tool Adapter Connector

LEGEND:
1 - GT Config Tool Adapter Connector
1. Locate GT config tool adapter connector (1). For GTT controller location, see JDLink™ System
Harnesses (W50, W51, W52, W53, and W54) Component Location—If Equipped . (Group 9015-15.)
2. NOTE:
CV90-J1006 GlobalTRACS® Config Tool Cable is included in the 65-J1115-11 PC

based JDLink™ Tool Kit.
Connect one end of CV90-J1006 GlobalTRACS® Config Tool Cable to the GT config tool adapter
connector (1), and connect the other end to a COM port on the computer.
NOTE:
If the computer is not equipped with COM ports, a USB-to-serial adapter cable will be
required to simulate a COM port for use with the GT Configuration Tool software.
For more information on connecting to the GTT, see Connect PC Laptop to

GlobalTRACS® Terminal (GTT) . (CTM114519.)
JDLink™ Connection Procedure—With Modular Telematics Gateway (MTG)
Connect to JDLink™ using Service ADVISOR™ . See Service ADVISOR™ Connection Procedure . (Group
901520.)
AA95137,0000C23-19-20170315
639
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.)
LD30992,00001C7-19-20060921
640
1. Locate service laptop close to machine, or in the cab if diagnostics are to be performed while machine is
being operated.
2.
TX1002844A-UN: Service ADVISOR Machine Connection (PDM shown)

LEGEND:
1 - Diagnostic Connector
2 - PDM
3 - Service Laptop
4 - PDM to Machine Cable
5 - PDM to Service Laptop Cable
Open left-side compartment behind cab and remove cap from diagnostic connector (1).
3. Connect service laptop to machine using appropriate cables (4 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.
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.)
LD30992,00001C8-19-20060921
641
TX1002938A-UN: Service ADVISOR—Diagnostic Trouble Codes

LEGEND:
1 - Diagnostics Shortcut Bar
2 - Connected Diagnostic Trouble Codes Folder
3 - Readings Tab
4 - Connected Diagnostic Trouble Codes Tab
1. Connect service laptop to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
2. Open Service ADVISOR and display appropriate model information.
3. From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).
4. Click the Connected Diagnostic Trouble Codes folder (2).
642
5.
TX1002997A-UN: Connection Options Dialog Box

Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.
6.
TX1003001A-UN: Select Readings Adapter Dialog Box

LEGEND:
5 - Available Adaptors Drop-Down List
6 - Selected Models List
7 - Change Selected Models Button
On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not,
select correct adapter from drop-down list (5). Options include:
Electronic Data Link (EDL) Stand-alone USB Device
Electronic Data Link (EDL) Using Bluetooth
Parallel Data Module (PDM)
Parallel Data Module (PDM) With USB Adapter
7. Make sure correct machine to connect to displays in the Selected Models list (6). If not, click the Change
Selected Models button (7).
8. Click OK to connect to machine.
9. After Service ADVISOR connects to machine, both the Readings tab (3) and Connected Diagnostic
Trouble Codes tab (4) display.
643
10. Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed
description for servicing that diagnostic trouble code.
11. NOTE:
Use the lock topic feature within Service ADVISOR to open multiple windows if machine
is transmitting more than one diagnostic trouble code. Refer to Service ADVISOR
system instructions for using this feature.
Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic
trouble codes.
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644
Fuse Test
Fuse Test
TX1000782-UN: Fuse Block Layout

LEGEND:
F1 - Work and Drive Lights 20 A Fuse (Marked LAMP)
F2 - Windshield Wiper and Washer 10 A Fuse (Marked WIPER)
F3 - Heater and Air Conditioner 20 A Fuse (Marked HEATER)
F4 - Solenoid 10 A Fuse (Marked SOLENOID)
F5 - Travel Alarm 5 A Fuse (Marked OPT. 1 [ALT])
F6 - 12 Volt Power Outlet 10 A Fuse (Marked OPT. 2 [ALT])
F7 - Start Aid 20 A Fuse (Marked START AID) (Not Used) (Field Option)
F8 - Engine Control Unit (ECU) 20 A Fuse (Marked ECM)
F9 - Radio Backup 10 A Fuse (Marked BACK UP)
F10 - Information Controller and Main Controller Battery Power 5 A Fuse (Marked CONTROLLER)
F11 - Radio and Dome Light 5 A Fuse (Marked RADIO)
F12 - Lighter 10 A Fuse (Marked LIGHTER)
F13 - Cab Auxiliary Power Connector 1 10 A Fuse (Marked AUX.)
F14 - Not Used
F15 - Heater and Air Conditioner 5 A Fuse (Marked AIRCON)
F16 - Controller Key Switch Signal 5 A Fuse (Marked POWER ON)
F17 - Horn 10 A Fuse (Marked HORN)
F18 - Service Advisor Diagnostic Connector Power 5 A Fuse (Marked DIAG)
F19 - Controller 5 A Fuse (Marked SW. BOX)
F20 - Optional Equipment 5 A Fuse (Marked (OPT. 3 [BATT])
Some symptoms may indicate an expensive component failure, 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 Test
Fuse Test
645
Fuse Test
Fuse Test Results of Fuse Failure
F1—Work and Drive Lights 20 A Fuse Turn key switch ON. Work and drive lights will
(Marked LAMP) Turn light switch to first or second not operate.
position. If work or drive lights operate,
fuse is OK.
F2—Windshield Wiper and Washer 10 A Turn key switch ON. Windshield wiper will not
Fuse (Marked WIPER) Turn windshield wiper ON. If wiper operate.
operates, fuse is OK.
F3—Heater and Air Conditioner 20 A Turn key switch ON. Heater and air conditioner
Fuse (Marked HEATER) Push blower speed switch. If blower blower will not operate.
operates in any speed, fuse is OK.
F4—Solenoid 10 A Fuse (Marked Start machine. If hydraulic system Travel and stick functions
SOLENOID) functions normally, fuse is OK. will not operate.
F5—Travel Alarm 5 A Fuse (Marked Check with multimeter. Optional equipment will not
OPT. 1 [ALT]) operate.
F6—12 Volt Power Outlet 10 A Fuse Check with multimeter. 12 Volt power outlet will not
(Marked OPT. 2 [ALT]) operate.
F7—Start Aid 20 A Fuse (Marked START If start aid works, fuse is OK. (Field Engine starts hard when
AID) (Not Used) (Field Option) Option) cold.
Start aid will not operate.
F8—Engine Control Unit (ECU) 20 A Turn key switch to START. Engine cranks but will not
Fuse (Marked ECM) If engine starts, fuse is OK. start.
F9—Radio Backup 10 A Fuse (Marked Turn key switch ON. Radio clock will not work
BACK UP) Turn radio ON. If clock is not reset, and with key OFF and will reset
station presets are saved, fuse is OK. with key ON.
Radio station presets will
not be saved.
F10—Information Controller and Main Start machine. RPM dial will not work.
Controller Battery Power 5 A Fuse If RPM dial works, fuse is OK. Engine will run at 1200
(Marked CONTROLLER) RPM.
F11—Radio and Dome Light 5 A Fuse Turn key switch ON. Radio will not operate.
(Marked RADIO) Turn radio ON. If radio and dome light Dome light will not operate.
operate, fuse is OK.
F12—Lighter 10 A Fuse (Marked Turn key switch ON. Lighter will not operate.
LIGHTER) Push lighter. If lighter gets hot, fuse is
OK.
F13—Cab Auxiliary Power Connector 1 Turn key switch ON. Optional equipment will not
10 A Fuse (Marked AUX.) If optional equipment works, fuse is OK. operate.
F15—Heater and Air Conditioner 5 A Turn key switch ON. If air conditioner Air conditioner and heater
Fuse (Marked AIRCON) and heater operate, fuse is OK. will not operate.
Air conditioner display will
not illuminate.
F16—Controller Key Switch Signal 5 A Turn key switch to START. Engine cranks but will not
Fuse (Marked POWER ON) If engine starts, fuse is OK. start.
646
Fuse Test
F17—Horn 10 A Fuse (Marked HORN) Turn key switch ON. Horn will not operate.
Push horn switch. If horn operates, fuse
is OK.
F18—Service Advisor Diagnostic If Service Advisor will connect to engine Service Advisor will not
Connector Power 5 A Fuse (Marked control unit, fuse is OK. connect to engine control
DIAG) unit.
F19—Controller 5 A Fuse (Marked SW. With key switch OFF, push hour meter Fuel and hour check
BOX) button. If Fuel and hour check are function will not operate.
displayed, fuse is OK.
F20—Optional Equipment 5 A Fuse Check with multimeter. Optional equipment will not
(Marked (OPT. 3 [BATT]) operate.
TX1000660-UN: Auxiliary Fuse Block Layout

LEGEND:
F21 - Air Suspension Seat 10 A Fuse (Marked SEAT HEATER)
F22 - Front Cab Light 1 10 A Fuse (Marked CAB LAMP FRONT)
F23 - Rear Cab Light 10 A Fuse (Marked CAB LAMP REAR)
F24 - 12 Volt Power Unit 10 A Fuse (Marked 12V UNIT)
F25 - IMOBI 5 A Fuse (Marked IMOBI)
F26 - Quick Hitch 5 A Fuse (Marked QUICK HITCH)
F28 - Not Used
F29 - Not Used
F30 - Not Used
F31 - Seat Compressor 10 A Fuse (Marked SEAT COMPR)
F32 - Front Cab Light 2 10 A Fuse (Marked CAB LAMP FRONT+2)
F33 - Warning Lamp 10 A Fuse (Marked WARNING LAMP)
F35 - Not Used
F36 - Not Used
F37 - Not Used
F38 - Not Used
647
Fuse Test
F39 - Not Used
F40 - Not Used
-: Fuse Test
Fuse Test
F21—Heated Air Seat 10 A Fuse (Marked SEAT HEATER) Check with Optional equipment will not
multimeter. operate.
F22—Front Cab Light One 10 A Fuse (Marked CAB LAMP Check with Optional equipment will not
FRONT) multimeter. operate.
F23—Rear Cab Light 10 A Fuse (Marked CAB LAMP Check with Optional equipment will not
REAR multimeter. operate.
F24—12 Volt Power Unit 10 A Fuse (Marked 12V UNIT) Check with Optional equipment will not
F25—IMOBI 5 A Fuse (Marked IMOBI) Check with Optional equipment will not
F26—Quick Hitch 5 A Fuse (Marked QUICK HITCH) Check with Optional equipment will not
F27—Cab Auxiliary Power Connector 3 5 A Fuse (Marked Check with Optional equipment will not
AUX.3) multimeter. operate.
F31—Seat Compressor 10 A Fuse (Marked SEAT Check with Optional equipment will not
COMPR) multimeter. operate.
F32—Front Cab Light 2 10 A Fuse (Marked CAB LAMP Check with Optional equipment will not
FRONT+2) multimeter. operate.
F33—Warning Lamp 10 A Fuse (Marked WARNING Check with Optional equipment will not
LAMP) multimeter. operate.
F34—Cab Auxiliary Power Connector 2 10 A Fuse (Marked Check with Optional equipment will not
AUX.2) multimeter. operate.
-: Fuse Test
Fuse Test
F60—Fusible Link 65A Turn key switch ON. All accessories other than radio will
If accessories operate, not work.
fuse is OK.
F61—Fusible Link 45A Turn key switch to START. Engine will not crank.
If engine cranks, fuse is All accessories will not work.
OK.
F62—Wiper Motor Assembly Circuit Breaker Turn key switch ON. Wiper Motor will not operate.
If wiper motor operates
fuse is OK.
F63—Glow Plug 50 A Fuse (6.8L Only) Not Used Not Used
648
Fuse Test
F64—Fuel Transfer Pump 15 A Fuse (9.0 L Not Used Not Used

Only)
F66—Fuel Transfer Pump 10 A Fuse (6.8L Not Used Not Used

Only) (Not Used)
RR71361,00001BE-19-20070118
649
Relay Test
Relay Test
T141788-UN: Relay Test
For location of relays See Cab Harness (W1) Component Location . (Group 9015-10.)
Connect a multimeter to terminals 1 and 2.
About 360—420 ohms must be measured. If not, relay has failed.
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.
CAUTION:
Do not connect relay directly to battery. Use a fused power source such as Cab Harness
Auxiliary Power Connector 1 (X25) in cab or external power supply.
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.
RR71361,00001BF-19-20070109
650
Pressure Sensor Resistance Test
1. A suspect pressure sensor can be checked by switching positions with a known good sensor. If the
problem follows the suspect pressure sensor, it has failed.
If the problem remains, the harness has failed.
2. To check a pressure sensor using a multimeter, remove it from the machine.
3. NOTE:
Resistance values for pump 1 delivery pressure sensor (B35) and pump 2 delivery
pressure sensor (B37) may vary widely. To verify the sensor's functionality, use the on-
board monitor or check for diagnostic trouble codes and to monitor the sensor's output.
See Monitor Data Items . (Group 9015-20.) See SERVICE ADVISOR™ Diagnostic
Application . (Group 9015-20.)
Measure resistance as indicated. Resistance may vary from one sensor to another.

Pressure Sensor Resistance Ranges
Pump 1 Control Pressure Sensor (B36) Resistance 5k—15k ohms (Pins 1—2)
30k—50k ohms (Pins 2—3)
Pump 2 Control Pressure Sensor (B38) Resistance 5k—15k ohms (Pins 1—2)
Boom Up Pressure Sensor (B30) Resistance 5k—15k ohms (Pins 1—2)
Front Attachment Pressure Sensor (B32) Resistance 5k—15k ohms (Pins 1—2)
Travel Pressure Sensor (B34) Resistance 5k—15k ohms (Pins 1—2)
Swing Pressure Sensor (B33) Resistance 5k—15k ohms (Pins 1—2)
Arm In Pressure Sensor (B31) Resistance 5k—15k ohms (Pins 1—2)
For location of pressure sensors, See Pump Harness (W8) Component Location and See Machine
Harness (W2) Component Location . (Group 9015-10.)
Pressure Sensor Voltage Test
1. No voltage at pressure sensors will generate diagnostic trouble codes. Disconnect harness connector
from a pressure sensor.
2. With key switch ON, measure voltage between terminals 1 and 3 of pressure sensor harness connector.
651

Pressure Sensor Voltage Ranges
Pump 1 Control Pressure Sensor (B36) Voltage 4.5—5.5 volts
Pump 1 Delivery Pressure Sensor (B35) Voltage 4.5—5.5 volts
Pump 2 Control Pressure Sensor (B38) Voltage 4.5—5.5 volts
Pump 2 Delivery Pressure Sensor (B37) Voltage 4.5—5.5 volts
Boom Up Pressure Sensor (B30) Voltage 4.5—5.5 volts
Arm In Pressure Sensor (B31) Voltage 4.5—5.5 volts
Front Attachment Pressure Sensor (B32) Voltage 4.5—5.5 volts
Travel Pressure Sensor (B34) Voltage 4.5—5.5 volts
Swing Pressure Sensor (B33) Voltage 4.5—5.5 volts
3. See Pump Harness (W8) Component Location and See Machine Harness (W2) Component Location
and See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
RR71361,00001C0-19-20061107
652
Solenoid Test
Solenoid Test
1. A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem
follows the suspect solenoid, it has failed.
2. To check a solenoid using an ohmmeter, remove it from the machine.
3. Measure resistance as indicated. Resistance may vary from one solenoid to another.

Excavator Solenoids
Reversing Fan Solenoid (Y9) Resistance 28—38 ohms
Pilot Shut-Off Solenoid (Y10) Resistance 42—58 ohms
RR71361,00001C1-19-20061027
653
1. A suspect solenoid can be checked by switching positions with a known good solenoid. If the problem
follows the suspect solenoid, it has failed.
2. To check a solenoid using an ohmmeter, remove it from the machine.
3. Measure resistance as indicated. Resistance may vary from one solenoid to another.

Main Controller Solenoids
Proportional Fan Speed Solenoid (Y8) Resistance 20—30 ohms
Pump 2 Flow Rate Limit Solenoid (Y20) (SB) Resistance 15.2—22.8 ohms
Torque Control Solenoid (Y21) (ST) Resistance 15.2—22.8 ohms
Dig Regenerative Solenoid (Y22) (SF) Resistance 15.2—22.8 ohms
Arm Regenerative Solenoid (Y23) (SC) Resistance 15.2—22.8 ohms
Power Dig Solenoid (Y24) (SG) Resistance 15.2—22.8 ohms
Travel Speed Solenoid (Y25) (SI) Resistance 15.2—22.8 ohms
RR71361,00001C2-19-20130311
654
JDG1478 Digital Multimeter
1. To check a sensor using a multimeter, remove the sensor from the machine.
2. Measure resistance as indicated. Resistance may vary from one sensor to another.
-: Hydraulic Oil Temperature Sensor Ranges
Hydraulic Oil Temperature Sensor Ranges
Resistance Temperature
14600—17800 ohms -20°C

-68°F
5880 ohms 0°C

32°F
2210—2690 ohms 20°C

68°F
1140 ohms 40°C

104°F
534 ohms 60°C

140°F
322 ohms 80°C

176°F
-: Ambient Air Temperature Sensor Ranges
Ambient Air Temperature Sensor Ranges
Resistance Temperature
8900 ohms 0°C

32°F
2500 ohms 20°C

68°F
For machine location of hydraulic oil temperature sensor (B40) and ambient air temperature sensor (B22), See
Machine Harness (W2) Component Location . (Group 9015-10.)
RR71361,00001C3-19-20070109
655
Alternator Test
Alternator Test
TX1045884-UN: Common Alternator Circuit

LEGEND:
1 - Battery
2 - Alternator
3 - Key Switch
4 - To Accessories
5 - ACC
6 - Alternator Excitation Diode
7 - Excitation Terminal (marked D+)
8 - B+
9 - Exciter Diodes
10 - Positive Diodes
11 - Negative Diodes
12 - Stator
13 - Excitation Winding (field)
14 - Regulator
15 - AC Terminal (marked W)
16 - To Display Module (indicator lamp)
1. 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground.
Voltage should be 13.5 VDC or greater [Note: For 12 V systems with maintenance free batteries, D+
and B+ voltage should be 14.1 VDC or greater.] .
2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be
13.5 VDC or greater [Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage
should be 14.1 VDC or greater.] .
3. If voltage from previous steps is below 13.5 VDC [ Note: For 12 V systems with maintenance free
batteries, D+ and B+ voltage should be 14.1 VDC or greater.] , check excitation by placing a jumper wire
between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC
or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire
656
Alternator Test
to D+ terminal).
4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be
6—7 VAC .
5. Repeat above steps with lights on to load the alternator.
6. If alternator does not produce specified voltage after testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator assembly if necessary. Test and repair if possible. If
alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
1. 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground.
Voltage should be 27.5 VDC or greater [Note: For 24 V systems with maintenance free batteries, D+
and B+ voltage should be 28.2 VDC or greater.] .
2. With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be
27.5 VDC or greater [Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage
should be 28.2 VDC or greater.] .
3. If voltage from previous steps is below 27.5 VDC [ Note: For 24 V systems with maintenance free
batteries, D+ and B+ voltage should be 28.2 VDC or greater.] , check excitation by placing a jumper wire
between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC
or greater, check for an open diode, wiring problem, or blown fuse in the alternator excitation circuit
(wire to D+ terminal).
4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be
12—14 VAC .
5. Repeat above steps with lights on to load the alternator.
6. If alternator does not produce specified voltage after testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator assembly if necessary. Make specific test and repair
procedures. If alternator still malfunctions, replace it. If alternator tests OK, check indicator light circuit.
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The following checks can be used to test electrical components in all machine circuits.
1 Component Checks
1A Key Switch Check

Action:
T8357AK-UN: Key Switch Check

LEGEND:
1 - B Terminal
2 - G1 Terminal
3 - G2 Terminal
4 - ACC Terminal
5 - M Terminal
6 - ST Terminal
Remove harness from key switch.
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?
Result:
YES:
Key switch is OK. Check the wiring harness. See Right Console Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Key switch has failed. Replace the key switch. See Key Switch Remove and Install . (Group 9015-20.)
658
1B Battery Relay Check
Action:
T8182AK-UN: Battery Relay Check
See Machine Harness (W2) Component Location . (Group 9015-10.)
Disconnect harness from relay.
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?
Result:
YES:
Relay is OK. Check the wiring harness. See Machine Harness (W2) wiring Diagram . (Group 9015-10.)
NO:
Relay has failed. Replace the relay.
1C Battery Voltage Check

Action:
T7487AF-UN: Voltage Check
Measure battery voltage by connecting a multimeter to (-) negative battery terminal grounded to frame and
(+) positive battery terminal connected to machine harness.
LOOK: Are 24 to 28 volts measured?
659
Result:
YES:
Batteries are OK.
NO:
Batteries are undercharged. Charge batteries. See Using Battery Charger . (Operator's Manual.)
1D Fusible Link Check
Action:
TX1077075-UN: Fusible Link Check

LEGEND:
1 - Locking Tab
2 - Lift Direction
Press locking tab on side of fusible link and lift from holder.
Connect a multimeter to female terminals inside fusible link.
LOOK: Does the multimeter read continuity?
Result:
YES:
Fusible link is OK. Check the wiring harness. See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:
Fusible link has failed. Replace the fusible link. See Fuse and Relay Specifications . (Group 9015-10.)
1E Diode Check
Action:
660
T164619B-UN: Diode Check
Remove diode from connector.
Test diode using diode test function of multimeter.
LISTEN: Does the multimeter beep?
Reverse multimeter probes.
LISTEN: Does the multimeter beep?
Result:
YES:
If multimeter beeps in both checks, diode has failed in a shorted mode. Replace the diode.
NO:
If multimeter does not beep in either check, diode has failed in an open mode. Replace the diode.
NO:
If multimeter beeps in one check and not the other, diode is OK.
1F Travel Alarm Check
Action:
T158291-UN: Travel Alarm Harness Check
Disconnect travel alarm harness connector.
661
Connect multimeter to travel alarm connector pin B and frame ground.
LOOK: Is battery voltage measured?
Connect multimeter to travel alarm connector pin D and frame ground.
LOOK: Is continuity measured?
Connect multimeter to travel alarm connector pin A and frame ground.
LOOK: Is continuity measured when the travel alarm cancel switch is pressed?
Result:
YES:
Harness is OK. Check travel alarm 5 A fuse (F5). See Fuse and Relay Specifications . (Group 9015-10.)
Travel alarm has failed. Replace the travel alarm. See Travel Alarm Remove and Install . (Group 9015-20.)
See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:
Check travel alarm cancel switch. See Travel Alarm Cancel Switch Harness (W15) Wiring Diagram . (Group
9015-10)
1G CAN Bus Terminator Check

Action:
Turn key switch (S1) OFF.
Disconnect harness from CAN bus terminator. See Engine Interface Harness (W5) Component Location .
(Group 9015-10)
T140697B-UN: CAN Bus Terminator
662
Measure resistance across terminator pins.
LOOK: Does the multimeter read 105—135 ohms?
Result:
YES:
CAN bus terminator is OK.
NO:
CAN bus terminator has failed. Replace the CAN bus terminator.
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1. CAUTION:
Battery gas can explode. Keep sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal object across the posts. Use a
voltmeter or hydrometer.
Always remove grounded (-) battery clamp first and replace it last.
TS204-UN: Prevent Battery Explosions
664
TX1013798-UN: Batteries, Support and Cables

LEGEND:
1 - Battery Cover (2 used)
2 - Wing Nut (4 used)
3 - Washer (4 used)
4 - Spacer (4 used)
5 - Jam Nut (8 used)
6 - Washer (4 used)
7 - Clip (2 used)
8 - Battery Bracket (2 used)
9 - Jumper Cable
10 - Positive (+) Cable
11 - Battery (2 used)
12 - Ground (-) Cable
665
Remove wing nuts (2) and washers (3).
2. Remove battery covers (1).
3. Remove spacers (4), jam nuts (5) and washers (6).
4. Disconnect battery ground (-) cable (12), positive (+) cable (10) and jumper cable (9).
5. Remove battery brackets (8).
6. CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting
device.
Remove batteries (11).

Battery Weight 38 kg approximate
84 lb approximate
7. Check battery cables and clamps for wear and corrosion.
8. Repair or replace parts as necessary.
9. IMPORTANT:
If one battery in a 24-volt system has failed, replace both batteries.
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting
device.
Install batteries.

Battery Weight 38 kg approximate
84 lb approximate
10. Connect battery cables.
11. Install brackets and covers.
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1.
TX1005108A-UN: Rear Cover

LEGEND:
1 - Diffuser
2 - Rear Cover
3 - Cap Screw (2 used)
4 - Plug, O-Ring, and Screw (6 used)
5 - Power Outlet
6 - Lighter
7 - Fuse Cover
Remove fuse cover (7).
2. Loosen cap screws (3).
3. Remove plugs, O-rings, and screws (4).
4. Lift and remove diffuser (1).
5. Disconnect electrical connections to power outlet (5) and lighter (6).
6. Lift and remove rear cover (2).
8. Install rear cover.
9. Connect electrical connections.
10. Install diffuser.
11. Install fuse cover.
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667
1. Disconnect battery ground (-) cable.
TX1000923A-UN: Main Controller
TX1000925A-UN: Main Controller

LEGEND:
1 - Electrical Connectors
3 - Screw (4 used)
2. Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
3. Disconnect electrical connectors (1).
4. Remove cap screws (2).
5. Remove main controller and mounting bracket.
6. Remove screws (3).
7. Replace as necessary.
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1. NOTE:
The engine control unit (ECU) is located in the engine compartment below the hood
latch.
TX1013944A-UN: Engine Control Unit (ECU)

LEGEND:
2 - Mounting Bracket
3 - Engine Control Unit (ECU)
5 - Electrical Connector (2 used)
Disconnect battery ground (-) cable.
3. Remove cap screws (1) to remove mounting bracket (2).
4. Remove cap screws (4) to remove engine control unit (ECU) (3).
6. IMPORTANT:
When replacing engine control unit, new software must be loaded after installation.
Install ECU and mounting bracket.
7. Connect electrical connectors.
8. Connect battery ground (-) cable.
669
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TX1000910A-UN: Information controller

LEGEND:
1 - Electrical Connector (2 used)
2 - Screw (3 used)
1. Disconnect battery ground (-) cable.
2. Remove rear cover. See Rear Cover Remove and Install . (Group 9015-20.)
5. Replace information controller as necessary.
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1.
TX1005150A-UN: Monitor Controller and Side Cover
TX1005152A-UN: Side Cover Air Duct

LEGEND:
1 - Monitor Controller
2 - Side Cover
3 - Plug and Cap Screw (2 used)
4 - Plug and Screw (3 used)
5 - Air Duct
6 - Screw (2 used)
Remove plugs and cap screws (3).
2. Remove plugs and screws (4).
3. Rotate side cover (2) and monitor controller (1).
4. Remove screws (6) to remove air duct (5).
672
5.
TX1005153A-UN: Monitor Controller Mounting Plate and Harness Connection

LEGEND:
7 - Screw (2 used)
8 - Mounting Plate
9 - Harness Connectors (3 used)
Disconnect harness connectors (9).
6. Remove screws (7) to remove monitor controller (1) and mounting plate (8).
7.
TX1005154A-UN: Monitor Controller and Mounting Plate

LEGEND:
8 - Mounting Plate
10 - Screw (2 used)
Remove screws (10) to remove mounting plate.
9. Install mounting plate and monitor controller.
10. Route harness through opening in side cover and connect harness connectors to monitor controller.
11. Install air duct.
12. Install side cover to machine.
673
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674
1.
TX1000507A-UN: Pilot Control Lever Boot
TX1000512A-UN: Key Switch Legend Plate
TX1000513A-UN: Key Switch

LEGEND:
1 - Screw (4 used)
2 - Cover
3 - Key Switch Legend Plate
4 - Screw (3 used)
Disconnect battery ground (-) cable.
3. Remove cover (2).
4. Remove key switch legend plate (3).
675
6. Disconnect electrical connector.
7. Replace key switch as necessary.
8. Connect battery ground (-) cable.
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1.
TX1005211A-UN: Pilot Control Lever Boot

LEGEND:
1 - Switch Panel
2 - Pilot Control Lever Boot
3 - Screw and Spacer (4 used)
4 - Console Cover
Lift pilot control lever boot (2) and remove screws and spacers (3).
2. Pull up pilot control lever boot and console cover.
3.
TX1005212A-UN: Switch Panel Cap Screws

LEGEND:
5 - Plug and Screw (2 used)
Remove plugs and screws (5) and remove cap screws (6).
4. Pull switch panel assembly forward and gently tilt back. Disconnect harness connector to key switch.
677
5.
TX1005213A-UN: Switch Panel Mounting Plate

LEGEND:
1 - Switch Panel
7 - Mounting Plate
8 - Screw (6 used)
9 - Tie Band
Remove tie band (9) and screws (8).
7. Install mounting plate.
8. Connect harness to key switch.
9. Install switch panel.
10. Install console cover.
11. Install Pilot Control Lever Boot.
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T142707B-UN: Travel Alarm

LEGEND:
2 - Electrical Connector
1. NOTE:
The travel alarm is located in the hydraulic pump compartment below the main hydraulic
pump.
Disconnect electrical connector (2).
2. Remove cap screws (1).
3. Remove travel alarm.
4. Replace alarm as necessary.
5. Install travel alarm.
6. Connect electrical connector (2).
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1.
TX1005218A-UN: Left Console Switches

LEGEND:
1 - Pilot Control Lever Boot
2 - Screw and Spacer (4 used)
3 - Left Console
4 - Cap Screw
Lift pilot control lever boot (1) to remove screws and spacers (2).
2. Remove cap screw (4).
3. Lift left console (3) and disconnect harness to switch.
5. Install switch and connect harness.
6. Install left console and cap screw.
7. Install pilot control lever boot.
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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.
T7535AE-UN: Retainer Tab

LEGEND:
A - Retainer Tab
Push retainer tab (A).
2. While holding tab in, grasp other half of connector and pull connector halves apart.
3. To connect, push connector halves together until retainer “clicks”.
LD30992,0000202-19-20060925
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T8197AO-UN: Spring Wire Clip Connectors
1. Remove wire clip from connector.
Grasp connector; move connector halves from side-to-side as they're being pulled apart. Do not pull on
wiring leads.
2. To reconnect, install wire clip on connector half, push connector halves together until wire retainer
“clicks” over tabs.
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Replace DEUTSCH™ Connectors
TS0124-UN: Extractor Tool
TS120-UN: Slide Extractor Tool
1. Select correct size extractor tool for size of wire to be removed:
JDG361 Extractor Tool for 12 to 14 gauge wire.

JDG362 Extractor Tool for 16 to 18 gauge wire.
JDG363 Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool over wire at handle (A).
3. Slide extractor tool rearward along wire until tool tip snaps onto wire.
4. IMPORTANT:
Do NOT twist tool when inserting in connector.
Slide extractor tool along wire into connector body until it is positioned over terminal contact.
5. Pull wire out of connector body, using extractor tool.
6. IMPORTANT:
Install contact in proper location using correct size grommet.
683
TS122-UN: Push Contact
Push contact straight into connector body until positive stop is felt.
7. Pull on wire slightly to be certain contact is locked in place.
8. Transfer remaining wires to correct terminal in new connector.
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Replace DEUTSCH™ Rectangular or Triangular Connectors
1. NOTE:
Connector shown is the female half or a 4-pin square connector. Other similar styles of
Deutsch connectors can be serviced using the same procedure.
T130688B-UN: Removing Locking Wedge

LEGEND:
1 - Connector
2 - Locking Wedge
Pull connector (1) apart. Inspect and clean connector seal and contacts.
2. Remove locking wedge (2) from connector using hook on JDG1383 service tool.
3.
T130689B-UN: Releasing Primary Latch
685
T130690B-UN: Removing Wire

LEGEND:
3 - Primary Locking Latches
Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service
tool.
4. Gently pull wire out from back of connector.
5. Replace connector contact as necessary.
6. Install wire terminal back into connector until it clicks into place.
7. NOTE:
Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to
terminals.
Install locking wedge until it snaps into place.
LD30992,0000205-19-20060925
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Install DEUTSCH™ Contact
TS117-UN: Crimper
1. Strip 6 mm (1/4 in.) insulation from wire.
2. Adjust selector (A) on JDG360 Crimper for correct wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
4. IMPORTANT:
Select proper size contact "sleeve" or "pin" to fit connector body.
TS0134-UN: Adjusting Screw

Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).
5. Tighten lock nut (C).
6. IMPORTANT:
Contact must remain centered between indentors while crimping.
TS118-UN: Crimp
Insert wire in contact and crimp until handle touches stop.
687
7. Release handle and remove contact.
8. IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.
NOTE:
Readjust crimping tool for each crimping procedure.
TS0135-UN: Inspect Contact

Inspect contact to be certain all wires are in crimped barrel.
LD30992,0000206-19-20060925
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Replace WEATHER PACK™ Connector
TS0128-UN: Terminal Contact

IMPORTANT:
Identify wire color locations with connector terminal letters.
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.
4. IMPORTANT:
TS0130-UN: Connector Body

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.
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.
689
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Install WEATHER PACK™ Contact
TS0136-UN: Correct Size Cable
TS1623-UN: Strip Insulation
NOTE:
Cable seals are color coded for three sizes of wire:
Green - 18 to 20 gauge wire

Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
3. NOTE:
Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge
wire b) #19 for 18 to 20 gauge wire
Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal
Applicator.
4. IMPORTANT:
691
TS0139-UN: Contact Installation

Proper contact installation for "sleeve" (A) and "pin” (B) is shown.
Secure cable seal to contact as shown, using JDG783 Terminal Applicator.
LD30992,0000208-19-20060925
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RW16933-UN: Connector
RW16934-UN: Socket
RW16935-UN: Terminals
LEGEND:
A - Connector
B - “T” Pin
C - Body Socket
D - Locking Tab
E - Push Terminal
Disconnect the Metri-Pack [Metri-Pack is a trademark of Packard Electric] connector (A). Remove tie bands and
tape.
Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C).
NOTE:
Use JDG777 [Included in JT07195A Electrical Repair Kit] Terminal Extraction Tool or “T” pin to
remove terminals.
Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.
Remove “T” pin and push terminal (E) out of socket.
693
Remove terminal, cut strip and crimp wire through connector.
Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in
connector body socket.
NOTE:
Terminal will seat only one way. If terminal does not pull into the connector body socket, check to
make sure terminal is aligned correctly.
LD30992,0000209-19-20060925
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RW21325-UN: Push Type Connector

LEGEND:
A - Connector Lock
B - Extraction Tool JDG777
C - Connector Body Socket
D - Terminal
E - Locking Tab
Disconnect the Metri-Pack [Metri-Pack is a trademark of Packard Electric] connector. Remove the tie bands and
tape.
Remove the connector lock (A), and mark wire colors for identification.
Identify wire color locations with connector terminal letters.
Insert JDG776 or JDG777 [Included in JT07195A Electrical Repair Kit] Terminal Extraction Tool (B) into connector
body socket (C) pushing the terminal locking tab inward.
NOTE:
Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 series METRI-PACK terminals.
Remove extraction tool and pull terminal (D) out of the socket.
Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.
Push terminal into connector body socket until terminal locks.
LD30992,000020A-19-20060925
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Replace CINCH™ Connectors
1.
T132105B-UN: Unlock Secondary Lock

LEGEND:
1 - Extraction Tool
2 - Secondary Lock Locking Tabs
3 - Secondary Lock
Remove extraction tool (1) from the loading side of connector.
2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the
connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other
locking tab.
NOTE:
After unlocking one side of the secondary lock, a screw driver or similar device may
need to be used to hold it in the unlocked position while unlocking the second locking
tab.
3.
T132301B-UN: Remove Secondary Lock

696
LEGEND:
3 - Secondary Lock
Remove secondary lock (3).
4.
T132107B-UN: Removing Terminals

Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary
lock cavity (4). This will release the primary contact locking tab.
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.
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Install CINCH™ Contact
1.
T138057-UN: Tool Position For Insertion

LEGEND:
A - Top of Tool
B - Contact Support
C - Locator
D - Wire
E - Micro Timer Slot
F - Junior Timer Slot
G - Contact
I - Wire Tab
J - Insulation Tab
Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool
handles together and allow them to open fully.
2. IMPORTANT:
Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT
attempt to crimp an improperly positioned contact.
Position the contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire
and insulation tabs (I and J) should point to top of tool (A). Butt wire tab (I) against the movable locator
(C).
3. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to
hold the contact in position. Do NOT deform wire and insulation tabs (I and J).
4. Insert stripped wire into contact insulation and wire tabs until it is butted against locator (C).
5. Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open
and remove crimped contact.
6. Install contact into connector. (Go to procedure in this group.)
698
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699
Repair 32 and 48 Way CINCH™ Connectors
1.
RXA0070459-UN: CINCH Connector
RXA0070462-UN: CINCH Cover Lock Tabs
RXA0070463-UN: CINCH Cover

LEGEND:
A - Tab
B - Locking Cam
C - Cover Locks
D - Cover
Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox.
2. Move cover locks (C) slightly outward with a small screwdriver.
3. Remove cover (D) away from wires.
700
4.
RXA0070464-UN: Terminal Lock

LEGEND:
A - Terminal Lock
Pull terminal lock (A) out as far as it will go, but do not force its removal.
5. NOTE:
JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for smaller 20
gauge holes (A), and 1.5 for larger 16 and 18 gauge holes (B).
RXA0070471-UN: Connector Holes
RXA0070472-UN: CINCH Connector Terminal Holes
701
RXA0070473-UN: CINCH Terminal Extraction Tool

LEGEND:
A - 20 Gauge Holes
B - 16 & 18 Gauge Holes
C - Holes
D - Terminal Hole
E - Terminal
Insert JDG1725 Terminal Extractor Toolinto holes (C) next to terminal opening (D) to unlock terminal.
6. Pull wire and terminal (E) from connector body.
7.
RXA0070479-UN: Crimp terminal
RXA0070480-UN: CINCH Terminal Crimping Tool
702
RXA0070481-UN: Terminal Crimping Tool

LEGEND:
A - CINCH Terminal Crimping Tool
B - Terminal Receptacle
C - Terminal
D - Wire
Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
8. Grip JDG1727 Terminal Crimping Tool (A) securely, and squeeze ratcheting mechanism until it bottoms
out. Then allow it to open completely
9. With tool in ready position (open handle), open terminal receptacle (B).
10. Insert terminal (C) into proper wire gauge window, crimp wings facing up.
11. Close terminal receptacle (B).
12. Squeeze handle until two clicks are heard.
13. Insert stripped wire (D) into terminal.
14. Hold wire stationary and squeeze tool together until ratchet releases.
15. Remove terminated wire from tool.
16. Push 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.
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703
RW4218-UN: Blade Terminals
1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original position (B) before installing connector body.
LD30992,000020E-19-20060925
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Table of Contents
Section 9020: Power Train

705
TX1073389-UN: Track Adjuster And Recoil Spring

LEGEND:
1 - Grease Fitting
2 - Valve
3 - Grease Relief Passage
4 - Cylinder
5 - Yoke
6 - Front Idler
7 - Piston
8 - Recoil Spring
9 - Grease
10 - Track Adjuster and Recoil Spring
The track adjuster and recoil spring (10) is supported by the track frame. Shock loads on the track and front idler
(6) are absorbed by the recoil spring (8).
To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease
pushes the piston (7) against the yoke moving the front idler (6) out, reducing track sag. The grease fitting (1) is
protected from excess pressure by a check ball.
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
706
grease relief passage (3). When releasing grease from the cylinder, only loosen the valve (2).
MD46667,0000131-19-20060928
707
TX1073389-UN: Track Adjuster And Recoil Spring

LEGEND:
1 - Grease Fitting
2 - Valve
3 - Grease Relief Passage
4 - Cylinder
5 - Yoke
6 - Front Idler
7 - Piston
8 - Recoil Spring
9 - Grease
10 - Track Adjuster and Recoil Spring
The track adjuster and recoil spring (10) is supported by the track frame. Shock loads on the track and front idler
(6) are absorbed by the recoil spring (8).
To decrease track sag, grease (9) is pumped into the cylinder (4) through the grease fitting (1). The grease
pushes the piston (7) against the yoke moving the front idler (6) out, reducing track sag. The grease fitting (1) is
protected from excess pressure by a check ball.
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
708
grease relief passage (3). When releasing grease from the cylinder, only loosen the valve (2).
MD46667,0000131-19-20060928
709
TX1001983-UN: Travel Gearbox Operation

LEGEND:
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
11 - First Stage Carrier
12 - First Stage Sun Gear (Input Shaft)
13 - Thrust Pad
710
14 - First Stage Planet Gear
15 - Second Stage Planet Gear
16 - Third Stage Planet Gear
17 - Drum
18 - Sprocket
Travel Gearbox Operation The travel gearbox is a triple reduction planetary drive gearbox. The gearbox is
interchangeable from the right to the left side of the machine. The travel motor housing (2), which is fastened to
the track frame, serves as the main support for the drum (17), and planetary gears (6—12 and 14—16).
The travel motor is connected to and drives the gearbox through first stage sun gear (input shaft) (12). The third
stage carrier (7) is fixed to the housing. A replaceable thrust pad (13) is used in the gearbox cover to keep the first
stage sun gear in position.
MD46667,0000134-19-20061109
711
NOTE:
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely and most difficult to verify.
Noisy or Loose Track Chain

1 Incorrect track sag adjustment

Action:
Check track sag. See Check and Adjust Track Sag . (Operator's Manual.)
Is track sag within specification?
Result:
YES:
Go to Loose track shoes.
NO:
Adjust track sag.
2 Loose track shoes
Action:
Remove loose track shoes to clean material from between shoe and link. Install track shoes and tighten cap
screws in proper sequence. See Track Shoe Remove and Install . (Group 0130.)
Are track shoes properly installed?
Result:
YES:
Go to Grease leaking from track adjuster seals, grease fitting, or relief valve.
NO:
Install track shoes.
3 Grease leaking from track adjuster seals, grease fitting, or relief valve
Action:
Check that grease fitting and valve are tight. Replace grease fitting or valve. See Track Adjuster Cylinder
Disassemble and Assemble for seal replacement. (Group 0130.)
Are grease fitting, valve and seal properly installed?
712
Result:
YES:
Diagnostic checkout complete.
NO:
Install grease fitting, valve and seal.
Tight Track Chain

1 Material packing in sprocket
Action:
Clean material from sprocket.
Is sprocket free of material?
Result:
YES:
Go to Track sag less than specification.
NO:
2 Track sag less than specification

Action:
Result:
YES:
NO:
Adjust track sag.
Frequent Track Chain Sag Adjustment Required

713
1 Grease leaking from track adjuster seals, grease fitting or relief valve
Action:
Result:
YES:
NO:
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
1 Loose plug, worn or damaged O-ring, or metal faced seal
Action:
Check for loose, worn or damaged plug, O-ring, or metal faced seal.
Are plug, O-ring, and metal faced seal properly installed?
Result:
YES:
NO:
Tighten plug. Replace O-ring or metal face seal.
Replace seals. See Front Idler Remove and Install . (Group 0130.)
Replace seals. See Track Roller Remove and Install . (Group 0130.)
Replace seals. See Track Carrier Roller Remove and Install . (Group 0130.)
Bent Track Shoes

1 Excessive grouser wear

Action:
Measure grouser height specification for rebuilding or replacing track shoes. See 200DLC and 225DLC
714
Three Bar Grouser Height . (SP326 Undercarriage Appraisal Manual.)
Is grouser height to specification?
Result:
YES:
NO:
Repair or replace track shoes. See Track Shoe Remove and Install . (Group 0130.)
2 Loose track shoes

Action:
Result:
YES:
Go to Excessive high speed operation on rough and rocky terrain.
NO:
3 Excessive high speed operation on rough and rocky terrain

Action:
Reduce travel speed on rough and rocky terrain. Place travel speed switch in slow speed (turtle) mode.
Is travel speed switch in slow speed (turtle) mode?
Result:
YES:
NO:
Place travel speed switch in slow speed (turtle) mode.
“Popping” Of Track
715
1 High travel loads in reverse

Action:
High travel loads in reverse can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize
travel loads in reverse.
Are travel loads in reverse minimized?
Result:
YES:
Go to Material packing in sprocket.
NO:
Minimize travel loads in reverse.
Action:
Result:
YES:
NO:
Cracked Track Link

Action:
Repair or replace cracked track link. See Track Chain Repair . (Group 0130.) or See Track Chain Remove
and Install . (Group 0130.)
716
Result:
YES:
Go to Track shoes too wide for ground conditions.
NO:
2 Track shoes too wide for ground conditions

Action:
Use the narrowest shoes possible for required flotation.
Are the narrowest shoes possible for required flotation being used?
Result:
YES:
NO:
Select the narrowest shoes possible for required flotation.
Chipped Link Rails

1 Repeated high impacts with roller tread on flanges caused by a loose or snaky track, or using
shoes that are too wide
Action:
Check track chain pitch specification. See 200DLC Track Chain Pitch . (SP326 Undercarriage Appraisal
Manual.)
Are the correct track components installed on machine? Do they meet specifications?
Result:
YES:
NO:
717
Install correct track components to specifications.
Individual Undercarriage Component Wear

1 Some wear is normal

Action:
Measure components to determine if they can be rebuilt using weld. See Component Rebuild . (SP326
Undercarriage Appraisal Manual.)
Is component wear within specification?
Result:
YES:
NO:
Repair or replace components as necessary.
MD46667,0000135-19-20100512
718
NOTE:
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely and most difficult to verify.
Noisy or Loose Track Chain

1 Incorrect track sag adjustment

Action:
Result:
YES:
NO:
Adjust track sag.
2 Loose track shoes
Action:
Result:
YES:
Go to Grease leaking from track adjuster seals, grease fitting, or relief valve.
NO:
3 Grease leaking from track adjuster seals, grease fitting, or relief valve
Action:
719
Result:
YES:
NO:
Tight Track Chain

Action:
Result:
YES:
Go to Track sag less than specification.
NO:
2 Track sag less than specification

Action:
Result:
YES:
NO:
Adjust track sag.
Frequent Track Chain Sag Adjustment Required

720
1 Grease leaking from track adjuster seals, grease fitting or relief valve
Action:
Result:
YES:
NO:
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers
1 Loose plug, worn or damaged O-ring, or metal faced seal
Action:
Check for loose, worn or damaged plug, O-ring, or metal faced seal.
Are plug, O-ring, and metal faced seal properly installed?
Result:
YES:
NO:
Tighten plug. Replace O-ring or metal face seal.
Replace seals. See Front Idler Remove and Install . (Group 0130.)
Replace seals. See Track Roller Remove and Install . (Group 0130.)
Replace seals. See Track Carrier Roller Remove and Install . (Group 0130.)
Bent Track Shoes

1 Excessive grouser wear

Action:
721
Three Bar Grouser Height . (SP326 Undercarriage Appraisal Manual.)
Is grouser height to specification?
Result:
YES:
NO:
Repair or replace track shoes. See Track Shoe Remove and Install . (Group 0130.)
2 Loose track shoes

Action:
Result:
YES:
Go to Excessive high speed operation on rough and rocky terrain.
NO:

Action:
Result:
YES:
NO:
“Popping” Of Track
722
1 High travel loads in reverse

Action:
High travel loads in reverse can cause the recoil spring to retract allowing sprocket to slip in chain. Minimize
travel loads in reverse.
Are travel loads in reverse minimized?
Result:
YES:
Go to Material packing in sprocket.
NO:
Minimize travel loads in reverse.
Action:
Result:
YES:
NO:
Cracked Track Link

Action:
Repair or replace cracked track link. See Track Chain Repair . (Group 0130.) or See Track Chain Remove
723
Result:
YES:
Go to Track shoes too wide for ground conditions.
NO:
2 Track shoes too wide for ground conditions

Action:
Are the narrowest shoes possible for required flotation being used?
Result:
YES:
NO:
Select the narrowest shoes possible for required flotation.
Chipped Link Rails

1 Repeated high impacts with roller tread on flanges caused by a loose or snaky track, or using
shoes that are too wide
Action:
Check track chain pitch specification. See 200DLC Track Chain Pitch . (SP326 Undercarriage Appraisal
Manual.)
Are the correct track components installed on machine? Do they meet specifications?
Result:
YES:
NO:
724
Install correct track components to specifications.
Individual Undercarriage Component Wear

1 Some wear is normal

Action:
Measure components to determine if they can be rebuilt using weld. See Component Rebuild . (SP326
Undercarriage Appraisal Manual.)
Is component wear within specification?
Result:
YES:
NO:
Repair or replace components as necessary.
MD46667,0000135-19-20100512
725
-: Specifications
SPECIFICATIONS
Swing Bearing Play (new) 0.2—1.0 mm

0.008—0.039 in.
Swing Bearing Play (limit of use) 2.0—3.0 mm

0.079—0.118 in.
Dial Indicator
1. CAUTION:
Stay clear of moving parts. Position dial indicator so it can be seen while the
operator can see you.
NOTE:
Two people are needed to take the measurement. One to operate the machine and one
to take the readings.
726
T140090-UN: Dial Indicator Location
727
T7886AJ-UN: Machine Positions For Check

Check that swing bearing-to-main frame and undercarriage cap screws are tightened to specification.
See Upperstructure Remove and Install for specification. (Group 4350.)
2. Check that swing bearing is lubricated with the specified grease. See Track Adjuster, Working Tool
Pivot, Swing Bearing, And Swing Bearing Gear Grease . (Operator's Manual.)
3. Check that bearing rotation is smooth and without noise.
4. NOTE:
Readings vary depending on the location of dial indicator base with respect to the swing
bearing support tower. To obtain an accurate reading, the base for dial indicator must
be attached to the support tower or as close to it as possible.
Install dial indicator with needle point contacting bottom face of bearing outer race and base attached to
the swing bearing support tower or as close to it as possible.
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 reading.

728

Swing Bearing Play (new) 0.2—1.0 mm
0.008—0.039 in.
Play (limit of use) 2.0—3.0 mm
0.079—0.118 in.
If play is more than specified, check for wear to balls, spacers, and bearing race. See Swing Bearing
Remove and Install . (Group 4350.)
MD46667,0000136-19-20061207
729
Table of Contents
Section 9025: Hydraulic System

730
Table of Contents
Cylinder Operation
731
Table of Contents
Machine Mistracks
Group 25: Tests

732
Table of Contents
Pump Flow Test
Fan Speed Test
733
TX1139146-UN: Hydraulic System Diagram

LEGEND:
15 - Pump 1
16 - Pump 2
31 - Hydraulic Oil Tank
35 - Suction Screen
36 - Hydraulic Oil Cooler
52 - Swing Motor
61 - Right Travel Motor
63 - Left Travel Motor
73 - Right Control Valve (4-spool)
74 - Left Control Valve (5-spool)
75 - Right Travel Spool
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
734
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
107 - Auxiliary Spool
110 - Left Travel Spool
124 - Hydraulic Oil Cooler Bypass Valve
125 - Boom Cylinders
126 - Bucket Cylinder
127 - Arm Cylinder
136 - Restriction Valve
150 - Auxiliary Attachment
Main hydraulic system is open-center hydraulic system.
The main pump consists of pump 1 (15), pump 2 (16) in a common housing, the pump drive gearbox, and
coupling. A pilot pump is mounted to the gearbox adjacent to pump 2. Pump 2 is driven directly by the engine
through the coupler. Pump 1 and the pilot pump are driven by pump 2 through the gear train in gearbox. The
engine to pump gear ratio for pump 1, pump 2, and pilot pump is 1:1.
As viewed from the right side of machine, pump 1 is to the right (towards the front of machine) and pump 2 is to
the left (towards the rear of machine).
Hydraulic oil flow is through suction screen (35), out of the hydraulic oil tank (31), and through the suction line to
the pumps. Pump 1 delivers supply oil to the right control valve (4-spool) (73). Pump 2 delivers supply oil to the
left control valve (5-spool) (74). Supply oil is routed to motors (52, 61, and 63), cylinders (125, 126, and 127) and
auxiliary attachment (150) by valve spools (75, 76, 81, 90, 95, 97,104, 107, and 110) 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.
Return oil from the motors and cylinders is routed into return passages in control valve by the valve spools. From
the return passages, return oil flows out of control valve, through hydraulic oil cooler (36), through the restriction
valve (136), and then through the return filter in the hydraulic oil tank. The restriction valve is used in the return
line after the hydraulic oil cooler to create some back pressure in the return passage of control valve. The back
pressure ensures a flow of makeup oil to keep the swing motor case full of oil and a flow of oil through the
anticavitation valves to prevent cylinder cavitation.
The hydraulic oil cooler bypass valve (124) opens to route return oil around hydraulic oil cooler and directly to
hydraulic oil tank when resistance to flow through oil cooler becomes high because the oil is cold (high viscosity),
there is a surge of return oil, or oil cooler becomes plugged. The pressure setting for the bypass valve is higher
than the restriction valve.
TP97644,0000093-19-20130626
735
TX1139146-UN: Hydraulic System Diagram

LEGEND:
15 - Pump 1
16 - Pump 2
35 - Suction Screen
52 - Swing Motor
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
736
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
127 - Arm Cylinder
Main hydraulic system is open-center hydraulic system.
The main pump consists of pump 1 (15), pump 2 (16) in a common housing, the pump drive gearbox, and
coupling. A pilot pump is mounted to the gearbox adjacent to pump 2. Pump 2 is driven directly by the engine
through the coupler. Pump 1 and the pilot pump are driven by pump 2 through the gear train in gearbox. The
engine to pump gear ratio for pump 1, pump 2, and pilot pump is 1:1.
As viewed from the right side of machine, pump 1 is to the right (towards the front of machine) and pump 2 is to
the left (towards the rear of machine).
Hydraulic oil flow is through suction screen (35), out of the hydraulic oil tank (31), and through the suction line to
the pumps. Pump 1 delivers supply oil to the right control valve (4-spool) (73). Pump 2 delivers supply oil to the
left control valve (5-spool) (74). Supply oil is routed to motors (52, 61, and 63), cylinders (125, 126, and 127) and
auxiliary attachment (150) by valve spools (75, 76, 81, 90, 95, 97,104, 107, and 110) 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.
Return oil from the motors and cylinders is routed into return passages in control valve by the valve spools. From
the return passages, return oil flows out of control valve, through hydraulic oil cooler (36), through the restriction
valve (136), and then through the return filter in the hydraulic oil tank. The restriction valve is used in the return
line after the hydraulic oil cooler to create some back pressure in the return passage of control valve. The back
pressure ensures a flow of makeup oil to keep the swing motor case full of oil and a flow of oil through the
anticavitation valves to prevent cylinder cavitation.
The hydraulic oil cooler bypass valve (124) opens to route return oil around hydraulic oil cooler and directly to
TP97644,0000093-19-20130626
737
TX1113333-UN: Fan Drive Hydraulic System Schematic—If Equipped

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
132 - Fan Drive Pump
133 - Fan Drive Motor
134 - Fan Speed Control Valve
145 - Supply Oil
149 - Return or Pressure-Free Oil
Y8 - Proportional Fan Speed Solenoid Valve
738
TX1113341-UN: Fan Drive Hydraulic System Schematic—Reversing (if equipped)

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
135 - Fan Speed and Reversing Control Valve
145 - Supply Oil
149 - Return or Pressure Free Oil
Y9 - Reversing Fan Solenoid Valve
Standard Hydraulic Fan Function—If Equipped
See Fan Drive Hydraulic System Schematic . (Group 9025-15.)
739
See Fan Drive Hydraulic System Component Location . (Group 9025-15.)
A hydraulic-powered cooling fan is used to provide air flow for the machine's cooling package. The fan drive
system consists of:
Gear type fan drive pump (132)

Fan speed control valve (134) or fan speed and reversing control valve—if equipped (135)
Gear type fan drive motor (133)
The fan drive pump is directly driven off the front gear train of the engine. Oil flow to the pump comes from the
hydraulic oil tank (31). Return oil from the fan drive motor is routed through the hydraulic oil cooler (36) to the
return filter (32) in the hydraulic oil tank.
The fan speed solenoid valve regulates oil flow and pressure buildup in the fan drive system. The more oil flow to
the fan drive motor, the greater the fan speed. How much oil flow is routed to the fan drive motor depends on the
current applied to the fan speed solenoid valve from the engine control unit (ECU).
The ECU uses four parameters to control the current sent to the proportional fan speed solenoid valve (Y8). The
engine coolant temperature sensor (B4), hydraulic oil temperature sensor (B40), turbocharger compressor inlet
temperature sensor (B7), and ambient air temperature sensor (B22) send system temperatures to the ECU.
When machine systems are cold, the ECU sends maximum current to the proportional fan speed solenoid valve.
This shifts the solenoid valve to allow most oil flow to be returned to the hydraulic oil tank and bypass the fan
drive motor. The fan drive motor and cooling fan operate at a low speed.
As the machine warms up during operation, the ECU decreases the current to the fan speed solenoid valve. The
decrease in current applied causes the solenoid valve to shift and restrict oil flow through the fan speed solenoid
valve, increasing oil flow to the fan drive motor. As oil flow to the fan drive motor increases, cooling fan speed
increases.
When maximum cooling is required, the ECU supplies no current to the proportional fan speed solenoid valve.
With the solenoid valve de-energized, the proportional fan speed solenoid valve is fully shifted to allow maximum
oil flow to the fan drive motor. The fan drive motor and cooling fan operate at maximum speed.
This controlled fan speed is more economical and fuel efficient.
Reverse Fan Function—If Equipped
The optional reversing function reverses the cooling fan to help clean the machine cooling package of dirt and
debris. The reversing function can be initiated manually by the operator or automatically by the ECU. If set to
reverse automatically, the ECU will reverse the fan at a preset interval.
See Reversing Cooling Fan Switch—If Equipped . (Operator's Manual.)
The fan speed and reversing control valve is used with the optional reverse fan function. The control valve
controls both fan speed and reversing fan direction.
To start a reversing cycle, the ECU first removes current to the proportional fan speed solenoid valve in the fan
speed and reversing control valve and then applies maximum current. The ECU briefly applies maximum current
to stop the fan while the reversing fan solenoid (Y9) shifts to reverse oil flow. The ECU then removes current to
the proportional fan speed solenoid valve, to operate the fan at maximum speed in reverse for a short period of
time. Returning to normal operation, the ECU briefly applies maximum current to the proportional fan speed
solenoid valve while the reversing fan solenoid resets to normal operation.
740
MB00333,0000086-19-20120518
741

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
742
TX1113341-UN: Fan Drive Hydraulic System Schematic—Reversing (if equipped)

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
Standard Hydraulic Fan Function—If Equipped
See Fan Drive Hydraulic System Schematic . (Group 9025-15.)
743
A hydraulic-powered cooling fan is used to provide air flow for the machine's cooling package. The fan drive
system consists of:
Gear type fan drive pump (132)

Fan speed control valve (134) or fan speed and reversing control valve—if equipped (135)
Gear type fan drive motor (133)
The fan drive pump is directly driven off the front gear train of the engine. Oil flow to the pump comes from the
hydraulic oil tank (31). Return oil from the fan drive motor is routed through the hydraulic oil cooler (36) to the
return filter (32) in the hydraulic oil tank.
The fan speed solenoid valve regulates oil flow and pressure buildup in the fan drive system. The more oil flow to
the fan drive motor, the greater the fan speed. How much oil flow is routed to the fan drive motor depends on the
current applied to the fan speed solenoid valve from the engine control unit (ECU).
The ECU uses four parameters to control the current sent to the proportional fan speed solenoid valve (Y8). The
engine coolant temperature sensor (B4), hydraulic oil temperature sensor (B40), turbocharger compressor inlet
temperature sensor (B7), and ambient air temperature sensor (B22) send system temperatures to the ECU.
When machine systems are cold, the ECU sends maximum current to the proportional fan speed solenoid valve.
This shifts the solenoid valve to allow most oil flow to be returned to the hydraulic oil tank and bypass the fan
drive motor. The fan drive motor and cooling fan operate at a low speed.
As the machine warms up during operation, the ECU decreases the current to the fan speed solenoid valve. The
decrease in current applied causes the solenoid valve to shift and restrict oil flow through the fan speed solenoid
valve, increasing oil flow to the fan drive motor. As oil flow to the fan drive motor increases, cooling fan speed
increases.
When maximum cooling is required, the ECU supplies no current to the proportional fan speed solenoid valve.
With the solenoid valve de-energized, the proportional fan speed solenoid valve is fully shifted to allow maximum
oil flow to the fan drive motor. The fan drive motor and cooling fan operate at maximum speed.
This controlled fan speed is more economical and fuel efficient.
Reverse Fan Function—If Equipped
The optional reversing function reverses the cooling fan to help clean the machine cooling package of dirt and
debris. The reversing function can be initiated manually by the operator or automatically by the ECU. If set to
reverse automatically, the ECU will reverse the fan at a preset interval.
See Reversing Cooling Fan Switch—If Equipped . (Operator's Manual.)
The fan speed and reversing control valve is used with the optional reverse fan function. The control valve
controls both fan speed and reversing fan direction.
To start a reversing cycle, the ECU first removes current to the proportional fan speed solenoid valve in the fan
speed and reversing control valve and then applies maximum current. The ECU briefly applies maximum current
to stop the fan while the reversing fan solenoid (Y9) shifts to reverse oil flow. The ECU then removes current to
the proportional fan speed solenoid valve, to operate the fan at maximum speed in reverse for a short period of
time. Returning to normal operation, the ECU briefly applies maximum current to the proportional fan speed
solenoid valve while the reversing fan solenoid resets to normal operation.
744
TX04577,000011B-19-20120518
745
TX1011681-UN: Pilot System Diagram and Operation

LEGEND:
Y10 - Pilot Shutoff Solenoid Valve
Y20 - Pump 2 Flow Rate Limit Solenoid Valve
Y21 - Torque Control Solenoid Valve
Y22 - Dig Regenerative Solenoid Valve (port SF)
Y23 - Arm Regenerative Solenoid Valve (port SC)
Y24 - Power Digging Solenoid Valve (port SG)
Y25 - Travel Speed Solenoid Valve (port SI)
17 - Pump 1 Regulator
746
22 - Pilot Pump
29 - Pilot Filter and Bypass Valve
30 - Pilot Pressure Regulating Valve
35 - Suction Screen
37 - Solenoid Valve Manifold
38 - Travel Pilot Control Valve
39 - Left Pilot Control Valve
40 - Right Pilot Control Valve
41 - Pilot Signal Manifold
45 - From Swing Park Brake Release Pilot Valve (port SH)
52 - Swing Motor
66 - Travel Speed Change Valve
74 - Control Valve
77 - Bucket Flow Rate Control Valve (valve and poppet)
84 - Dig Regenerative Valve
85 - Boom Reduced Leakage Valve (valve and check valve)
91 - Arm 2 Flow Rate Control Valve (valve and poppet)
93 - Bypass Shutoff Valve
94 - Arm Regenerative Valve
101 - Arm Reduced Leakage Valve (valve and poppet)
108 - Auxiliary Flow Rate Control Valve (valve and poppet)
117 - Main Relief and Power Digging Valve
118 - Auxiliary Flow Combiner Valve
120 - Travel Flow Combiner Valve
131 - To Control Valve Pilot Caps
Pilot system is used to operate control circuits for pump 1 and pump 2 regulators (17 and 18), to shift the control
valve (74) spools, to release the swing park brake, and as a supply source for the functions of solenoid valve
manifold (37).
The pilot pump (22) supplies oil to the pilot system. From the pilot pump, pilot oil flows to the pilot filter and bypass
valve (29), and pilot pressure regulating valve (30). From the filter, oil is supplied to the pump 1 and 2 regulators,
the small end of pump servo pistons, torque control solenoid valve (Y21), the solenoid valve manifold, and the
pilot shutoff solenoid valve (Y10). When no functions are activated, the oil returns to hydraulic oil tank through the
pilot pressure regulating valve.
See Pilot Pump, Pressure Regulating Valve and Filter Operation . (Group 9025-05.)
See Pilot Shutoff Solenoid Valve Operation . (Group 9025-05.)
See Pilot Operation of Control Valve Operation . (Group 9025-05.)
See Pilot Signal Manifold Operation . (Group 9025-05.)
See Pump 1, Pump 2 and Drive Gearbox Operation . (Group 9025-05.)
See Pump 1 and Pump 2 Regulator Operation . (Group 9025-05.)

747
See Control Valve Operation . (Group 9025-05.)
See Swing Motor Park Brake Release Circuit Operation . (Group 9025-05.)
See Travel Motor Speed Circuit Operation . (Group 9025-05.)
TP97644,000005A-19-20070111
748
TX1011706-UN: Pilot Pump, Pressure Regulating Valve, and Filter

LEGEND:
1 - Pilot Pump
2 - Driven Gear
3 - From Hydraulic Pump Suction Line
4 - Drive Gear
5 - Regulated Pilot Oil (port PE) to Pump 1 and 2
6 - Return Oil (port TA) to Hydraulic Return Manifold
7 - Plug (port PC)
8 - Plug (port PG)
10 - Regulated Pilot Oil (port PD) to Solenoid Valve Manifold
11 - Test Port (port PF)
12 - From Pilot Pump Outlet (port PA)
13 - Pilot Filter Element
14 - Pilot Pressure Regulating Valve Spool
15 - Spring
16 - Shim (as required)
Pilot filter element (13), bypass valve, and pilot pressure regulating valve (9) are incorporated into one assembly.
Pilot filter bypass valve senses differential pressure between inlet side and outlet side of filter element. During
normal operation, bypass valve is held closed by a spring and pilot oil flows through filter element to pilot pressure
regulating valve (9) and out to pilot circuit. When the filter element becomes plugged, pressure on inlet side
increases forcing bypass valve open. Pilot oil now bypasses the filter element and unfiltered oil flows to pilot
pressure regulating valve spool (14) and out to the pilot circuit.
The pilot pressure regulating valve is a relief valve that is used to regulate pilot oil pressure to a constant pressure
in pilot oil circuit. When pressure in pilot circuit increases to pressure setting of spring (15), spool is pushed
against spring. Regulated pilot oil flows from port PD to solenoid valve manifold (10) and from port PC to pump 1
and 2 servo pistons and regulators (5). Oil not needed to maintain pressure in pilot circuit flows out port TA to
hydraulic return manifold (7).
See Hydraulic System Schematic for pilot filter, bypass valve, and pilot pressure regulating valve in Pilot Control
Valves and Pilot Signal Manifold Schematic (Group 9025-15.)
749
TP97644,000005B-19-20060908
750
TX1000386-UN: Pilot Shutoff Solenoid Valve Port Locations

LEGEND:
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)
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
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.)
751
TX1000357-UN: De-Energized Pilot Shutoff Solenoid Valve Schematic
752
TX1000366-UN: De-Energized Pilot Shutoff Solenoid Valve Section

LEGEND:
T4 - To Hydraulic Oil Tank
147 - Pilot Oil
149 - Return Oil
With the pilot control shutoff lever in the locked position, the lever is pulled rearward. The solenoid for the pilot
shutoff solenoid valve is de-energized. Pilot oil from the pilot pump (P) is blocked by the spool. Ports to the pilot
control valves (A1—A3) and pilot signal manifold port PI are open to the hydraulic oil tank (T4) through the spool.
Therefore, no hydraulic function is actuated when a control lever for a pilot control valve is operated.
753
TX1000359-UN: Energized Pilot Shutoff Solenoid Valve Schematic
754
TX1000367-UN: Energized Pilot Shutoff Solenoid Valve Section

LEGEND:
T4 - To Hydraulic Oil Tank
147 - Pilot Oil
149 - Return Oil
With the pilot control shutoff lever in the unlocked position, the lever is pushed forward. The solenoid for the pilot
shutoff solenoid valve is energized. Ports to the pilot control valves (A1—A3) and pilot signal manifold port PI (A4)
are now open to pilot oil from pilot pump (P). Now, operating a control lever actuates a function.
TP97644,000005C-19-20060908
755
T143081-UN: Metering and Full Stroke

LEGEND:
1 - Control Lever
2 - Plunger
3 - Spring Guide
4 - Balance Spring
5 - Return Spring
6 - Orifice
7 - Spool
8 - Hole (4 used)
9 - Housing
10 - Work Port 1, 2, 3, or 4 to Control Valve Pilot Caps
11 - Port P from Pilot Shutoff Solenoid Valve
12 - Port T to Pilot Shutoff Solenoid Valve
13 - Deadband Area
14 - Initial Movement
15 - Pilot Oil
16 - Return Oil
The left and right pilot control valves regulate the pilot oil (15) pressure to actuate the pilot valves in the pilot
signal manifold and to shift the control valve spools to actuate the dig 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.)
Each pilot control valve contains four valves, one for each dig 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
756
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 (16)
through the holes (8) to port T is blocked before pilot oil flows from port P through the holes down through the
spool to the work port and out to the control valve pilot caps (10). Pilot oil also flows through the orifice (6) to the
top of spool to dampen the upward movement of spool. Pilot oil pressure out the work port increases until the
pressure is equal to the force of balance spring pushing the spool up until the oil flow through the holes is blocked
in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the control lever is
again actuated.
When the control lever is actuated to full stroke, the plunger contacts the spool, pushing it down until the plunger
contacts a shoulder in the housing. Oil pressure to the control valve pilot caps is now approximately equal to pilot
system pressure.
When the control lever is returned to neutral, the spool is pushed up by the return spring (5), 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.
TP97644,000005D-19-20060908
757
TX1000485-UN: Travel Pilot Control Valve

LEGEND:
1 - Spool
2 - Washer
3 - Spring Guide
4 - Plunger
5 - Adjustment Screw
6 - Cam and Pedal
7 - Sleeve
8 - Balance Spring
758
9 - Return Spring
10 - Port T To Hydraulic Oil Tank
11 - Port P From Pilot Shutoff Solenoid Valve
12 - Port 1, 2, 3, or 4 To Control Valve Pilot Cap
13 - Pilot Oil
14 - Return Oil
15 - Travel Pilot Control Valve—Full Stroke
The travel pilot control valve regulates the pilot oil (13) pressure to actuate the pilot valves in the pilot signal
manifold and to shift the control valve spools to actuate the travel functions.
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 against the plunger (4). The ports (10, 11, and 12) in housing are identified by
numbers and letters next to each port.
In neutral, the spool is pushed up by the return spring (8) pushing the plunger up. The return springs hold the
pedal in the neutral position. With the spool up, ports 1, 2, 3, and 4 to the control valve pilot cap (12) are open to
port T to the hydraulic oil tank (10) through the passage and holes in spool. Port P for pilot oil from the pilot
shutoff solenoid valve (11) is blocked by the spool.
When the pedal is pushed to move the machine, the cam pushes the plunger and spring guide down against the
return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed down and
the holes move through the deadband area, the passage from control valve pilot cap to the hydraulic oil tank is
closed and then opened to the pilot oil from pilot shutoff solenoid valve. Pilot oil pressure increases until it is equal
to the force applied by the balance spring pushing the spool moves up until the oil flow through the holes is
blocked in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the pedal is
again actuated.
When the pedal 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.
TP97644,000005E-19-20060908
759
TX1011116-UN: Pilot Operation of Control Valve

LEGEND:
B34 - Travel Pressure Sensor (port TR)
Y24 - Power Dig Solenoid Valve (port SG)
1 - Boom Up Function
4 - Arm In Function
11 - Right Travel Forward Function
28 - Pilot Pump
42 - Boom Down Shockless Valve
44 - Travel Flow Combiner Pilot Valve (port SL)
45 - Swing Park Brake Release Pilot Valve (port SH)
46 - Bucket Flow Rate Pilot Valve (port SK)
66 - To Travel Speed Change Valve
76 - Bucket Spool
77 - Bucket Flow Rate Control Valve
81 - Boom 1 Spool
83 - Boom Flow Rate Control Valve (valve and poppet)
85 - Boom Reduced Leakage Valve
90 - Arm 2 Spool
760
95 - Swing Spool
97 - Arm 1 Spool
101 - Arm Reduced Leakage Valve
104 - Boom 2 Spool
108 - Auxiliary Flow Rate Control Valve (not connected)
117 - Pilot Signal Manifold Operation
147 - Pilot Oil
The left and right pilot control valves and travel pilot control valves are connected to the control valve by pilot lines
through the pilot signal manifold (41). Actuating a pilot control valve routes pilot oil (147) 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.
See Pilot Signal Manifold Operation for more information. (Group 9025-05.)
The following valves in the control valve are controlled by pilot oil from the pilot control valves and pilot valves:
Auxiliary Flow Combiner Valve (118),

Left and Right Travel Valve Spools (75 and 110),
Bucket Flow Rate Control Valve (77),
Bucket Spool (76),
Boom 1 and Boom 2 Valve Spools (81 and 104),
Arm In Pressure Sensor (B31),
Boom Flow Rate Control Valve (83),
Boom Reduced Leakage Valve (85),
Arm 2 and Arm 1 Spools (90 and 97),
Bypass Shutoff Valve (93) (with an auxiliary function installed),
Swing Spool (95),
Arm Reduced Leakage Valve (101),
Boom Up Pressure Sensor (B30),
Auxiliary Spool (107),
Auxiliary Flow Rate Control Valve (108),
Travel Flow Combiner Valve (120).
The following valves in the control valve and left and right travel motors are controlled by the solenoid valves (Y22
—Y25) in the solenoid valve manifold:
Main Relief And Power Digging Valve (117),

Dig Regenerative Valve (84),
Arm Regenerative Valve (94) and Arm 2 Flow Rate Control Valve (91),
Travel Speed Change Valve (66).
TP97644,000005F-19-20060908
761
TX1000243-UN: Pilot Signal Manifold Pilot Valves and Ports

LEGEND:
1, A - Boom Up
2, B - Boom Down
3, C - Arm Out
4, D - Arm In
5, E - Swing Left
6, F - Swing Right
7, G - Bucket Curl
8, H - Bucket Dump
9, I - Left Travel Forward
10, J - Left Travel Reverse
11, K - Right Travel Forward
12, L - Right Travel Reverse
13, M - Plug (auxiliary)
14, N - Plug (auxiliary)
15 - Control Valve Side of Pilot Signal Manifold
16 - Pilot Control Valve Side of Pilot Signal Manifold
43 - Arm 1 Flow Rate Pilot Valve (port SE)
762
47 - Pump 2 Flow Rate Pilot Valve (port SB)
48 - Pump 1 Flow Rate Pilot Valve (port SA)
129 - Orifice
DF - To Hydraulic Oil Tank
TR - Travel Pressure Sensor
S3 - Swing Pressure Sensor
SA - To Pump 1 Regulator Remote Control Spool
SB - To Pump 2 Regulator Remote Control Spool
SE - To Arm 1 (Swing Priority) Flow Rate Control Valve
SH - To Swing Park Brake
SK - To Bucket Flow Rate Control Valve
SL - To Travel Flow Combiner Valve
SM - To Hydraulic Oil Tank
SN - Plug (not used)
SP - To Solenoid Valve Manifold (port DP)
PH - Plug
PI - From Pilot Shutoff Solenoid Valve
NOTE:
The numbers 1—14 and letters A—N, DF, TR, S3, SA, SB, SE, SH, SK, SL, SM, SN, SP, PH,
and PI are next to the respective ports on the pilot signal manifold.
Ports SA and SB are located on the pilot control valve side of pilot signal manifold but, for
simplification of the schematic, are shown schematically on the control valve side of pilot signal
manifold.
The pilot signal manifold is in the pilot system between the left and right pilot control valves, travel pilot control
valve, control valve, and pump 1 and 2 regulators.
Actuating a pilot control valve sends control pilot oil through the manifold to the pilot caps to shift the control valve
spools. At the same time the control pilot oil is routed directly or by the shuttle valves to shift the pilot valves (43—
48) and to actuate the swing and/or travel pressure sensors.
The pilot valves (45, 47, 48) sends primary pilot oil to the pump 1 and/or pump 2 regulators and swing park brake
release circuit. The primary pilot oil is from port A4 of the pilot shutoff solenoid valve to the pilot signal manifold
through port PI.
Arm 1 flow rate pilot valve (43) routes left or right swing control pilot oil to the arm 1 flow rate control valve in the
control valve. Bucket flow rate pilot valve (46) routes boom up control pilot oil to the bucket flow rate control valve
in control valve. Travel flow combiner pilot valve (44) routes primary pilot oil from the swing park brake release
pilot valve (45) to the travel flow combiner valve in control valve.
See Hydraulic System Schematic . (Group 9025-05.)
See Control Valve Operation . (Group 9025-05.)
763
TX1011120-UN: Boom Down Shockless Valve

LEGEND:
A - From Pilot Control Valve—Boom Up
1 - To Bottom Pilot Cap
43 - Orifice
44 - Spring B Cavity
45 - Passage 3
46 - Oil Chamber
47 - Passage 2
764
48 - Spring A Cavity
49 - Passage 1
50 - Tapered Land
Boom Down Shockless Valve (17)
The boom down shockless valve 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 control pilot oil from pilot control valve—boom up (A) to port A of pilot signal manifold.
Control pilot oil flows past the tapered land (50) of boom down shockless valve spool and into the oil chamber
(46). The tapered land acts as a variable orifice between the spool and manifold as the spool is shifted back and
forth. Control pilot oil flows from the oil chamber, through the orifice (43), into passage 2 (47), and out port 1 to the
bottom pilot cap (1).
Control pilot oil also flows through passage 3 (45) into spring B cavity (44) and passage 1 (49) into spring A cavity
(48). Because spring B is the larger spring, the increasing pressure of control pilot oil shifts the valve spool to the
left, opening the passage from port A to port 1 and allowing control pilot oil to flow unrestricted to the bottom pilot
cap shifting the boom 1 and boom 2 valve spools.
Actuating boom down sends return oil from the bottom pilot cap to port 1. From port 1 return oil flows through
passage 1 (49) to spring A cavity (48) and through passage 2 (47), through the orifice (43), and into the oil
chamber (46). From the oil chamber return oil flows through passage 3 (45) to spring B cavity (44) and past the
tapered land to port A. Because of the pressure drop across the orifice, the return oil pressure in the oil chamber
and spring B cavity is less than the return oil pressure in spring A cavity. The increasing return oil pressure shifts
the valve spool to the right causing the tapped land to restrict and then block the flow of return oil from port 1 to
port A. When the tapered land blocks the return oil flow, the pressure increases in the oil chamber and spring B
cavity. The valve spool now shifts to the left allowing return oil to flow past the tapered land to port A. The opening
and closing continues until the return oil is gradually returned through port A controlling the movement of boom 1
and boom 2 spools.
765
TX1011427-UN: Pump 1 or Pump 2 Flow Rate Pilot Valve
LEGEND:
56 - Spring Chamber
57 - To Hydraulic Oil Tank by Port DF
58 - Port SA to Pump 1 Regulator or Port SB to Pump 2 Regulator
59 - Sensing Passage
60 - Pump 1 or 2 Flow Rate Pilot Valve
61 - Primary Pilot Oil From Port PI
62 - Control Pilot Oil From Actuated Pilot Control Valve
63 - Shuttle Valve
Pump 1 Flow Rate Pilot Valve (port SA) and Pump 2 Flow Rate Pilot Valve (port SB)
The function of pump 1 and pump 2 flow rate pilot valves (60) is to deliver a regulated amount of primary pilot oil
to the pump 1 and/or 2 regulators in proportion to the control pilot oil applied to the flow rate pilot valve by the
actuated pilot control valves (62). The primary pilot oil is from port A4 of the pilot shutoff solenoid valve to the pilot
signal manifold through port PI (61).
Pump 1 flow rate pilot valve delivers primary pilot oil to pump 1 through port SA. Pump 2 flow rate pilot valve
delivers primary pilot oil to pump 2 through port SB. The control pilot oil from the actuated pilot control valve is
routed to the flow rate pilot valves by the shuttle valves (63).
Actuating a pilot control valve sends a control pilot oil signal to the pilot signal manifold. The control pilot oil flows
through the manifold to the control valve pilot cap and within the manifold is routed by shuttle valves to the end of
flow rate pilot valve. The pilot valve is shifted to the left against the spring force allowing a regulated amount of
primary pilot oil to flow past the pilot valve and out port SA to pump 1 regulator or port SB to pump 2 pump
regulator (58) and through the sensing passage (59) into spring chamber (56). The pressure of primary pilot oil to
the pump regulators and spring chamber increases pushing the pilot valve back to the right until the pressure of
primary pilot oil and spring force balances with the pressure of control pilot oil stopping the increase of primary
pilot oil pressure to pump regulators.
NOTE:
Ports SA and SB are located on the pilot control valve side of pilot signal manifold but, for
simplification of the schematic, are shown schematically on the control valve side of pilot signal
manifold.
When the pilot control valve is returned to neutral, control pilot oil on the end of pilot valve is released to the
hydraulic oil tank through the pilot control valve. The pilot valve is pushed to the right by the spring releasing the
primary pilot oil in the pump regulator and spring chamber to the hydraulic oil tank through port DF (57).
766
T149303-UN: Bucket Flow Rate Pilot Valve

LEGEND:
51 - Control Pilot Oil From Arm In
52 - To Hydraulic Oil Tank
53 - To Bucket Flow Rate Control Valve
54 - Control Pilot Oil From Boom Up
55 - Spring
Bucket Flow Rate Pilot Valve (port SK)
Bucket flow rate pilot valve is shifted directly by the control pilot oil from arm in (51) through port D. The pilot valve
then routes a portion of the control pilot oil from boom up through port A (54) out port SK to the bucket flow rate
control valve (53) in the control valve.
The bucket flow rate control valve restricts the flow of supply oil to the bucket spool during arm in and boom up
combined operation to ensure a flow of supply oil to the boom 1 spool.
See Bucket Flow Rate Control Valve Circuit Operation . (Group 9025-05.)
T149303-UN: Travel Flow Combiner Pilot Valve

LEGEND:
51 - Control Pilot Oil
53 - To Travel Flow Combiner Valve
54 - Primary Pilot Oil
55 - Spring
Travel Flow Combiner Pilot Valve (port SL)
Travel flow combiner pilot valve is shifted by control pilot oil (51) from the right side of travel pilot control valve
through port L (right reverse) or port K (right forward) and the shuttle valve. The pilot valve then routes primary
pilot oil (54) from the swing park brake release pilot valve to the travel flow combiner valve in the control valve.
The primary pilot oil is from port A4 of the pilot shutoff solenoid valve to the pilot signal manifold through port PI.
During travel and dig function combined operation, pump 1 supply oil to the right travel spool is also routed to the
left travel spool by the travel flow combiner valve. Pump 2 supply oil is used for the dig functions.
767
See Travel Flow Combiner Valve Operation . (Group 9025-05.)
T149303-UN: Swing Park Brake Release Pilot Valve

LEGEND:
53 - To Travel Flow Combiner Valve
55 - Spring
Swing Park Brake Release Pilot Valve (port SH)
Swing park brake release pilot valve is shifted by control pilot oil (51) from one of the following:
boom up to port A,
boom down to port B,
arm out to port C,
arm in to port D,
swing left to port E,
swing right to port F,
bucket curl to port G,
bucket dump to port H,
auxiliary to port M or N.
The control pilot oil is routed to the pilot valve within the pilot signal manifold by the shuttle valves.
The pilot valve routes primary pilot oil (54) out port SH to the park brake piston in the swing motor through port
SH. The primary pilot oil is from port A4 of the pilot shutoff solenoid valve to the pilot signal manifold through port
PI.
T149303-UN: Arm 1 Flow Rate Control Pilot Valve

LEGEND:
51 - Control Pilot Oil From Arm In
768
53 - To Arm 1 Flow Rate Control Valve
54 - Control Pilot Oil From Swing
55 - Spring
Arm 1 Flow Rate Pilot Valve (port SE)
Arm 1 flow rate pilot valve is shifted directly by the control pilot oil from arm in (51) through port D. Pilot valve then
routes a portion of the control pilot oil from swing (54), port E or F, through the shuttle valve, and out port SE to
the arm 1 flow rate control valve (53) in control valve.
The function of arm 1 flow rate control valve is to restrict the flow of supply oil to the arm 1 spool during arm in to
ensure a flow of supply oil (swing priority) to the swing spool.
See Arm 1 Flow Rate Control Valve Circuit Operation . (Group 9025-05.)
TX1001507-UN: Pilot Signal Manifold Shuttle Valve

LEGEND:
24 - Auxiliary
25 - Swing and Auxiliary
26 - Swing
27 - Bucket
28 - Arm, Boom Up, Swing, Auxiliary
29 - Boom, Arm, Bucket, Swing, Auxiliary
30 - Boom, Arm, Bucket
31 - Boom, Arm, Bucket, Left Travel, Swing
32 - Arm, Boom Up
33 - Boom
769
34 - Boom, Arm, Bucket, Right Travel
35 - Boom, Arm
36 - Arm
37 - Boom, Arm, Bucket, Right Travel
38 - Right Travel
39 - Left Travel, Right Travel
40 - Left Travel
42 - Check Valve (4 used)
Shuttle Valves (24—40)
Control pilot oil from the actuated left, right, and travel pilot control valves to the pilot signal manifold is routed by
the shuttle valves (24—40) to shift the respective pilot valves (19—22) and actuate the travel pressure sensor
(port TR) and swing pressure sensor (port S3). The bucket flow rate pilot valve (18) and arm 1 flow rate pilot valve
(23) are shifted directly by control pilot oil .
-: Actuated Function To Shift Pilot Valve
Actuated Function To Shift Pilot Valve
Function and Pump 1 Flow Pump 2 Flow Travel Flow Bucket Flow Swing Park Brake Arm 1 Flow
Pilot Signal Rate Pilot Rate Pilot Combiner Pilot Rate Pilot Release Pilot Rate Pilot
Manifold Ports Valve, SA Valve, SB Valve, SL Valve, SK Valve, SH Valve, SE
Boom Up, A X X X
Boom Down, B X X
Arm In, D X X X X X
Arm Out, C X X X
Bucket Curl, G X X
Bucket Dump, H X X
Right Swing, F X X
Left Swing, E X X
Right Travel, L, X X
K
Left Travel, I, J X
Auxiliary, N, M X X
There are six outputs of the pilot signal manifold other than providing passages for control pilot oil to shift control
valve spools.
-: Six Additional Outputs of Pilot Signal Manifold
Six Outputs of Pilot Signal Manifold
Output Input Number 1 Input Number 2
Travel Flow Combiner Any Dig or Swing Function Right Travel
Bucket Flow Rate Control Arm In Boom Up
Arm 1 Flow Rate Control Arm In Swing
770
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
TP97644,0000060-19-20090119
771
TX1012204-UN: Pumps and Gearbox

LEGEND:
2 - Pump Drive Gearbox
3 - Dampener Drive (Flex Coupling)
4 - Drive Shaft
5 - Air Bleed Plug (2 used)
9 - Pump 1 Discharge Port
10 - Pump 1 Attenuator Port
11 - Pump 2 Attenuator Port
12 - Pump 2 Discharge Port
772
13 - Dipstick
14 - Fill Plug
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
29 - Suction Line Port
TX1012206-UN: Pump Cross Section

LEGEND:
4 - Drive Shaft
19 - Servo Piston
21 - Cylinder Block
22 - Valve Plate
24 - Drive Gear
25 - Center Shaft
26 - Feedback Link
27 - Piston (7 used)
Pump 1 (15), pump 2 (16) and pilot pump (28) are driven by the engine at engine speed through the drive gear
773
(24) in pump drive gearbox (2). The pump 2 drive shaft is connected to the engine flywheel through a dampener
drive (flex coupling).
Pump 1 and pump 2 are variable displacement, bent-axis, piston type pumps. Two identical pumps are used to
generate supply oil flow in the hydraulic system. The pumps can vary from minimum displacement to maximum
displacement depending on hydraulic demand of the system.
Pump 1 regulator (17) and pump 2 regulator (18) are attached to the top of pump housing. The regulators control
the movement of the servo piston (19) by sending or releasing oil from the large end of the piston. The servo
piston moves the valve plate (22) and cylinder block (21) changing the pump displacement. The feedback link
(26), connected to the valve plate, provides a mechanical feedback to the remote control sleeve in the regulator.
The remote control sleeve blocks the flow of oil and traps the oil at both ends of the servo piston, stopping its
movement at the flow rate in proportion to the control lever actuation. See Pump 1 and Pump 2 Regulator
The pump displacement, or flow rate, is varied by changing the angle of the cylinder block with respect to the
drive shaft. Expanding the angle increases the distance that each piston travels into and out of the bore, which
increases displacement. Decreasing the angle reduces the distance that each piston travels into and out of the
bore, which decreases displacement.
An attenuator hose is connected from each pump discharge port (10 and 11) to the machine frame. The
attenuator hoses help reduce pump vibrations during operation.
TX04577,0000137-19-20070104
774
TX1013306-UN: Pump Regulator Component Identification

LEGEND:
1 - Flow Adjusting Cartridge (Track Cycle Time)
2 - Maximum Flow Adjusting Screw
3 - Spring
4 - Remote Control Sleeve
5 - Remote Control Spool
6 - Piston
7 - Minimum Flow Adjusting Screw
8 - Load Adjusting Cartridge (Outer Spring)
9 - Load Adjusting Screw (Inner Spring)
10 - Inner Spring
11 - Outer Spring
12 - Load Sleeve
13 - Load Spool
14 - Load Piston 2
15 - Load Piston 1
16 - Feedback Link
Pump Regulator Component Identification— Function of pump 1 and pump 2 regulators is to control pump 1
and pump 2 flow rates (displacement) in response to various oil pressure signals so pump drive torque does not
exceed engine torque.
Piston (6) controls the remote control spool (5) movement against spring in response to pump control pilot oil from
pump 1 and pump 2 flow rate pilot valves. Actuating the control levers or pedals send control pilot oil through the
pilot signal manifold to shift the control valve spools. Within the pilot signal manifold the control pilot oil also shifts
the pump 1 and/or pump 2 flow rate pilot valves. See Pilot Signal Manifold Operation for pump 1 or pump 2 flow
rate pilot valve operation. (Group 9025-05.)
Load piston 1 (15) and load piston 2 (14) controls the load spool (13) movement against inner and outer springs
(10 and 11) in response to torque control pilot oil pressure from the torque control solenoid valve and supply oil
775
pressure from pump 1 and pump 2. Supply oil pressure from pump 1 is sensed on one shoulder of load piston 2
and from pump 2 on the other shoulder.
The torque control solenoid valve controls pilot oil pressure to load piston 1 (15) in response to an electrical signal
from the main controller (MCF). The electrical signal is generated by the main controller monitoring the 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 System Functional Schematic for the main controller.
Remote control sleeve (4) and load sleeve (12) are moved by the feedback link (16) blocking flow of oil to or from
large end of servo piston. The feedback link is connected to the valve plate which is located between the servo
piston and cylinder block. See Pump 1, Pump 2 and Drive Gearbox Operation for more information.
Pump 1 and pump 2 regulators are mounted on top of the pump housing. Torque control solenoid valve and pump
2 flow rate limit solenoid valve are located in housing on top of pump 2 regulator. Pump 1 and 2 control pressure
sensors are located in their respective regulator. The pump 2 flow rate limit solenoid valve is used with
accessories when a reduced pump flow rate is required. The solenoid valve reduces the pump control pilot oil to
the piston (6) by routing some of the pilot oil to return. See System Functional Schematic for the solenoids and
pressure sensor.
See Pump Harness (W8) Wiring Diagram .
See the following test and adjustment 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.)
776
TX1013788-UN: Pump 1 and 2 Regulators Control by Pump 1 and 2 Flow Rate Pilot Valves—Increasing
LEGEND:
3 - Spring
6 - Piston
10 - Inner Spring
11 - Outer Spring
12 - Load Sleeve
13 - Load Spool
14 - Load Piston 2
15 - Load Piston 1
16 - Feedback Link
17 - Servo Piston
18 - To Large End of Servo Piston
19 - Return to Pump Housing
20 - Pump 1 Pressure Inlet
22 - Torque Control Port
23 - From Pump 1 or 2 Flow Rate Pilot Valve (port SA or SB)
24 - Pilot Oil Inlet
777
25 - Supply Oil
27 - Pump Control Pilot Oil
28 - Torque Control Pilot Oil
Pump Regulator Control by Flow Rate Pilot Valve— Primary pilot oil (26) from pilot pump is constantly
supplied through drilled passages in pump housing to small end of servo pistons, to pilot oil inlet (24) at the pump
1 and 2 regulators, and to torque control solenoid valve located on top of pump 2 regulator.
Pump flow rate (displacement) is changed by sending pilot oil to or releasing it from the large end of servo piston
(17) through the passages to large end of servo piston (18).
Pump control pilot oil (27) from pump 1 or 2 flow rate pilot valves (23) in pilot signal manifold is sensed by the
piston (6) in its respective regulator.
Supply oil (25) 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.
Torque control pilot oil (28) from torque control solenoid valve is routed through steel lines to torque control port
(22) in each pump regulator.
Increasing Flow Rate (Displacement)— Actuating a control lever or pedal increases the pump control pilot oil
(27) pressure from the pump 1 and/or 2 flow rate pilot valve to the piston (6). Pilot oil pressure pushes the piston
and remote control spool (5) to left against the spring (3).
Movement of spool opens the passage from large end of servo piston (18) to return in pump housing (19). Primary
pilot oil on small end of servo piston pushes piston down, increasing pump angle which increases flow rate
(displacement). Movement of the cylinder block, valve plate, and servo piston is transmitted to remote control
sleeve (4) and load sleeve (12) by the feedback link (16). Sleeves move left until passage to return is closed. Oil
at large end of servo piston is now trapped, holding the pump at flow rate (displacement) that is proportional to
pressure of pump control pilot oil from the pump 1 and/or 2 flow rate pilot valve to the piston.
Maximum Flow Rate (Displacement)— When control lever or pedal is actuated to full stroke, pump control pilot
oil (27) from pump 1 or 2 flow rate pilot valve (port SA or SB) (23) to piston (6) increases to its maximum pressure.
Oil pressure pushes the piston and remote control spool to left until spool contacts maximum flow adjusting screw
(2). Movement of spool opens the passage from large end of servo piston (18) to return in pump housing (19).
Pilot oil on small end of servo piston pushes piston down, increasing pump flow rate (displacement). As flow rate
(displacement) increases, servo piston movement is transmitted to remote control sleeve (4) and load sleeve (12)
by feedback link (16). Sleeves move left until passage to return is closed. Oil at large end of servo piston is now
trapped, holding pump at maximum flow rate (displacement).
Decreasing Flow Rate (Displacement)— As control lever or pedal is returned to neutral, the pump control pilot
oil (27) pressure sensed at piston (6) also decreases. Spring (3) pushes remote control spool and piston to the
right. Movement of spool opens a passage for primary pilot oil (26) from pilot oil inlet (24) to flow to large end of
servo piston (18). Pilot oil pressure applied to large end of servo piston (17) pushes it up against pilot oil pressure
applied to small end decreasing pump flow. Remote control spool continues to move to right in response to
decreasing pump control pilot oil pressure until it contacts piston cylinder. As pump flow rate (displacement)
decreases, Movement of cylinder block, valve plate, and servo piston is transmitted to remote control sleeve (4)
and load sleeve (12) by the feedback link (16). Sleeves move right until passage for pilot oil is closed. Oil at large
end of servo piston is now trapped, holding pump at flow rate (displacement) that is proportional to pressure of
pump control pilot oil.
778
TX1013800-UN: Pump Regulator Control by Supply Oil Pressure—Decreasing

LEGEND:
3 - Spring
6 - Piston
10 - Inner Spring
11 - Outer Spring
12 - Load Sleeve
13 - Load Spool
14 - Load Piston 2
15 - Load Piston 1
16 - Feedback Link
17 - Servo Piston
779
25 - Supply Oil
26 - Pilot Oil
Pump Regulator Control by Supply Oil Pressure— Supply oil (25) pressure (load) for each pump is sensed on
shoulders of load piston 2 (14) through pump 1 and pump 2 pressure inlets (20 and 21) in each pump regulator.
The area of each shoulder is equal. Therefore, force applied through load spool 2 (14) to inner and outer springs
(10 and 11) is an average of supply oil pressures. Springs are adjusted against the average pressure so flow rate
of each pump is approximately equal and uses approximately one-half engine torque.
Increasing supply oil pressure (load) pushes the load piston 2 and load spool against inner and outer springs,
opening passage for primary pilot oil (26) to flow from pilot oil inlet (24), through load sleeve (12) to large end of
servo pistons (18). Flow rate decreases until feedback link (16) moves load sleeve and remote control sleeve (4)
blocking the flow of oil. Flow rate of both pumps decreases so load on pumps does not exceed engine torque.
When supply oil pressure (load) decreases, the inner and outer springs push the load spool and pistons to the
right against supply oil pressure. The movement opens the passage for oil to flow from large end of servo piston
(18) through load sleeve and remote control sleeve to return in pump housing (19). Flow rate increases until
feedback link moves load sleeve and remote control sleeve blocking the flow of oil.
Engine torque is not exceeded, even if one pump is loaded relatively high while other pump stays relatively low.
As long as a control lever or pedal is held constant, the pump control pilot oil (27) pressure from pump 1 or 2 flow
rate pilot valve (23) to the piston (6) does not change as supply oil pressure changes.
780
TX1013821-UN: Pump Regulator Control by Speed Sensing (Torque Control Solenoid Valve)—Decreasing
LEGEND:
3 - Spring
6 - Piston
10 - Inner Spring
11 - Outer Spring
12 - Load Sleeve
13 - Load Spool
14 - Load Piston 2
15 - Load Piston 1
16 - Feedback Link
17 - Servo Piston
25 - Supply Oil
Pump Regulator Control by Engine Speed Sensing (Torque Control Solenoid Valve)— As engine speed
changes, the main controller calculates speed difference between target and actual engine speed. Main controller
then actuates torque control solenoid valve to increase or decrease torque control pilot oil (28) pressure to torque
control port (22) and load piston 1 (15).
As the load on engine increases, speed difference between target and actual engine speed increases. Main
controller decreases electrical signal to torque control solenoid valve, which increases torque control pilot oil (28)
pressure to load piston 1. Torque control pilot oil along with supply oil pressure on load piston 2 (14) shifts load
spool (13) so primary pilot oil (26) flows to large end of servo piston (18), decreasing flow rate (displacement). As
flow rate of both pumps decreases, load on engine also decreases allowing actual engine speed to increase.
As the load on engine decreases, speed difference between target and actual engine speed decreases. Main
controller increases electrical signal to torque control solenoid valve, which decreases torque control pilot oil
pressure to load piston 1. Inner and outer springs (10 and 11) shifts load spool in response to decreasing torque
control pilot oil pressure, releasing oil from large end of servo piston to return in pump housing (19) allowing pump
flow (displacement) to increase. As pump flow rate increases, engine output is used more efficiently.
Pump Regulator Control by Travel Torque-Up Control (Slow Speed Sensing)— The function of travel 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,
781
pump 1 and 2 flow rates are increased to prevent mistracking which can occur at the lower flow rate if there are
differences between the pumps 1 and 2.
When the engine speed requested by the engine speed dial is slow, the main controller processes electrical
signals from the travel pressure sensor and pump 1 and 2 delivery pressure sensors. Main controller then
increases the electrical signal to torque control solenoid valve, which decreases torque control pilot oil (28)
pressure to load piston 1. Inner and outer springs shift the load spool in response to decreasing torque control
pilot oil pressure, releasing oil from large end of servo piston allowing pump displacement to go to maximum. The
pump flow rate increases and the machine does not mistrack at slow engine speed. The increased flow rate
continues even if a dig function is actuated while traveling at slow engine speed. See Engine Speed Sensing
Control Circuit Operation . (Group 9025-05.)
TP97644,0000094-19-20070119
782
T143118-UN: Engine Speed Sensing Control Circuit
T143373-UN: Torque Control Solenoid Valve

LEGEND:
1 - Main Controller (MCF)
3 - Travel Pressure Sensor
4 - Crankshaft Position Sensor
5 - Pump 2 Delivery Pressure Sensor
9 - Torque Control Solenoid Valve
10 - Spring
11 - Spool Return Spring
12 - Inlet Port
13 - Sleeve
14 - Outlet Port to Load Piston
783
15 - Spool
16 - Return Port to Pump Case
17 - Supply Oil
18 - Pilot Oil
19 - Electrical Signal
20 - Return Oil
Engine Speed Sensing Control (Torque Control Solenoid Valve)— The function of 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.
The main controller (1) calculates the speed difference between target and actual engine speed. The main
controller then actuates the torque control solenoid valve (9) 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. Actual engine
speed is sensed by the crankshaft position sensor (4).
As a load on the engine increases, the actual engine speed becomes less than the target engine speed. The
main controller decreases the electrical signal to the torque control solenoid valve, which increases the pilot oil
(18) pressure to the load piston 1 in the pump 1 and pump 2 regulators (8 and 6). Pilot oil pressure on load piston
1 and supply oil pressure on load piston 2 shifts the load spool 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 main controller increases the electrical signal to the torque control solenoid valve, which decreases the pilot
oil pressure to the load piston in the regulators. The spring 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 and Pump 2 Regulator
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 the pumps 1 and 2.
When the engine speed requested by the engine speed dial (2) is slow, the main controller (1) processes the
electrical signals from the travel pressure sensor (3), pump 1 delivery pressure sensor (7), and pump 2 delivery
pressure sensor (5). The main controller sends an increasing electrical signal to the torque control solenoid valve
(9) 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.
The increased flow rate continues even if a dig function is actuated while traveling at slow engine speed.
TP97644,0000033-19-20070111
784
TX1156826-UN: Component Identifications—Right and Bottom

LEGEND:
76 - Bucket Spool
77 - Bucket Flow Rate Control Valve (switch valve and poppet)
79 - Bucket Dump Circuit Relief and Anticavitation Valve
80 - Bucket Curl Circuit Relief and Anticavitation Valve
81 - Boom 1 Spool
83 - Boom Flow Rate Control Valve (switch valve and poppet)
85 - Boom Reduced Leakage Valve (switch 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
91A - Switch Valve for Arm 2 Flow Rate Control Valve
91B - Poppet for Arm 2 Flow Rate Control Valve
92 - Check Valve (lift check)—Arm 2 Neutral Passage
785
95 - Swing Spool
102 - Arm In Circuit Relief and Anticavitation Valve
106 - Check Valve—Dig Regenerative Circuit
109 - Plug
116 - Main Relief Valve Isolation Check Valve (4-spool)
121 - Check Valve—Travel Flow Combiner Valve Circuit
130 - Manual Boom Lower Screw
TX1225121-UN: Component Identification—Left

LEGEND:
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
96 - Check Valve (lift check)—Swing Neutral Passage
786
97 - Arm 1 Spool
98 - Arm 1 Flow Rate Control Valve (switch valve and poppet)
100 - Check Valve (lift check)—Dig Regenerative Circuit
101 - Arm Reduced Leakage Valve (switch valve and poppet)
103 - Arm Out Circuit Relief and Anticavitation Valve
104 - Boom 2 Spool
105 - Check Valve (lift check)—Boom 2 Power Circuit
108 - Auxiliary Flow Rate Control Valve (switch valve and poppet)
109 - Plug (3 used)
112 - Check Valve (lift check)—Left Travel Power Passage
115 - Main Relief Valve—Isolation Check Valve (5-spool)
119 - Check Valve—Auxiliary Flow Combiner Valve Circuit
TX1225124-UN: Component Identification—Front

LEGEND:
787
109 - Plug (2 used)
111 - Check Valve (lift check)—Left Travel Neutral Passage
122 - Check Valve (lift check) and Orifice—Travel and Bucket Combiner Circuit
The control valve consists of two monoblock valves referred to as the left control valve (5-spool) and right control
valve (4-spool). The 4-spool and 5-spool valves are mounted back-to-back so the oil passages in the valves are
connected. The spools are selectively fitted. There is a spool in each valve to control the boom, arm, and travel
functions. All other functions are supplied by a single spool in one or the other of the valves. All spools are moved
by pilot oil. Check valves are used as lift checks and to route supply oil between the 4-spool and 5-spool valves
for combined operation. The control valve is an open-center type valve. Each valve section controls the flow rate
and direction for its hydraulic circuit.
See Hydraulic System Schematic for more information. (Group 9025-05.)
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) and orifice—travel and bucket combiner
circuit (122) and check valve—travel flow combiner valve circuit (121). (Group 9025-05.)
788
TX1001195-UN: Neutral and Power Passages Operation

LEGEND:
15 - Pump 1 (4-spool)
16 - Pump 2 (5-spool)
52 - Swing Motor
76 - Bucket Spool
81 - Boom 1 Spool
789
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
127 - Arm Cylinder
142 - Neutral and Power Passages
143 - Combiner Passage
144 - Return Passage
Supply oil from pump 1 (4-spool) (15) flows to the right control valve (4-spool) (73). Supply oil from pump 2 (5-
spool) (16) flows to the left control valve (5-spool) (74). When all functions are in neutral, supply oil flows through
the neutral and power passages (142) for each valve spool section and then into the return passage (144).
Neutral and power passages in the left and right control valves are used to route supply oil for the combined
operation of functions. Arm 1 and 2 spools (97 and 90) and the boom 1 and 2 spools (81 and 104) are connected
by combiner passages (143) so supply oil from both pump 1 and pump 2 flows to the cylinders during a single
operation. Supply oil from pump 2 can be combined with supply oil from pump 1 by the auxiliary combiner power
passage to supply the auxiliary spool (107).
TX1012161-UN: Front Section Cross Section From Rear

LEGEND:
790
119 - Check Valve—Auxiliary Flow Combiner Valve
See Main Relief and Power Digging Valve Circuit Operation for main relief and power digging valve (117). (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 check valve—auxiliary flow combiner valve (119). (Group
9025-05.)
See Travel Flow Combiner Valve Operation for travel flow combiner valve (120). (Group 9025-05.)
TX1012162-UN: Left and Right Travel Valve Cross Section From Rear
LEGEND:
791
TX1012163-UN: Auxiliary and Bucket Valve Sections From Rear

LEGEND:
13 - Plug—Auxiliary (pilot)
76 - Bucket Spool
78 - Bucket Regenerative Valve
109 - Plug (2 used)
See Bucket Flow Rate Control Valve Circuit Operation for bucket flow rate control valve (switch valve and poppet)
(77). (Group 9025-05.)
See Bucket Regenerative Valve Circuit Operation for bucket regenerative valve (78). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for bucket dump and curl circuit relief and anticavitation
valves (79 and 80). (Group 9025-05.)
Auxiliary spool (107) and auxiliary flow rate control valve (switch valve and poppet) (108) are used when optional
attachments are installed on the machine. See Auxiliary Flow Rate Control Valve Circuit Operation for auxiliary
flow rate control valve. (Group 9025-05.)
792
TX1012164-UN: Boom 2 and Boom 1 Valve Cross Section From Rear

LEGEND:
81 - Boom 1 Spool
82 - Boom Regenerative Valve
104 - Boom 2 Spool
See Boom Regenerative Valve Circuit Operation for boom regenerative valve (82). (Group 9025-05.)
See Boom Flow Rate Control Valve Circuit Operation for boom flow rate control valve (switch valve and poppet)
(83). (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation for boom reduced leakage valve (switch valve and check
valve) (85). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for boom down circuit relief and anticavitation valve (89).
(Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—boom 2 power circuit
(105). (Group 9025-05.)
See Lower Boom With Engine Stopped for use of manual boom lower screw. (Operator's Manual.)
793
See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for boom up
pressure sensor (B30). (Group 9015-10.)
TX1156829-UN: Boom-to-Arm Section Cross Section From Rear

LEGEND:
86 - Orifice
91B - Poppet of Arm 2 Flow Rate Control Valve
See Dig Regenerative Valve Circuit Operation for dig regenerative valve (84). (Group 9025-05.)
See Circuit Relief and Anticavitation Valve Operation for arm out circuit relief and anticavitation valve (103).
(Group 9025-05.)
See Arm 2 Flow Rate Control Valve Circuit Operation for poppet of arm 2 flow rate control valve (91B).
See Boom Lower Meter-In Cut Valve Operation for boom lower meter-in cut valve (87). (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—dig regenerative circuit
(100). (Group 9025-05.)
794
TX1012167-UN: Arm 2 and Arm 1 Valve Cross Section From Rear

LEGEND:
90 - Arm 2 Spool
91A - Switch Valve of Arm 2 Flow Rate Control Valve
97 - Arm 1 Spool
See Circuit Relief and Anticavitation Valve Operation for boom up and arm in circuit relief and anticavitation
valves (88 and 102). (Group 9025-05.)
See Arm 2 Flow Rate Control Valve Circuit Operation for switch valve of arm 2 flow rate control valve (91A).
(Group 9025-05.)
See Arm 1 Flow Rate Control Valve Circuit Operation for arm 1 flow rate control valve (switch valve and poppet)
(98). (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation for arm reduced leakage valve (switch valve and poppet)
(101). (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—arm 2 neutral passage
(92). (Group 9025-05.)
795
TX1012169-UN: Swing Valve and Rear Section Cross Section From Rear
LEGEND:
95 - Swing Spool
See Arm Regenerative Valve Circuit Operation for arm regenerative valve (94). (Group 9025-05.)
See Control Valve Check Valves Identification and Operation for check valve (lift check)—swing neutral passage
(96). (Group 9025-05.)
Bypass shutoff valve (93) is used when optional attachments are installed on the machine.
TP97644,0000089-19-20161019
796
TX1014069-UN: Control Valve Check Valves

LEGEND:
15 - Pump 1 (right, 4-spool)
16 - Pump 2 (left, 5-spool)
76 - Bucket Spool
77 - Bucket Flow Rate Control Valve (valve and poppet)
797
81 - Boom 1 Spool
83 - Boom Flow Rate Control Valve (valve and poppet)
86 - Orifice
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
99 - Check Valve (lift check)—Arm 1 Regenerative Circuit
104 - Boom 2 Spool
113 - Orifice—Left Travel Power Passage
115 - Main Relief Valve Isolation Check Valve—5-Spool
118 - Auxiliary Function Flow Combiner Valve
119 - Check Valve—Auxiliary Function Flow Combiner Valve Circuit
122 - Check Valve (lift check)—Bucket
123 - Orifice—Bucket Power Circuit
See Control Valve Operation for location of check valves and orifices in the right and left control valves (73 and
74). (Group 9025-05.)
798
Check Valves (92, 96, and 111): Check valves function as lift checks in the neutral passages.
Check Valves (105 and 112): Check valves function as lift checks in the power passages.
Check Valve (lift check)—Dig Regenerative Circuit (100): Functions as a lift check for arm in function when dig
regenerative solenoid valve is actuated. See Dig Regenerative Valve Circuit Operation for solenoid valve
operation. (Group 9025-05.)
See Control Valve Operation for location and operation of dig regenerative valve. (Group 9025-05.)
Orifice—Left Travel Power Passage (113): Restricts the flow of supply 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 supply oil pressure from pump 2
(16). Return oil combines with the supply oil flow to the head end of arm cylinder preventing cavitation.
When supply 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 digging. 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—5-Spool (115): One main relief and power digging valve (117) is
used to limit the supply 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 digging valve.
Operational Check: Pump 2 (16) supply 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 digging valve
pressure setting, inspect isolation check valve (115). Also, power and neutral passage oil flow pressure for the 5-
spool side is high because oil is flowing past the isolation check valve (115).
Main Relief Valve Isolation Check Valve—4-Spool (116): Operational Check: Pump 1 (15) supply oil pressure
becomes hard to increase. Operate swing function at stall and check pressure at pump 2. If pressure is less than
swing crossover relief valve pressure setting, inspect the isolation check valve (116). Also, neutral passage oil
flow pressure for the 4-spool side is high because oil is flowing past the isolation check valve (116).
Check Valve—Auxiliary Function Flow Combiner Valve Circuit (119): For pump 1 (15) and pump 2 (16)
combined flow to the auxiliary spool (107), a pilot line from the auxiliary spool pilot cap must be connected to shift
the auxiliary function flow combiner valve (118) and bypass shutoff valve (93). Check valve closes if supply oil
pressure in the left control valve (74) power passage becomes higher than supply oil pressure in the right control
valve (73) neutral passage.
Check Valve—Travel Flow Combiner Valve Circuit (121): Blocks a higher supply oil pressure in the left control
valve (5-spool) (74) from flowing to the right control valve (4-spool) (73) in travel flow combiner circuit.
Operational Check: Machine mistracks to the left, forward or reverse, when traveling and operating a dig function.
To check, operate a dig function over relief while traveling. If mistracking stops, inspect check valve (121).
Circuit Relief and Anticavitation Valves (79, 80, 88, 89, 102, and 103) The anticavitation valves open when
799
return oil pressure becomes greater than supply oil pressure to provide make-up 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).
Supply oil flow from pump 1 to the bucket spool is blocked by the right travel spool (75) when actuated. Supply 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 supply oil to the bucket spool.
Operational Check: Actuate left and right travel and bucket functions. If bucket does not move, inspect check
valve and orifice.
Check Valve—Dig Regenerative Circuit (106): Not used in this configuration.
Hydraulic Oil Cooler Bypass Valve (124): Opens to route return oil around hydraulic oil cooler and directly to
Operation Check: Hydraulic oil continues to run hot. Check for an open bypass valve.
Restriction Valve (136): Used in the return line after the hydraulic oil cooler to create some back pressure in the
return passage of control valve. The back pressure ensures a flow of makeup oil to keep the swing motor case full
of oil and a flow of oil through the anticavitation valves to prevent cylinder cavitation. The pressure setting for the
hydraulic oil cooler bypass valve is higher than the restriction valve.
TP97644,0000035-19-20061024
800
T142362-UN: Main Relief And Power Digging Valve

LEGEND:
1 - First Adjusting Plug
2 - 27 mm Nut
3 - Second Adjusting Plug
4 - 32 mm Nut
5 - Piston
6 - Left Control Valve Housing
7 - Pilot Poppet Spring
8 - Pilot Poppet
9 - Main Poppet Spring
10 - Main Poppet
11 - Return Passage
12 - Power Passage
13 - Normal Operation
14 - Power Digging Operation
15 - Supply Oil
16 - Pilot Oil
Main Relief and Power Digging Valve— The function of main relief and power digging valve is to limit the main
hydraulic system operating pressure. Main relief and power digging valve is pilot operated poppet type relief valve
with a piston (5).
When the supply oil 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.
801
For power digging operation (14), pilot oil (16) from the power digging solenoid valve pushes the piston (5) down
to the bottom of its 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 supply oil
pressure to the main relief and power digging 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 digging valve. See Control Valve Check Valves Identification and Operation for main relief valve
isolation check valves. (Group 9025-05.)
TX1001267-UN: Power Digging Control Circuit

LEGEND:
16 - Pilot Oil
20 - Pump 2
21 - Pump 1
23 - Power Digging Solenoid Valve (port SG)
24 - Power Dig Switch
Power Digging Control Circuit— The function of circuit is to increase the system operating pressure
temporarily.
When the power dig switch (24) is pushed and held, the main controller (19) sends an electrical signal (18) to
energize the power digging solenoid valve (23) coil. Pilot oil (16) flows from the valve to the piston in main relief
and power digging valve (22). The pilot oil pressure pushes the piston in the main relief valve and power digging
valve down increasing the pressure setting. Main hydraulic system now operates at the higher operating
pressure.
The power digging 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 digging control circuit. A
timer circuit in the main controller controls the length of time control circuit is actuated. Releasing the switch
802
before 8 seconds, causes the power digging control circuit to turn off.
TX1001268-UN: Auto-Power Digging Control Circuit

LEGEND:
16 - Pilot Oil
20 - Pump 2
21 - Pump 1
25 - Boom Up Pressure Sensor
26 - Arm In Pressure Sensor
Auto-Power Digging Control Circuit— The function of 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 (19) actuates the power digging solenoid valve (23) under the
following conditions:
During boom up operation, the main controller (19) actuates the power digging solenoid valve (23) 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 (25) sensor sending an electrical signal to the
main controller.
Pump 1 (21) delivery pressure is high. Pump 1 delivery pressure sensor (27) sends an electrical signal
to the main controller indicating the high pressure.
Control lever for arm in is in neutral. Electrical signal for arm in pressure sensor (26) is at zero.
When all conditions are met the main controller sends an electrical signal to energize the power digging solenoid
803
valve (23) coil allowing pilot oil (16) to flow to the piston in main relief and power digging valve (22). The pilot oil
pressure pushes the piston in the main relief and power digging valve down increasing the pressure setting. The
main hydraulic system now operates at the higher operating pressure.
T216853-UN: Power Digging Solenoid Valve (port SG)

LEGEND:
16 - Solenoid Coil
17 - Adjusting Screw
18 - Nut
19 - From Pilot Shutoff Solenoid Valve
20 - To Main Relief and Power Digging Valve
22 - Spool
23 - Pressure Equals Magnetic Force
24 - Pilot Oil
25 - Reduced Pilot Oil
26 - Return Oil
Power Digging Solenoid Valve (port SG) Operation— The power digging solenoid valve (Y24) is a proportional
solenoid valve type. The solenoid valve is activated by an electrical signal from the main controller (MCF). The
electrical signal is DC voltage that is turned on and off to form a pulse-width modulated signal. Solenoid coil (16)
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 (25) is sent to the main relief and power digging 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 digging valve is then
connected to the hydraulic oil tank (21) through the spool.
804
When energized, the magnetic force shifts the spool left against the spring. Pilot oil (24) flows past the spool
flange and out the port as a reduced pilot oil to the main relief and power digging 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 digging 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.
TP97644,0000061-19-20070314
805
T143483-UN: Circuit Relief and Anticavitation Valve

LEGEND:
1 - To Return
2 - Piston
3 - From Work Circuit
4 - Anticavitation Valve
5 - Pilot Poppet
6 - Check Valve Spring
7 - Pilot Poppet Spring
8 - Screw
9 - Piston Spring
10 - Main Poppet
11 - Relief Operation
12 - Anticavitation Operation
13 - Relief Pressure Oil
14 - Supply Oil
15 - Reduced Pressure Oil
16 - Return Oil
17 - Low Pressure Oil (cavitation)
The circuit relief valves are pilot operated relief valves and include a anticavitation valve.
At pressures below the circuit relief setting, the main poppet (10) remains closed. In relief operation (11), the relief
valve opens in three steps.
1. 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.
2. In the second step, the piston seats against the pilot poppet (5). The seating of piston further reduces oil
flow into the cavity and greatly decreases the pressure against the back side of main poppet.
3. In the third step the main poppet opens.
806
During anticavitation operation (12), the anticavitation valve (4) retracts to allow oil to flow from the return passage
into the work circuit. During normal operation, the supply oil (14) on the inner shoulder holds the anticavitation
valve against its seat. As the pressure in the work circuit decreases the pressure holding the anticavitation valve
closed also decreases. The return oil (16) on the outer shoulder pushes the anticavitation valve, main poppet, and
piston against the springs to open the valve.
TP97644,0000062-19-20060908
807
TX1001464-UN: Travel and Arm In Functions

LEGEND:
76 - Bucket Spool
808
90 - Arm 2 Spool
97 - Arm 1 Spool
123 - Orifice—Bucket Power Passage
127 - Arm Cylinder
145 - Supply Oil
147 - Pilot Oil
149 - Return Oil
When travel only is actuated, supply oil (145) from pump 2 (16) flows through the neutral passage of swing, arm 1
(97), boom 2, and auxiliary spools, then through the left travel spool (110) and out to the left travel motor (63).
Supply oil from pump 1 (15) flows through the right travel spool (75) and out to the right travel motor (61). Right
travel spool blocks the flow of supply oil through the neutral passage of bucket (76), boom 1, and arm 2.
When dig functions are actuated at the same time as travel, the travel flow combiner valve (120) is shifted by pilot
oil (147) from the travel flow combiner pilot valve (port SL) in the pilot signal manifold. See Pilot Signal Manifold
Operation for operation of pilot valves. (Group 9025-05.)
Supply oil from pump 1 flows to right travel spool and now through the travel flow combiner valve to the left travel
spool and bucket spool. Supply oil from pump 1 to both left and right travel motors prevents mistracking.
Supply oil from pump 2 is used for the swing, arm, and boom functions and when connected, the auxiliary
function.
When travel is not actuated, return oil and spring force keeps the travel flow combiner valve closed.
809
TX1001466-UN: Travel Flow Combiner Valve and Check Valve

LEGEND:
121 - Check Valve—Travel Flow Combiner Valve Passage
147 - Pilot Oil From Travel Flow Combiner Pilot Valve (port SL)
151 - To Control Valve Return Passage
152 - From Pump 1 (4-spool)
153 - To Left Travel Spool By Combiner Passage
TP97644,0000038-19-20061211
810
TX1012521-UN: Boom Lower Meter-In Cut Valve Circuit Operation Schematic

LEGEND:
2 - Boom Down (pilot)
15 - Pump 1
16 - Pump 2
81 - Boom 1 Spool
104 - Boom 2 Spool
145 - Supply Oil
146 - Low Pressure Oil
148 - Trapped Oil
149 - Return Oil
150 - Regenerative Oil
The boom lower meter-in cut valve (87), located in the boom lower circuit, controls the boom flow rate control
valve (83) and control pilot oil to the boom 2 spool (104).
During boom down (2) operation the boom lower meter-in cut valve is shifted by regenerative oil from the boom
cylinders. See Boom Regenerative Valve Circuit Operation . (Group 9025-05.) The boom lower meter-in cut valve
blocks control pilot oil to the boom 2 spool and directs it to the switch valve in the boom flow rate control valve.
The poppet of boom flow rate control valve now restricts supply oil flow from pump 1 to the boom 1 spool. See
Boom Flow Rate Control Valve Circuit Operation . (Group 9025-05.)
During operation of boom down and other function, the boom lowers due to own weight.
811
Supply oil is restricted to the boom 1 spool. Regenerative oil from the boom cylinder head end is routed through
the boom regenerative valve (82) to the boom cylinder rod end. Supply oil flows unrestricted to the other circuits
that pump 1 supplies.
When boom cylinder return oil pressure drops, the boom lower meter-in cut valve shifts. The switch valve in the
boom flow rate control valve opens and allows supply oil from pump 1 to flow to the boom 1 spool. Boom down
control pilot oil can now shift the boom 2 spool.
TX1012551-UN: Boom Lower Meter-In Cut Valve

LEGEND:
2 - From Boom Down (pilot)
3 - From Boom Cylinders
4 - Orifice
5 - Spring Chamber
6 - From Boom 2 Spool
7 - To Boom Flow Rate Control Valve (switch valve)
149 - Return Oil
During boom down operation, control pilot oil (147) flows to the boom 2 spool through boom lower meter-in cut
812
valve.
Regenerative oil from the boom cylinders flows to the spring chamber (5) in boom lower meter-in cut valve through
the orifice (4).
When pressure in the spring chamber becomes larger than the spring force, the boom lower meter-in cut valve is
shifted.
Therefore, return oil is directed to the hydraulic oil tank through the passage in the boom lower meter-in cut valve.
Boom 2 spool is returned to the neutral position.
Control pilot oil flows to and shifts the switch valve in the boom flow rate control valve. See Boom Flow Rate
Control Valve Circuit Operation . (Group 9025-05.)
During combined operation of boom lower and other functions, more supply oil is available to the other functions
to ensure priority to them.
TP97644,0000039-19-20070109
813
TX1000026-UN: Boom Regenerative Valve Circuit Schematic

LEGEND:
57 - Orifice
81 - Boom 1 Spool
86 - Drilled Passage
125 - Boom Cylinder (2 used)
145 - Supply Oil
147 - Pilot Oil
149 - Return Oil
The boom regenerative valve (82) is located inside the boom 1 spool (81). The boom regenerative valve improves
boom control and prevents boom cylinder cavitation during boom down operation.
Under the following operating conditions, low pump 1 delivery pressure and pilot oil pressure to the pilot cap for
boom down, the weight of boom, arm, and bucket causes the boom to lower faster than the pump can supply oil
to the boom cylinder rod end.
Pilot oil (147) shifts the boom 1 spool to the boom down position. The pilot oil also shifts the boom reduced
leakage valve (85) to allow oil to flow from the head end of the boom cylinders. See Boom and Arm Reduced
Leakage Valves Operation . (Group 9025-05.) Oil then flows to the boom 1 spool. At the boom 1 spool, oil flows
through a drilled passage (86) to the center of the spool.
When regenerative oil (150) pressure is more than pump 1 supply oil (145) pressure, the boom regenerative valve
814
(82) is open. Regenerative oil is combined with pump 1 supply oil and both are supplied to the boom cylinders rod
end.
When pump 1 supply oil pressure is more than regenerative oil pressure, the boom regenerative valve is closed.
Pump 1 supply oil only flows to the boom cylinders rod end. Regenerative oil passes through an orifice (57) and
on to the oil tank.
TX1017424-UN: Boom Regenerative Valve Circuit Cross Section

LEGEND:
15 - Pump 1 Supply Oil
16 - Pump 2 Supply Oil
81 - Boom 1 Spool
102 - Boom 2 Spool
145 - Supply Oil
815
147 - Pilot Oil
149 - Return Oil
201 - From Boom Cylinder Head End
202 - To Boom Cylinder Rod End
TP97644,000003A-19-20070109
816
TX1014140-UN: Dig Regenerative Valve Circuit Schematic

LEGEND:
15 - Pump 1
16 - Pump 2
81 - Boom 1 Spool
90 - Arm 2 Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
127 - Arm Cylinder
145 - Supply Oil
146 - Combined Oil (supply and return oil)
149 - Return Oil
The function of dig regenerative valve circuit is to maintain arm in control and prevents arm cylinder (127)
cavitation during combined operations of boom up and arm in. During the combined operations, gravity can pull
the arm in faster than pump 1 and 2 can supply oil to the arm cylinder head end.
The main controller (MCF) (A3) actuates the dig regenerative solenoid valve (Y22) under the following conditions:
817
boom up pressure sensor (B30) is actuated.

pressure reading from pump 1 and 2 delivery pressure sensors (B35 and B37) is high.
pressure reading from arm in pressure sensor (B31) is high.
The main controller sends an electrical signal (300) to the dig regenerative solenoid valve to energize the coil. The
solenoid valve then sends reduced pilot oil (147) pressure to shift the dig regenerative valve (84).
Return oil from the rod end of boom cylinders (125) flows through boom 1 spool (81) and dig regenerative valve to
the arm 1 spool (97). At arm 1 spool the return oil combines with supply oil from pump 2 (16) and combined oil
(146) flows through the spool. After the arm 1 spool, the combined oil flow also combines with the supply oil from
pump 1 (15) that flows through the arm 2 spool (90) and then out to the arm cylinder (127) head end.
See the following for flow rate control valves and boom and arm reduced leakage valves operation:
See Boom Flow Rate Control Valve Circuit Operation . (Group 9025-05.)
See Boom and Arm Reduced Leakage Valves Operation . (Group 9025-05.)
TX1014159-UN: Dig Regenerative Valve

LEGEND:
16 - From Pump 2
146 - Combined Oil (supply and return oil)
149 - Return Oil
301 - To Arm 1 Spool
302 - Spring
303 - From Boom Cylinder Rod End
Y22 - From Dig Regenerative Solenoid Valve (port SF)
818
T216853-UN: Dig Regenerative Solenoid Valve

LEGEND:
16 - Solenoid
18 - Nut
19 - From Pilot Control Shut-Off Valve
20 - To Dig Regenerative Valve
22 - Spool
24 - Pilot Oil
26 - Return Oil
The Dig Regenerative Solenoid Valve (port SF) (Y22) is a proportional type solenoid valve. The solenoid valve
is activated by an electrical signal from the main controller. The electrical signal is DC voltage that is turned on
and off to form a pulse-width modulated signal. Solenoid (16) 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 (25) is sent to the dig
regenerative valve (20). The reduced pilot oil pressure is in proportion to the electrical signal to the solenoid.
When de-energized, the spool is pushed to the right by a spring. The valve function port is then connected to
hydraulic oil tank (21).
flange and out the valve function port as a reduced pilot oil (25) to the dig regenerative valve (20). 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 dig
819
regenerative valve is trapped. The spool is moving constantly to maintain the reduced pilot oil pressure in
response to the electrical signal to the solenoid.
TP97644,000009F-19-20070104
820
TX1077175-UN: Arm Regenerative Circuit Schematic

LEGEND:
4 - Arm In (pilot)
15 - Pump 1
16 - Pump 2
90 - Arm 2 Spool
91 - Arm 2 Flow Rate Control Valve
97 - Arm 1 Spool
821
127 - Arm Cylinder
145 - Supply Oil
147 - Pilot Oil
149 - Return Oil
150 - Regenerative Return Oil
The Arm Regenerative Valve improves arm control and prevents arm cylinder cavitation during arm in operation
by combining the return oil from arm cylinder rod end with the pump supply oil to the arm cylinder head end.
Under the following operating conditions: low pump 2 delivery pressure, control pilot oil to the pilot cap for arm in,
and boom up or swing actuated, gravity can pull the arm in faster than the pumps can supply oil to the arm
cylinder head end. The operating conditions are sensed by the pump 2 delivery pressure sensor (B37), arm in
pressure sensor (B31), boom up pressure sensor (B30), and swing pressure sensor (B33). The sensors send
electrical signals to the main controller (A3). The main controller sends an electrical signal to the arm
regenerative solenoid valve (Y23). The arm regenerative solenoid valve sends primary pilot oil to the arm
regenerative valve (94) blocking the passage to hydraulic oil tank. The return oil from the arm cylinder rod end is
combined with supply oil from pump 2 and routed to the arm cylinder head end.
822
TX1001552-UN: Arm Regenerative Valve Section

LEGEND:
4 - Arm In (pilot)
90 - Arm 2 Spool
91 - Arm 2 Flow Rate Control Valve (poppet)
97 - Arm 1 Spool
145 - Supply Oil
147 - Pilot Oil
149 - Return Oil
150 - Regenerative Return Oil
201 - From Arm Cylinder Rod End
202 - To Arm Cylinder Head End
Y23 - From Arm Regenerative Solenoid Valve (port SC)
823
T216853-UN: Arm Regenerative Solenoid Valve (SC) Operation

LEGEND:
16 - Solenoid
18 - Nut
19 - From Pilot Shut-Off Solenoid Valve
20 - To Arm Regenerative Valve
22 - Spool
26 - Return Oil
The Arm Regenerative Solenoid Valve (port SC) (Y23) is a proportional type solenoid valve. The solenoid valve
is activated by an electrical signal from the main controller. The electrical signal is DC voltage that is turned on
and off to form a pulse-width modulated signal. Solenoid (16) 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 (25) is sent to the arm
regenerative valve (20). The reduced pilot oil pressure is in proportion to the electrical signal to the solenoid.
When de-energized, the spool is pushed to the right by a spring. The valve function port is then connected to the
When energized, the magnetic force shifts the spool left against the spring. Control pilot oil (24) flows past the
spool flange and out the valve function port as a reduced pilot oil to the arm regenerative valve (20). Because the
824
than the magnetic force (23), the spool is pushed to the right, closing the passage. The reduced pilot oil to the arm
regenerative valve is trapped. The spool is moving constantly to maintain the reduced pilot oil pressure in
TP97644,000003C-19-20160928
825
TX1017430-UN: Bucket Regenerative Valve Circuit Schematic

LEGEND:
7 - Bucket Curl (pilot)
15 - From Pump 1
57 - Orifice
76 - Bucket Spool
86 - Orifice
145 - Supply Oil
149 - Return Oil
201 - Regenerative Oil from Bucket Cylinder Rod End
202 - Regenerative Oil to Bucket Cylinder Head End
The bucket regenerative valve (78) is located inside the bucket spool (76). The bucket regenerative valve
combines return oil (149) from the bucket cylinder rod end with supply oil (145) from pump 1 (15) to prevent
cavitation and improve function control.
The bucket regenerative valve functions under the following operating conditions:
Low supply oil pressure

Control pilot oil (147) to the pilot cap for bucket curl (7).
When bucket curl function is actuated, control pilot oil shifts the bucket spool to the bucket curl position.
826
Regenerative oil (150) flows through an orifice (86) in the bucket spool. If pressure of the oil returning from the
bucket cylinder rod end is higher than the supply oil pressure, the bucket regenerative valve is opened.
Regenerative oil is combined with supply oil from pump 1 and routed to the bucket cylinder head end. Oil not used
flows to the return passage and out to the hydraulic oil tank.
When the cylinder is moved to full stroke or the digging load increases oil pressure to the bucket cylinder head
end increases above the oil pressure from the bucket cylinder rod end. Therefore, the bucket regenerative valve is
closed and regenerative operation stops. Only supply oil 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 hydraulic oil tank.
TX1000131-UN: Bucket Regenerative Valve Section

LEGEND:
15 - From Pump 1
827
57 - Orifice
76 - Bucket Spool
86 - Orifice
145 - Supply Oil
149 - Return Oil
201 - Regenerative Oil from Bucket Cylinder Rod End
202 - Regenerative Oil to Bucket Cylinder Head End
TP97644,000003D-19-20070109
828
T143761-UN: Boom Reduced Leakage Valve Operation

LEGEND:
1 - Boom 2 Valve Spool
2 - Boom 1 Valve Spool
3 - Control Pilot Oil from Pilot Control Valve
5 - Boom Reduced Leakage Valve Switch Valve
7 - Boom Reduced Leakage Valve Check Valve
8 - To Boom Cylinders Head End
829
9 - Boom Cylinders
11 - Trapped Oil
12 - Pilot Oil
13 - Supply Oil
Reduced leakage valves are used in the boom head end circuit and arm rod end circuit. The function of a reduced
leakage valve is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve.
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.
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 check valve (7) through the boom reduced leakage valve switch valve
(5). The check valve is held closed against the seat in housing trapping the oil from the cylinders at the work port.
When a function is actuated, control pilot oil from the pilot control valve (3) shifts the switch valve (5). 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 the hydraulic oil
tank (4). 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 (6) is used to lower the boom if the engine stops with the boom in the raised
position. See Lower Boom with Engine Stopped . (Operator's Manual.)
TP97644,000003E-19-20070104
830
TX1011799-UN: Arm 1 Flow Rate Control Valve Circuit Schematic

LEGEND:
SE - From Pilot Signal Manifold (port SE)
4 - Arm In Pilot
5 - Swing Left Pilot
15 - Pump 1
16 - Pump 2
52 - Swing Motor
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
145 - Supply Oil
146 - Restricted Supply Oil
147 - Pilot Oil
148 - Trapped Oil
149 - Return Oil
The function of arm 1 flow rate control valve (switch valve and poppet) (98) is to restrict the flow of supply oil from
pump 2 (16) to the arm 1 spool (97) to ensure a priority flow of supply oil to the swing spool (95) during combined
operation.
831
TX1012194-UN: Arm 1 Flow Rate Control Valve Normal Operation

LEGEND:
1 - Check Valve
2 - Poppet
3 - To Arm 1 Spool
4 - From Arm 1 Flow Rate Pilot Valve (port SE)
6 - From Pump 2
7 - To Solenoid Valve Manifold (port DE)
8 - Switch Valve
145 - Supply Oil
149 - Return Oil
Normal Operation— Supply oil (145) from pump 2 opens the check valve (1) in the poppet (2) of arm 1 flow rate
control valve because the switch valve (8) is open. Supply oil flows through the check valve and switch valve to
the arm 1 spool (3). As the load increases, the pressure increases pushing the poppet open and supply oil flows
through the poppet to arm 1 spool.
832
TX1012197-UN: Arm 1 Flow Rate Control Valve Combined Operation

LEGEND:
1 - Check Valve
2 - Poppet
3 - To Arm 1 Spool (Restricted)
4 - From Arm 1 Flow Rate Pilot Valve (port SE)
6 - Supply Oil From Pump 2
8 - Switch Valve
145 - Supply Oil
148 - Trapped Oil
149 - Return Oil
Combined Operation— During swing and arm in combined operation, the arm 1 flow rate pilot valve (port SE), in
the pilot signal manifold, is shifted by control pilot oil (147) from arm in. The pilot valve then routes a portion of
control pilot oil from swing to the switch valve (8) of arm 1 flow rate control valve (98). See Pilot Signal Manifold
Operation for operation of pilot valves. (Group 9025-05.)
The control pilot oil shifts the switch valve trapping oil in the backside of poppet (2) which forces the poppet
towards the close position. The poppet now restricts the flow of supply oil (145) to arm 1 spool. Supply oil now
flows through the swing spool to the swing motor against the higher load pressure.
833
TP97644,000003F-19-20061128
834
TX1011938-UN: Arm 2 Flow Rate Control Valve Circuit Schematic

LEGEND:
1 - Boom Up Pilot
2 - Boom Down Pilot
3 - Arm Out Pilot
4 - Arm In Pilot
5 - Swing Left Pilot
7 - Pilot Oil From Arm Regenerative Solenoid Valve
15 - Pump 1
16 - Pump 2
81 - Boom 1 Spool
90 - Arm 2 Spool
104 - Boom 2 Spool
127 - Arm Cylinder
145 - Supply Oil
147 - Pilot Oil
148 - Trapped Oil
149 - Return Oil
The function of arm 2 flow rate control valve (switch valve and poppet) (91) is to restrict the flow of supply oil from
pump 1 (15) to the arm 2 spool (90) to ensure a priority flow of supply oil to the boom 1 spool (81) during arm in,
boom up and swing combined operation.
835
TX1012239-UN: Arm 2 Flow Rate Control Valve (Switch Valve)
836
TX1012251-UN: Arm 2 Flow Rate Control Valve (Poppet)

LEGEND:
6 - Check Valve
86 - Orifice
91A - Switch Valve for Arm 2 Flow Rate Control Valve
91B - Poppet for Arm 2 Flow Rate Control Valve
92 - Check Valve (Lift Check)—Arm 2 Neutral Passage
The switch valve (91A) and poppet (91B) of arm 2 flow rate control valve 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. See Control Valve Operation for layout of the hydraulic control valve. (Group
9025-05.)
Normal Operation— Supply oil from pump 1 opens the check valve in the poppet of arm 2 flow rate control valve
because the switch valve is open. The supply oil flows through the check valve and switch valve to the arm 2
spool. As the load increases, the pressure increases pushing the poppet open and supply oil flows through the
poppet to arm 2 spool.
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.
With the switch valve shifted, supply oil is trapped on the backside of poppet which forces the poppet towards the
closed position. The poppet now restricts the flow of supply oil to arm 2 spool. Consequently, more pump 1 supply
837
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 supply oil and the arm 1 spool
regenerative circuit. See Arm Regenerative Valve Circuit Operation . (Group 9025-05.)
TP97644,000004C-19-20061211
838
TX1012403-UN: Bucket Flow Rate Control Valve Circuit Operation

LEGEND:
1 - Boom Up Pilot
2 - Boom Down Pilot
3 - Arm Out Pilot
4 - Arm In Pilot
7 - Bucket Curl Pilot
8 - Bucket Dump Pilot
14 - To Solenoid Manifold Valve (port DK)
15 - Pump 1
16 - Pump 2
17 - From Bucket Flow Rate Pilot Valve (port SK)
18 - From Arm Regenerative Solenoid Valve (port SL)
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
127 - Arm Cylinder
145 - Supply Oil
147 - Pilot Oil
148 - Trapped Oil
839
The function of the bucket flow rate control valve (switch valve and poppet) (77) is to restrict the flow of supply oil
from pump 1 (15) to the bucket spool (76) during bucket, arm in and boom up combined operation. Restriction of
supply oil to the bucket spool ensures a priority flow of supply oil to the boom 1 spool (81) during combined
operation.
TX1012431-UN: Bucket Flow Rate Control Valve (Normal Operation)

LEGEND:
1 - Check Valve
2 - Poppet
3 - To Bucket Spool
6 - From Pump 1
8 - Switch Valve
145 - Supply Oil
149 - Return Oil
Normal Operation— Supply oil from pump 1 opens the check valve in the poppet of bucket flow rate control
valve because the switch valve is open. The supply oil flows through the check valve and switch valve to the
bucket spool. As the load increases, the pressure increases pushing the poppet open and supply oil flows through
the poppet to bucket spool.
840
TX1012432-UN: Bucket Flow Rate Control Valve (Combined Operation)

LEGEND:
1 - Check Valve
2 - Poppet
3 - To Bucket Spool
6 - From Pump 1
8 - Switch Valve
77 - Boom Flow Rate Control Valve
145 - Supply Oil
148 - Trapped Oil
149 - Return Oil
Combined Operation— During bucket, arm in and boom up combined operation, the bucket flow rate pilot valve
(port SK), in the pilot signal manifold, is shifted by control pilot oil from arm in. See Pilot Signal Manifold Operation
for operation of pilot valves. (Group 9025-05.)
Boom up control pilot oil now flows from port SK to the switch valve, shifting it trapping supply oil on the backside
of poppet. The poppet now restricts the flow of supply oil to the bucket spool. Supply oil now flows to the arm 2
and boom 1 spools to ensure priority flow of supply oil to the arm in and boom up functions.
Also, the arm 2 flow rate control valve circuit is actuated during the combined operation of bucket, arm in and
841
boom up. Priority is given to the boom up function. See Arm 2 Flow Rate Control Valve Circuit Operation . (Group
9025-05.)
TP97644,000004D-19-20070104
842
TX1012103-UN: Boom Flow Rate Control Valve Circuit Schematic

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
15 - Pump 1
16 - Pump 2
81 - Boom 1 Spool
90 - Arm 2 Spool
97 - Arm 1 Spool
127 - Arm Cylinder
145 - Supply Oil
148 - Trapped Oil
The purpose of the boom flow rate control valve (switch valve and poppet) (83) is to restrict supply oil (145) in the
circuit to ensure that there will be sufficient supply oil for other functions during boom down. Also to restrict supply
oil through boom 1 spool (81) during boom down so that boom regenerative in boom 1 spool works properly.
During boom down the boom flow rate control valve restricts supply oil that flows to the boom 1 spool from pump 1
843
(15).
Therefore, during boom down and other functions, the boom lowers due to own weight by the regenerative circuit
and uses supply oil from the pump for other functions. This ensures that other functions will maintain normal
operation.
TX1012414-UN: Boom Flow Rate Control Valve Normal Operation

LEGEND:
15 - From Pump 1
81 - To Boom 1 Spool
145 - Supply Oil
149 - Return Oil
200 - Check Valve
201 - Poppet
203 - Switch Valve
204 - From Boom Lower Meter-In Cut Valve
Normal Operation— When boom down is actuated, supply oil flows to the 4-spool side of the control valve from
pump 1. Supply oil opens the check valve (200) in the poppet (201) of the boom flow rate control valve because
the switch valve is open due to no control pilot oil. Supply oil flows through boom flow rate control valve without
any restriction and continues on to the boom 1 spool (81).
844
TX1012417-UN: Boom Flow Rate Control Valve Combined Operation

LEGEND:
15 - From Pump 1
145 - Supply Oil
148 - Trapped Oil
149 - Return Oil
200 - Check Valve
201 - Poppet
203 - Switch Valve
Combined Operation— When boom down is actuated, return oil (149) from the boom cylinders is under pressure
from the weight of the boom, return oil is now greater pressure then supply oil (145). Pressure increase in the
return circuit causes the boom regenerative valve (82) to shift the boom lower meter-in cut valve (87). See Boom
Regenerative Valve Circuit Operation . (Group 9025-05.) See Boom Lower Meter-In Cut Valve Operation . (Group
9025-05.)
Control pilot oil (147) from boom down shifts the switch valve (203) in the boom flow rate control valve.
845
Supply oil is trapped on the backside of the poppet in the boom flow rate control valve. Supply oil from pump
1(15) continues to flow to the poppet.
Trapped oil (148) on the backside of poppet causes supply oil to be restricted as it travels through the check valve
in the poppet to boom 1 spool.
Restricted supply oil (146) is less than return oil from boom cylinders, allowing the return oil to shift the check
valve and travel through the regenerative valve in the boom 1 spool.
Restricted supply oil at the boom flow rate control valve ensures there is supply oil for other functions to be
actuated during boom down.
TP97644,000004B-19-20070109
846
TX1203094-UN: Auxiliary Flow Rate Control Valve Schematic (auxiliary spool shifted and swing left active)
LEGEND:
5 - Swing Left (pilot)
6 - Swing Right (pilot)
13 - Auxiliary (pilot)
15 - Pump 1
16 - Pump 2
52 - Swing Motor
847
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
124 - Oil Cooler Bypass Valve
143 - From Auxiliary Shuttle Valve
156 - From Flow Rate Select Solenoid Valve (2 used)
600 - High-Pressure Oil
602 - Low-Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
DY - To Solenoid Valve Manifold (port DY)
Auxiliary flow rate control valve is used when two pump combined flow kit is installed on the machine.
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.
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:
Two-speed on (combined flow on).

Pressure on attachment pressure sensor (B45).
Combined with any of these inputs:
Pressure on arm out pressure sensor (B46).

Pressure on arm out pressure sensor (B46) and boom up pressure sensor (B30).
Pressure on swing pressure sensor (B33).
Pressure on travel pressure sensor (B34).
For more information on sensors, see System Functional Schematic . (Group 9015-10.)
For auxiliary flow rate control valve circuit location information, see Control Valve Operation . (Group 9025-05.)
848
TX1166252-UN: Auxiliary Flow Rate Control Valve (normal operation)

LEGEND:
16 - From Pump 2
107 - To Auxiliary Spool
108 - Auxiliary Flow Rate Control Valve
156 - To Flow Rate Select Solenoid Valve
300 - Check Valve
301 - Poppet
302 - Switch Valve
604 - Return Oil
DY - To Solenoid Manifold Valve (port DY)
Normal Operation— Supply oil from pump 2 (16) opens check valve (300) in the poppet (301) of auxiliary flow
rate control valve (108) because the switch valve (302) is open. The supply oil flows through the check valve and
switch valve to auxiliary spool (107). As the load increases, the pressure increases pushing poppet open, allowing
supply oil to flow through the poppet to auxiliary spool.
849
TX1166253-UN: Auxiliary Flow Rate Control Valve (control operation)

LEGEND:
16 - From Pump 2
107 - To Auxiliary Spool
156 - From Flow Rate Select Solenoid Valve
300 - Check Valve
301 - Poppet
302 - Switch Valve
602 - Low-Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
DY - To Solenoid Manifold Valve (port DY)
Control Operation— Auxiliary flow rate valve is shifted by pilot oil from flow rate select solenoid valve (156) when
combined with one of the following operations:
850
Arm in
Boom up
Swing
Travel
See Flow Rate Select Solenoid Valve Operation and see Two Pump Combined Flow Kit Operation . (Group 9025-
05.)
Pilot oil (609) from flow rate select solenoid valve shifts switch valve (302), creating trapped oil (606) on the
backside of poppet (301). The poppet now restricts the flow of supply oil from pump 2 (16) to auxiliary spool (107).
Supply oil from pump 2 flows to arm, boom, and swing spools to ensure priority flow of supply oil to these
functions.
DF89619,00B55EA-19-20151012
851
T143016-UN: Swing Gearbox Cross Section

LEGEND:
1 - Swing Motor Shaft
2 - First Stage Planet Gear
3 - Ring Gear
4 - Second Stage Planet Gear
5 - Shaft
6 - Second Stage Carrier
7 - Second Stage Sun Gear
8 - First Stage Carrier
9 - First Stage Sun Gear
Swing gearbox is two stage planetary type gearbox. First and second stage ring gears (3) are attached to gearbox
housing. First stage carrier (8) transfers power from first stage sun gear (9) to second stage sun gear (7). Second
stage carrier (6) transfers power from second stage sun gear (7) to shaft (5).
TP97644,0000040-19-20060920
852
T143083-UN: Swing Motor

LEGEND:
1 - Swing Crossover Relief Valve
2 - Spring
3 - Brake Piston
4 - Brake Pack
5 - Piston
6 - Shaft
7 - Swash Plate
8 - Shoe
9 - Housing
10 - Cylinder Block
11 - Valve Plate
12 - Cover
Swing Motor— The swing motor is a fixed displacement axial piston motor consisting of swash plate (7), cylinder
block (10), valve plate (11), housing (9) and swing park brake (spring (2), brake piston (3) and brake pack (4)).
Piston (5) is inserted into cylinder block (10) which is splined to shaft (6). Piston (5) is pushed by pressurized oil
from pump. Shoe (8) slides over swash plate (7) so that cylinder block (10) rotates. Shaft (6) is splined to the first
stage sun gear of swing reduction gearbox. Therefore, the rotation of shaft (6) is transmitted to the swing
reduction gearbox. See Swing Reduction Gearbox Operation . (Group 9025-05.)
853
T143098-UN: Swing Crossover Relief Valve and Make-Up Check Valve

LEGEND:
13 - Make-Up Check Valve
14 - Poppet
15 - Crossover Relief Valve
16 - Passage
17 - Piston
18 - Cavity
19 - Cavity
20 - Passage
21 - Cavity
22 - Spring
23 - Poppet
24 - Orifice
854
TX1012651-UN: Exploded View of Crossover Relief Valve

LEGEND:
15 - Crossover Relief Valve
16 - Passage
17 - Piston
18 - Cavity
19 - Cavity
20 - Passage
21 - Cavity
22 - Spring
23 - Poppet
24 - Orifice
25 - Low Pressure Port
26 - High Pressure Port
Swing Motor Crossover Relief Valve— The swing motor crossover relief valves are direct acting relief valves
with a shock reducing function.
Low Pressure Relief Operation (Shockless Function): Pressure at port (26) flows into cavity (19) through poppet
(23). Pressure oil from cavity (19) flows into cavity (21 and 18) via passages (16 and 20). Cavity (18) is larger than
cavity (21) 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, pressure oil flows to port
(25). 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): After the piston is moved full stroke, the spring is
compressed, circuit pressure becomes the set-pressure. If pressure at port (26) increases more than the spring
set-pressure, the poppet is open and pressure oil flows to port (25). When pressure at port (26) 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
855
crossover relief valve. The make-up check valve (13) provides oil to the low pressure side of the swing motor to
prevent cavitation.
TP97644,0000041-19-20061220
856
TX1014236-UN: Time to Pressure Output Curve For Inlet Side
TX1014237-UN: Time to Pressure Output Curve For Return Side

LEGEND:
1 - Time
2 - Pressure
3 - Without Swing Dampener Valve
4 - With Swing Dampener Valve
857
TX1014230-UN: Swing Dampener Valves—When Relieving

LEGEND:
5 - Swing Dampener Valve A
6 - Swing Dampener 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
19 - High Pressure Oil
22 - Trapped Oil
The function of swing dampener valves A (5) and B (6) is to relieve the pressure spike and aftershock at swing
858
motor (17) when control valve swing spool (18) is returned to neutral.
In neutral, the swing spool stops the flow of supply oil to the inlet side of swing motor and blocks the flow of return
oil 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 dampener 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 dampener valves operate as follows:
Swing Crossover Relief Valves:
1. High pressure oil (19) 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 .
Swing Dampener Valve A (5):
1. High pressure oil pushes the ball (11) off seat of poppet (7) and then flows through the plunger (12) to
chamber N (14).
2. Pressure in chamber N increases pushing the piston (15) against the plug.
3. When pressure increase becomes greater than the force of springs (8 and 13), plunger, ball, and poppet
are pushed to the right compressing the springs.
Swing Dampener 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).
859

LEGEND:
1 - Time
2 - Pressure
860
TX1014232-UN: Swing Dampener Valves—Pressure Begins to Decrease

LEGEND:
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
20 - Medium Pressure Oil
22 - Trapped Oil
When swing motor (17) rotation due to the inertia force of upperstructure is reduced, the pressure spike at return
861
side of swing motor also decreases. Between B and C (pressure begins to decrease) the swing dampener valves
operate as follows:
1. When pressure spike at return side of swing motor (17) begins to decrease to medium pressure oil (20),
pressure in chamber N (14) also begins to decrease. When pressure becomes less than force of spring
(13), 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.
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).
862

LEGEND:
1 - Time
2 - Pressure
863
TX1014233-UN: Swing Dampener Valves—Pressure at Return Side Decreases

LEGEND:
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
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 dampener valves
864
operate as follows:
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.
1. When pressure spike at return side of swing motor decreases to low pressure oil (21), pressure in
chamber N (14) also decreases. When pressure becomes less than force of spring (13), plunger (12) is
pushed to the right.
2. At the same time, poppet (9) is pushed to the right by its spring (8). Poppet moves slowly because oil in
chamber M (10) must flow through the orifice (7) causing pressure in chamber M to increase.
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 (8).
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).
865

LEGEND:
1 - Time
2 - Pressure
866
TX1014234-UN: Swing Dampener Valves—During Aftershock

LEGEND:
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
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 dampener valves operate as follows:
867
1. Medium pressure oil (20) 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).
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.
The valves repeat these operation until pressure spike is controlled and aftershock is relieved.
When pressures at the inlet and return side of swing motor decrease completely, the dampener valves stop
operating.
TP97644,00000AF-19-20100622
868
TX1002396-UN: Swing Park Brake Release Circuit Operation

LEGEND:
1 - Spring
2 - Brake Piston
3 - Orifice
4 - Check Valve
5 - Brake Piston Chamber
6 - Friction Plate
7 - Plate
8 - Cylinder Block
52 - Swing Motor
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. The spring (1) pushes the brake piston down, forcing the
oil through the orifice (3) into the swing motor case. The orifice prevents the brake piston from moving quickly and
delays the application of the swing park brake until the upperstructure is stopped or nearly stopped. The spring
force on the brake piston engages the friction plate (6), which acts on the cylinder block (8), and the plate (7),
which acts on the inside of the swing motor housing, securing the upperstructure from moving.
TP97644,0000042-19-20080124
869
T143136-UN: Center Joint

LEGEND:
1 - Drain
2 - Left Travel Forward
3 - Left Travel Reverse
4 - Right Travel Forward
5 - Right Travel Reverse
6 - Travel Speed Change
7 - Return Oil
8 - Supply Oil
9 - Pilot Oil
The center joint 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 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.
Oil flows into and through the spindle to passages in the housing, and then out of the housing to the travel motors.
Sealing rings stop oil from leaking between the spindle and housing into adjacent passages.
TP97644,0000043-19-20060809
870
TX1077076-UN: Travel Motor and Brake Valve Schematic

LEGEND:
60 - Right Travel Device
62 - Left Travel Device
64 - Travel Park Brake
65 - Servo Piston
67 - Shuttle Valve
871
68 - Travel Motor Crossover Relief Valve
69 - Check Valve
70 - Orifice
71 - Counterbalance Valve
72 - Center Joint
75A - From Right Travel Spool Bottom Port—Reverse
75B - From Right Travel Spool Top Port—Forward
110A - From Left Travel Spool Top Port—Forward
110B - From Left Travel Spool Bottom Port—Reverse
Y25 - From Travel Speed Solenoid Valve (port SI)
148 - Trapped Oil
TX1002506-UN: Travel Motor and Brake Valve Components

LEGEND:
1 - Drive Shaft
2 - Valve Plate
3 - Cylinder Block
5 - Piston (9 used)
6 - Ball Guide
7 - Swash Plate
8 - Servo Piston
21 - Spring
22 - Park Brake Piston
23 - Brake Valve Housing
Travel Motor and Brake Valve— The travel motor is a variable-displacement, swash plate, axial-piston type
872
motor that includes the brake valve housing (23) and travel park brake (4). Brake valve housing consist of the
following components:
Travel Speed Change Valve

Shuttle Valve
Orifice
Counterbalance Valve
Travel Motor Crossover Relief Valve (2 used)
Check Valve (2 used)
Travel Park Brake— The travel park brake is a wet-type multi-disk brake. The brake is spring applied and
hydraulically released (negative type). The brake is released when travel function is actuated and supply oil is
routed to the park brake piston by the counterbalance valve. The brake is applied when no functions or only the
dig and swing functions are actuated.
When travel function is released, the counterbalance valve returns to center position blocking the supply oil acting
on park brake piston (22). The disk spring pushing against the park brake piston forces the oil to flow through the
orifice in the piston and into propel motor housing. The delay caused by oil flowing through the orifice is enough to
slow engagement to ensure that park brake is only fully applied after the machine has stopped.
TX1001826-UN: Travel Motor Slow Speed Operation

LEGEND:
873
65 - Servo Piston
67 - Shuttle Valve
140 - Swash Plate
141 - Piston (9 used)
142 - Orifice
143 - Spring
144 - From Travel Speed Solenoid Valve (port SI)
149 - Return Oil
Travel Motor Slow Speed— At slow speed (turtle), the oil acting on the travel speed change valve (66) is open to
return through the travel speed solenoid valve (144). Travel speed change valve is held up by the spring (143).
See Travel Motor Speed Circuit Operation for more information.
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 supply oil to the servo piston. Supply oil from the pressurized motor
work port is routed to the valve by the shuttle valve (67).
The swash plate (140) is held at maximum displacement. At maximum displacement the motor turns at slow
speed with high torque.
874
TX1001831-UN: Travel Motor Fast Speed Operation
LEGEND:
65 - Piston
67 - Shuttle Valve
140 - Swash Plate
141 - Servo Piston
142 - Orifice
143 - Spring
144 - From Travel Speed Solenoid Valve (port SI)
145 - Supply Oil
147 - Pilot Oil
149 - Return Oil
Travel Motor Fast (Rabbit) Speed— At fast speed (rabbit), pilot oil (147) from the travel speed solenoid valve
(144) pushes the travel speed change valve down. See Travel Motor Speed Circuit Operation for more
information.
Supply oil (145) flows from the motor work port, through the shuttle valve (67), travel speed change valve, orifice
(142), and to the servo piston (65). The piston then moves the swash plate (140) to its minimum angle. At
minimum angle, the travel motors turn at fast speed with reduced torque. Orifice controls the flow of supply oil to
the piston to modulate the change in speed.
875
TX1002508-UN: Brake Valve Housing—Braking Operation

LEGEND:
1 - Travel Motor Work Port
2 - Travel Motor Work Port
3 - Orifice
5 - Check Valve
6 - Check Valve
7 - Orifice
9 - Piston
10 - Shuttle Valve
11 - To Travel Speed Solenoid Valve (SI)
876
12 - Spring
13 - Poppet
14 - Restriction
15 - Not Used
16 - To Control Valve Work Port
17 - To Control Valve Work Port
18 - To Fast Speed Servo Piston
21 - To Park Brake Piston
22 - Spring
23 - To Travel Motor
61 - Travel Motor
65 - Servo Piston
67 - Shuttle Valve
69 - Check Valve
149 - Return Oil
Counterbalance Valve (4)— When the travel spools in the control valve are in neutral, counterbalance valve is
held in the center position by springs (22). Both travel motor work ports (1 and 2) are open to return through the
control valve return passage. The check valves (5 and 6) and counterbalance valve traps the oil in each motor
holding them stationary.
When travel function is first actuated, supply oil pressure builds on one side of motor due to the motor's resistance
to turning and because the check valve (5) and counterbalance valve blocks the flow of return oil from the motor.
The increased pressure is sensed at the end of counterbalance valve through orifice (3) and begins to shift the
counterbalance valve. As the valve shifts, a path is opened for return oil to flow to the control valve. Supply oil
flows to the park brake piston (21) to release the travel park brake (64). Supply oil flows around counterbalance
valve and opens the check valve (6) to supply the motor.
When a machine is traveling down a hill, the weight can cause it to overrun the travel motors. Overrunning would
cause faster travel than desired and cavitation in the motors. As pressure decreases in the work port of motor, the
spring begins to shift the counterbalance valve towards the neutral position. A restriction (14) is created restricting
the flow of return oil (149) 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 (7) and moves the piston (9), a pressure difference is
created from one side of the poppet (13) 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— 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 (145)
is then created in the return side of motor and low pressure oil (146) on the other. When pressure in the return
side becomes higher than the low pressure side of motor, the check valve (6) is pushed open. Return oil from the
return side flows to low pressure side preventing cavitation.
877
TP97644,0000044-19-20061214
878
TX1012677-UN: Travel Motor Speed Circuit Fast Speed Operation

LEGEND:
141 - Main Controller
142 - Slow (Turtle) Speed
143 - Fast (Rabbit) Speed
144 - Electrical Voltage
147 - Pilot Oil
Travel Motor Slow (Turtle) Speed When the travel speed switch (S11) is in the slow (turtle) position, the travel
speed solenoid valve (Y25) is de-energized. The travel speed change valve (66) is open to return through the
travel speed solenoid valve, and the travel motors are at slow speed. See Travel Motor and Park Brake Valve
Travel Motor Fast (Rabbit) Speed— When travel speed switch is in the fast (rabbit) speed (143) position, the
travel speed solenoid valve (Y25) is energized. Pilot oil (147) is routed to the travel speed change valve (66), and
879
the travel motors are shifted to fast speed. See Travel Motor and Park Brake Valve Operation . (Group 9025-05.)
The solenoid for travel speed solenoid valve is energized only when all of the following conditions are met:
Travel speed switch is at 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
Either pump 1 or pump 2 control pressure sensor must indicate high pressure
See System Functional Schematic, Component Location, and Wiring Diagram Master Legend for electrical circuit
information. (Group 9015-10.)
Once the machine is operating in fast (rabbit) speed, a dig or swing function will not cause the travel speed to
change to slow (turtle) speed, even though pressure is sensed at the front attachment pressure sensor.
TX1012678-UN: Travel Speed Solenoid Valve (port SI)—Energized

LEGEND:
3 - Travel Speed Solenoid Valve (port SI)
4 - Dig Regenerative Solenoid Valve (port SF)
5 - Arm Regenerative Solenoid Valve (port SC)
6 - Solenoid
7 - Adjusting Screw
8 - From Pilot Shutoff Solenoid Valve
9 - To Travel Speed Change Valve
880
11 - Spool
13 - Pilot Oil
15 - Return Oil
Travel Speed Solenoid Valve (port SI)— The solenoid (6) for travel speed solenoid valve (3) is a proportional
solenoid type. The solenoid is activated by an electrical signal from the main controller. The electrical signal is DC
voltage that is turned on and off to form a pulse-width modulated signal. Solenoid reacts to the “average” voltage
to create a magnetic force to shift the spool (11) left against the spring. When shifted left, reduced pilot oil (14) is
sent to the travel speed change valve (9). The reduced pilot oil pressure is in proportion to the electrical signal to
the solenoid.
When de-energized, the spool is pushed to the right by the spring. The valve function port is then connected to the
flange and out the valve function port as reduced pilot oil (14) to the travel speed change valve. Because the
than the magnetic force, the spool is pushed to the right, closing the passage. The reduced pilot oil to the travel
speed change valve is trapped. The spool is moving constantly to maintain the reduced pilot oil pressure in
TP97644,0000045-19-20070105
881
Cylinder Operation
Cylinder Operation
TX1073387-UN: Cylinder Operation

LEGEND:
A - Snap Ring
B - Wiper Seal
C - Back-Up Ring
D - U-Cup Seal
E - Buffer Ring
F - Wear Ring
G - Snap Ring
H - Piston
I - Buffer Ring (2 used)
J - Wear Ring (2 used)
K - Cap Seal
L - Set Screw
M - Nut
N - Cushion
O - Barrel
P - Cylinder Rod
Q - Rod Guide
R - Bucket Cylinder
Boom, Arm, and Bucket Cylinders
The boom, arm, and bucket cylinders are similar in design. The bucket cylinder (R) is illustrated. The rod guide
(Q) is fastened to the cylinder barrel with cap screws and is fitted with a wear ring (F) held in place by a snap ring
(G). A buffer ring (E), U-cup seal (D), back-up ring (C), and wiper seal (B) are used in the rod guide. A snap ring
(A) is used to help hold wiper seal in place. The U-cup seal (D) is protected against high pressure by the buffer
ring (E) and stops the small amount of oil that may pass by the buffer ring.
882
Cylinder Operation
The piston (H) is a slip fit on the cylinder rod (P) and is retained with a nut (M). A set screw (L) prevents loosening
of the nut. The piston is fitted with a cap seal (K), wear rings (J), and buffer rings (I).
Boom, bucket, and arm cylinders have a cushion (N) 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.
TP97644,0000046-19-20070626
883
TX1012944-UN: Return Filter Operation

LEGEND:
1 - Return Filter Bypass Operation
2 - Return Filter Normal Operation
3 - Bypass Valve
4 - Filter Element
5 - Return Oil From Oil Cooler
6 - Return Oil From Control Valve
The filter element (4) is located in a chamber inside the hydraulic oil tank. O-rings are used at each end of the
filter element to prevent leakage. A spring holds the filter element on its seat.
Return oil from the oil cooler (5) and the control valve (6) flow through the filter element from the outside to the
center. Filtered oil flows out the bottom of filter into the hydraulic oil tank.
A bypass valve (3) is located at the top of the filter. The valve opens to protect the filter element against pressure
surges in the return circuit and allows a path for return oil if the filter element becomes plugged. During bypass
operation, oil flows into the chamber faster than it can flow through the filter element causing the pressure to
increase. The higher pressure forces the bypass valve open allowing oil to flow down the center of the filter
element and into the hydraulic oil tank. The bypass valve closes when the pressure decreases below the pressure
setting of the bypass valve.
TP97644,0000047-19-20070105
884
NOTE:
For auxiliary attachments to work properly multiple kits may be required.
The auxiliary system consist of a pilot control system to shift the auxiliary control valve spool. The shifted auxiliary
control valve spool allows high pressure oil flow to work port of the auxiliary attachment depending on attachment
and kits installed.
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.)
Low Flow Kit, for more information, see Low Flow Kit Operation . (Group 9025-05.)
Secondary Auxiliary Relief Kit, for more information, 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.
JJ03229,000087A-19-20130814
885
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.
TX1142562-UN: Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)
LEGEND:
28 - Pilot Pump
56 - To Swing Park Brake
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
886
97 - Arm 1 Spool
104 - Boom 2 Spool
117 - Main Relief
171 - To Pump 2 Flow Rate Solenoid Valve
604 - Return Oil
609 - Pilot Oil
Y22 - Dig Regenerative Solenoid (marked SF)
Y23 - Arm Regenerative Solenoid (marked SC)
Y24 - Power Dig Solenoid (marked SG)
Y25 - Travel Speed Solenoid (marked SI)
887
TX1000485-UN: Auxiliary Pilot Control Valve

LEGEND:
1 - Spool
2 - Washer
3 - Spring Guide
4 - Plunger
5 - Adjustment Screw
6 - Pedal
7 - Sleeve
8 - Balance Spring
9 - Return Spring
10 - To Pilot Shutoff Solenoid Valve Port T2
888
11 - From Pilot Shutoff Solenoid Valve Port A3
12 - Port 13 or 14 To Control Valve Pilot Cap
13 - Pilot Oil
14 - Return Oil
15 - Auxiliary Pilot Control Valve—Full Stroke
One pilot control valve is used to control the auxiliary functions. The pilot control valve contains two valve
assemblies. The valves are controlled by movement of the pedals against the plunger (4). The ports (10, 11, and
12) in housing are identified by numbers and letters next to each port.
In neutral, the spool is pushed up by the return spring (8) pushing the plunger up. The return springs hold the
pedal in the neutral position. With the spool up, ports 13 and 14 to the control valve pilot cap (12) are open to pilot
shutoff solenoid valve port T2 (10) through the passage and holes in spool. Pilot oil from the pilot shutoff solenoid
valve port A3 (11) is blocked by the spool.
When the pedal is pushed to actuate an auxiliary function, the pedal pushes the plunger and spring guide down
against the return spring and balance spring. The balance spring pushes the spool down. As the spool is pushed
down and the holes move through the deadband area, the passage from control valve pilot cap to the hydraulic oil
tank is closed and then opened to the pilot oil from pilot shutoff solenoid valve. Pilot oil pressure increases until it
is equal to the force applied by the balance spring pushing the spool moves up until the oil flow through the holes
is blocked in the deadband area. With the oil flow blocked, the control valve spool is held stationary until the pedal
is again actuated.
When the pedal is pushed to full stroke, the plunger is pushed down farther by the balance spring opening the
passage through the spool to pilot oil pressure. When pressure to the control valve pilot cap is equal to the force
applied by the balance spring, the spool moves up until it contacts the plunger. The plunger holds the spool down
so the passage through the spool remains open to pilot oil pressure. Oil pressure to the control valve pilot cap
now approximately equals pilot oil pressure.
TX1141687-UN: Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
LEGEND:
28 - Pilot Pump
889
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
117 - Main Relief
148 - Auxiliary Pilot Solenoid Valve
149 - Auxiliary Pilot Pressure reducing Valve
604 - Return Oil
609 - Pilot Oil
890
TX1136522-UN: Auxiliary Solenoid Valve Operation

LEGEND:
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
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 output on port B7 of the control valve to the
auxiliary attachment.
891
TX1136519-UN: Auxiliary Solenoid Valve Operation

LEGEND:
604 - Return Oil
609 - Pilot Oil
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 output on port A7 of control valve to the auxiliary attachment.
DF89619,00B552D-19-20131002
892
TX1135894-UN: Flow Rate Select Solenoid Valve Schematic (2-speed solenoid energized)
LEGEND:
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
Y44 - Flow Rate Adjustment Solenoid Valve
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:
Two-speed on (combined flow on)
893
Pressure on attachment pressure sensor (B45)
Combined with any of these inputs:
Pressure on arm out pressure sensor (B46)

Pressure on arm out pressure sensor (B46) and boom up pressure sensor (B30)
Pressure on swing pressure sensor (B33)
Pressure on travel pressure sensor (B34)
For more information on sensors, see System Functional Schematic . (Group 9015-10.)
NOTE:
Two-Speed control will not work properly unless appropriate kits are installed on machine.
When energized, 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).
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
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 Pump 2 Flow Rate Adjustment . (Operator’s Manual.) When de-
energized, the flow rate adjustment solenoid valve spring tension shifts the valve allowing the circuit to drain to
hydraulic oil tank.
DF89619,00B55EC-19-20150922
894
TX1135893-UN: Flow Rate Pressure Reducing Valve Schematic

LEGEND:
41 - From Pilot Signal Manifold Port SN
74 - To Control Valve Port SN
157 - Flow Rate Reducing Valve
The function of the flow rate reducing valve (157) is to control the amount of pump 1 flow that is directed to the
auxiliary spool when combining auxiliary with a pump 1 function.
Pilot pressure is sent from pilot signal manifold port SN (41) when a pump 1 function is activated. The pilot oil is
then routed through the flow rate pressure reducing valve (157) to control valve port SN (74). This shifts the
auxiliary flow combiner valve to stop the flow of pump 1 high-pressure oil to the auxiliary spool, “de-combining” the
flow. Flow rate reducing valve is adjustable, turn counterclockwise to give auxiliary priority flow over pump 1
functions or clockwise to give pump 1 functions priority over auxiliary.
When pilot oil pressure to control valve port SN exceeds set pressure of flow rate reducing valve, the valve shifts
allowing pilot oil to control valve port SN to flow to hydraulic oil tank (219) allowing the auxiliary flow combiner
895
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.)
JJ03229,000087D-19-20130905
896
TX1136497-UN: Secondary Relief Valve Solenoid Valve

LEGEND:
158 - Secondary Auxiliary Relief Valve Solenoid Valve
160 - To Secondary Auxiliary Relief Control Valve
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.
The secondary auxiliary relief valve solenoid valve is controlled by settings in MP Dr and Service ADVISOR™ .
See Attachment Control Circuit Theory of Operation . (Group 9015-15.)
When the secondary auxiliary relief valve solenoid valve (158) is activated, valve is shifted and pilot oil from
solenoid valve manifold port PE (218) is sent to secondary auxiliary relief control valve (160). This shifts the
secondary auxiliary relief control valve to route high-pressure oil to the secondary auxiliary relief valve.
When the secondary auxiliary relief valve solenoid valve is deactivated, spring tension shifts the valve. Pilot oil to
secondary auxiliary relief control valve is sent to hydraulic oil tank (219). This shifts the secondary auxiliary relief
control valve to stop routing high-pressure oil to the secondary auxiliary relief valve.
For more information, see Secondary Auxiliary Relief Kit Operation . (Group 9015-15.)
JJ03229,000087E-19-20130702
897
TX1136498-UN: Secondary Pilot Relief Control Valve

LEGEND:
158 - From Secondary Auxiliary Relief Valve Solenoid Valve
159 - To Secondary Auxiliary Relief Valve
160 - Secondary Auxiliary Relief Control Valve
217 - From Head End Auxiliary Cylinder
The function of the secondary auxiliary relief control valve (160) is to open or close flow of high-pressure oil from
head end auxiliary cylinder (217) 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.)
JJ03229,000087F-19-20130614
898
TX1136501-UN: Secondary Auxiliary Relief Valve Operation

LEGEND:
159 - Secondary Auxiliary Relief Valve
150 - From Auxiliary Attachment
The function of the secondary auxiliary relief valve (159) is to limit the auxiliary hydraulic pressure on the work
port side of an attachment.
At pressures below the circuit relief setting, spring tension in the secondary auxiliary relief valve closes flow of
auxiliary high-pressure oil from auxiliary attachment to hydraulic oil tank. When pressure exceeds the secondary
auxiliary relief valve setting, auxiliary high-pressure oil overcomes spring tension and shifts secondary auxiliary
relief valve, opening flow of auxiliary high-pressure oil from auxiliary attachment (160) to hydraulic oil tank.
For more information, see Secondary Auxiliary Relief Kit Operation . (Group 9025-05.)
JJ03229,0000880-19-20130816
899
TX1136973-UN: Selector Valve Solenoid Valve Schematic

LEGEND:
154 - Selector Valve Solenoid Valve
155 - To Selector Valve
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:
The selector valve solenoid valve is controlled by MPDr or Service ADVISOR™ . See Attachment Control Circuit
When the selector valve solenoid valve is energized, pilot oil from solenoid valve manifold port PE (218) is
directed to selector valve (155). When the selector valve is de-energized spring tension shifts the spool and pilot
oil to the selector will flow to hydraulic oil tank (219).
For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)
JJ03229,00008A0-19-20130816
900
TX1136970-UN: Selector Valve Operation

LEGEND:
37 - To Solenoid Valve Manifold Port DM
74 - Control Valve Port A7
154 - From Selector Valve Solenoid Valve
155 - Selector Valve
222 - From Auxiliary Cylinder Rod End
The function of the selector valve (155) is to allow the attachment to operate in one-way flow or two-way flow.
NOTE:
One-Way Flow Operation
Pilot oil from selector valve solenoid valve (154) shifts selector valve (155) allowing high-pressure oil from
auxiliary cylinder rod end (222) to flow directly to hydraulic oil tank (219).
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.
For more information, see Auxiliary High Flow Line Kit Operation . (Group 9025-05.)
901
JJ03229,0000882-19-20130814
902
TX1136621-UN: Auxiliary Flow Combiner Valve Schematic (auxiliary spool shifted by auxiliary (pilot) (13) and 2
speed active)
LEGEND:
15 - Pump 1
16 - Pump 2
76 - Bucket Spool
108 - Auxiliary Flow Rate Control Valve Spool
150 - Auxiliary Cylinder
157 - To Flow Rate Pressure Reducing Valve
604 - Return Oil
609 - Pilot Oil
The function of auxiliary function flow combiner valve spool (118) is to combine high-pressure oil from pump 1
(15) with high-pressure oil from pump 2 (16) for operation of auxiliary functions.
NOTE:
Auxiliary flow combiner valve will not work properly unless appropriate kits are installed on
machine.
903
TX1136622-UN: Auxiliary Flow Combiner Valve Pump 1 and Pump 2 Combined Flow
LEGEND:
2 - Check Valve
3 - Spring
15 - From Pump 1
16 - From Pump 2
17 - Pump 1 and Pump 2 Combined Flow
118 - Auxiliary Function Flow Combiner Valve Spool
157 - From Flow Rate Pressure Reducing Valve
604 - Return Oil
609 - Pilot Oil
Combined Flow Operation: When the 2-speed activation solenoid valve is energized, pilot oil is sent from flow
rate select solenoid valve (156) to left control valve (5-spool) (74) port SM. Pilot oil pressure from flow rate select
solenoid valve (156) overcomes tension on spring (3), shifting auxiliary function flow combiner valve spool (118)
allowing high-pressure oil from pump 1 (15) and high-pressure oil from pump 2 (16) to combine, creating pump 1
and pump 2 combined flow (17). Check valve (2) prevents back flow of pump 1 high-pressure oil to pump 2 power
passages.
904
TX1136623-UN: Auxiliary Flow Combiner Valve No Combined Flow

LEGEND:
2 - Check Valve
3 - Spring
15 - From Pump 1
16 - From Pump 2
118 - Auxiliary Function Flow Combiner Valve Spool
157 - From Flow Rate Pressure Reducing Valve
609 - Pilot Oil
Decombined Flow Operation (pump 1 priority control): When the 2-speed activation solenoid valve is
energized, pilot oil is sent from flow rate select solenoid valve (156) to left control valve (5-spool) (74) port SM.
Flow rate pressure reducing valve shifts to allow pilot oil from flow rate pressure reducing valve (157) port SN to
flow to auxiliary function flow combiner valve spool (118) port SN. Pilot oil pressure from flow rate select solenoid
valve (156) and from flow rate pressure reducing valve (157) being approximately equal, tension in spring (3)
shifts spool (118) closing the passage between high-pressure oil from pump 1 (15) and high-pressure oil from
pump 2 (16) decombining pump 1 and pump 2 high-pressure oil.
JJ03229,0000883-19-20130904
905
TX1141531-UN: Auxiliary Shuttle Valve Schematic
906
TX1141532-UN: Auxiliary Shuttle Valve

LEGEND:
41 - To Pilot Signal Manifold (port SP)
74 - To Control Valve (port SM)
87 - From Boom Lower Meter-In Cut Valve (port P19)
93 - To Bypass Shutoff Valve (port SJ2)
109 - Plug
143 - Auxiliary Shuttle Valve
156 - From Flow Rate Select Solenoid Valve (port A1)
The auxiliary shuttle valve (143) allows pilot oil from flow rate select solenoid valve (156) or from boom lower
meter cut-in valve (87) to shift bypass shutoff valve (93). Pilot oil from flow rate select solenoid valve port A1 or
boom lower meter-in cut valve, via control valve port P19, is sent to bypass shutoff valve, via control valve port
SJ2, without backfeeding between the circuits.
For more information, see Control Valve Operation and see Two Pump Combined Flow Kit Operation . (Group
9025-05.)
DF89619,00B553C-19-20130806
907
TX1141686-UN: Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted by auxiliary pilot oil 13)
LEGEND:
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
604 - Return Oil
609 - Pilot Oil
The function of the auxiliary high flow line kit is to operate auxiliary function in one-way flow operation or two-way
908
flow operation.
NOTE:
Auxiliary attachments will not work properly unless appropriate kits are installed on machine.
The selector valve solenoid valve (154) is controlled by Settings in the monitor. See Attachment Control Circuit
Theory of Operation for more information. (Group 9015-15.)
TX1138748-UN: Selector Valve Solenoid Valve De-Energized

LEGEND:
604 - Return Oil
609 - Pilot Oil
Selector Valve Solenoid Valve De-Energized— For operation of selector valve solenoid valve (154) see
Selector Valve Solenoid Valve Operation . (Group 9025-05.)
909
TX1138751-UN: Selector Valve Solenoid Valve Energized

LEGEND:
604 - Return Oil
609 - Pilot Oil
Selector Valve Solenoid Valve Energized— For operation of selector valve solenoid valve (154) see Selector
Valve Solenoid Valve Operation . (Group 9025-05.)
TX1138757-UN: Selector Valve One-Way Operation

LEGEND:
910
604 - Return Oil
609 - Pilot Oil
Selector Valve One-Way Operation— For operation of the selector valve see Selector Valve Operation . (Group
9025-05.)
TX1138756-UN: Selector Valve Two-Way Operation

LEGEND:
604 - Return Oil
Selector Valve Two-Way Operation— For operation of the selector valve see Selector Valve Operation . (Group
9025-05.)
DF89619,00B5537-19-20130801
911
TX1141687-UN: Two-Way Solenoid Auxiliary Pilot Operation of Control Valve (auxiliary spool shown shifted)
LEGEND:
28 - Pilot Pump
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
912
117 - Main Relief
604 - Return Oil
609 - Pilot Oil
NOTE:
Two way solenoid kit can be used on auxiliary high flow and auxiliary low flow.
The function of two way solenoid kit is to operate the auxiliary function from the left or right pilot control lever
momentary and proportional switches.
NOTE:
The right pilot control lever switches are standard from the factory, left pilot control lever switches
are a field kit installation.
Pressure Reducing Valve— The auxiliary pressure reducing valve (149) reduces the pressure to the auxiliary
solenoid valve (148) to limit the control valve auxiliary spool movement. The pressure reducing valve is
adjustable, turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure.
913
TX1136522-UN: Auxiliary Solenoid Valve Schematic

LEGEND:
149 - Auxiliary Pressure reducing Valve
604 - Return Oil
609 - Pilot Oil
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 B7 of the control valve to the
auxiliary attachment.
914
TX1136519-UN: Auxiliary Solenoid Valve Schematic

LEGEND:
149 - Auxiliary Pressure reducing Valve
604 - Return Oil
609 - Pilot Oil
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 A7 of the control valve to the auxiliary attachment.
DF89619,00B5538-19-20131002
915
TX1141533-UN: Two Pump Combined Flow Kit Schematic (Y43 energized and Y44 de-energized)
LEGEND:
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
45 - Swing Park Brake Release Pilot Valve
47 - Pump 2 Flow Rate Pilot Valve
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
117 - Main Relief and Power Dig Valve
157 - Flow Rate Select Reducing Valve
172 - To Torque Control Solenoid Valve
604 - Return Oil
609 - Pilot Oil
916
NOTE:
Two pump combined flow kit will not work properly unless appropriate kits are installed on
machine.
The function of the two pump combined flow kit is to control auxiliary function flow combiner valve (118) and
auxiliary flow rate control valve (valve and poppet) (108) when multiple function are used with auxiliary
attachments.
TX1141531-UN: Auxiliary Shuttle Valve Schematic

LEGEND:
41 - To Pilot Signal Manifold (port SP)
74 - To Control Valve (port SM)
87 - From Boom Lower Meter-In Cut Valve (port P19)
917
93 - To Bypass Shutoff Valve (port SJ2)
156 - From Flow Rate Select Solenoid Valve (port A1)
Auxiliary Shuttle Valve— For more information, see Auxiliary Shuttle Valve Operation . (Group 9025-05.)
TX1142564-UN: Flow Rate Pressure Reducing Valve Operating Below Set Pressure
LEGEND:
28 - Pilot Pump
41B - From Pilot Signal Manifold Port SN
41C - To Pilot Signal Manifold Port SP
74A - To Control Valve Port SY
74B - To Control Valve Port SN
143 - To Auxiliary Shuttle Valve
604 - Return Oil
609 - Pilot Oil
918
Flow Rate Pressure Reducing Valve Operating Below Set Pressure— For more information, see Flow Rate
Pressure Reducing Valve Operation . (Group 9025-05.)
TX1142566-UN: Flow Rate Pressure Reducing Valve Operating Above Set Pressure
LEGEND:
28 - Pilot Pump
604 - Return Oil
609 - Pilot Oil
Flow Rate Pressure Reducing Valve Above Set Pressure— For more information, see Flow Rate Pressure
Reducing Valve Operation . (Group 9025-05.)
919
TX1142567-UN: Flow Rate Select Solenoid Valve Energized

LEGEND:
28 - Pilot Pump
604 - Return Oil
609 - Pilot Oil
Flow Rate Select Solenoid Valve Energized— For more information, see Flow Rate Select Solenoid Valve
920
TX1142569-UN: Flow Rate Solenoid Valve De-Energized

LEGEND:
28 - Pilot Pump
604 - Return Oil
609 - Pilot Oil
Flow Rate Solenoid Valve De-Energized— For more information, see Flow Rate Select Solenoid Valve
DF89619,00B5539-19-20130909
921
TX1141685-UN: Secondary Auxiliary Relief Kit Schematic (auxiliary spool shifted by auxiliary (pilot) (13))
LEGEND:
16 - Pump 2
28 - Pilot Pump
95 - Swing Spool
97 - Arm 1 Spool
922
104 - Boom 2 Spool
136 - Auxiliary Circuit Relief and Anticavitation Valve
604 - Return Oil
609 - Pilot Oil
Secondary auxiliary relief kit is used when optional attachments are installed on the machine needing work port
pressure relief.
NOTE:
Secondary auxiliary relief will not work properly unless secondary auxiliary relief kit is installed on
machine.
The function of the secondary auxiliary relief kit is to give pressure relief to high-pressure oil (600) work side line
of 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.)
TX1135787-UN: Auxiliary Secondary Relief Solenoid Valve De-Energized

LEGEND:
217 - From Auxiliary Attachment Work Port
923
218 - From Solenoid Valve Manifold

604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
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).
TX1136506-UN: Auxiliary Secondary Relief Solenoid Valve Energized

LEGEND:
217 - From Auxiliary Attachment Work Port
604 - Return Oil
609 - Pilot Oil
Auxiliary Secondary Relief Solenoid Valve Energized— When the secondary auxiliary relief valve solenoid
valve (159) 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).
924
DF89619,00B553A-19-20130822
925
TX1139037-UN: Low Flow Kit Schematic (foot pedal operated)

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
8 - Bucket Dump (pilot)
9 - Left Travel Forward (pilot)
10 - Left Travel Reverse (pilot)
11 - Right Travel Forward (pilot)
12 - Right Travel Reverse (pilot)
13 - Auxiliary A1 (pilot)
14 - Auxiliary B1 (pilot)
141 - Pilot Shutoff Valve
144 - Low Flow Control Valve
145 - Pilot Low Flow Pump
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
926
TX1139385-UN: Low Flow Kit Schematic (solenoid operated)

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
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.
927
A pilot low flow pump (145) is installed to replace the existing pilot pump, this sends high-pressure oil (600) 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.
DF89619,00B55F4-19-20130912
928
All Hydraulic Functions Slow Diagnostic Procedure

1 Machine Operation
Action:
Verify machine operation. See Cycle Times Check . (Group 9005-10.)
Do cycle times meet specification?
Result:
YES:
Checks complete.
NO:
Go to Low Pilot Oil Pressure.
2 Low Pilot Oil Pressure

Action:
Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)
Does pilot oil pressure meet specification?
Result:
YES:
Go to Pump Control Pilot Pressure Signal Low.
NO:
Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter
3 Pump Control Pilot Pressure Signal Low

Action:
Check pump control pilot pressure. Perform Pump Control Pilot Pressure Signal Test . (Group 9025-25.)
Does pump control pilot pressure meet specification?
Result:
YES:
929
Go to Pilot Circuit Obstruction.
NO:
Check pump 1 or pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
4 Pilot Circuit Obstruction
Action:
Check pilot circuit for obstructions. See Pilot System Diagram and Operation . (Group 9025-05.)
Are all lines and hoses straight and in good condition; not kinked, worn from rubbing, or weather checked?
Result:
YES:
Go to Main Relief Valve Setting Too Low or Malfunctioning.
NO:
Repair or replace pilot circuit.
5 Main Relief Valve Setting Too Low or Malfunctioning

Action:
Verify proper main relief valve setting and operation. See Main Relief Valve Test and Adjustment . (Group
9025-25.)
Do main relief valve settings meet specification?
Result:
YES:
Go to Restricted Hydraulic Oil Tank Suction Screen.
NO:
Adjust, repair, or replace main relief valve. See Left Control Valve (5-Spool) Disassemble and Assemble .
(Group 3360.)
6 Restricted Hydraulic Oil Tank Suction Screen
Action:
Inspect hydraulic oil tank suction screen. See Replace Hydraulic Oil Tank Filter . (Operator’s Manual.)
Is hydraulic oil tank suction screen free of restriction?
930
Result:
YES:
Go to Torque Control Solenoid Malfunction.
NO:
Clean or replace hydraulic oil tank suction screen.
7 Torque Control Solenoid Malfunction
Action:
Check torque control solenoid connection. Check torque control solenoid. See Proportional Solenoid Test .
(Group 9015-20.)
Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment . (Group
9025-25.)
Do torque control solenoid and solenoid valve operate correctly?
Result:
YES:
Go to Worn Pump.
NO:
Repair or replace torque control solenoid and solenoid valve.
8 Worn Pump
Action:
Check pump flow. See Pump Flow Test . (Group 9025-25.)
Does pump flow meet specification?
Result:
YES:
Checks complete.
NO:
Repair or replace pump. See Pump 1 and 2 Remove and Install . (Group 3360.)
DF89619,00B579B-19-20160428
931
All Hydraulic Functions Slow Diagnostic Procedure

1 Machine Operation
Action:
Do cycle times meet specification?
Result:
YES:
Checks complete.
NO:
Go to Low Pilot Oil Pressure.
2 Low Pilot Oil Pressure

Action:
Check pilot oil pressure. See Pilot Pressure Regulating Valve Test and Adjustment . (Group 9025-25.)
Does pilot oil pressure meet specification?
Result:
YES:
Go to Pump Control Pilot Pressure Signal Low.
NO:
Adjust, repair, or replace pilot pressure regulating valve. See Pilot Pressure Regulating Valve and Filter
3 Pump Control Pilot Pressure Signal Low

Action:
Result:
YES:
932
NO:
(Group 3360.)
Action:
Result:
YES:
NO:

Action:
9025-25.)
Result:
YES:
NO:
(Group 3360.)
Action:
933
Result:
YES:
Go to Torque Control Solenoid Malfunction.
NO:
7 Torque Control Solenoid Malfunction
Action:
Check torque control solenoid connection. Check torque control solenoid. See Proportional Solenoid Test .
(Group 9015-20.)
Check torque control solenoid valve. See Torque Control Solenoid Valve Test and Adjustment . (Group
9025-25.)
Do torque control solenoid and solenoid valve operate correctly?
Result:
YES:
Go to Worn Pump.
NO:
Repair or replace torque control solenoid and solenoid valve.
8 Worn Pump
Action:
Check pump flow. See Pump Flow Test . (Group 9025-25.)
Does pump flow meet specification?
Result:
YES:
Checks complete.
NO:
DF89619,00B579B-19-20160428
934
Hydraulic Oil Overheats Diagnostic Procedure

1 Low Hydraulic Oil Level

Action:
Check hydraulic oil level. See Check Hydraulic Oil Tank Level . (Operator’s Manual.)
Is hydraulic oil at proper level?
Result:
YES:
Go to Cooling Package Check.
NO:
Fill hydraulic tank to proper level.
2 Cooling Package Check

Action:
Inspect cooling package for missing or damaged baffles or seals.
Are baffles or seals missing or damaged?
Result:
YES:
Repair or replace parts.
NO:
Go to Restricted Hydraulic Oil Cooler.
3 Restricted Hydraulic Oil Cooler
Action:
Inspect cooling package.
Is cooling package free of debris?
Result:
YES:
Go to Fan Drive Malfunction.
935
NO:
Clear debris from cooling package.
4 Fan Drive Malfunction

Action:
Inspect fan drive.
Does fan drive operate properly?
Result:
YES:
Go to Machine Lift Capacity Exceeded.
NO:
Repair or replace fan drive. See Fan, Fan Guard, and Fan Shroud Remove and Install . (Group 0510.)
5 Machine Lift Capacity Exceeded

Action:
Check machine lift capacity. See Miscellaneous—Specifications . (Operator's Manual.)
Is amount of weight being lifted within machine lifting capacity?
Result:
YES:
NO:
Reduce amount of weight being lifted.
Action:
9025-25.)
Result:
YES:
936
Go to Restricted Hydraulic Oil Return Filter.
NO:
(Group 3360.)
7 Restricted Hydraulic Oil Return Filter
Action:
Check hydraulic oil return filter for restriction. See Replace Hydraulic Oil Tank Filter . (Operator’s Manual.)
Is hydraulic oil tank return filter restricted?
Result:
YES:
Replace hydraulic oil tank return filter.
NO:
Go to Oil Cooler Bypass Valve Stuck Open.
8 Oil Cooler Bypass Valve Stuck Open

Action:
Inspect oil cooler bypass valve. See Oil Cooler Bypass Valve Remove and Install . (Group 3360.)
Does oil cooler bypass valve operate correctly?
Result:
YES:
Go to Restriction Valve Stuck Closed.
NO:
Replace oil cooler bypass valve.
9 Restriction Valve Stuck Closed
Action:
Inspect oil cooler restriction valve in outlet of hydraulic oil cooler.
Does restriction valve operate correctly?
Result:
937
YES:
Checks complete.
NO:
Replace restriction valve.
DF89619,00B579C-19-20160428
938
No Hydraulic Functions Diagnostic Procedure

1 Pilot Shutoff Lever Position

Action:
Check position of pilot shutoff lever.
Is pilot shutoff lever in unlocked (DOWN) position?
Result:
YES:
Go to Pilot Shutoff Solenoid Malfunction.
NO:
Place pilot shutoff lever in unlocked (DOWN) position.
2 Pilot Shutoff Solenoid Malfunction

Action:
Check pilot shutoff solenoid. See Solenoid Test . (Group 9015-20.)
Does pilot shutoff solenoid operate correctly?
Result:
YES:
Go to Pilot Shutoff Solenoid Voltage Check.
NO:
Repair or replace solenoid. See Pilot Shutoff Solenoid Valve Remove and Install . (Group 3360.)
3 Pilot Shutoff Solenoid Voltage Check
Action:
Key switch OFF.
Disconnect pilot shutoff solenoid.
Key switch ON.
Pilot shutoff lever in unlocked (DOWN) position.
Measure voltage at pin 1 and pin 2 of pilot shutoff solenoid connector.
Is approximately 24 volts indicated?
939
Result:
YES:
Go to Pilot Shutoff Valve Pilot Pressure.
NO:
See No Hydraulic Functions—Electrical Checks . (Group 9025-15.)
4 Pilot Shutoff Valve Pilot Pressure

Action:
Measure pressure from solenoid valve manifold port PF to pilot shutoff valve at port P.
For pilot shutoff solenoid valve port identification, see Pilot Shutoff Solenoid Valve Operation .
(Group 9025-05.)
For pilot shutoff solenoid valve line identification, see Pilot Control Valve-to-Pilot Signal Manifold
Component Location—Excavator Pattern . (Group 9025-15.)
For pilot pressure specification, see Pilot Pressure Regulating Valve Test and Adjustment . (Group
9025-25.)
Does pressure meet specification?
Result:
YES:
NO:
Verify proper operation of pilot pressure regulating valve. See Pilot Pressure Regulating Valve Test and
Adjustment . (Group 9025-25.)
Action:
Measure pressure at pilot shutoff valve port A4.
For pilot shutoff solenoid valve port identification, see Pilot Shutoff Solenoid Valve Operation .
(Group 9025-05.)
For pilot pressure specification, see Pilot Pressure Regulating Valve Test and Adjustment . (Group
9025-25.)
Result:
YES:
940
NO:
Inspect pilot shutoff valve. See Pilot Shutoff Solenoid Valve Remove and Install . (Group 3360.)
Repair or replace as necessary.
Action:
Result:
YES:
Go to Pump Drive Malfunction.
NO:
6 Pump Drive Malfunction

Action:
Check damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install . (Group 0752.)
Does damper drive (flex coupling) operate correctly?
Result:
YES:
Checks complete.
NO:
Repair or replace damper drive (flex coupling).
DF89619,00B579D-19-20160318
941
No Hydraulic Functions—Electrical Checks Diagnostic Procedure
For more information, see Pilot Shutoff Circuit Theory of Operation . (Group 9015-15.)
1 Diagnostic Trouble Code Check

Action:
Check for active diagnostic trouble codes (DTCs) using monitor, Service ADVISOR™ , or MPDr.
See Reading Diagnostic Trouble Codes with Monitor Display . (Group 9015-20.)
See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group
9015-20.)
See MPDr Application.
Are any DTCs present?
Result:
YES:
Diagnose DTC. See specific diagnostic procedure in Group 9001.
NO:
Go to Fuse Check.
2 Fuse Check
Action:
Remove solenoid 20 A fuse (marked SOLENOID) (F4) from fuse block. See Fuse and Relay Specifications .
(Group 9015-10.) Check fuse F4 for continuity.
Result:
YES:
Go to Pilot Shutoff Switch Malfunction.
NO:
Replace fuse.
3 Pilot Shutoff Switch Malfunction

Action:
View pilot control shut-off lever switch position in Service ADVISOR™ or MPDr. See Service ADVISOR™
Diagnostic Application . (Group 9015-20.) Move pilot shutoff lever to locked (UP) position and unlocked
(DOWN) position.
942
Does lever position match monitor status?
Result:
YES:
Go to Pilot Shutoff Solenoid Relay Malfunction.
NO:
Inspect and repair pilot shutoff switch harness (W17). See Pilot Shutoff Switch Harness (W17) Component
Location . (Group 9015-10.)
4 Pilot Shutoff Solenoid Relay Malfunction
Action:
Test pilot shutoff solenoid relay (K2). See Relay Test . (Group 9015-20.)
Is pilot shutoff solenoid relay OK?
Result:
YES:
Go to Pilot Shutoff Solenoid Malfunction.
NO:
Replace pilot shutoff solenoid relay.
5 Pilot Shutoff Solenoid Malfunction

Action:
Check pilot shutoff solenoid (Y10). See Solenoid Test . (Group 9015-20.)
Does pilot shutoff solenoid operate correctly?
Result:
YES:
Go to Pilot Shutoff Solenoid Voltage Check.
NO:
Replace pilot shutoff solenoid. See Pilot Shut-Off Solenoid Valve Remove and Install . (Group 3360.)
6 Pilot Shutoff Solenoid Voltage Check
Action:
Key switch OFF.

943
Disconnect pilot shutoff solenoid (Y10).
Key switch ON.
Measure voltage at pin 1 and pin 2 of pilot shutoff solenoid connector.
Result:
YES:
Repair or replace pilot shutoff valve. See Pilot Shut-Off Solenoid Valve Remove and Install . (Group 3360.)
NO:
Go to Pilot Shutoff Circuit Check.
7 Pilot Shutoff Circuit Check

Action:
Key switch OFF.
Disconnect pilot shutoff solenoid (Y10).
Key switch ON.
Measure voltage at pin 1 and machine ground.
Result:
YES:
Inspect pilot shutoff valve harness on cab harness (W1) for open ground circuit. See Pilot Shutoff Circuit
Theory of Operation . (Group 9015-15.) See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
NO:
Inspect pilot shutoff valve harness on cab harness (W1) for open power circuit. See Pilot Shutoff Circuit
Theory of Operation . (Group 9015-15.) See Cab Harness (W1) Wiring Diagram . (Group 9015-10.)
DF89619,00B57E3-19-20160317
944
Function Does Not Stop When Control Lever Released Diagnostic Procedure
1 Cold Hydraulic Oil

Action:
Check hydraulic oil temperature. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
Does hydraulic oil temperature meet specification?
Result:
YES:
Go to Mechanical Control Lever Pattern Selector (if equipped).
NO:
Perform hydraulic system warm-up procedure.
2 Mechanical Control Lever Pattern Selector (if equipped)

Action:
Verify mechanical control lever pattern selector (if equipped) is properly positioned.
Is mechanical control lever pattern selector properly positioned?
Result:
YES:
NO:
Adjust mechanical control lever pattern selector position.
Action:
Result:
YES:
Go to Pilot Control Valve Malfunction.
945
NO:
4 Pilot Control Valve Malfunction

Action:
Check control valve spool actuating pressure. See Control Valve Spool Actuating Pilot Pressure Test .
(Group 9025-25.)
Does control valve spool actuating pressure meet specification?
Result:
YES:
Go to Control Valve Spool Stuck.
NO:
Go to Pilot Control Valve Spool Malfunction.
5 Pilot Control Valve Spool Malfunction
Action:
Inspect pilot control valve spools. See Left and Right Pilot Valve Remove and Install or see Travel Pilot
Control Valve Remove and Install . (Group 3360.)
Do pilot control valve spools move freely?
Result:
YES:
NO:
Repair or replace pilot control valve.
6 Control Valve Spool Stuck

Action:
Inspect control valve for stuck spool. See Control Valve Operation . (Group 9025-05.)
Do control valve spools move freely?
Result:
946
YES:
Checks complete.
NO:
Repair or replace control valve components. See Left Control Valve (5-Spool) Disassemble and Assemble
and see Right Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
DF89619,00B57A0-19-20160421
947
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure
1 Cylinder Drift
Action:
Verify proper operation of machine cylinders. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group
9025-25.)
Does cylinder drift meet specification?
Result:
YES:
Checks complete.
NO:
Go to Boom Manual Lower Screw Loose.
2 Boom Manual Lower Screw Loose
Action:
Inspect boom manual lower screw. See Lower Boom With Engine Stopped . (Operator’s Manual.)
Is boom manual lower screw tightened to specification?
Result:
YES:
Go to Circuit Relief Valve Setting Too Low or Malfunctioning.
NO:
Tighten boom manual lower screw to specification.
3 Circuit Relief Valve Setting Too Low or Malfunctioning

Action:
Check circuit relief valve drifting function. Swap circuit relief valves for a particular function.
Does cylinder drift continue on same function?
Result:
YES:
948
Go to Reduced Leakage Valve.
NO:
Adjust, repair, or replace circuit relief valve. See Circuit Relief Valve Test and Adjustment . (Group 9025-25.)
See Left Control Valve (5-Spool) Disassemble and Assemble and see Right Control Valve (4-Spool)
Disassemble and Assemble . (Group 3360.)
4 Reduced Leakage Valve
Action:
NOTE:
Reduced leakage valve check should only be completed on machines showing symptoms of
arm in or boom down cylinder drift.
Inspect reduced leakage valve pilot valve and poppet. For component identification, see Control Valve
Operation . (Group 9025-05.) See Left Control Valve (5-Spool) Disassemble and Assemble and see Right
Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
Is reduced leakage valve pilot valve or poppet scored or sticking?
Result:
YES:
Replace reduced leakage valve pilot valve or poppet.
NO:
Go to Control Valve Leakage.
5 Control Valve Leakage
Action:
Inspect control valve for leakage. See Hydraulic System Component Location . (Group 9025-15.)
Is control valve free of leaks?
Result:
YES:
Go to Cylinder Leakage.
NO:
6 Cylinder Leakage
Action:
949
Inspect machine cylinders. See Boom Cylinder Remove and Install , see Arm Cylinder Remove and Install ,
and see Bucket Cylinder Remove and Install . (Group 3360.)
Are machine cylinders in proper working condition?
Result:
YES:
Checks complete.
NO:
Repair or replace cylinder.
DF89619,00B57A6-19-20160201
950
Load Falls When Control Valve is Actuated to Raise Load Diagnostic Procedure
1 Lift Check Valve Leakage

Action:
Inspect control valve check valves and flow rate control valve poppets for leakage. See Control Valve Check
Valves Identification And Operation and see Control Valve Operation . (Group 9025-05.)
Are check valve and flow rate control valve poppets operating correctly?
Result:
YES:
Checks complete.
NO:
DF89619,00B57A7-19-20160318
951
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic
Procedure
For more information, see Engine Speed Control System Operation . (Group 9010-05.)

Action:
9015-20.)
Result:
YES:
NO:
Go to Work Mode.
2 Work Mode
Action:
Check work mode setting. See Monitor Functions . (Operator’s Manual.)
Is bucket mode enabled?
Result:
YES:
Go to Machine Settings.
NO:
Change work mode setting to bucket mode.
3 Machine Settings
Action:
Verify H/P mode is enabled using Service ADVISOR™ or MPDr. See Service ADVISOR™ Diagnostic
Application . (Group 9015-20.)
952
NOTE:
H/P mode option can be disabled using MPDr, causing H/P mode selection to be disabled in
monitor.
Is H/P mode enabled?
Result:
YES:
Go to Slow Engine Speed.
NO:
Change machine setting using monitor or MPDr.
4 Slow Engine Speed
Action:
Verify engine speed meets H/P mode requirements. See Engine Speed Control System Operation . (Group
9010-05.)
Does engine speed meet specification?
Result:
YES:
Go to Pressure Sensor Malfunction.
NO:
Select correct engine speed.
5 Pressure Sensor Malfunction

Action:
Check pressure readings of the following pressure sensors:
Pump 1 Delivery Pressure

Boom Raise Pilot Pressure
Arm Roll-In Pilot Pressure
Pressure readings can be viewed using the monitor service menu. See Monitor Service Menu Operation .
(Group 9015-16.) See Monitor Data Items . (Group 9015-20.)
Actuate arm in or boom up function to view reading.

Compare pump 1 and pump 2 pressure readings to main relief valve specification. See
Main Relief Valve Test and Adjustment and see Travel Speed Solenoid Valve Test and
Adjustment . (Group 9025-25.)
953
Compare boom up and arm in pressure readings to control valve spool actuating pilot
pressure specification. See Control Valve Spool Actuating Pilot Pressure Test . (Group
9025-25.)
Do pressure readings meet specification?
Result:
YES:
Checks complete.
NO:
Action:
Install gauges to verify sensor readings. See Main Relief Valve Test and Adjustment and see Control Valve
Spool Actuating Pilot Pressure Test . (Group 9025-25.)
Operate boom up and arm in functions.
Do gauge readings match pressure sensor readings?
Result:
YES:
Inspect hydraulic plumbing. Repair or replace parts as necessary.
NO:
Verify proper operation of sensors and harnesses. See 11200.04—Pump 1 Delivery Pressure Sensor
Voltage Low , see 11202.04—Pump 2 Delivery Pressure Sensor Voltage Low , see 11302.04—Boom Up
Pilot Pressure Sensor Voltage Low , or see 11303.04—Arm In Pilot Pressure Sensor Voltage Low . (Group
9001-10.)
DF89619,00B57C4-19-20160428
954
Diagnostic Procedure
If machine shows these characteristics repeatedly, submit a fluid sample to a designated regional lab for testing.
See Location of Fluid Sampling Test Ports—If Equipped . (Operator’s Manual.)

Action:
Remove and set aside boom reduced leakage valve poppet and spring. See Control Valve Operation .
(Group 9025-05.) See Right Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
Install boom reduced leakage valve pilot valve only.
CAUTION:
Prevent possible crushing injury from heavy component. Boom down drift will
increase with reduced leakage valve poppet removed. Keep work area clear of
bystanders.
Operate machine.
Does boom down function operate properly?
Result:
YES:
Replace boom reduced leakage valve components.
NO:
Checks complete.
DF89619,00B57BE-19-20160318
955
Diagnostic Procedure
If machine shows these characteristics repeatedly, submit a fluid sample to a designated regional lab for testing.
See Location of Fluid Sampling Test Ports—If Equipped . (Operator’s Manual.)
1 System Check
Action:
View pump 1 and pump 2 delivery pressure in monitor. See Monitor Data Items . (Group 9015-20.)
Perform controlled arm in function. Monitor pump 1 and pump 2 delivery pressure while arm is in motion.
Are both pump 1 and pump 2 delivery pressures near main relief specification? For specification, see Main
Relief Valve Test and Adjustment . (Group 9025-25.)
Result:
YES:
Go to Reduced Leakage Valve.
NO:
Action:
Perform controlled arm in function. Monitor pump 1 and pump 2 delivery pressure while arm is in motion.
Is only pump 1 delivery pressure near main relief specification? For specification, see Main Relief Valve Test
Result:
YES:
Go to Arm 1 Flow Rate Control Valve .
NO:
Go to Arm 2 Flow Rate Control Valve .

Action:
Remove and set aside arm reduced leakage valve poppet and spring. See Control Valve Operation . (Group
9025-05.) See Left Control Valve (5-Spool) Disassemble and Assemble . (Group 3360.)
Install arm reduced leakage valve pilot valve only.
956
CAUTION:
Prevent possible crushing injury from heavy component. Arm in drift will increase
with reduced leakage valve poppet removed. Keep work area clear of bystanders.
Operate machine.
Does arm in function operate properly?
Result:
YES:
Replace arm reduced leakage valve components.
NO:
Checks complete.
3 Arm 1 Flow Rate Control Valve

Action:
Inspect arm 1 flow rate control valve components. See Left Control Valve (5-Spool) Disassemble and
Are arm 1 flow rate control valve components scored or sticking?
Result:
YES:
Repair or replace arm 1 flow rate control valve components.
NO:
Checks complete.
Action:
Inspect arm 2 flow rate control valve components. See Right Control Valve (4-Spool) Disassemble and
Result:
YES:
957
NO:
Checks complete.
DF89619,00B57D0-19-20160428
958
Swing Speed Slow During Arm In Function Diagnostic Procedure

1 Arm 1 Flow Rate Pilot Valve

Action:
Measure pressure from arm 1 flow rate pilot valve (port SE) during swing and arm in over relief.
For pressure specification, see Control Valve Spool Actuating Pilot Pressure Test . (Group 9025-
25.)
For port identification, see Control Valve Line Identification . (Group 9025-15.)
For line identification, see Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-
15.)
Does pilot pressure meet specification?
Result:
YES:
Go to Arm 1 Flow Rate Control Valve.
NO:
Repair or replace arm 1 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group
3360.)

Action:
Inspect arm 1 flow rate control valve components. See Left Control Valve (5-Spool) Disassemble and
Result:
YES:
Checks complete.
NO:
DF89619,00B57D7-19-20160318
959
Boom Cannot Raise Track Off Ground Diagnostic Procedure

1 Function Test
Action:
CAUTION:
Avoid possible injury from unexpected machine movement. Machine could slide and
cause personal injury. Keep angle between boom and arm at 90—110°.

Swing the upperstructure 90° and lower the bucket to raise track off ground. Keep angle between boom and
arm at 90—110°.
Using boom down function, can track be raised?
Result:
YES:
Checks complete.
NO:
Action:
960
Result:
YES:
NO:
Action:
(Group 9025-25.)
Result:
YES:
Go to Cylinder Drift.
NO:
Inspect, repair, or replace pilot control valve. See Left and Right Pilot Valve Remove and Install . (Group
3360.)
4 Cylinder Drift
Action:
Verify proper operation of machine cylinders. See Cylinder Drift Test—Boom, Arm, and Bucket . (Group
9025-25.)
Does cylinder drift meet specification?
Result:
YES:
Go to Boom Lower Meter-In Cut Valve Circuit.
NO:
Repair or replace boom cylinders. See Boom Cylinder Remove and Install . (Group 3360.)
5 Boom Lower Meter-In Cut Valve Circuit

Action:
Install pressure gauge and measure boom down pilot pressure to boom lower meter-in cut valve during boom
down operation.
961
25.)
For component identification, see Control Valve Operation . (Group 9025-05.)
For port identification, See Control Valve Line Identification . (Group 9025-15.)
For more information, See Hydraulic System Schematic . (Group 9025-15.)
Result:
YES:
NO:
Inspect pilot circuit for obstruction.
Action:
Install pressure gauge and measure boom down pilot pressure from boom lower meter-in cut valve during
boom down operation.
25.)
For more information, see Hydraulic System Schematic . (Group 9025-15.)
Result:
YES:
Go to Bypass Shutoff Valve Circuit Check .
NO:
Action:
Inspect boom lower meter-in cut valve. See Right Control Valve (4-Spool) Disassemble and Assemble .
(Group 3360.)
Is boom lower meter-in cut pilot valve scored or sticking?
Result:
YES:
Repair or replace boom lower meter-in cut valve.
962
NO:
6 Bypass Shutoff Valve Circuit Check

Action:
Install pressure gauge and measure boom down pilot pressure from boom lower meter-in cut valve to bypass
shutoff valve during boom down operation.
25.)
For more information, see Hydraulic System Schematic . (Group 9025-15.)
Result:
YES:
NO:
Action:
Inspect bypass shutoff valve. See Right Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
Is bypass shutoff valve scored or sticking?
Result:
YES:
Repair or replace bypass shutoff valve.
NO:
Checks complete.
DF89619,00B57D3-19-20160524
963
Swing Function Does Not Operate in Both Directions Diagnostic Procedure

1 Isolation Check Valve

Action:
Perform combined operation of bucket curl and swing.
Does swing function operate?
Result:
YES:
Repair or replace main relief isolation check valve (4-spool). See Right Control Valve (4-Spool) Disassemble
and Assemble . (Group 3360.)
NO:
Go to Left Travel Power Passage Check Valve.
2 Left Travel Power Passage Check Valve
Action:
Perform combined operation of left travel and swing.
Does swing function operate?
Result:
YES:
Repair or replace left travel power passage check valve. See Left Control Valve (5-Spool) Disassemble and
NO:

Action:
(Group 9025-25.)
964
Result:
YES:
NO:
3360.)
4 Control Valve Spool Stuck
Action:
Inspect control valve for stuck spool. For component location, see Control Valve Operation . (Group 9025-
05.)
Does swing valve spool move freely?
Result:
YES:
Go to Swing Park Brake Pilot Valve.
NO:
Repair or replace control valve components as necessary. See Left Control Valve (5-Spool) Disassemble
5 Swing Park Brake Pilot Valve

Action:
View front attachment pressure sensor value in monitor. See Monitor Service Menu Operation . (Group
9015-16.) See Monitor Data Items . (Group 9015-20.) Actuate a dig function.
Does front attachment pressure sensor value change?
Result:
YES:
Go to Case Drain Leakage.
NO:
Repair or replace swing park brake pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
6 Case Drain Leakage
Action:
Inspect swing motor for leakage. See Swing Motor Leakage Test . (Group 9025-25.)
Does observed leakage meet specification?

965
Result:
YES:
Go to Swing Park Brake Not Fully Released.
NO:
Repair or replace swing motor and park brake. See Swing Motor and Park Brake Remove and Install .
(Group 4360.)
7 Swing Park Brake Not Fully Released

Action:
Inspect swing park brake. See Swing Motor and Park Brake Remove and Install . (Group 4360.)
Is swing park brake OK?
Result:
YES:
Checks complete.
NO:
Repair or replace swing park brake.
DF89619,00B57DF-19-20160317
966
Swing Speed Slow in Both Directions Diagnostic Procedure

1 Machine Operation
Action:
Do swing cycle times meet specification?
Result:
YES:
Checks complete.
NO:
Go to Pump 2 Flow Rate Pilot Valve.
2 Pump 2 Flow Rate Pilot Valve

Action:
Check pump control pilot pressure. See Pump Control Pilot Pressure Signal Test . (Group 9025-25.)
Result:
YES:
NO:
Check pump 2 flow rate pilot valve. See Pilot Signal Manifold Disassemble and Assemble . (Group 3360.)
Action:
(Group 9025-25.)
Result:
YES:
967
Go to Isolation Check Valve.
NO:
3360.)
4 Isolation Check Valve
Action:
Perform combined operation of bucket curl and swing.
Does swing speed increase?
Result:
YES:
Repair or replace main relief isolation check valve (4-spool). See Right Control Valve (4-Spool) Disassemble
NO:
Go to Left Travel Neutral Passage Check Valve.
5 Left Travel Neutral Passage Check Valve

Action:
Perform combined operation of left travel and swing.
Does swing speed increase?
Result:
YES:
Repair or replace left travel neutral passage check valve. See Left Control Valve (5-Spool) Disassemble and
NO:
Go to Swing Motor Leakage.
6 Swing Motor Leakage
Action:
Does swing motor meet specification?
968
Result:
YES:
Go to Pump 2 Worn.
NO:
Repair or replace swing motor. See Swing Motor and Park Brake Remove and Install . (Group 4360.)
7 Pump 2 Worn
Action:
Slow travel cycle times may indicate worn pump. Check travel cycle times. See Cycle Times Check . (Group
9005-10.)
If travel cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.)
Do travel cycle times and pump flow meet specification?
Result:
YES:
Checks complete.
NO:
DF89619,00B57A8-19-20160726
969
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure

Action:
(Group 9025-25.)
Result:
YES:
Go to Swing Motor Crossover Relief Valve Malfunction.
NO:
3360.)
2 Swing Motor Crossover Relief Valve Malfunction
Action:
Swap right swing motor crossover relief valve with left swing motor crossover relief valve. See Crossover
Relief Valve and Make-Up Check Valve Remove and Install . (Group 4360.)
Is swing speed slow in same direction?
Result:
YES:
Go to Swing Motor Make-Up Check Valve Leakage.
NO:
Repair or replace swing motor crossover relief valve. See Crossover Relief Valve and Make-Up Check Valve
3 Swing Motor Make-Up Check Valve Leakage

Action:
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check
Valve Operation . (Group 9025-05.)
Are swing motor make-up check valves OK?
970
Result:
YES:
Go to Control Valve Sticking.
NO:
Repair or replace swing motor make-up check valve. See Crossover Relief Valve and Make-Up Check Valve
4 Control Valve Sticking
Action:
Inspect control valve for sticking spool. For component location, see Control Valve Operation . (Group 9025-
05.)
Does control valve spool move freely?
Result:
YES:
Checks complete.
NO:
DF89619,00B57A9-19-20150820
971
Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure

1 Upperstructure Drift Check

Action:
Measure upperstructure drift. See Swing Park Brake and Circuit Drift Check . (Group 9005-10.)
Is upperstructure drift within specification?
Result:
YES:
Checks complete.
NO:
Go to Park Brake Operation.
2 Park Brake Operation

Action:
Inspect swing motor and park brake for proper application and release. See Swing Motor Park Brake
Release Circuit Operation . (Group 9025-05.)
Does swing continue to drift after releasing controller for 10 seconds?
Result:
YES:
Go to Swing Park Brake Pilot Valve .
NO:
Go to Drift Direction.
3 Drift Direction
Action:
Operate machine and check for drift in both directions.
Does drift occur in both directions?
Result:
YES:
972
Go to Case Drain Leakage.
NO:
Go to Swing Motor Make-Up Check Valve Leakage .
4 Case Drain Leakage
Action:
Does observed leakage meet specification?
Result:
YES:
Go to Swing Motor Make-Up Check Valve Leakage.
NO:
(Group 4360.)
5 Swing Motor Make-Up Check Valve Leakage

Action:
Inspect swing motor make-up check valves. See Swing Motor, Crossover Relief Valve, and Make-Up Check
Valve Operation . (Group 9025-05.)
Are swing motor make-up check valves OK?
Result:
YES:
Go to Swing Motor Crossover Relief Valve Malfunction.
NO:
Repair or replace swing motor make-up check valves. See Crossover Relief Valve and Make-Up Check
Valve Remove and Install . (Group 4360.)
6 Swing Motor Crossover Relief Valve Malfunction
Action:
Remove crossover relief valves and install in opposite ports in park brake housing. See Crossover Relief
Valve and Make-Up Check Valve Remove and Install . (Group 4360.)
Does swing drift change directions?
973
Result:
YES:
Repair or replace crossover relief valves. See Crossover Relief Valve and Make-Up Check Valve Remove
NO:
Checks complete.
7 Swing Park Brake Pilot Valve

Action:
View front attachment pressure sensor value in monitor. See Monitor Data Items . (Group 9015-20.) Actuate
a dig function.
Does front attachment pressure sensor value change?
Result:
YES:
Go to Swing Park Brake Not Fully Engaging.
NO:
Repair or replace swing park brake pilot valve spool. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
8 Swing Park Brake Not Engaging
Action:
Inspect swing motor and park brake. See Swing Motor Park Brake Release Circuit Operation . (Group 9025-
05.) See Swing Motor and Park Brake Inspection . (Group 4360.)
Are swing motor and park brake OK?
Result:
YES:
Checks complete.
NO:
(Group 4360.)
DF89619,00B57AA-19-20160428
974
Machine Freewheels Down an Incline Diagnostic Procedure

1 Park Brake Housing

Action:
Swap park brake housing with other travel motor. See Travel Motor and Park Brake Disassemble and
Operate travel functions.
Does same track freewheel?
Result:
YES:
Go to Mechanical Malfunction of Travel Motor and Gear Case.
NO:
Replace park brake housing. See Travel Motor Cover Disassemble and Assemble . (Group 0260.)
2 Mechanical Malfunction of Travel Motor and Gear Case
Action:
Check travel motor leakage. See Travel Motor Leakage Test . (Group 9025-25.)
Does motor leakage meet specification?
Result:
YES:
Checks complete.
NO:
Inspect gear case components. If no issues are found, repair or replace travel motor. See Travel Gearbox
DF89619,00B57E1-19-20140806
975
Track Will Not Move in Either Direction Diagnostic Procedure


Action:
(Group 9025-25.)
Result:
YES:
Go to Control Valve Stuck.
NO:
Inspect, repair, or replace pilot control valve. See Travel Pilot Control Valve Remove and Install . (Group
3360.)
2 Control Valve Stuck
Action:
Inspect control valve for stuck travel valve spool. For component location, see Control Valve Operation .
(Group 9025-05.)
Does travel valve spool move freely?
Result:
YES:
Go to Travel Motor Leakage.
NO:
and Assemble and see Right Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
3 Travel Motor Leakage

Action:
976
Result:
YES:
Go to Counterbalance Valve Spool Stuck.
NO:
Repair or replace travel motor. See Travel Gearbox Remove and Install . (Group 0250.)
4 Counterbalance Valve Spool Stuck

Action:
Inspect counterbalance valve.
Does counterbalance valve spool move freely?
Result:
YES:
Go to Park Brake Housing.
NO:
Repair or replace counterbalance valve. See Travel Motor Cover Disassemble and Assemble . (Group
0260.)
5 Park Brake Housing
Action:
Swap park brake housing with other travel motor. See Travel Motor and Park Brake Disassemble and
Operate travel functions. Does same track not move in either direction?
Result:
YES:
Go to Mechanical Malfunction of Travel Motor or Gear Case.
NO:
Replace park brake housing.
6 Mechanical Malfunction of Travel Motor or Gear Case

Action:
Inspect travel motor and gear case for mechanical malfunction. See Travel Gearbox Remove and Install .
(Group 0250.)
Is travel motor and gear case OK?

977
Result:
YES:
Go to Center Joint Leakage.
NO:
Repair or replace travel motor or gear case.
7 Center Joint Leakage

Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 4360.)
Is center joint OK?
Result:
YES:
Checks complete.
NO:
Repair or replace center joint. See Center Joint Remove and Install . (Group 4360.)
DF89619,00B57AE-19-20140724
978
Machine Mistracks
Machine Mistracks Diagnostic Procedure

1 Machine Tracking
Action:
Check machine tracking. See Travel System Tracking Check . (Group 9005-10.)
Does tracking meet specification?
Result:
YES:
Checks complete.
NO:
Go to Incorrect Track Sag Adjustment.
2 Incorrect Track Sag Adjustment

Action:
Result:
YES:
Go to Fast Travel Check.
NO:
Adjust track sag.
3 Fast Travel Check
Action:
Operate machine in fast and slow travel speeds.
Does machine mistrack at both speeds?
Result:
YES:
Go to Travel System Check.
979
Machine Mistracks
NO:
Inspect travel speed change components. See Travel Motor Cover Disassemble and Assemble . (Group
0260.)
4 Travel System Check

Action:
Swap left travel hoses with right travel hoses at top of center joint. See Travel Hydraulic System Line
Connection . (Group 9025-15.)
Operate travel functions.
Does machine mistrack in same direction?
Result:
YES:
Go to Travel Motor Leakage.
NO:
Go to Pilot Control Valve Malfunction .
5 Travel Motor Leakage

Action:
Result:
YES:
Go to Center Joint Leakage.
NO:
6 Center Joint Leakage

Action:
Inspect center joint for leakage. See Center Joint Air Test . (Group 4360.)
Is center joint OK?
980
Machine Mistracks
Result:
YES:
NO:
Repair or replace center joint. See Center Joint Remove and Install . (Group 4360.)
Action:
(Group 9025-25.)
Result:
YES:
Go to Pump Control Pilot Pressure Signal.
NO:
Inspect, repair, or replace pilot control valve. See Travel Pilot Control Valve Remove and Install . (Group
3360.)
8 Pump Control Pilot Pressure Signal

Action:
Result:
YES:
Go to Worn Pump.
NO:
(Group 3360.)
9 Worn Pump
Action:
Slow cycle times may indicate a worn pump. Check cycle times. See Operational Checkout . (Group 9005-
10.)
If cycle times do not meet specification, check pump flow. See Pump Flow Test . (Group 9025-25.)
981
Machine Mistracks
Do cycle times and pump flow meet specification?
Result:
YES:
Replace pump 1 or pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install . (Group 3360.)
NO:
DF89619,00B57AF-19-20160202
982
Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure
NOTE:
During combined travel and dig functions, hydraulic functions will be slow, but machine should not
mistrack.
1 Travel Flow Combiner Pilot Valve Stuck
Action:
Measure pressure from travel flow combiner pilot valve (port SL) during combined travel and dig functions.
25.)
For line identification, see Pilot Signal Manifold-to-Control Valve Line Connection . (Group 9025-
15.)
Does pilot pressure meet specification?
Result:
YES:
Go to Travel Flow Combiner Valve and Check Valves Stuck.
NO:
Repair or replace travel flow combiner pilot valve. See Pilot Signal Manifold Disassemble and Assemble .
(Group 3360.)
2 Travel Flow Combiner Valve and Check Valves Stuck
Action:
Inspect travel flow combiner valve and check valves. See Left Control Valve (5-Spool) Disassemble and
Assemble and see Right Control Valve (4-Spool) Disassemble and Assemble . (Group 3360.)
Do travel flow combiner valve and check valves move freely?
Result:
YES:
Checks complete.
NO:
Repair or replace control valve components.
983
DF89619,00B57E0-19-20160318
984
Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure
For more information, see Travel Motor Speed Circuit Operation (S.N. 501493— ) or see Travel Motor Speed
Circuit Operation (S.N. —501492) . (Group 9025-05.) Also see Main Controller (MCF) Circuit Theory of Operation
. (Group 9015-15.)

Action:
9015-20.)
Result:
YES:
NO:
Go to Fuse Check.
2 Fuse Check
Action:
Remove solenoid 20 A fuse (marked SOLENOID) (F4) from fuse block. See Fuse and Relay Specifications .
(Group 9015-10.) Check fuse F4 for continuity.
Result:
YES:
Go to Travel Speed Function.
NO:
Replace fuse.
3 Travel Speed Function
Action:
NOTE:
985
Fast (rabbit) travel speed function will not be enabled if travel functions are held over relief.
Travel mode switch in fast (rabbit) position.
View travel mode control pressure in monitor. See Monitor Service Menu Operation . (Group 9015-16.) See
Fully actuate travel functions.
Is travel control pressure approximately 3.0 MPa?
Result:
YES:
NO:
Go to Travel Mode Switch Check .
4 Solenoid Check
Action:
Verify proper operation of travel speed solenoid (marked SI) (Y25). See Travel Speed Solenoid Valve Test
Does power dig valve pressure meet specification?
Result:
YES:
Go to Travel Speed Circuit Check .
NO:
Action:
Test power dig solenoid (marked SG) (Y24). See Proportional Solenoid Test . (Group 9015-20.)
Is solenoid within specification?
Result:
YES:
986
NO:
Replace solenoid.
Action:
Test travel speed solenoid (marked SI) (Y25). See Proportional Solenoid Test . (Group 9015-20.)
Is solenoid within specification?
Result:
YES:
NO:
Replace solenoid.
Action:
Inspect travel speed solenoid valve for scoring or debris.
Is travel speed solenoid valve OK?
Result:
YES:
NO:
Repair or replace power dig/travel speed solenoid valve.
5 Harness Check
Action:
Check harness and harness connectors for damage, corrosion, or debris.
Are harness and harness connectors in good condition?
Result:
YES:
Go to Travel Speed Circuit Check.
NO:
Repair or repair harness as necessary.
987
6 Travel Speed Circuit Check
Action:
Inspect travel speed circuit.
See Hydraulic System Schematic . (Group 9025-15.)

See Center Joint Operation . (Group 9025-05.)
See Travel Hydraulic System Line Connection (S.N. 501493— ) or see Travel Hydraulic System
Line Connection (S.N. —501492) . (Group 9025-15.)
Result:
YES:
Checks complete.
NO:
Repair or replace lines or hoses as necessary.
7 Travel Mode Switch Check

Action:
View travel mode switch in monitor. See Monitor Service Menu Operation . (Group 9015-16.) See Monitor
Data Items . (Group 9015-20.)
Move travel mode switch to fast (rabbit) position and slow (turtle) position.
Do switch positions match monitor status?
Result:
YES:
Go to Front Attachment Pressure Sensor Check.
NO:
Repair or replace travel mode switch or harness.
8 Front Attachment Pressure Sensor Check

Action:
View front attachment control pilot pressure in monitor. See Monitor Service Menu Operation . (Group 9015-
16.) See Monitor Data Items . (Group 9015-20.)
Fully actuate dig function and return pilot control levers to neutral to view reading.
Does indicated pressure rise above 3.0 MPa and return to 0.0 MPa?
988
Result:
YES:
Go to Travel Pressure Sensor Check.
NO:
Test front attachment pressure sensor. See Pressure Sensor Test . (Group 9015-20.)
9 Travel Pressure Sensor Check

Action:
View travel control pilot pressure in monitor. See Monitor Service Menu Operation . (Group 9015-16.) See
Fully actuate travel function and return pilot control valve to neutral to view reading.
Does indicated pressure rise above 3.0 MPa and return to 0.0 MPa?
Result:
YES:
Go to Pump Delivery Pressure Sensor Check.
NO:
Test travel pressure sensor. See Pressure Sensor Test . (Group 9015-20.)
10 Pump Delivery Pressure Sensor Check
Action:
View pump 1 delivery pressure and pump 2 delivery pressure in monitor. See Monitor Service Menu
Operation . (Group 9015-16.) See Monitor Data Items . (Group 9015-20.)
Actuate arm in or boom up function to view reading.
Compare pump 1 and pump 2 pressure readings to main relief and power dig valve specification. See Main
Relief Valve Test and Adjustment . (Group 9025-25.)
Do pressure readings meet specification?
Result:
YES:
Go to Pump Control Pressure Sensor Check.
NO:
Replace pump delivery pressure sensor.
989
11 Pump Control Pressure Sensor Check

Action:
Verify proper operation of pump control pressure sensors. See Pump Control Pilot Pressure Signal Test .
(Group 9025-25.)
Do pump control pilot pressure readings meet specification?
Result:
YES:
Checks complete.
NO:
Test pump control pressure sensors. See Pressure Sensor Test . (Group 9015-20.)
DF89619,00B5889-19-20170314
990
TX1016994-UN: Pump 1, Pump 2, and Pilot Pump Line Identification

LEGEND:
1 - From Pilot Filter -to-Pump 2 Regulator
2 - From Pilot Filter -to-Return Manifold
3 - From Pilot Filter -to-Solenoid Valve Manifold (port PD)
4 - Pilot Pump Suction
5 - From Pilot Signal Manifold (port SB) -to-Pump 2 Regulator
6 - From Pump 2 -to-Control Valve (5 spool)
7 - From Pilot Signal Manifold (port SA) -to-Pump 1 Regulator
8 - From Pump 1 -to-Control Valve (4 spool)
9 - Pump 1 Attenuator
10 - Pump 1, Pump 2 Suction
11 - Pump 2 Attenuator
12 - From Pilot Pump -to-Pilot Filter
15 - Pump 1 (right, 4 spool)
16 - Pump 2 (left, 5 spool)
28 - Pilot Pump
991
128 - Hydraulic Oil Sampling Port
TP97644,00000A5-19-20061219
992
TX1001309-UN: Left Control Valve (5-spool)

LEGEND:
1 - From Power Digging Solenoid Valve (port SG)
2 - From Pilot Signal Manifold Left Travel Reverse (port 10)
3 - From Pilot Signal Manifold Right Travel Reverse (port 12)
4 - From Pilot Signal Manifold Bucket Curl (port 7)
6 - From Pilot Signal Manifold Boom Down (port 2)
7 - From Pilot Signal Manifold Arm In (port 4)
9 - From Pilot Signal Manifold Swing Right (port 6)
10 - To Oil Cooler
12 - From Boom 2 Spool
13 - To Swing Motor Swing Left (port B)
14 - From Pump 2
15 - To Swing Motor Swing Right (port A)
993
16 - To Arm Cylinder Head End
18 - From Pilot Signal Manifold (port SE)
19 - To Arm Cylinder Rod End
20 - To Solenoid Valve Manifold (port DY)
21 - To Center Joint Rear Left Port—Left Travel Reverse
22 - To Solenoid Valve Manifold (port DY)
23 - To Center Joint Front Left Port—Left Travel Forward
25 - To Arm In Pressure Sensor (B31)
53 - Left Control Valve (5-Spool)
54 - Right Control Valve (4-Spool)
57 - To Swing Motor
TX1001308-UN: Right Control Valve (4-spool)

LEGEND:
14 - From Pump 2
24 - To Solenoid Valve Manifold (port DK)
994
26 - To Boom Cylinder Head End
29 - From Boom Spool 1
30 - To Bucket Cylinder Rod End
32 - To Center Joint Rear Right Port—Right Travel Reverse
33 - To Pilot Signal Manifold (port DS)
34 - From Pump 1
35 - To Center Joint Front Right Port—Right Travel Forward
36 - To Bucket Cylinder Head End
37 - To Boom Cylinder Head End
38 - From Pilot Signal Manifold (port SL)
39 - From Pilot Signal Manifold Right Travel Forward Pilot (port 11)
40 - To Solenoid Valve Manifold (port DN)
41 - From Pilot Signal Manifold Left Travel Forward Pilot (port 9)
42 - Bucket Dump Pilot (port 8)
43 - Boom Up Pilot (port 1)
44 - To Boom Up Pressure Sensor (B30)
45 - To Solenoid Valve Manifold (port DZ)
46 - From Dig Regenerative Solenoid Valve (port SF)
47 - Arm Out Pilot (port 3)
48 - Swing Left Pilot (port 5)
49 - Plug
51 - To Solenoid Valve Manifold (port DD)
58 - From Arm Regenerative Solenoid Valve (port SC)
995
TX1001924-UN: Control Valve Line Identification (Front)

LEGEND:
55 - To Solenoid Valve Manifold (port DN)
TP97644,00000A6-19-20141111
996
TX1016991-UN: Swing Motor Line Identification

LEGEND:
1 - From Pilot Signal Manifold (port SH)
2 - To Control Valve
3 - To Return Manifold
4 - From Control Valve Swing Right
5 - From Control Valve Swing Left
51 - Swing Device
TP97644,00000A7-19-20061219
997
TX1073414-UN: Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

LEGEND:
1 - Port 1
2 - Port 2
3 - Port 3
4 - Port 4
8 - Pilot Control Shutoff Valve
9 - To Travel Pilot Controller
10 - From Travel Pilot Controller
A - Port A
B - Port B
C - Port C
D - Port D
E - Port E
F - Port F
G - Port G
H - Port H
P - Port P
T - Port T
PI - Port PI
-: Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern
Excavator Pattern
998
Pilot Signal Manifold

Functions Pilot Control Valve Ports
Pilot Control Valve Side Control Valve Side
Bucket Dump 1 H 8
Boom Down 2 B 2
Right
Bucket Curl 3 G 7
Boom Up 4 A 1
P Pilot Shutoff Valve A2
T Pilot Shutoff Valve T2
Swing Right 1 F 6
Arm Out 2 C 3
Swing Left 3 E 5
Left
Arm In 4 D 4
NOTE: Letters and numbers are on the housings next to the ports.
TP97644,00000A8-19-20061201
999
TX1073415-UN: Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

LEGEND:
1 - Port 1
2 - Port 2
3 - Port 3
4 - Port 4
8 - Pilot Control Shutoff Valve
9 - To Travel Pilot Controller
10 - From Travel Pilot Controller
A - Port A
B - Port B
C - Port C
D - Port D
E - Port E
F - Port F
G - Port G
H - Port H
P - Port P
T - Port T
PI - Port PI
-: Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern
Backhoe Pattern
1000
Pilot Signal Manifold

Functions Pilot Control Valve Ports
Pilot Control Valve Side Control Valve Side
Bucket Dump 1 H 8
Arm Out 2 C 3
Right
Bucket Curl 3 G 7
Arm In 4 D 4
Swing Right 1 F 6
Boom Down 2 B 2
Swing Left 3 E 5
Left
Boom Up 4 A 1
NOTE: Letters and numbers are on the housings next to the ports.
TP97644,00000A9-19-20061201
1001
TX1002361-UN: Pilot Signal Manifold-to-Control Valve Line Connection—Top

LEGEND:
2 - Port 2 to Boom Down Pilot Cap
4 - Port 4 to Arm In Pilot Cap
6 - Port 6 to Swing Right Pilot Cap
7 - Port 7 to Bucket Curl Pilot Cap
10 - Port 10 to Left Travel Reverse Pilot Cap
12 - Port 12 to Right Travel Reverse Pilot Cap
73 - Control Valve
1002
SE - Port (SE) to Arm 1 (Swing Priority) Flow Rate Control Valve
SK - Port (SK) to Bucket Flow Rate Pilot Valve
TX1002362-UN: Pilot Signal Manifold-to-Control Valve Line Connection—Bottom

LEGEND:
1 - Port 1 to Boom Up Pilot Cap
3 - Port 3 to Arm Out Pilot Cap
5 - Port 5 to Swing Left Pilot Cap
8 - Port 8 to Bucket Dump Pilot Cap
9 - Port 9 to Left Travel Forward Pilot Cap
11 - Port 11 to Right Travel Forward
74 - Control Valve (bottom)
1003
SL - Port (SL) to Travel Flow Combiner Valve
TP97644,00000AA-19-20061201
1004
TX1002232-UN: Travel System Component Location

LEGEND:
15 - Pump 1 (right)
16 - Pump 2 (left)
28 - Pilot Pump
72 - Center Joint
1005
TP97644,00000AC-19-20061205
1006
TX1026196-UN: Travel Hydraulic System Line Connection

LEGEND:
72 - Center Joint
160 - Left Travel Forward
161 - Right Travel Forward
162 - Left Travel Reverse
163 - Right Travel Reverse
164 - Return Line to Hydraulic Oil Tank
Y25 - Travel Speed Solenoid Valve (SI)
I - Left Travel Forward (pilot)
J - Left Travel Reverse (pilot)
K - Right Travel Forward (pilot)
L - Right Travel Reverse (pilot)
PI - From Pilot Shutoff Solenoid Valve
1007
TP97644,00000AB-19-20070905
1008
TX1142562-UN: Auxiliary Pilot Control Valve Schematic (auxiliary spool shown shifted)
LEGEND:
28 - Pilot Pump
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
1009
117 - Main Relief
604 - Return Oil
609 - Pilot Oil
TX1141687-UN: Auxiliary Solenoid Valve Operation of Control Valve (auxiliary spool shown shifted)
LEGEND:
28 - Pilot Pump
1010
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
117 - Main Relief
604 - Return Oil
609 - Pilot Oil
1011
TX1141686-UN: Auxiliary High Flow Line Kit Schematic (auxiliary spool shifted by auxiliary (pilot) (13))
LEGEND:
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
604 - Return Oil
609 - Pilot Oil
1012
TX1141533-UN: Two Pump Combined Flow Kit Schematic (Y43 energized and Y44 de-energized)
LEGEND:
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
45 - Swing Park Brake Release Pilot Valve
76 - Bucket Spool
81 - Boom 1 Spool
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
117 - Main Relief and Power Dig Valve
172 - To Torque Control Solenoid Valve
604 - Return Oil
609 - Pilot Oil
1013
TX1139037-UN: Low Flow Kit Schematic (foot pedal operated)

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
1014
TX1139385-UN: Low Flow Kit Schematic (solenoid operated)

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
604 - Return Oil
606 - Trapped Oil
609 - Pilot Oil
1015
TX1141685-UN: Secondary Auxiliary Relief Kit Schematic

LEGEND:
16 - Pump 2
28 - Pilot Pump
95 - Swing Spool
97 - Arm 1 Spool
104 - Boom 2 Spool
1016
604 - Return Oil
609 - Pilot Oil
DF89619,00B552A-19-20131002
1017
TX1141691-UN: High Flow Line Connections

LEGEND:
28 - Pilot Pump
1018
TX1141692-UN: Two Pump Combined Flow Kit Line Connections

LEGEND:
28 - Pilot Pump
DF89619,00B552B-19-20130814
1019
TX1077077-UN: Pilot Control Valves and Pilot Signal Manifold Schematic—Excavator Pattern
LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
14 - Plug—Auxiliary( pilot)
17 - To Pump 1 Regulator
18 - To Pump 2 Regulator
28 - Pilot Pump
49 - Filter Screen (17 used)
1020
50 - Shuttle Valve (17 used)
77 - From Bucket Flow Rate Control Valve (switch valve and poppet)
83 - From Boom Flow Rate Control Valve (switch valve and poppet)
84 - From Dig Regenerative Valve
91 - From Arm 2 Flow Rate Control Valve (switch valve and poppet)
93 - From Bypass Shutoff Valve
118 - From Auxiliary Flow Combiner Valve
129 - Orifice—Boom Down Shockless Valve
147 - Pilot Oil
B33 - Swing Pressure Sensor (port S3)
Y22 - Dig Regenerative Solenoid (port SF)
Y23 - Arm Regenerative Solenoid (port SC)
Y24 - Power Dig Solenoid (port SG)
Y25 - Travel Speed Solenoid (port SI)
TX1077079-UN: Pilot Control Valves and Pilot Signal Manifold Schematic—Backhoe Pattern
LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
9 - Left Forward (pilot)
10 - Left Reverse (pilot)
11 - Right Forward (pilot)
12 - Right Reverse (pilot)
1021
17 - To Pump 1 Regulator and Servo Piston
18 - To Pump 2 Regulator and Servo Piston
28 - Pilot Pump
43 - Arm 1 Flow Rate Control Pilot Valve (port SE)
49 - Filter Screen (17 used)
50 - Shuttle Valve (17 used)
77 - From Bucket Flow Rate Control Valve (switch valve and poppet)
83 - From Boom Flow Rate Control Valve (switch valve and poppet)
84 - From Dig Regenerative Valve (switch valve and poppet)
93 - From Bypass Shutoff Valve
98 - From Arm 1 Flow Rate Control Valve
118 - From Auxiliary Flow Combiner Valve
129 - Orifice—Boom Down Shockless Valve
147 - Pilot Oil
B33 - Swing Pressure Sensor (port S3)
Y10 - Pilot Control Shutoff Solenoid Valve
1022
TX1077080-UN: Control Valve Schematic

LEGEND:
1 - Boom Up (pilot)
3 - Arm Out (pilot)
4 - Arm In (pilot)
37A - To Solenoid Valve Manifold (port DH)
37B - To Solenoid Valve Manifold (port DZ)
37C - From Dig Regenerative Solenoid Valve (port SF)
37D - To Solenoid Valve Manifold (port DD)
37E - To Solenoid Valve Manifold (port DK)
37F - From Arm Regenerative Solenoid Valve (port SC)
37G - To Solenoid Valve Manifold (port DE)
37H - To Solenoid Valve Manifold (port DY)
37I - To Solenoid Valve Manifold (port DY)
37J - To Solenoid Valve Manifold (port DN)
37K - To Solenoid Valve Manifold (port DN)
1023
37L - From Power Digging Solenoid Valve (port SG)

43 - From Arm 1 Flow Rate Pilot Valve (pilot signal manifold port SE)
44 - From Travel Flow Combiner Pilot Valve (pilot signal manifold port SL)
46 - From Bucket Flow Rate Pilot Valve (pilot signal manifold port SK)
52 - Swing Motor
- To Swing Motor Make-Up Port
61 - Right Travel Motor (port A—reverse, port B—forward)
63 - Left Travel Motor (port B—reverse, port A—forward)
76 - Bucket Spool
81 - Boom 1 Spool
86 - Orifice
90 - Arm 2 Spool
95 - Swing Spool
97 - Arm 1 Spool
99 - Check Valve (lift check)—Arm 1 Regenerative Circuit
104 - Boom 2 Spool
109 - Plug
1024
113 - Orifice—Left Travel Power Passage
114 - Orifice—Air Bleed (9 used)
119 - Check Valve—Auxiliary Function Combiner Valve Circuit
123 - Orifice—Bucket Power Circuit
127 - Arm Cylinder
145 - Supply Oil
148 - Trapped Oil
TX1077081-UN: Swing Motor Schematic

LEGEND:
45 - From Swing Park Release Pilot Valve (Port SH)
51 - Swing Device
52 - Swing Motor
53 - Swing Motor Make-Up Check Valve
54 - Swing Crossover Relief Valve
55 - Swing Dampener Valve
1025
56 - Swing Park Brake
57 - Orifice
58 - Check Valve
73 - From Right Control Valve Return Passage
95A - From Swing Spool Top Port-Right Swing
95B - From Swing Spool Bottom Port-Left Swing
TX1077076-UN: Travel Motor Schematic

LEGEND:
1026
65 - Piston
67 - Shuttle Valve
69 - Check Valve
70 - Orifice
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
110B - From Left Travel Spool Bottom Port-Reverse
Y25 - From Travel Speed Solenoid (SI)
148 - Trapped Oil
TX1077082-UN: Pump 1 and Pump 2 Regulators

LEGEND:
27 - Attenuator Hose (2 used)
28 - Pilot Pump
1027
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
37M - To Solenoid Valve Manifold (port PD)
37N - From Solenoid Valve Manifold (port DS)
41 - From Pilot Signal Manifold (port DF)
47 - From Pump 2 Flow Rate Pilot Valve (port SB)
48 - From Pump 2 Flow Rate Pilot Valve (port SA)
52 - From Swing Motor
72 - From Center Joint
73 - To Right Control Valve (4 spool)
74 - To Left Control Valve (5 spool)
114 - From Pilot Circuit Orifice Air Bleed
128 - Hydraulic Oil Sampling Port
138 - From Left Control Valve
Y10 - From Pilot Shutoff Solenoid (port T4)
Y20 - Pump 2 Flow Rate Limit Solenoid
Y21 - Torque Control Solenoid Valve
145 - Supply Oil
147 - Pilot Oil
TP97644,00000A4-19-20090114
1028
TX1003088-UN: Hydraulic System Component Location

LEGEND:
15 - Pump 1
16 - Pump 2
28 - Pilot Pump
51 - Swing Device
72 - Center Joint
TP97644,00000AD-19-20061206
1029
TX1016254-UN: Hydraulic System Line Connections

LEGEND:
1 - Bucket Cylinder
2 - Arm Cylinder
8 - Swing Motor
9 - Center Joint
10 - Pump 1
11 - Pump 2
12 - Pilot Pump
13 - Pilot Pressure Regulating Valve, Pilot Filter and Bypass Valve
TP97644,00000AE-19-20061206
1030
TX1015973-UN: Fan Drive Hydraulic System Component Location—Standard Fan Speed Control Valve (If
Equipped)
LEGEND:
1 - Case Drain Line—Fan Motor-to-Hydraulic Tank
2 - Sump Line—Hydraulic Tank-to-Fan Drive Pump
3 - Supply Pressure—Fan Pump-to-Fan Speed Control Valve
4 - Return line—Fan Motor-to-Fan Speed Control Valve
5 - Supply Pressure—Fan Speed Control Valve-to-Fan Motor
6 - Return Line—Fan Speed Control Valve-to-Hydraulic Cooler
136 - Fan Speed and Reversing Control Valve Connections
Y8 - Proportional Speed Solenoid
TX04577,000011A-19-20080701
1031

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
1032
TX1113341-UN: Fan Drive System Hydraulic Schematic—Reversing (if equipped)

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
1033
MB00333,000008B-19-20120518
1034

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
1035
TX1113341-UN: Fan Drive System Hydraulic Schematic—Reversing (if equipped)

LEGEND:
32 - Return Filter
34 - Filter Bypass
35 - Suction Screen
145 - Supply Oil
1036
TX04577,0000119-19-20120518
1037
T6808CE-UN: JT05800 Digital Thermometer

LEGEND:
A - Temperature Probe
B - Cable
C - JT05800 Digital Thermometer
1. Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.
2. Wrap temperature probe and line with a shop towel.
CED,TX08227,2895-19-19971119
1038
T6808CE-UN: JT05800 Digital Thermometer

LEGEND:
A - Temperature Probe
B - Cable
C - JT05800 Digital Thermometer
1. Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.
2. Wrap temperature probe and line with a shop towel.
CED,TX08227,2895-19-19971119
1039
T8543AI-UN: JT02156A Digital Pressure/Temperature Analyzer

LEGEND:
A - Digital Pressure/Temperature Analyzer
B - 3 400 kPa (35 bar) (500 psi) Transducer
- 34 000 kPa (350 bar) (5000 psi) Transducer
- 70 000 kPa (700 bar) (10,000 psi Transducer
JT02156A Digital Pressure/Temperature Analyzer
JT02158 Digital Pressure/Temperature Analyzer
JT02159 20 ft Cable with Couplers
JT02161 500 psi Transducer
JT02162 5000 psi Transducer
JT05969 Thermo-Coupler
312883 Carry Case
JT02160 10,000 psi Transducer (Optional, Order Separately)
Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate
temperature reader.
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.
CED,TX08227,2896-19-20010702
1040
For cleanup instructions using portable filter caddy, see Hydraulic Oil Cleanup Procedure Using Portable Filter
Caddy . (Group 3360.)
TP97644,0000052-19-20160428
1041
-: Specifications
SPECIFICATIONS
Engine Speed 1300—1400 rpm if below -18°C

1300—1400 rpm if below 0°F
1750—1850 rpm if above -18°C
1750—1850 rpm if above 0°F
Power Mode Switch Position E (Economy) Mode if below -18°C

E (Economy) Mode if below 0°F
HP (High Power) Mode if above -18°C
HP (High Power) Mode if above 0°F
Auto Idle Switch Position OFF
Travel Speed Switch Position Slow (Turtle)

110—130°F
IMPORTANT:
If machine temperature is below -18°C (0°F), start procedure in the E (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 HP (High
Power) mode .
Below -18°C (0°F) an extended warm-up period may be necessary. Hydraulic functions will move slowly and
lubrication of parts may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic
functions move at or close to normal cycle times.
Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed.
Operate a function by moving it a short distance in each direction. Continue operating the function increasing the
distance traveled in each cycle until full stroke is reached.
For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct
viscosity oil to minimize warm-up period. See Hydraulic Oil . (Operator's Manual.)
1. Connect one of the following test equipment to monitor the coolant temperature, hydraulic oil
temperature and actual engine speed.
See Monitor Service Menu Operation for instruction to actuate the service menu on monitor in
cab. (Group 9015-16.)
Select the following items from Monitoring list:
Coolant Temperature
Hydraulic Oil Temperature
Actual Engine Speed
SERVICE ADVISOR™ application. See SERVICE ADVISOR™ Connection Procedure for
instruction. (Group 9015-20.)
Access Hydraulic Warm-Up
Or select the following items from the menu:

1042
Coolant Temperature
Actual Engine Speed
2. CAUTION:
Avoid possible serious injury from machine movement during warm-up
procedure. Clear the area of all bystanders before doing the warm-up procedure.
Clear the area of all bystanders to allow for machine movement.
3. Start engine. Run engine at approximately 1300 rpm for approximately 5 minutes before operating any
functions.
4. Run machine at specification.

Engine Speed 1300—1400 rpm if below -18°C
1300—1400 rpm if below 0°F
1750—1850 rpm if above -18°C
1750—1850 rpm if above 0°F
Power Mode Switch Position E (Economy) Mode if below -18°C
E (Economy) Mode if below 0°F
HP (High Power) Mode if above -18°C
HP (High Power) Mode if above 0°F
5. Slowly turn upperstructure so boom is to the side.
6. CAUTION:
Avoid possible serious injury from machine sliding backwards. Keep angle
between boom and arm at 90—110°.
Keeping the angle between boom and arm at 90—110°, lower boom to raise track off the ground.
7. Operate travel function (side with track off ground) for approximately 5 minutes.
8. When oil temperature is above -18°C (0°F), increase engine speed to 1750—1850 rpm and turn power
mode switch to HP (high power).
9. IMPORTANT:
Holding a function over relief for more than 10 seconds can cause damage due to hot spots in the
control valve.
Operate the travel function (side with track off the ground). Also operate the bucket curl function over
relief for 10 seconds and then stop for 5 seconds. Repeat the cycle until oil is heated to specifications.
10. Stop periodically and operate all hydraulic functions to distribute the heated oil.
1043
11. Continue procedure until oil temperature is within specifications.

110—130°F
TP97644,0000053-19-20100512
1044
-: Specifications
SPECIFICATIONS

110—130°F
Engine Speed 1750—1850 rpm and 750—850 rpm
Power Mode Switch Position P (Standard) Mode
Auto-Idle Switch Position OFF
Pilot Pressure Regulating Valve Pressure 3.3—4.8 MPa at 750—850 rpm

3309—4826 kPa at 750—850 rpm
33.1—48.3 bar at 750—850 rpm
480—700 psi at 750—850 rpm
3.5—5.0 MPa at 1750—1850 rpm
3509—5012 kPa at 1750—1850 rpm
35.1—50.1 bar at 1750—1850 rpm
509—727 psi at 1750—1850 rpm
Pilot Pressure Regulating Valve Shim Pressure Change 0.078 MPa approximate per 0.25 mm (0.010 in.)
78 kPa approximate per 0.25 mm (0.010 in.)
0.78 bar approximate per 0.25 mm (0.010 in.)
11 psi approximate per 0.25 mm (0.010 in.)
0.160 MPa approximate per 0.5 mm (0.020 in.)
Plug to Pilot Pressure Regulating Valve Housing Torque 25 N˙m

220 lb-in.
4200465 (1/4 M BSPP ORB x 7/16-20 M 37°) Adapter
JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
Gauge 7000 kPa (70 bar) (1000 psi)
Purpose of test is to ensure there is enough pilot pressure to operate all the pilot system functions and to adjust
the pressure as necessary. The pilot pressure regulating valve is used to regulate the pilot system pressure.
1045
1. Release hydraulic oil tank pressure by pushing pressure release button at top of hydraulic oil tank.
2.
TX1001996A-UN: Pilot Pressure Regulating Valve and Test Port

LEGEND:
1 - Test Port Plug
Connect a gauge to test port.
Remove test port plug (1).Install 4200465 Adapter.
Connect the JT02156A Digital Pressure/Temperature Analyzer and JT02162 Transducer or 7000 kPa
(70 bar) (1000 psi) gauge.
3. 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 1750—1850 rpm and
then actuate arm in function over relief. The pressure reading displayed is from the arm
in pressure sensor located in the pilot cap.
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.)
Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine
speed.
cab. (Group 9015-16.)
Arm In Pilot Pressure
1046
Actual Engine Speed
Access Pilot Pressure Regulating Valve Test and Adjustment .

Actual Engine Speed
4. Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
5. Run machine at specification:

110—130°F
6. Compare pressure readings to specifications. Make adjustments as necessary.

Pilot Pressure Regulating Valve Pressure 3.3—4.8 MPa at 750—850 rpm
3309—4826 kPa at 750—850 rpm
33.1—48.3 bar at 750—850 rpm
480—700 psi at 750—850 rpm
3.5—5.0 MPa at 1750—1850 rpm
3509—5012 kPa at 1750—1850 rpm
35.1—50.1 bar at 1750—1850 rpm
509—727 psi at 1750—1850 rpm
1047
8.
TX1001996A-UN: Pilot Pressure Regulating Valve and Test Port

LEGEND:
1 - Test Port Plug
Remove pilot pressure regulating valve (2). Add shims to increase pressure. Remove shims to decrease
pressure.
Pilot Pressure Regulating Valve Pressure 0.078 MPa approximate per 0.25 mm (0.010
Shim Change in.)
9. Tighten plug to specification.

Plug to Pilot Pressure Regulating Valve Housing Torque 25 N˙m
220 lb-in.
10. Check the pressure settings again.
TP97644,0000063-19-20100512
1048
-: Specifications
SPECIFICATIONS

110—130°F
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
203836 (9/16-18 F Sw 37° x 7/16-20 M 37° x 9/16-18 M 37° ) Tee
Purpose of test is to ensure that the pilot pressure to the valve spools is enough to completely shift the spools.
2. NOTE:
Spool actuating pressure can be checked for each function by installing a tee and gauge
in pilot line and then actuating that function.
1049
TX1002098A-UN: Control Valve Spool Actuating Pilot Pressure Test

LEGEND:
1 - 203836 Tee
2 - JT02162 Transducer
Install 203836 Tee in pilot line for function being tested.
3. Install JT02156A Digital Pressure/Temperature Analyzer and JT02162 Transducer or 7000 kPa (70 bar)
(1000 psi) gauge.
4. NOTE:
Spool actuating pressure for boom up, arm in, left and right swing, and all travel
functions can also be measured with the monitor.
Connect one of the following test equipment to monitor pressure reading, hydraulic oil temperature and
actual engine speed.
cab. (Group 9015-16.)

Actual Engine Speed
Access Control Valve Spool Actuating Pilot Pressure Test .

Actual Engine Speed
1050

110—130°F
7. Actuate the function to be checked to full stroke. Record pressure.
8. Compare pressure to specifications.

Control Valve Spool Actuating Pressure 3.4—4.0 MPa
3432—4021 kPa
34.3—40.2 bar
495—583 psi
If valve spool actuating pressure is not to specification check pilot system pressure. See Pilot Pressure
Regulating Valve Test and Adjustment . (Group 9025-25.)
If pilot system pressure is to specification then check pressure at the solenoid valve manifold, pilot
control shutoff solenoid valve, pilot controllers, and pilot signal manifold.
TP97644,0000064-19-20100512
1051
-: Specifications
SPECIFICATIONS

110—130°F
Engine Speed 1750—1850 rpm
Dig Regenerative Solenoid Valve (port Monitor Reading ± 0.2 MPa

SF) Pressure 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 0.069 MPa approximate per 1/4 turn
Pressure Change 69 kPa approximate per 1/4 turn
0.69 bar approximate per 1/4 turn
10 psi approximate per 1/4 turn
End of Adjusting Screw-to-Nut Length 2 mm maximum

0.079 in. maximum
Solenoid Valve Adjusting Screw-to- 3.0 N˙m

Housing Nut Torque 27 lb-in.
JT03464 (1/4 M BSPP ORB x 7/16-20 M 37° x M14-1.5 M 45°) Tee
Purpose of test is to check that the output pressure for the dig regenerative solenoid valve is within specification.
1052
2.
TX1000227-UN: Solenoid Valve Manifold

LEGEND:
19 - To Travel Motors
Remove the elbow (20) for dig regenerative solenoid valve (Y22).
3. Install JT03464 Tee.
(1000 psi) gauge.
5. NOTE:
Pressure reading displayed on the monitor is calculated from an electrical signal in the
main controller (MCF). The reading does not change when valve adjustment is made.
Connect one of the following test equipment to monitor the digging regenerative valve reading, hydraulic
oil temperature and actual engine speed.
cab. (Group 9015-16.)
Digging Regenerative Valve

1053
Actual Engine Speed
Access Dig Regenerative Solenoid Valve Test and Adjustment .
Digging Regenerative Valve

Actual Engine Speed

110—130°F
8. Operate arm in over relief. Record monitor and gauge pressure readings.
9. Calculate the pressure range using calculated reading from monitor and specify tolerance.
Check that actual reading from gauge is within the pressure range.

Dig Regenerative Solenoid Pressure Monitor Reading ± 0.2 MPa
Valve (port SF) Monitor Reading ± 200 kPa
Actual Reading From Gauge Must Be Within Pressure
Range of Monitor Reading and Tolerance
-: Example of Monitor Calculated Reading
Example of Calculated Reading From Monitor
Actuated Non Actuated
Example Monitor Reading 3.19 MPa 0.03 MPa

3190 kPa 30 kPa
31.9 bar 0.3 bar
463 psi 4 psi
1054
10.
T101709-UN: Solenoid Valve Adjustment

LEGEND:
H - Solenoid Valve
I - Adjusting Screw
J - Nut
Adjust the solenoid valve (H) as needed.

1. IMPORTANT:
Turning adjusting screw out too far may cause oil leakage because the O-ring has come off its
seat.
Loosen nut (J).
2. Turn adjusting screw (I) 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.).

Solenoid Valve Adjusting Screw Pressure Change 0.069 MPa approximate per 1/4 turn
69 kPa approximate per 1/4 turn
0.079 in. maximum
3. Hold adjusting screw and tighten nut.

Solenoid Valve Adjusting Screw-to-Housing Nut Torque 3.0 N˙m
27 lb-in.
11. Check the pressure setting again.
TP97644,0000065-19-20100512
1055
-: Specifications
SPECIFICATIONS

110—130°F
Arm Regenerative Solenoid Valve (port Monitor Reading ± 0.2 MPa

SC) Pressure Monitor Reading ± 200 kPa

0.079 in. maximum

Purpose of test is to check that the output pressure for the arm regenerative solenoid valve is within specification.
1056
2.

LEGEND:
Remove the elbow (21) for arm regenerative solenoid valve (Y23).
(1000 psi) gauge.
5. NOTE:
Connect one of the following test equipment to monitor the arm regeneration proportional valve reading,
hydraulic oil temperature and actual engine speed.
cab. (Group 9015-16.)
Arm Regeneration Proportional Valve

1057
Actual Engine Speed
Access Arm Regenerative Solenoid Valve Test and Adjustment .
Arm Regeneration Proportional Valve

Actual Engine Speed

110—130°F
8. Operate boom up and arm in at the same time. Record monitor and gauge pressure readings.
Check that the actual reading from gauge is within the pressure range.

Arm Regenerative Solenoid Pressure Monitor Reading ± 0.2 MPa
Valve (port SC) Monitor Reading ± 200 kPa

2740 kPa 1190 kPa
27.4 bar 11.9 bar
397 psi 173 psi
1058
10.

LEGEND:
H - Solenoid Valve
I - Adjusting Screw
J - Nut

1. IMPORTANT:
seat.
Loosen nut (J).
pressure setting. The length from end of adjusting screw to nut must not exceed specification.

0.079 in. maximum

27 lb-in.
TP97644,0000066-19-20100512
1059
-: Specifications
SPECIFICATIONS

110—130°F
Power Digging Solenoid Valve (port SG) Monitor Reading ± 0.2 MPa
Pressure Monitor Reading ± 200 kPa

0.079 in. maximum

Purpose of test is to check that the output pressure from the power digging solenoid valve is within specification.
1060
2.

LEGEND:
Remove the elbow (18) for power dig solenoid valve (Y24).
(1000 psi) gauge.
5. NOTE:
Connect one of the following test equipment to monitor the power digging control pressure reading,
hydraulic oil temperature and actual engine speed
cab. (Group 9015-16.)
Power Digging Control Pressure

1061
Actual Engine Speed
Access Power Digging Solenoid Valve Test and Adjustment .
Select the following items from the menu:
Power Digging Control Pressure

Actual Engine Speed

110—130°F
8. Push the power digging button. Record monitor and gauge pressure readings.

Power Digging Solenoid Pressure Monitor Reading ± 0.2 MPa
Valve (port SG) Monitor Reading ± 200 kPa

2990 kPa 710 kPa
29.9 bar 7.1 bar
434 psi 103 psi
1062
10.

LEGEND:
H - Solenoid Valve
I - Adjusting Screw
J - Nut

1. IMPORTANT:
seat.
Loosen nut (J).
in.).

0.079 in. maximum

27 lb-in.
TP97644,0000067-19-20100512
1063
-: Specifications
SPECIFICATIONS

110—130°F
Travel Speed Solenoid Valve (port SI) Monitor Reading ± 0.2 MPa

0.079 in. maximum

JT03191 (7/16-20 M 37° x 7/16-20 F 37° x 7/16-20 M 37°) Tee
Purpose of test is to check that the output pressure from the travel speed solenoid valve is within specification.
1064
2.

LEGEND:
Disconnect hose from elbow (19) for travel speed solenoid valve (Y25).
3. NOTE:
Tee fitting may be installed at opposite end of hose from solenoid valve manifold, at
connection near center joint.
Install JT03191 Tee.
(1000 psi) gauge.
5. NOTE:
Connect one of the following test equipment to monitor the travel mode proportional valve reading,
hydraulic oil temperature and actual engine speed
1065
cab. (Group 9015-16.)
Travel Mode Proportional Valve

Actual Engine Speed
Access Travel Speed Solenoid Valve Test and Adjustment .
Travel Mode Proportional Valve

Actual Engine Speed

110—130°F
8. Push both travel levers to FORWARD at full speed. Record monitor and gauge pressure readings.

Travel Speed Solenoid Pressure Monitor Reading ± 0.2 MPa
Valve (port SI) Monitor Reading ± 200 kPa
1066

2990 kPa 500 kPa
29.9 bar 5.0 bar
434 psi 73 psi
10.

LEGEND:
H - Solenoid Valve
I - Adjusting Screw
J - Nut

1. IMPORTANT:
seat.
Loosen nut (J).
in.).

0.079 in. maximum

27 lb-in.
1067
12.
TP97644,0000068-19-20100512
1068
-: Specifications
SPECIFICATIONS

110—130°F
Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure 1.03 MPa approximate
1030 kPa approximate
10.3 bar approximate
149 psi approximate
Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure 3.64 MPa approximate
529 psi approximate
The function of the pump 1 and pump 2 flow rate pilot valves (port SA and SB) is to send a regulated pilot control
pressure signal to its respective pump regulator to change pump flow in response to the actuation of pilot control
valves to shift the control valve spools.
The purpose of test is to check that the regulated pump control pilot pressure signal from the flow rate pilot valves
to the remote control spool in pump 1 and pump 2 regulators increases as a function is actuated and decreases
when function is returned to neutral. The pressure signals are checked by monitoring the pump 1 and pump 2
control pressure sensors.
See Pilot Signal Manifold Operation for the flow rate pilot valves. (Group 9025-05.)
See Pump 1 and Pump 2 Regulator Operation for the remote control spools. (Group 9025-05.)
1. Connect one of the following test equipment to monitor pump 1 and pump 2 control pressure, hydraulic
oil temperature and actual engine speed
cab. (Group 9015-16.)
Pump 1 Pump Control Pressure

Actual Engine Speed
Access Pump Control Pilot Pressure Signal Test .
1069
Actual Engine Speed

110—130°F
4. Return all control levers and pedals to the neutral position. Check that pilot shutoff lever is forward in the
unlock position.
5. Record the pressure readings from monitor.

Pump 1 and Pump 2 Pump Control Pressure in Neutral Pressure 1.03 MPa approximate
149 psi approximate
6. Slowly actuate the control lever for boom up to full stroke while observing the monitor.
The pressures must increase smoothly and evenly as function is actuated to full stroke.
7. Hold the control lever at full stroke. Record the pressure readings from monitor.

Pump 1 and Pump 2 Pump Control Pressure at Full Actuation Pressure 3.64 MPa approximate
529 psi approximate
8. Check the following if the pressure signal does not increase smoothly and evenly or is not to
specification.
Check the hoses from the pilot signal manifold to the pump 1 and pump 2 regulators for
damage.
Perform Pressure Sensor Test to check pump 1 and pump 2 control pressure sensors. (Group
9015-20.)
See Pilot Signal Manifold Disassemble and Assemble for instruction to remove and inspect the
pump 1 and pump 2 flow rate pilot valves. (Group 3360.)
1070
TP97644,0000069-19-20100512
1071
-: Specifications
SPECIFICATIONS

110—130°F
Torque Control Solenoid Valve Monitor Reading ± 0.2 MPa

Actual Reading From Gauge Must Be Within Pressure Range of Monitor
Reading and Tolerance
Adjusting Screw Pressure 0.069 MPa approximate per 1/4 turn

Change 69 kPa approximate per 1/4 turn
End of Adjusting Screw-to-Nut 2 mm or less

Length 0.079 in. or less
Adjusting Screw-to-Housing Nut 3 N˙m

Torque 27 lb-in.
Purpose of test is to check that the output pressure from the torque control solenoid valve is within specification.
1072
2.
TX1001576A-UN: Pump 1 and Pump 2 Regulators

LEGEND:
2 - Test Port
3 - Torque Control Solenoid Valve
Remove the plug from test port (2) in pump 1 regulator (1).
3. Install the 4200465 Adapter.
(1000 psi) gauge.
5. NOTE:
Connect one of the following test equipment to monitor the pump torque proportional valve pressure
reading, hydraulic oil temperature and actual engine speed.
cab. (Group 9015-16.)
Pump Torque Proportional Valve

Actual Engine Speed
Access Torque Control Solenoid Valve Test and Adjustment .
1073
Pump Torque Proportional Valve
Actual Engine Speed

110—130°F
8. Return all control levers and pedals to the neutral position.
Record the pressure readings from monitor and gauge.

Torque Control Pressure Monitor Reading ± 0.2 MPa
Solenoid Valve Monitor Reading ± 200 kPa
NOTE:
An example of monitor reading is given in the chart below for the pump torque
proportional valve (torque control solenoid valve).
When a function is actuated, the readings starts to decrease. The reading will vary
depending on the load on the function.
Neutral (Non Actuated) Actuated

3480 kPa 330 kPa
34.8 bar 3.3 bar
508 psi 48 psi
1074
10.

LEGEND:
H - Solenoid Valve
I - Adjusting Screw
J - Nut

1. IMPORTANT:
seat.
Loosen nut (J).
2. Turn adjusting screw (I) 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.

Adjusting Screw Pressure Change 0.069 MPa approximate per 1/4 turn
End of Adjusting Screw-to-Nut Length 2 mm or less
0.079 in. or less
3. Hold adjusting screw. Tighten nut.

Adjusting Screw-to-Housing Nut Torque 3 N˙m
27 lb-in.
TP97644,000006A-19-20100512
1075
-: Specifications
SPECIFICATIONS

110—130°F
Main Relief Valve Pressure 33.8—36.2 MPa

33 833—36 285 kPa
338—362 bar
4910—5260 psi
Power Digging Valve Pressure 35.3—38.2 MPa

35 304—38 246 kPa
353—382 bar
5120—5550 psi
Second Adjusting Plug Pressure Change 7.1 MPa approximate per 1/4 turn
71 bar approximate per 1/4 turn
32 mm Nut Torque 83 N·m

60 lb-ft
First Adjusting Plug Pressure Change 5.3 MPa approximate per 1/4 turn

47 lb-ft
Gauge 70 000 kPa (700 bar) (10,000 psi)
JT02160 Transducer, 70 000 kPa (700 bar) (10,000 psi)
17, 27, and 32 mm Combination Wrenches
The purpose of main relief valve is to limit the maximum hydraulic system pressure. Power digging is a temporary
increase of the system pressure. The valve is checked and adjusted to protect components from damage caused
1076
by excessive pressures.
1.
T101614-UN: Pump 1 and Pump 2 Test Ports

LEGEND:
A - 4200465 Adapter
B - Pump 2
C - Pump 1
Connect one of the following test equipment to monitor pump 1 and 2 delivery pressure, hydraulic oil
cab. (Group 9015-16.)

Actual Engine Speed
Access Main Relief and Power Digging Valve Test and Adjustment .

Actual Engine Speed
Connect a gauge to test port in pump 1 and/or pump 2.
Release hydraulic oil tank pressure by pushing pressure release button at top of
hydraulic oil tank.
1077
Remove the plug from test port in pump 1 and/or pump 2. Install the 4200465
Adapter.
Install JT02156A Digital Pressure/Temperature Analyzer and JT02160 Transducer or
70 000 kPa (700 bar) (10,000 psi) gauge.

110—130°F
4. Actuate arm out function over relief. Record main relief pressure reading.
5. Actuate arm out function over relief while pushing power digging switch. Record power digging pressure
reading.
6. NOTE:
If pressure setting cannot be raised by adjusting main relief and power digging valve,
arm out circuit relief valve pressure setting may be low. See Circuit Relief Valve Test
and Adjustment before continuing. (Group 9025-25.)
1078
TX1000964-UN: Main Relief and Power Digging Valve

LEGEND:
1 - 17 mm Nut
2 - First Adjusting Plug
3 - 27 mm Nut
4 - Second Adjusting Plug
5 - 32 mm Nut
6 - Piston
1079
Adjust the main relief and power digging valve (7) pressures as needed.
Main Relief Valve Pressure 33.8—36.2 MPa
33 833—36 285 kPa
338—362 bar
4910—5260 psi
Power Digging Valve Pressure 35.3—38.2 MPa
35 304—38 246 kPa
353—382 bar
5120—5550 psi
7. Loosen 17 mm nut (1) to prevent twisting power digging pilot line. Tighten nut before starting engine.
8. Loosen 27 mm nut (3).
9. Turn first adjusting plug (2) in until piston (6) is against bottom of bore in second adjusting plug (4).
Tighten nut finger tight.
11. Start the engine.
12. Actuate arm in function over relief.
13. Turn second adjusting plug (4) in to increase power digging relief pressure; turn adjusting plug out to
decrease pressure.

Second Adjusting Plug Pressure Change 7.1 MPa approximate per 1/4 turn
Hold second adjusting plug. Tighten 32 mm nut to specification.

60 lb-ft
15. Actuate the arm in function over relief.
16. Turn the first adjusting plug (2) out to decrease pressure to get the specified pressure for main relief
valve.

First Adjusting Plug Pressure Change 5.3 MPa approximate per 1/4 turn
17. Hold first adjusting plug. Tighten 27 mm nut to specification.
1080

47 lb-ft
18. Tighten 17 mm nut (1) on the elbow.
19. Check the pressures again.
TP97644,000006B-19-20100512
1081
-: Specifications
SPECIFICATIONS

110—130°F
Engine Speed Dial Position 1300 rpm approximate
Work Mode Switch Preload Dig Mode
Bucket Curl Pressure 37.2—38.3 MPa

37 232—38 266 kPa
372—383 bar
5400—5550 psi
Bucket Dump Pressure 39.3—40.3 MPa

39 300—40 300 kPa
393—403 bar
5700—5845 psi
Arm In Pressure 37.2—38.3 MPa

37 232—38 266 kPa
372—383 bar
5400—5550 psi
Arm Out Pressure 39.3—40.3 MPa

39 300—40 300 kPa
393—403 bar
5700—5845 psi
Boom Up Pressure 39.3—40.3 MPa

39 300—40 300 kPa
393—403 bar
5700—5845 psi
Boom Down Pressure 37.2—38.3 MPa

37 232—38 266 kPa
372—383 bar
5400—5550 psi
Circuit Relief Valve Pressure Change 5.2 MPa approximate per 1/4 turn
Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque 29.5 N·m

22 lb-ft
1082
Gauge 70 000 kPa (700 bar) (10,000 psi)
The purpose of circuit relief valves is to relieve high pressure spikes caused by external forces when functions are
in neutral. The valves are checked and adjusted to specification to protect components from damage.
1.

LEGEND:
A - 4200465 Adapter
B - Pump 2
C - Pump 1
cab. (Group 9015-16.)

Actual Engine Speed
1083
Access Circuit Relief Valve Test and Adjustment .

Actual Engine Speed
hydraulic oil tank.
Adapter.
70 000 kPa (700 bar) (10,000 psi) gauge.
2. Turn second adjusting plug of main relief and power digging valve in 1/2 turn to increase pressure
setting. See Main Relief and Power Digging Valve Test and Adjustment for adjustment procedure.
(Group 9025-25.)

110—130°F
Engine Speed Dial Position 1300 rpm approximate
Work Mode Switch Preload Dig Mode
1084
5.
TX1001113-UN: 5-Spool Side Circuit Relief and Anticavitation Valves
1085
TX1001112-UN: 4-Spool Side Circuit Relief and Anticavitation Valves

LEGEND:
Actuate the function over relief for circuit relief valve (79, 80, 88, 89, 102, and 103) being checked.
Record pressure reading.
1086

Bucket Curl Pressure 37.2—38.3 MPa
37 232—38 266 kPa
372—383 bar
5400—5550 psi
Bucket Dump Pressure 39.3—40.3 MPa
39 300—40 300 kPa
393—403 bar
5700—5845 psi
Arm In Pressure 37.2—38.3 MPa
37 232—38 266 kPa
372—383 bar
5400—5550 psi
Arm Out Pressure 39.3—40.3 MPa
39 300—40 300 kPa
393—403 bar
5700—5845 psi
Boom Up Pressure 39.3—40.3 MPa
39 300—40 300 kPa
393—403 bar
5700—5845 psi
Boom Down Pressure 37.2—38.3 MPa
37 232—38 266 kPa
372—383 bar
5400—5550 psi
6. Adjust the circuit relief valve as needed. Turn adjusting screw in to increase pressure setting; turn
adjusting screw out to decrease pressure setting. Hold screw and tighten nut to specification.

Circuit Relief Valve Pressure Change 5.2 MPa approximate per 1/4 turn
Circuit Relief Valve Adjusting Screw-to-Plug Nut Torque 29.5 N·m
22 lb-ft
7. Check pressures again.
8. Turn second adjusting plug of main relief and power digging valve out to its original setting. Check main
pressure setting. See Main Relief and Power Digging Valve Test and Adjustment for adjustment
procedure. (Group 9025-25.)
TP97644,000006C-19-20100512
1087
-: Specifications
SPECIFICATIONS

110—130°F
Engine Speed 1300 rpm approximate
Swing Motor Crossover Relief Valve Pressure 32.8—35.1 MPa

32 852—35 108 kPa
328—351 bar
4765—5090 psi
Crossover Relief Valve Shim Pressure Change 0.62 MPa per 0.1 mm (0.004 in.)
620 kPa per 0.1 mm (0.004 in.)
6.2 bar per 0.1 mm (0.004 in.)
90 psi per 0.1 mm (0.004 in.)
Crossover Relief Valve Plug Torque 118 N˙m

90 lb-ft
Gauge 70 000 kPa (700 bar) (10,000 psi)
Purpose of test is to check that the swing motor crossover relief valve pressures are within specification.
The 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 upperstructure. They also protect the
components from pressure spikes from external forces when the control valve is in neutral.
1088
1.

LEGEND:
A - 4200465 Adapter
B - Pump 2
C - Pump 1
Connect one of the following test equipment to monitor pump 2 delivery pressure, hydraulic oil
cab. (Group 9015-16.)

Actual Engine Speed
Access Swing Motor Crossover Relief Valve Test and Adjustment .

Actual Engine Speed
Connect a gauge to test port in pump 2.
hydraulic oil tank.
Remove the plug from test port in pump 2. Install the 4200465 Adapter.
70 000 kPa (700 bar) (10,000 psi) gauge.
1089

110—130°F
4. Actuate the swing function over relief. Record pressure reading. Repeat for opposite direction.
Make adjustments as necessary.

Swing Motor Crossover Relief Valve Pressure 32.8—35.1 MPa
32 852—35 108 kPa
328—351 bar
4765—5090 psi
1090
5.
TX1012649-UN: Crossover Relief Valve Location
T143550-UN: Swing Crossover Relief Valve Shims

LEGEND:
1 - Left Swing Crossover Relief Valve
2 - Right Swing Crossover Relief Valve
3 - Spring
4 - Spring Seat
5 - Shims
6 - Piston
7 - Sleeve
1091
8 - Plug
Stop machine. Release hydraulic oil tank pressure by pushing pressure release button at top of
hydraulic oil tank. Add or remove shims (5) by removing plug (8), sleeve (7), and piston (6) to increase
or decrease pressure.
620 kPa per 0.1 mm (0.004 in.)
6.2 bar per 0.1 mm (0.004 in.)
90 psi per 0.1 mm (0.004 in.)
6. Tighten plug (8) to specification.

Crossover Relief Valve Plug Torque 118 N˙m
90 lb-ft
7. Actuate the swing function over relief to check adjustment.
TP97644,0000070-19-20100512
1092
-: Specifications
SPECIFICATIONS

110—130°F
Travel Motor Crossover Relief Valve Pressure 34.9—36.3 MPa

34 855—36 300 kPa
349—363 bar
5055—5265 psi
900 kPa per 0.5 mm (0.02 in.)
9 bar per 0.5 mm (0.02 in.)
130 psi per 0.5 mm (0.02 in.)
Crossover Relief Valve Torque 310 N˙m

230 lb-ft
Gauge 70 000 kPa (700 bar) (10,000 psi)
76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used)
Purpose of test is to check that the travel motor crossover relief valve pressure is within specification.
1093
1.

LEGEND:
A - 4200465 Adapter
B - Pump 2
C - Pump 1
cab. (Group 9015-16.)

Actual Engine Speed
Access Travel Motor Crossover Relief Valve Test and Adjustment .

Actual Engine Speed
hydraulic oil tank.
Adapter.
1094
70 000 kPa (700 bar) (10,000 psi) gauge.
3.
T101856-UN: Travel Motor Stalled Using Pin

LEGEND:
D - 76.2 mm (3 in.) OD Pin
Install 76.2 mm (3 in.) OD pins or round bar stock between the sprockets and track frames to stall travel
motors.

110—130°F
1095
5.
TX1000688-UN: Travel Motor Crossover Relief Locations

LEGEND:
20 - Forward Crossover Relief Valve
21 - Reverse Crossover Relief Valve
Hold power dig switch. Slowly actuate the travel function for the crossover relief valve (20 or 21) being
checked.
Record the pressure reading. Make adjustments as necessary.

Travel Motor Crossover Relief Valve Pressure 34.9—36.3 MPa
34 855—36 300 kPa
349—363 bar
5055—5265 psi
6. Stop engine. Release hydraulic oil tank pressure by pushing pressure release button at top of hydraulic
oil tank.
1096
7.
TX1000689-UN: Travel Motor Crossover Relief Valve Shims

LEGEND:
22 - Poppet
23 - Spring Seat
24 - Shim
25 - Spring
Remove crossover relief valve. Add or remove shims (24) to adjust pressure.
900 kPa per 0.5 mm (0.02 in.)
9 bar per 0.5 mm (0.02 in.)
130 psi per 0.5 mm (0.02 in.)
8. Install crossover relief valve. Tighten to specification.

Crossover Relief Valve Torque 310 N˙m
230 lb-ft
9. Hold power dig switch. Actuate the travel function at stall to check adjustment.
TP97644,0000071-19-20100512
1097
-: Specifications
SPECIFICATIONS

110—130°F
One Revolution of Raised Track Cycle Time 34.7—36.7 seconds with pump regulator pilot line disconnected
7/16-20 M 37° (Parker No. 03CP-4) Plug (2 used)
Stop Watch
17 mm Combination Wrench
Flat Blade Screwdriver
The purpose of test is to check and adjust the minimum flow rate of pump 1 and 2 using the cycle time for travel
as an indicator of pump flow rate.
1. Check and adjust track sag. See Check and Adjust Track Sag . (Operator's Manual.)
2. Connect one of the following test equipment to monitor hydraulic oil temperature and actual engine
speed.
cab. (Group 9015-16.)

Actual Engine Speed
Access Pump Regulator Test and Adjustment-Minimum Flow .

Actual Engine Speed
1098

110—130°F
Stop engine.
5.
T143794-UN: Hydraulic Pump Regulator Pilot Lines

LEGEND:
1 - Hydraulic Pump 1 Pilot Line
2 - Hydraulic Pump 2 Pilot Line
3 - Hydraulic Pump 1 Regulator
4 - Hydraulic Pump 2 Regulator
Disconnect pump regulator pilot lines (1 and 2) at pump regulators (3 and 4). Install plugs in lines.Leave
the fittings on regulator open. Lay a shop towel over the fittings.
6. Run machine at specifications:
1099

7. Raise the left track off ground for pump 2 or the right track for pump 1.
8. Actuate travel function to full speed. Record the cycle time for one revolution.
9. IMPORTANT:
Do not turn adjusting screw more than two turns.
T103502-UN: Minimum Flow Adjusting Screw

LEGEND:
E - Minimum Flow Adjusting Screw
F - 17 mm Nut
Adjust the minimum flow adjusting screw (E) as needed to obtain the specified cycle time. Turn screw in
to decrease the cycle time (flow rate increases); turn screw out to increase the cycle time (flow rate
decreases). Hold the screw and tighten the 17 mm nut (F).
1100

One Revolution of Raised Cycle Time 34.7—36.7 seconds with pump regulator pilot line
Track disconnected
10. Repeat procedure for other pump.
Adjust regulators so cycle times are approximately the same.
TP97644,0000072-19-20100512
1101
-: Specifications
SPECIFICATIONS

110—130°F
End of Maximum Flow Adjusting Screw to 13 mm Nut Distance 3 mm

0.125 in. (1/8 in.)
Track Raised—3 Revolutions From a Running Start Cycle Time 17.1—21.1 seconds
Flat Blade Screwdriver
Stop Watch
Purpose of test is to check and adjust the maximum flow rate of pump 1 and 2 using the cycle time for travel are
approximately the same. Maximum flow rate cannot be significantly increased by turning out the flow adjusting
cartridge.
1. Check and adjust track sag. See 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.
cab. (Group 9015-16.)

Actual Engine Speed
Access Pump Regulator Test and Adjustment-Maximum Flow .

Actual Engine Speed
1102

110—130°F
4.
T143804-UN: Flow Adjusting Cartridge and Maximum Flow Adjusting Screw

LEGEND:
1 - Distance
3 - 13 mm Nut
4 - Flow Adjusting Cartridge (track cycle time)
5 - 30 mm Nut
Check the distance from the end of maximum flow adjusting screw (2) to the 13 mm nut (3) for both
pump 1 and pump 2 regulators. Adjust screw to specification as needed.
End of Maximum Flow Adjusting Screw to 13 mm Nut Distance 3 mm
0.125 in. (1/8 in.)
5. Run machine at specifications:

1103

Power Mode Switch Position HP (High Power) Mode
6. Raise the left track off ground for pump 2 or the right track for pump 1.
7. Actuate travel function to full speed. Record track cycle time for three revolutions.
Repeat procedure for the other pump.
8. Adjust flow adjusting cartridge (track cycle time) (4) on pump 1 and pump 2 regulators so track cycle
times are within the specification and approximately the same.

Track Raised—3 Revolutions From a Running Start Cycle Time 17.1—21.1 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). Do not turn flow
adjusting cartridge more than one turn. Tighten 30 mm nut after adjustment.
TP97644,0000073-19-20100512
1104
Pump Flow Test
Pump Flow Test
-: Specifications
SPECIFICATIONS

110—130°F
Pump 1 or Pump 2 Flow Rate—New 144—156 L/min at 20.6 MPa and 1750—1850 rpm
144—156 L/min at 20 600 kPa and 1750—1850
rpm
144—156 L/min at 206 bar and 1750—1850 rpm
38.4—41.6 gpm at 3000 psi and 1750—1850 rpm
207—213 L/min at 13 800 kPa and 1750—1850
rpm
54.2—55.8 gpm at 2000 psi and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—Minimum Allowable 109—119 L/min at 20.6 MPa and 1750—1850 rpm
109—119 L/min at 20 600 kPa and 1750—1850
rpm
29—32 gpm at 3000 psi and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—Minimum Allowable 157—162 L/min at 13.8 MPa and 1750—1850 rpm
157—162 L/min at 13 800 kPa and 1750—1850
rpm
41—42 gpm at 2000 psi and 1750—1850 rpm
Minimum Flow Adjusting Screw Turn 1/4 turn clockwise increases minimum pump flow
rate approximately 11.8 L/min
1/4 turn clockwise increases minimum pump flow
rate approximately 3.1 gpm
Minimum Flow Rate Adjusting Screw 17 mm Nut Torque 19.6 N·m

174 lb-in.
Maximum Flow Adjusting Screw Turn 1/4 turn clockwise decreases maximum pump flow
rate approximately 14.8 L/min
1/4 turn clockwise decreases maximum pump flow
Maximum Flow Rate Adjusting Screw 13 mm Nut Torque 9.8 N·m

87 lb-in.
1105
Pump Flow Test
SPECIFICATIONS
Flow Adjusting Cartridge (Track Cycle Time) Turn 1/4 turn clockwise decreases flow rate
approximately 20.8 L/min
1/4 turn clockwise decreases flow rate
approximately 5.5 gpm
Flow Adjusting Cartridge (Track Cycle Time) 30 mm Nut 29.4 N·m

Torque 260 lb-in.
Load Adjusting Cartridge (Outer Spring), (Pressure to Flow 1/4 turn clockwise increases flow rate
Control-Torque Adjustment) Turn approximately 27.3 L/min
1/4 turn clockwise increases flow rate
Load Adjusting Cartridge (Outer Spring), (Pressure to Flow 29.4 N·m

Control-Torque Adjustment) Torque 260 lb-in.
Load Adjusting Screw (Inner Spring), (Pressure to Flow 1/4 turn clockwise increases flow rate
Control-Torque Adjustment) Turn approximately 6.5 L/min
1/4 turn clockwise increases flow rate
Load Adjusting Screw (Inner Spring), (Pressure to Flow 19.6 N·m

Control-Torque Adjustment) Torque 174 lb-in.
Vacuum Pump
JT03452 Split Flange Connector Plate Kit
4198799 (-16 M BSPP ORB x -16 M ORFS) Elbow Fitting
Flowmeter
T107068 Flange Fitting Split Clamp Half (Code 62)
1020 mm (40 in.) x 1 in. hose with 90° flange fitting end (Code 62)
Gauge 70 000 kPa (700 bar) (10,000 psi)
Purpose of test is to determine the pump condition and should be performed only if a comparison of actual
machine cycle times to specified cycle times indicates low pump flow. Do the following appropriate procedures
before continuing test:
See Pump Regulator Test and Adjustment—Minimum Flow . (Group 9025-25.)

See Pump Regulator Test and Adjustment—Maximum Flow . (Group 9025-25.)
See Pump 1 and Pump 2 Regulator Operation for information on pump control pressure operation.
(Group 9025-05.)
See Pump Control Pilot Pressure Signal Test . (Group 9025-25.)
1106
Pump Flow Test
1.
TX1014633-UN: Flowmeter Connections

LEGEND:
1 - Pump 2 Delivery Port
2 - Pump 1 Delivery Port
3 - Pump 1 and 2 Regulators
4 - 4198799 Elbow Fitting
5 - Return Manifold
Release hydraulic oil tank pressure by pushing pressure release button at top of hydraulic oil tank.
2. Connect vacuum pump to hydraulic oil tank to minimize oil loss.
3. Disconnect pump-to-control valve line from pump 2 delivery port (1) and/or pump 1 delivery port (2).
Close end of line using plate from JT03452 Split Flange Connector Plate Kit or DFT1218 Split Flange
Hose Caps. See DFT1218 Split Flange Hose Cap for instruction. (Group 9900.)
4. NOTE:
Both pumps can be connected as shown but only one pump at a time can be checked
when only one return line is used.
An alternate method is to connect pump-to-control valve lines to outlet of flowmeters.

Return oil then flows through the control valve and hydraulic oil cooler to the hydraulic
oil tank.
Connect the flowmeter. If available, connect flowmeters to both pumps as shown.
1107
Pump Flow Test
5.
TX1014918-UN: Travel Forward Pilot Lines

LEGEND:
9 - Left Travel Forward Line
11 - Right Travel Forward Line
Disconnect the pilot lines (9 and 11) for left and right travel forward. Install plugs in the lines. Leave fitting
in pilot caps open. Cover with shop towel to avoid contamination.
NOTE:
Pilot lines are disconnected so travel function can be used to put pump 1 or pump 2 into
stroke and not turn the tracks.
6. Disconnect vacuum pump.
7. Check that the flowmeter loading valve is open.
1108
Pump Flow Test
8.

LEGEND:
A - 4200465 Adapter
B - Pump 2
C - Pump 1
cab. (Group 9015-16.)

Actual Engine Speed
Access Pump Flow Test .

Actual Engine Speed
Connect gauge to test port in pump 1 or pump 2.
hydraulic oil tank.
Remove the plug from test port in pump 1 or pump 2. Install the 4200465 Adapter.
70 000 kPa (700 bar) (10,000 psi) gauge.
1109
Pump Flow Test
9. Warm the hydraulic oil to specification by closing flowmeter loading valve to increase pressure.
10. Operate the machine at specification.

110—130°F
11. Actuate right travel for pump 1 or left travel for pump 2 to full actuation and hold throughout test.
12. Slowly close the loading valve on flowmeter to obtain the specified pressures. Record flow rate at each
pressure.

New
Pump 1 or Pump 2 Flow Rate—New 144—156 L/min at 20 600 kPa and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—New 144—156 L/min at 206 bar and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—New 38.4—41.6 gpm at 3000 psi and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—New 207—213 L/min at 13 800 kPa and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—New 207—213 L/min at 138 bar and 1750—1850 rpm
Pump 1 or Pump 2 Flow Rate—New 54.2—55.8 gpm at 2000 psi and 1750—1850 rpm

Minimum Allowable
Pump 1 or Pump Flow Rate—Minimum 109—119 L/min at 20.6 MPa and 1750—1850 rpm
2 Allowable
Pump 1 or Pump Flow Rate—Minimum 109—119 L/min at 20 600 kPa and 1750—1850
2 Allowable rpm
Pump 1 or Pump Flow Rate—Minimum 109—119 L/min at 206 bar and 1750—1850 rpm
2 Allowable
Pump 1 or Pump Flow Rate—Minimum 29—32 gpm at 3000 psi and 1750—1850 rpm
2 Allowable
Pump 1 or Pump Flow Rate—Minimum 157—162 L/min at 13.8 MPa and 1750—1850 rpm
2 Allowable
Pump 1 or Pump Flow Rate—Minimum 157—162 L/min at 13 800 kPa and 1750—1850
2 Allowable rpm
Pump 1 or Pump Flow Rate—Minimum 157—162 L/min at 138 bar and 1750—1850 rpm
2 Allowable
Pump 1 or Pump Flow Rate—Minimum 41—42 gpm at 2000 psi and 1750—1850 rpm
2 Allowable
1110
Pump Flow Test
13. Open loading valve. Stop the engine.
Pump flow rate can be increased some by adjusting pump 1 or pump 2 regulators.
14. IMPORTANT:
Do not turn adjusting screw more than two turns. Pump damage can occur.
TX1014480-UN: Pump 1 and Pump 2 Regulator Adjustment

LEGEND:
1 - 17 mm Nut
2 - Minimum Flow Adjusting Screw
3 - 17 mm Nut
4 - Load Adjusting Screw (Inner Spring), (Pressure to Flow Control-Torque Adjustment)
5 - Load Adjusting Cartridge (Outer Spring), (Pressure to Flow Control-Torque Adjustment)
6 - 30 mm Nut
7 - 13 mm Nut
10 - 30 mm Nut
11 - Hydraulic Oil Pressure
12 - Hydraulic Oil Flow Rate
Minimum flow rate:
2. Turn adjusting screw (2) clockwise 1/4 turn to increase minimum pump flow.
1111
Pump Flow Test

Minimum Flow Turn 1/4 turn clockwise increases minimum pump flow rate
Adjusting Screw approximately 11.8 L/min
1/4 turn clockwise increases minimum pump flow rate
3. Hold adjusting screw. Tighten 17 mm nut to specification.

Minimum Flow Rate Adjusting Screw 17 mm Nut Torque 19.6 N·m
174 lb-in.
15. IMPORTANT:
Do not increase the maximum pump flow rate over maximum flow specifications.
Do not turn adjusting screw more than two turns. Pump damage can occur.
Maximum flow rate:
2. Turn adjusting screw (8) clockwise 1/4 turn to decrease maximum pump flow.

Maximum Flow Turn 1/4 turn clockwise decreases maximum pump flow
Adjusting Screw rate approximately 14.8 L/min
1/4 turn clockwise decreases maximum pump flow

Maximum Flow Rate Adjusting Screw 13 mm Nut Torque 9.8 N·m
87 lb-in.
16. Flow Adjusting Cartridge (Track Cycle Time):
2. Turn adjusting cartridge (9) clockwise 1/4 turn to decrease flow rate.

Flow Adjusting Cartridge (Track Turn 1/4 turn clockwise decreases flow rate
Cycle Time) approximately 20.8 L/min
1/4 turn clockwise decreases flow rate
3. When adjusting cartridge (9) is turned clockwise, the maximum flow rate also decreases. To
maintain the maximum flow rate unchanged, turn adjusting screw (8) counterclockwise twice as
much as adjusting cartridge was turned clockwise.
4. Hold adjusting cartridge. Tighten 30 mm nut to specification.
1112
Pump Flow Test

Flow Adjusting Cartridge (Track Cycle Time) 30 mm Nut Torque 29.4 N·m
260 lb-in.
17. IMPORTANT:
Do not turn adjusting cartridge more than one turn. Pump damage can occur.
Load Adjusting Cartridge (Outer Spring), (Pressure to Flow Control-Torque Adjustment):
2. Turn adjusting cartridge (5) clockwise 1/4 turn to increase flow rate.

Load Adjusting Cartridge (Outer Spring), Turn 1/4 turn clockwise increases
(Pressure to Flow Control-Torque Adjustment) flow rate approximately 27.3
L/min
1/4 turn clockwise increases
flow rate approximately 7.2
gpm
3. Hold adjusting cartridge. Tighten 30 mm nut to specification.

Load Adjusting Cartridge (Outer Spring), (Pressure to Flow Torque 29.4 N·m
Control-Torque Adjustment) 260 lb-in.
18. IMPORTANT:
Do not turn adjusting screw more than one turn. Pump damage can occur.
Load Adjusting Cartridge (Inner Spring), (Pressure to Flow Control-Torque Adjustment):
2. Turn adjusting screw (4) clockwise 1/4 turn to increase flow rate.

Load Adjusting Screw (Inner Spring), (Pressure Turn 1/4 turn clockwise increases
to Flow Control-Torque Adjustment) flow rate approximately 6.5
L/min
1/4 turn clockwise increases
flow rate approximately 1.7
gpm

Load Adjusting Screw (Inner Spring), (Pressure to Flow Torque 19.6 N·m
Control-Torque Adjustment) 174 lb-in.
1113
Pump Flow Test
TP97644,0000074-19-20100622
1114
-: Specifications
SPECIFICATIONS

110—130°F
Swing Motor Swinging Leakage 0.2—0.3 L/min

0.05—0.08 gpm
Swing Motor Stalled Leakage 2.0—5.0 L/min

0.5—1.3 gpm
JT03023 (9/16-18 F 37°) (Parker No. 06CP-6) Cap
Calibrated Container

110—130°F
2. Release hydraulic oil tank pressure by pushing pressure release button on top of hydraulic oil tank.
1115
3.
T144086-UN: Swing Motor Drain Line

LEGEND:
1 - Swing Motor Drain Line
Disconnect drain line (1) from the return manifold. Install a JT03023 Cap on fitting in return manifold. Put
drain line in a calibrated container.

5. CAUTION:
To avoid personal injury, clear area of all bystanders before doing test. Slowly
swing through one complete revolution to ensure that the area is clear of objects
before doing test.
Raise and lower boom to pressurize hydraulic oil tank.
6. Operate swing function for one minute. Record amount of leakage.
Repeat for swing in opposite direction. Record amount of leakage.
Compare amount of leakage for each direction to specification.

Swing Motor Swinging Leakage 0.2—0.3 L/min
0.05—0.08 gpm
7. Stall swing function for one minute. Record the amount of leakage.
1116
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.

Swing Motor Stalled Leakage 2.0—5.0 L/min
0.5—1.3 gpm
8. Swing motor leakage over specified allowable amount can be caused by a malfunction in the swing
motor crossover relief valves.
9. Repair or replace swing motor if the leakage is over specified amount and crossover relief valves are
OK.
See Swing Motor and Park Brake Remove and Install . (Group 4360.)
TP97644,0000075-19-20070109
1117
-: Specifications
SPECIFICATIONS

110—130°F
Auto-Idle Position OFF
Travel Motor with Track Raised Leakage 10.0 L/min or less

2.6 gpm or less
Travel Motor Stalled Leakage 15.0 L/min or less

4.0 gpm or less
JT03025 (3/4-16 F 37°) (Parker No. 06CP—8) Cap
Calibrated Container
76.2 mm (3 in.) OD Pin or Round Bar Stock (2 used)
JT03221 (3/4-16 M 37°) (Parker No. 03CP—8) Plug

110—130°F
2. Release hydraulic oil tank pressure by pushing pressure release button on top of hydraulic oil tank.
1118
3.
T144139-UN: Center Joint and Return Manifold

LEGEND:
1 - 45° Elbow Fitting
2 - JT03025 Cap
3 - Travel Motor Drain Line
4 - Calibrated Container
5 - Center Joint
Disconnect the drain line (3) at return manifold. Put line in a calibrated container (4). Install a JT03025
Cap (2) on fitting (1).
4. Raise track off the ground for side being checked.

Auto-Idle Position OFF
6. For travel motor being checked, actuate travel forward function at full speed for one minute. Record
amount of leakage. Repeat procedure for reverse.
Compare leakage to specification. Repair or replace travel motor as necessary.

Travel Motor with Track Raised Leakage 10.0 L/min or less
2.6 gpm or less
1119
7.
T101856-UN: Travel Motor Stalled Using Pin

LEGEND:
D - 76.2 mm (3 in.) OD Pin
To check travel motor for leakage at stall, install pin (D) or round bar stock between the sprocket and
track frame on the side being tested.
8. Actuate the forward travel function being checked to full stroke for one minute. Record the amount of
leakage.
Repeat procedure by stalling the motor in several different positions and then take an average of
readings. Repeat procedure for reverse.

Travel Motor Stalled Leakage 15.0 L/min or less
4.0 gpm or less
9.
T144148-UN: Travel Motor Drain Line

LEGEND:
6 - Travel Motor Drain Line
7 - Line
1120
8 - Calibrated Container
For leakage that is substantially more in one direction than the other, a seal in the center joint may be
leaking. To isolate leakage in travel motor or center joint, check leakage at the travel motor.
Disconnect travel motor drain line (6) at travel motor. Install JT03221 Plug in the line.
Connect a line (7) to fitting on travel motor. Put line in a calibrated container (8).
Repeat test.
10. Travel motor leakage over specified allowable amount can be caused by a malfunction in travel motor
crossover relief valve.
See Travel Motor Crossover Relief Valve Test and Adjustment . (Group 9025-25.)
11. Repair or replace travel motor if leakage is over specified amount and the crossover relief valves are OK.
See Travel Motor and Park Brake Remove and Install . (Group 0260.)
TP97644,000006D-19-20070109
1121
-: Specifications
SPECIFICATIONS

110—130°F
Bucket Load Weight 1050 kg approximate

2315 lb approximate
Boom Cylinder Drift 5 mm maximum allowable for 5 minutes

0.20 in. maximum allowable for 5 minutes
Arm Cylinder Drift 10 mm maximum allowable for 5 minutes

Bucket Cylinder Drift 15 mm maximum allowable for 5 minutes

Bottom of Bucket-to-Ground Drift 100 mm maximum allowable for 5 minutes

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.

110—130°F
2. Fill the bucket or load it with specified weight.

Bucket Load Weight 1050 kg approximate
2315 lb approximate
1122
3.
T6904AG-UN: Boom and Bucket Position

Position arm cylinder so rod is extended approximately 50 mm (2.00 in.) from the retracted position.
4. Position bucket cylinder so rod is retracted 50 mm (2.00 in.) from the extended position.
5. Position the boom cylinders so bucket pivot pin is at the same height as the boom-to-main frame pin.
6. After 5 minutes, measure the amount of movement for boom, arm and bucket cylinders and from bottom
of bucket to the ground.

Boom Cylinder Drift 5 mm maximum allowable for 5 minutes
Arm Cylinder Drift 10 mm maximum allowable for 5 minutes
Bucket Cylinder Drift 15 mm maximum allowable for 5 minutes
Bottom of Bucket-to-Ground Drift 100 mm maximum allowable for 5 minutes
TP97644,000006F-19-20061030
1123
-: Specifications
SPECIFICATIONS

110—130°F
New, Typical Flow Rate 42 L/min

11 gpm
Used, Minimum Flow Rate 36 L/min

9.5 gpm
Fan Drive Circuit Pressure 20.7—21.0 MPa

20 700—21 000 kPa
207—210 bar
3000—3050 psi
JT05984 Flow Meter
-12 ORFS Female Ends Test Hose (2 used)
Use this procedure when diagnosing system overheating problems. See Diagnose Hydraulic System Malfunctions
. (Group 9025-15.)
2. Open the center access door on the left side of machine.
3. Remove bottom plate from the compartment to access the fan speed control valve and proportional fan
speed solenoid wire connector.
1124
4.
TX1013458A-UN: Fan Speed Control Valve
TX1013499A-UN: Fan Speed and Reversing Control Valve (optional)

LEGEND:
1 - Pump Pressure Line
2 - Return Line (Fan Control Valve-To-Cooler)
3 - Tee
135 - Fan Speed and Reversing Control Valve (optional)
Disconnect pressure line (1) coming from fan drive pump and connect JT05984 flow meter in-line using
hoses containing —12 ORFS Female ends.
5. Connect one of the following test equipment to display hydraulic oil temperature and actual engine
speed.
1. See Monitor Service Menu Operation for instruction to actuate the service menu on monitor in
cab. (Group 9015-16.)

Actual Engine Speed
2. SERVICE ADVISOR™ application. See SERVICE ADVISOR™ Connection Procedure for
Access Fan Drive Pump Flow Test .

1125
Actual Engine Speed

110—130°F
7. NOTE:
When the proportional fan speed solenoid (Y8) is disconnected all hydraulic oil is forced
through fan motor with the exception of a small portion is sent over circuit relief to tank.
This non adjustable circuit relief valve is built into the proportional solenoid.
Disconnect wire connector to proportional fan speed solenoid valve (Y8 ). Be aware of the hydraulic oil
temperature will cool rapidly due to high fan speed, so it is important to have this test done quickly and
with proper hydraulic test temperatures.
8. Run engine at specification.

9. Record fan drive pump flow and compare to specification.

New, Typical Flow Rate 42 L/min
11 gpm
Used, Minimum Flow Rate 36 L/min
9.5 gpm
Fan Drive Circuit Pressure 20.7—21.0 MPa
20 700—21 000 kPa
207—210 bar
3000—3050 psi
10. If fan drive circuit testing pressure is not to specifications change proportional solenoid (Y8) which
contains a built in relief valve.
If pump flow is below minimum specification, replace cooling fan drive pump.
If pump flow is within specification and overheating persists, perform the following:
Check proportional fan speed solenoid valve (Y8).

Check hydraulic lines to and from fan drive motor.
Replace fan drive motor.
11. Install bottom plate removed from compartment.
1126
12. Close left side access door.
TX04577,000013B-19-20110802
1127
Fan Speed Test
Fan Speed Test
-: Specifications
SPECIFICATIONS

122—140°F
Cooling Fan Speed 1700—1880 rpm
JT05709 Reflective Tape
JT05719 Handheld Digital Tachometer
NOTE:
The fan speed control valve is located inside the left side access door which also contains the air
cleaner. The bottom compartment plate must be removed for access to the fan proportional
solenoid which is located on the fan speed control valve.
Use this procedure when diagnosing system overheating problems. See Diagnose Hydraulic System Malfunctions
. (Group 9025-15.)
1.
TX1013450A-UN: Fan and Reflective Tape

LEGEND:
1 - Fan Blade
2 - Reflective Tape
Open engine hood and install JT05709 Reflective Tape (2) on one fan blade (1).
2. Open the center access door on the left side of machine.
1128
Fan Speed Test
3. Remove bottom plate from the compartment to access the fan speed control valve and proportional fan
speed solenoid wire connector.
4. Connect one of the following test equipment to display hydraulic oil temperature and actual engine
speed.
1. See Monitor Service Menu Operation for instruction to actuate the service menu on monitor in
cab. (Group 9015-16.)

Actual Engine Speed
2. SERVICE ADVISOR™ application. See SERVICE ADVISOR™ Connection Procedure for
Access Fan Speed Test .

Actual Engine Speed

122—140°F
6.
TX1013449A-UN: Fan Speed Control Valve
1129
Fan Speed Test
TX1013500A-UN: Fan Speed and Reversing Control Valve (if equipped)

LEGEND:
Disconnect wire connector to proportional fan speed solenoid valve (Y8). This will allow maximum oil
flow through fan drive motor.
7. Operate engine at specification.

8. Measure fan speed with JT05719 Handheld Digital Tachometer. Record result.
9. Compare reading to specification.

Cooling Fan Speed 1700—1880 rpm
10. If fan speed is below specification:
See Fan Drive Pump Flow Test . (Group 9025-25.)
If fan drive pump flow is in specification, check proportional fan speed solenoid valve (Y8).
11. Install bottom plate in side compartment.
12. Close the center access door on the left side of machine.
TX04577,000013A-19-20130729
1130
Table of Contents
Section 9031: Heating and Air Conditioning

Group 25: Tests
1131
T142307-UN: Refrigerant System Cycle of Operation

LEGEND:
1 - Evaporator
2 - Compressor
3 - Condenser
4 - Circulation Fan Motor
5 - Expansion Valve
6 - Receiver-Dryer
7 - High Pressure Liquid
8 - High Pressure Gas
9 - Low Pressure Liquid
10 - Low Pressure Gas
11 - Air Flow
The compressor is belt driven and engaged by an electro-magnetic clutch. The air conditioning circuit
automatically controls compressor engagement or disengagement when system is in operation.
Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes
temperature of refrigerant to rise higher than that of outside air.
High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to
outside air being drawn through condenser core by engine fan. Cooling refrigerant causes it to condense and
refrigerant leaves condenser as high pressure liquid.
High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are removed.
1132
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 very corrosive to metal surfaces and leakage will eventually develop. Receiver-dryer also
stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses will
allow a small amount of refrigerant to migrate through their walls.
Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid
entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator
and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn
from evaporator by compressor and cycle is repeated.
A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed
moisture is drained away through drain tubes connected to drain pan under evaporator.
System pressure is monitored by the high and low pressure switch, located at the receiver-dryer. If pressure
becomes too high or too low the switch opens and stops compressor, interrupting the cycle.
MT89988,0000052-19-20060825
1133
T142307-UN: Refrigerant System Cycle of Operation

LEGEND:
1 - Evaporator
2 - Compressor
3 - Condenser
4 - Circulation Fan Motor
5 - Expansion Valve
6 - Receiver-Dryer
7 - High Pressure Liquid
8 - High Pressure Gas
9 - Low Pressure Liquid
10 - Low Pressure Gas
11 - Air Flow
The compressor is belt driven and engaged by an electro-magnetic clutch. The air conditioning circuit
automatically controls compressor engagement or disengagement when system is in operation.
Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes
temperature of refrigerant to rise higher than that of outside air.
High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to
outside air being drawn through condenser core by engine fan. Cooling refrigerant causes it to condense and
refrigerant leaves condenser as high pressure liquid.
High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are removed.
1134
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 very corrosive to metal surfaces and leakage will eventually develop. Receiver-dryer also
stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses will
allow a small amount of refrigerant to migrate through their walls.
Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid
entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator
and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn
from evaporator by compressor and cycle is repeated.
A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed
moisture is drained away through drain tubes connected to drain pan under evaporator.
System pressure is monitored by the high and low pressure switch, located at the receiver-dryer. If pressure
becomes too high or too low the switch opens and stops compressor, interrupting the cycle.
MT89988,0000052-19-20060825
1135
NOTE:
Diagnostic charts are arranged from most probable and simplest to verify, to least likely more
difficult to verify.
NOTE:
Prior to diagnosis and component tests Perform Heater and Air Conditioner Operational Checks .
(Group 9031-25.) These conditions may affect diagnostic and test results.
Symptom Problem Solution
Air Conditioning Heater and Air Replace fuse. See Replacing Fuses . (Operator's Manual.) See Fuse
System Does Conditioner 5 A Fuse and Relay Specifications . (Group 9015-10.)
Not Operate (Marked AIRCON)
(F15)
Heater and Air Replace fuse. See Replacing Fuses . (Operator's Manual.) See Fuse
Conditioner 20 A Fuse and Relay Specifications . (Group 9015-10.)
(Marked HEATER)
(F3)
Fan motor failed or Check blower motor resistor and thermofuse (R16). See Right
operating too slow Console Harness (W7) Wiring Diagram . (Group 9015-10.)
Check fan motor. See Right Console Harness (W7) Wiring Diagram .
(Group 9015-10.) See Heater and Air Conditioner Remove and Install .
(Group 1830.)
Air conditioner See Heater and Air Conditioner Component Location . (Group 9031-
high/low pressure 15.) See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
switch malfunction
Compressor clutch See Air Conditioner Compressor Clutch Test . (Group 9031-25.)
Air conditioner freeze See Heater and Air Conditioner Operational Checks . (Group 9031-
control switch 25.) See Right Console Harness (W7) Wiring Diagram . (Group 9015-
malfunction 10.)
Air conditioner and Check door for obstructions and test servo motor. See Heater and Air
heater mixer Conditioner Remove and Install . (Group 1830.) See Right Console
servomotor door open Harness (W7) Wiring Diagram . (Group 9015-10.)
1136
Wiring harness Check cab harness wiring and air conditioner wiring. See Cab
Harness (W1) Wiring Diagram . (Group 9015-10.) See Right Console
Heater and air Replace controller. See Right Console Harness (W7) Wiring Diagram .
conditioner controller (Group 9015-10.)
malfunction
Air Conditioner Fresh air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
Does Not Cool restricted Air Filters . (Operator's Manual.)
Interior of Cab
Recirculating air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
restricted Air Filters . (Operator's Manual.)
Condenser fins Clean condenser fins. See Heater and Air Conditioner Component
restricted with debris Location . (Group 9031-15.)
Compressor belt loose Check compressor belt tension. See Check and Adjust A/C Belt .
(Operator's Manual.)
Refrigerant hose Re-route or re-index hoses. Replace collapsed hoses. See Heater and
kinked, pinched, or Air Conditioner Component Location . (Group 9031-15.) See
collapsed Refrigerant Hoses and Tubing Inspection . (Group 9031-25.)
Heater or evaporator Clean heater or evaporator fins. See Heater and Air Conditioner
fins restricted with dirt Component Location . (Group 9031-15.) See Heater and Air
or dust Conditioner Remove and Install . (Group 1830.)
Air conditioner and Check door for obstructions and test servomotor. See Right Console
heater mixer Harness (W7) Wiring Diagram . (Group 9015-10.)
servomotor door open
Compressor clutch Inspect and replace compressor clutch if necessary. Perform Air
slipping or failed Conditioner Compressor Clutch Test . (Group 9031-25.)
Warm outside air Inspect, repair, or replace door and window seals. See Windowpanes
leaking into cab Remove and Install . (Group 1810.) See Sliding Windows Remove and
System refrigerant Perform Charge R134a System . (Group 1830.) Perform Refrigerant
(R134a) charge low Leak Test . (Group 9031-25.)
1137
Evaporator fins Freeze control switch not positioned correctly in evaporator core.
frosting or freezing Reposition switch in evaporator core. See Heater and Air Conditioner
Heater and air Replace air conditioner controller. See Right Console Harness (W7)
conditioner controller Wiring Diagram . (Group 9015-10.) See Right Console Harness (W7)
malfunction Component Location . (Group 9015-10.)
Air Conditioner Freeze control switch Reposition freeze control switch in evaporator core. See Heater and
Runs not positioned in Air Conditioner Component Location . (Group 9031-25.)
Constantly, Too evaporator properly
Cold
Interior Air conditioning Push A/C switch to turn air conditioning on. See Cab Heater And Air
Windows system off Conditioner . (Operator's Manual.)
Continue to Fog
Fresh air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
MT89988,0000053-19-20100512
1138
NOTE:
NOTE:
Air Conditioning Heater and Air Replace fuse. See Replacing Fuses . (Operator's Manual.) See Fuse
System Does Conditioner 5 A Fuse and Relay Specifications . (Group 9015-10.)
Not Operate (Marked AIRCON)
(F15)
Heater and Air Replace fuse. See Replacing Fuses . (Operator's Manual.) See Fuse
Conditioner 20 A Fuse and Relay Specifications . (Group 9015-10.)
(Marked HEATER)
(F3)
Fan motor failed or Check blower motor resistor and thermofuse (R16). See Right
operating too slow Console Harness (W7) Wiring Diagram . (Group 9015-10.)
Check fan motor. See Right Console Harness (W7) Wiring Diagram .
(Group 9015-10.) See Heater and Air Conditioner Remove and Install .
(Group 1830.)
Air conditioner See Heater and Air Conditioner Component Location . (Group 9031-
high/low pressure 15.) See Machine Harness (W2) Wiring Diagram . (Group 9015-10.)
switch malfunction
Compressor clutch See Air Conditioner Compressor Clutch Test . (Group 9031-25.)
Air conditioner freeze See Heater and Air Conditioner Operational Checks . (Group 9031-
control switch 25.) See Right Console Harness (W7) Wiring Diagram . (Group 9015-
malfunction 10.)
Air conditioner and Check door for obstructions and test servo motor. See Heater and Air
heater mixer Conditioner Remove and Install . (Group 1830.) See Right Console
servomotor door open Harness (W7) Wiring Diagram . (Group 9015-10.)
1139
Wiring harness Check cab harness wiring and air conditioner wiring. See Cab
Harness (W1) Wiring Diagram . (Group 9015-10.) See Right Console
Heater and air Replace controller. See Right Console Harness (W7) Wiring Diagram .
conditioner controller (Group 9015-10.)
malfunction
Air Conditioner Fresh air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
Does Not Cool restricted Air Filters . (Operator's Manual.)
Interior of Cab
Recirculating air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
Condenser fins Clean condenser fins. See Heater and Air Conditioner Component
restricted with debris Location . (Group 9031-15.)
Compressor belt loose Check compressor belt tension. See Check and Adjust A/C Belt .
(Operator's Manual.)
Refrigerant hose Re-route or re-index hoses. Replace collapsed hoses. See Heater and
kinked, pinched, or Air Conditioner Component Location . (Group 9031-15.) See
collapsed Refrigerant Hoses and Tubing Inspection . (Group 9031-25.)
Heater or evaporator Clean heater or evaporator fins. See Heater and Air Conditioner
fins restricted with dirt Component Location . (Group 9031-15.) See Heater and Air
or dust Conditioner Remove and Install . (Group 1830.)
Air conditioner and Check door for obstructions and test servomotor. See Right Console
heater mixer Harness (W7) Wiring Diagram . (Group 9015-10.)
servomotor door open
Compressor clutch Inspect and replace compressor clutch if necessary. Perform Air
slipping or failed Conditioner Compressor Clutch Test . (Group 9031-25.)
Warm outside air Inspect, repair, or replace door and window seals. See Windowpanes
leaking into cab Remove and Install . (Group 1810.) See Sliding Windows Remove and
System refrigerant Perform Charge R134a System . (Group 1830.) Perform Refrigerant
(R134a) charge low Leak Test . (Group 9031-25.)
1140
Evaporator fins Freeze control switch not positioned correctly in evaporator core.
frosting or freezing Reposition switch in evaporator core. See Heater and Air Conditioner
Heater and air Replace air conditioner controller. See Right Console Harness (W7)
conditioner controller Wiring Diagram . (Group 9015-10.) See Right Console Harness (W7)
malfunction Component Location . (Group 9015-10.)
Air Conditioner Freeze control switch Reposition freeze control switch in evaporator core. See Heater and
Runs not positioned in Air Conditioner Component Location . (Group 9031-25.)
Constantly, Too evaporator properly
Cold
Interior Air conditioning Push A/C switch to turn air conditioning on. See Cab Heater And Air
Windows system off Conditioner . (Operator's Manual.)
Continue to Fog
Fresh air filter Clean or replace filter. See Clean Cab Fresh Air and Cab Recirculation
MT89988,0000053-19-20100512
1141
NOTE:
NOTE:
Heater Heater and Air Replace fuse.

System Does Conditioner 5 A Fuse
Not Operate (Marked AIRCON) See Fuse and Relay Specifications . (Group 9015-10.) See Replacing
(F15) Fuses . (Operator's Manual.)
Heater and Air Replace fuse.

Conditioner 20 A
Fuse (Marked See Fuse and Relay Specifications . (Group 9015-10.) See Replacing
HEATER) (F3) Fuses . (Operator's Manual.)
Fan motor failed or Check blower motor resistor and thermofuse (R16).
operating too slowly
See Fuse and Relay Specifications . (Group 9015-10.) See Right Console
Check fan motor.
See Right Console Harness (W7) Wiring Diagram . (Group 9015-10.) See
Right Console Harness (W7) Component Location . (Group 9015-10.) See
Heater and Air Conditioner Remove and Install . (Group 1830.)
Wiring harness Check cab harness wiring and heater harness wiring.
See Right Console Harness (W7) Wiring Diagram . (Group 9015-10.) See
Cab Harness (W1) Wiring Diagram . (Group 9015-10.) See Right Console
Harness (W7) Component Location . (Group 9015-10.)
Heater and air Replace air conditioner controller.

conditioner controller
malfunction See Right Console Harness (W7) Component Location . (Group 9015-10.)
See Right Console Harness (W7) Wiring Diagram . (Group 9015-10.)
1142
Heater Does Fresh air filter Clean or replace filter.

Not Warm restricted
Interior of See Clean Cab Fresh Air and Cab Recirculation Air Filters . (Operator's
Cab Manual.)
Recirculating air filter Clean or replace filter.

restricted
See Clean Cab Fresh Air and Cab Recirculation Air Filters . (Operator's
Manual.)
Heater hose kinked, Re-route or re-index hoses. Replace collapsed hoses.

pinched or collapsed
See Refrigerant Hoses and Tubing Inspection . (Group 9031-25.) See
Heater and Air Conditioner Component Location . (Group 9031-15.)
Heater core fins Clean heater fins.

clogged with dirt or
dust See Right Console Harness (W7) Component Location . (Group 9031-15.)
Interior Air conditioning Put A/C and heater ON/OFF switch to A/C position.
Windows system OFF
Continue to See Cab Heater and Air Conditioner . (Operator's Manual.)
Fog
Fresh air filter Clean or replace filter.

restricted
See Clean Cab Fresh Air and Cab Recirculation Air Filters . (Operator's
Manual.)
MT89988,0000054-19-20100512
1143
The air conditioning system has a six-step self-diagnosing function.
Step 0 Model Number
Step 1 Display Check
Step 2 Active Diagnostic Trouble Codes
Step 3 Inactive Diagnostic Trouble Codes
Step 4 Sensor Temperature
Step 5 Component Operation Check
Step 6 Selection of Celsius or Fahrenheit Temperature Indication
T144464-UN: Heater and Air Conditioner Control Panel

LEGEND:
1 - Fan Speed Increase Switch
2 - Monitor Display
3 - Air Conditioner (A/C) Switch
4 - OFF Switch
5 - Mode Switch
6 - Fan Speed Decrease Switch
To activate self diagnosis system, turn key switch to ON while pressing air conditioner (A/C) switch (3) and mode
switch (5).
To advance to next step, press fan speed increase switch (1).
To return to previous step, press fan speed decrease switch (6).
To exit, press OFF Switch (4) for three seconds.
1144
Step 0 Model Number— Upon activation, “Sd” will appear in the monitor display (2), indicating model number.
NOTE:
The system will automatically advance to Step 1 Display Check after five seconds.
Step 1 Display Check— The monitor display, display backlight and switch indicators should illuminate.
Step 2 Active Diagnostic Trouble Codes— The monitor display will show active diagnostic trouble codes. If
more than one active diagnostic trouble code is present they will be displayed in sequence.
NOTE:
If no active diagnostic trouble codes exist, “20” will be displayed.
-: Air Conditioning Diagnostic Trouble Codes
Diagnostic Trouble Code
Open Circuit Short

Circuit
Mix Door 21 -21
Mode Encoder 22 —
In-Cab Ambient Temperature 23 -23

Sensor
Outdoor Ambient Air 24 -24

Temperature Sensor
Coolant Temperature Sensor 25 -25
Solar Sensor 26 [When solar radiation sensor is in the shade, sensor indicates the -26
service code for open circuit.]
For detail information on diagnostic trouble codes See Air Conditioner Controller (ACF) Diagnostic Trouble Codes
. (Group 9001-40.)
1145
T144464-UN: Heater and Air Conditioner Control Panel

LEGEND:
2 - Monitor Display
4 - OFF Switch
5 - Mode Switch
Step 3 Inactive Diagnostic Trouble Codes— The monitor display will show inactive diagnostic trouble codes. If
more than one past inactive diagnostic trouble code exists, they will be displayed in sequence.
NOTE:
If no inactive diagnostic trouble codes exist, “30” will be displayed.
-: Air Conditioning Inactive Diagnostic Trouble Codes
Diagnostic Trouble Code
Open Circuit Short Circuit
Mix Door 21 -21
Mode Encoder 22 —
In-Cab Ambient Temperature Sensor 23 -23
Outdoor Ambient Temperature Sensor 24 -24
Coolant Temperature Sensor 25 -25
Solar Sensor — -26
To clear inactive diagnostic trouble codes press air conditioner (A/C) switch for three seconds. Air conditioner
(A/C) switch indicator will flash five times to indicate inactive diagnostic trouble codes are deleted. Normal
operation will resume after deleting diagnostic trouble codes.
For detail information on diagnostic trouble codes See Air Conditioner Controller (ACF) Diagnostic Trouble Codes
1146
. (Group 9001-40.)
T144489-UN: Air Conditioner Display

LEGEND:
1 - Fan Blade Indicator (4 used)
2 - Monitor Display
3 - Fresh Air Vent Switch
NOTE:
The sensor temperature can be displayed in either Celsius or Fahrenheit. See Step 6 to change
display type.
Step 4 Sensor Temperature— Temperature at the in-cab ambient temperature sensor (cab air temperature
sensor B42), outdoor ambient temperature sensor (ambient air temperature sensor B22), and engine coolant
temperature sensor (B4) will be indicated in the monitor display (2). Sensor temperatures automatically appear in
the display in sequence at three second intervals. To stop automatic display, press fresh air vent switch (3).
In-cab ambient temperature is displayed when one fan blade indicator (1) is illuminated.
Outdoor ambient temperature is displayed when two fan blade indicators (1) are illuminated.
Engine coolant temperature is displayed when three fan blade indicators (1) are illuminated. Temperature is
displayed as “H” when engine coolant temperature is above 21°C (70°F) or “L” when engine coolant temperature
is below 21°C (70°F).
1147
T144489-UN: Air Conditioner Display

LEGEND:
1 - Fan Blade Indicator (4 used)
2 - Monitor Display
Step 5 Component Operation Check— The system performs five checks to verify component operation (see
table below). Code indicated in monitor display (2) corresponds to component being checked. During each check,
the system will cycle through the operational sequence at ten second intervals. To go to next check, press fresh
air vent switch (3).
If air conditioner does not operate properly, a malfunction exists, and air conditioner must be replaced. See
Heater and Air Conditioner Remove and Install . (Group 1830.)
-: Component Operation Display Codes and Operational Sequence
Display
Component Operational Sequence Comments
Code
Air Mix 51 0% (Fully Closed) For damper positions, 0%, 50% and 100%, “C”,
Damper 50% [These are default settings in effect “5” and “H” are displayed to the right of decimal
during air conditioning component point respectively.
checks.]
100% (Fully Opened)
Fan 52 Low One, two, three and four fan blades are
Low Medium [These are default settings illuminated for the four fan speed settings.
in effect during air conditioning
component checks.]
High Medium
High
1148
Display
Component Operational Sequence Comments
Code
Air Vent 53 Front [These are default settings in effect Indicator corresponding to air vent selected
Location during air conditioning component illuminates.
checks.]
Front / Rear
Front / Foot
Foot
Fresh / 54 Circulation [These are default settings in Indicator corresponding to mode selected
Circulation effect during air conditioning component illuminates.
checks.]
Fresh Air
Air 55 Air conditioning ON [These are default Indicator illuminates when air conditioning is ON
Conditioner settings in effect during air conditioning and is extinguished when air conditioning is
component checks.] OFF
Air conditioning OFF.
TX1014855-UN: Air Conditioner Display

LEGEND:
NOTE:
Step 6 is accessed through special key sequence from step 5.
Step 6 Selection of Celsius or Fahrenheit Temperature Indication— Press and hold the air conditioner (A/C)
switch (2) and fan speed increase switch (1) for one second to access step 6.
The system can be set to display temperature in Celsius or Fahrenheit. Press the fresh air vent switch (3) to
alternate between Celsius and Fahrenheit.
1149
Press and hold the A/C switch and fan speed decrease switch (4) to return to step 5.
MT89988,0000055-19-20070103
1150
TX1016584-UN: Heater and Air Conditioner Component Location

LEGEND:
1 - Air Conditioner and Heater Controller
2 - Heater Core
3 - Evaporator
4 - Blower Motor
5 - Heater Hot Water Return Line
6 - Heater Hot Water Supply Line
7 - Evaporator-to-Compressor Low Pressure Line
8 - Receiver-Dryer-to-Evaporator High Pressure Line
9 - Condenser
10 - Receiver-Dryer
11 - High/Low Pressure Switch
12 - Ambient Air Temperature Sensor
13 - Condenser-to-Receiver-Dryer High Pressure Line
14 - Compressor-to-Condenser High Pressure Line
16 - Solar Sensor
MT89988,0000056-19-20070109
1151
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric
welding arc, electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will
develop high pressure, which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a
physician or hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system.
Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is
illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery
stations.
Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system
damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and
use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be
tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument
should be used before any testing or repair to system is performed.
Prism Pro Refrigerant Identification

Instrument.......JT02167A
To safely identify type and check purity of refrigerant
prior to recovery, recycling and recharging of A/C
systems.
MT89988,0000057-19-20060825
1152
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric
welding arc, electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will
develop high pressure, which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a
physician or hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system.
Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is
illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery
stations.
Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system
damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and
use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be
tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument
should be used before any testing or repair to system is performed.
Prism Pro Refrigerant Identification

Instrument.......JT02167A
To safely identify type and check purity of refrigerant
prior to recovery, recycling and recharging of A/C
systems.
MT89988,0000057-19-20060825
1153
NOTE:
Perform Visual Inspection of Components (Group 9031-25.) prior to diagnostics and tests. These
conditions may affect diagnostic and test results.
1 Visual Inspection of Components

1A Lines and Hoses Check

Action:
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?
LOOK/FEEL: Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to
prevent crushing or scuffing of hoses or lines?
Result:
YES:
Go to next check.
NO:
Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any
hoses or lines that will require replacement.
1B Air Conditioner Compressor Check

Action:
Inspect compressor.
LOOK/FEEL: Is belt properly tensioned on pulley?
LOOK/FEEL: Is belt in good condition, NOT frayed, worn, or glazed?
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?
LOOK/FEEL: Are electrical connections to compressor clean and tight? Is wiring in good condition?
1154
Result:
YES:
Go to next check.
NO:
Note any components that will require repair or replacement.
1C Condenser Check
Action:
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?
LOOK/FEEL: Are fins of core straight, NOT bent or damaged?
Result:
YES:
Go to next check.
NO:
Clean and straighten fins if necessary. Note any components that will require repair or replacement.
1D Engine Fan Check

Action:
Inspect engine fan.
LOOK/FEEL: Are fan blades in good condition, NOT worn, bent, broken, or missing?
LOOK/FEEL: Is fan securely installed?
Result:
YES:
Go to next check.
NO:
Note any components that will require repair or replacement.
1E Heater/Evaporator Core Check

Action:
Inspect heater/evaporator core.

1155
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?
LOOK/FEEL: Is condensation drain tube attached and in good condition, NOT kinked, damaged, or
clogged?
Result:
YES:
Go to next check.
NO:
Clean and straighten fins if necessary. Note any components that will require repair or replacement.
1F Freeze Control Switch Capillary Tube Check
Action:
Inspect freeze control switch capillary tube.
LOOK/FEEL: Is capillary tube straight, NOT kinked or broken?
LOOK/FEEL: Is capillary tube properly positioned and securely inserted in evaporator core?
Result:
YES:
Go to next check.
NO:
If capillary tube is kinked or broken, replace freeze control switch.
NO:
If capillary tube is improperly positioned, check freeze control switch.
1G Cab Air Filter Check

Action:
Inspect cab air filter.
LOOK/FEEL: Is filter clean and free of debris?
Result:
YES:
1156
Go to next check.
NO:
Replace cab air filter.
1H Cab Door and Window Seal Check
Action:
Open and close cab door and windows. Inspect seals.
LOOK/FEEL: Are seals present, properly installed, and in good condition?
LOOK/FEEL: Do door and windows contact seals evenly?
Result:
YES:
Check complete.
NO:
Adjust door and windows if necessary. Replace components as necessary.
MT89988,0000058-19-20070111
1157
-: Specifications
SPECIFICATIONS
Engine Speed Dial H (fast idle)
Auto-Idle Switch A/I Off
Power Mode Switch P (power) mode
Temperature Decrease Control Switch Position Maximum Cooling, “FC” will appear on display
Fan Speed High
-: Essential Tools
ESSENTIAL TOOLS
JT02045 R134A Deluxe Recovery/Recycling and Charging Station

JT02167A Prism Pro Refrigerant Identification Instrument
-: Service Equipment And Tools
Thermometer
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective
clothing.
IMPORTANT:
Use correct refrigerant recovery, recycling and charging stations. Never use refrigerant, hoses, fittings,
components or refrigerant oils intended for R12 refrigerant systems. Identify refrigerant before recovering,
recycling and charging system.
1. See Refrigerant Cautions and Proper Handling . (Group 1830.)
2. Stop the engine.
3. Identify refrigerant type using JT02167A Refrigerant Identification Instrument.
4. Connect refrigerant recovery/recycling and charging station. See R134a Refrigerant Recovery/Recycling
and Charging Station Installation Procedure . (Group 1830.)
5. Open both low and high pressure valves on refrigerant recovery/recycling and charging station.
6. Open cab door and windows.
7. Follow manufacturer's instructions when using the refrigerant recovery/recycling and charging system.
8. Start engine and run at specification.
1158

Engine Speed Dial Position H (fast idle)
Auto-Idle Switch Position A/I Off
Power Mode Switch Position P (power) mode
9. Press A/C switch ON. See Cab Heater and Air Conditioner . (Operator's Manual.)
10. Press lower half of temperature control switch until “FC” appears on the display.
11. Press upper half of temperature control switch until fan is running at high speed.
12. Check sight glass (if equipped) in receiver-dryer. Recharge air conditioning system if bubbles are seen in
the sight glass.
13. Run machine for at least 5 minutes.
14. Measure and record air temperature at condenser air inlet and at air ducts in air conditioning unit.
15. Observe low-side pressure and high-side pressure on gauges.
16. Compare pressures and air duct temperature readings to specifications shown.
NOTE:
Because low pressure switch is located on high pressure side of expansion valve, the
low pressure gauge readings shown do not affect the low pressure switch operating
range.
-: Low And High Pressures At Various Temperatures
Ambient Air Duct Low Pressure High Pressure

Temperature Temperature Gauge Gauge
10°C 5—11°C 58—278 kPa 213—758 kPa

50°F 41—52°F 0.58—2.78 bar 2.13—7.58 bar
8—40 psi 31—110 psi
13°C 5—11°C 38—258 kPa 312—857 kPa

55°F 41—52°F 0.38—2.58 bar 3.12—8.57 bar
6—37 psi 45—124 psi
16°C 5—11°C 36—256 kPa 371—916 kPa

60°F 41—52°F 0.36—2.56 bar 3.71—9.16 bar
5—37 psi 54—133 psi
18°C 5—11°C 44—264 kPa 414—959 kPa

65°F 41—52°F 0.44—2.64 bar 4.14—9.59 bar
6—38 psi 60—139 psi
21°C 5—11°C 55—275 kPa 461—1006 kPa

70°F 41—52°F 0.55—2.75 bar 4.61—10.06 bar
8—40 psi 67—146 psi
1159
Ambient Air Duct Low Pressure High Pressure

Temperature Temperature Gauge Gauge
24C 6—12°C 63—283 kPa 525—1070 kPa

75°F 43—54°F 0.63—2.83 bar 5.25—10.70 bar
9—41 psi 76—155 psi
27°C 7—13°C 66—286 kPa 617—1162 kPa

80°F 45—55°F 0.66—2.86 bar 6.17—11.62 bar
10—42 psi 90—169 psi
29°C 8—14°C 64—284 kPa 693—1288 kPa

85°F 46—57°F 0.64—2.84 bar 6.93—12.88 bar
9—41 psi 101—187 psi
32°C 9—15°C 58—278 kPa 803—1448 kPa

90°F 48—59°F 0.58—2.78 bar 8.03—14.48 bar
8—40 psi 116—210 psi
35°C 9—15°C 51—271 kPa 945—1640 kPa

95°F 48—59°F 0.51—2.71 bar 9.45—16.40 bar
7—39 psi 137—238 psi
38°C 9—15°C 51—271 kPa 1109—1854 kPa

100°F 48—59°F 0.51—2.71 bar 11.09—18.54 bar
7—39 psi 161—269 psi
41°C 9—15°C 64—284 kPa 1434—2079 kPa

105°F 48—59°F 0.64—2.84 bar 14.34—20.79 bar
9—41 psi 208—302 psi
17. Diagnose malfunction using Operating Pressure Diagnostic Chart. See Operating Pressure Diagnostic
Chart . (Group 9031-25.)
MT89988,0000059-19-20060828
1160
T144993-UN: A/C Compressor Clutch

LEGEND:
1 - Connector
1. Disconnect connector (1) from clutch.
2. Connect battery voltage to clutch connector pin with green wire.
3. Clutch solenoid should engage and will “click”.
4. If clutch solenoid does not engage, replace compressor. See Compressor Remove and Install . (Group
1830.)
5. If clutch solenoid engages, check harness.
MT89988,000005A-19-20060828
1161
1. Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system,
a small amount of oil is carried out with it.
2. A soap and water solution can be sprayed on the components in the system to form bubbles at the
source of the leak.
3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a
rate of 25 mm (1 in.) per second.
4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
MT89988,000005B-19-20060828
1162
IMPORTANT:
Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.
DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose
meeting SAE J2064 requirements.
When a component is disconnected from the system, special care should be given to inspecting hoses and tubing
for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or
fittings and cannot be removed by cleaning, then replace parts.
Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated
solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.
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.
MT89988,000005C-19-20170315
1163
See Check and Adjust A/C Belt . (Operator's Manual.)
MT89988,000005E-19-20060825
1164
-: Pressure Diagnostic Chart
Condition Low- High- Sight Suction Line Receiver- Liquid Discharge Discharge
side kPa side kPa Glass Dryer Line Line Air
(bar) (bar)
(psi) (psi)
Lack of Very Very Low Clear Slightly Cool Slightly Slightly Slightly Warm
Refrigerant Low Warm Warm Warm
Loss of Low Low Bubbles Cool Warm to Warm Warm to Slightly

Refrigerant Hot Hot Cool
High-side Low Low Clear Cool Cool, Cool, Hot to Slightly

Restriction Sweating Sweating Point of Cool
or or Restriction
Frosting Frosting
Expansion Valve Low Low Clear Cold, Sweating Warm Warm Hot Slightly
Closed or Frosting Cool
Heavily at Valve
Outlet
Loose Belt or High Low Clear Cool Warm Warm Warm Slightly
Compressor Cool
Failure
Condenser High High Clear to Slightly Cool to Hot Hot Hot Warm
Malfunction Occasional Warm
Bubbles
Refrigerant High High Bubbles Warm to Hot Warm Warm Hot Warm
Contaminated
and Air in
System
Expansion Valve High High Clear Cold, Sweating Warm Warm Hot Slightly
Open or Frosting Cool
Heavily
Plugged Normal High Clear Cool Warm Warm Hot Slightly

Condenser, Cool
Overcharge of
Refrigerant
Moisture in Normal Normal Clear Cool Warm Warm Hot Cool to

System (May (May Warm
Drop) Drop)
Heater Valve Normal Normal Clear Cool Warm Warm Hot Warm
Stuck Open
Lack of Normal Normal Occasional Warm to Hot Warm Warm Warm Slightly
Refrigerant and (No Bubbles Cool
Air in System Drop)
MT89988,000005F-19-20060825
1165
1166
Table of Contents
Section 9050: Reference Material

Group 05: Terminology Cross Reference Chart
1167
-: Terminology Cross Reference Chart
John Deere Service Information Term Alternate Term Used
Air Filter Restriction Switch Air Cleaner Restriction Switch
Ambient Air Temperature Sensor Outdoor Ambient Temperature Sensor
Arm In Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Arm: Bottom
Side)
Arm Out Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Arm: Rod Side)
Attenuator Hose Tail Hose
Boom Down Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Boom: Rod
Valve Side)
Boom Down Shockless Valve Shockless Valve
Boom Up Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Boom: Bottom
Side)
Boom Up Pressure Sensor Boom Raise Pressure Sensor
Bucket Curl Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Bucket: Bottom
Valve Side)
Bucket Dump Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Bucket: Rod
Valve Side)
Cab Air Temperature Sensor In Cab Ambient Temperature Sensor
Center Joint Rotary Manifold
Check Valve (lift check) Load Check Valve
Diagnostic Trouble Codes Error Codes, Fault Codes, Failure Codes
Engine Control Unit (ECU) Engine Control Module (ECM)
Engine Speed Dial Engine Control Dial or Engine RPM Dial
Front Attachment Pressure Sensor Dig and Swing Pressure Sensor
Hydraulic Pumps (pump 1, pump 2, pilot pump) Pump Device
Information Controller (ICF) ICX or ICF
Intercooler Charge Air Cooler
Light Lamp
Main Controller (MCF) MC, MCX
Main Relief and Power Digging Valve Main Relief Valve, System Relief Valve
Pilot Control Lever, Right/Left Control Lever, Right/Left
Pilot Shutoff Lever Pilot Control Shut-Off Lever
Pilot Pressure Regulating Valve Relief Valve, Pilot Relief Valve
1168
Pilot Shutoff Solenoid Valve Pilot Shut-off Valve
Pilot Signal Manifold Power Boost Switch, Signal Control Valve
Power Dig Switch Power Digging Switch
Pump 2 Flow Rate Limit Solenoid Valve Maximum Pump 2 Flow Rate Control Solenoid
Solar Sensor Solar Radiation Sensor
Solenoid Valve Manifold 4-Spool Solenoid Valve Unit
Starter Relay Starter Cut Relay
Swing Gearbox and Swing Motor Swing Device, Swing Reduction Gear
Swing Motor Make-Up Check Valve Make-Up Valve (Swing Device)
Switch Panel Switch Box
Travel Flow Combiner Pilot Valve Flow Combiner Valve Spool
Travel Motor Crossover Relief Valve Overload Relief Valve (Travel)
Travel Motor, Travel Park Brake, Travel Device Travel Device
Travel Park Brake Parking Brake
Travel Speed Switch Propel Speed Switch
LD30992,00005EC-19-20070122
1169
-: Terminology Cross Reference Chart
Air Filter Restriction Switch Air Cleaner Restriction Switch
Ambient Air Temperature Sensor Outdoor Ambient Temperature Sensor
Arm In Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Arm: Bottom
Side)
Arm Out Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Arm: Rod Side)
Attenuator Hose Tail Hose
Boom Down Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Boom: Rod
Valve Side)
Boom Down Shockless Valve Shockless Valve
Boom Up Circuit Relief and Anticavitation Valve Overload Relief Valve with Make-Up Function (Boom: Bottom
Side)
Boom Up Pressure Sensor Boom Raise Pressure Sensor
Bucket Curl Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Bucket: Bottom
Valve Side)
Bucket Dump Circuit Relief and Anticavitation Overload Relief Valve with Make-Up Function (Bucket: Rod
Valve Side)
Cab Air Temperature Sensor In Cab Ambient Temperature Sensor
Center Joint Rotary Manifold
Check Valve (lift check) Load Check Valve
Diagnostic Trouble Codes Error Codes, Fault Codes, Failure Codes
Engine Control Unit (ECU) Engine Control Module (ECM)
Engine Speed Dial Engine Control Dial or Engine RPM Dial
Front Attachment Pressure Sensor Dig and Swing Pressure Sensor
Hydraulic Pumps (pump 1, pump 2, pilot pump) Pump Device
Information Controller (ICF) ICX or ICF
Intercooler Charge Air Cooler
Light Lamp
Main Controller (MCF) MC, MCX
Main Relief and Power Digging Valve Main Relief Valve, System Relief Valve
Pilot Control Lever, Right/Left Control Lever, Right/Left
Pilot Shutoff Lever Pilot Control Shut-Off Lever
Pilot Pressure Regulating Valve Relief Valve, Pilot Relief Valve
1170
Pilot Shutoff Solenoid Valve Pilot Shut-off Valve
Pilot Signal Manifold Power Boost Switch, Signal Control Valve
Power Dig Switch Power Digging Switch
Pump 2 Flow Rate Limit Solenoid Valve Maximum Pump 2 Flow Rate Control Solenoid
Solar Sensor Solar Radiation Sensor
Solenoid Valve Manifold 4-Spool Solenoid Valve Unit
Starter Relay Starter Cut Relay
Swing Gearbox and Swing Motor Swing Device, Swing Reduction Gear
Swing Motor Make-Up Check Valve Make-Up Valve (Swing Device)
Switch Panel Switch Box
Travel Flow Combiner Pilot Valve Flow Combiner Valve Spool
Travel Motor Crossover Relief Valve Overload Relief Valve (Travel)
Travel Motor, Travel Park Brake, Travel Device Travel Device
Travel Park Brake Parking Brake
Travel Speed Switch Propel Speed Switch
LD30992,00005EC-19-20070122
1171
Table of Contents
Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools
1172
T142036-UN: 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.
TP97644,00000A0-19-20061027
1173
T142036-UN: 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.
TP97644,00000A0-19-20061027
1174
tm10076 - 200D and 200DLC Excavator

Technical Manual
MAIN SECTIONNS
Foreword
General Information
Safety
Diagnostics
Operational Checkout Procedure

Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
Monitor Operation
References
1175
Power Train
Theory of Operation
Hydraulic System
Theory of Operation
Tests
Heating and Air Conditioning

Theory of Operation
Tests
Reference Material
Dealer Fabricated Tools

Dealer Fabricated Tools
1176

TM10076 - John Deere 200D &amp; 200DLC Excavator Technical Manual - Operation and Test

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tm10076 - 200D and 200DLC Excavator Technical Manual

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Worksite Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostics

Main Controller (MCF) Diagnostic Trouble Codes

11000.02 - Abnormal EEPROM

11001.02 - Abnormal RAM

11002.02 - Abnormal A/D Conversion

11003.03 - Abnormal Sensor Voltage

11004.02 - Abnormal CAN Communication

11100.02 - Abnormal Engine Speed

11101.03 - Engine Control Dial Voltage High

11101.04 - Engine Control Dial Sensor Voltage Low

11200.03 - Pump 1 Delivery Pressure Sensor Voltage High

11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low

11202.03 - Pump 2 Delivery Pressure Sensor Voltage High

11202.04 - Pump 2 Delivery Pressure Sensor Voltage Low

11206.03 - Pump 1 Control Pressure Sensor Voltage High

11206.04 - Pump 1 Control Pressure Sensor Voltage Low

11208.03 - Pump 2 Control Pressure Sensor Voltage High

11208.04 - Pump 2 Control Pressure Sensor Voltage Low

11301.03 - Swing Pilot Pressure Sensor Voltage High

11301.04 - Swing Pilot Pressure Sensor Voltage Low

11302.03 - Boom Up Pilot Pressure Sensor Voltage High

11302.04 - Boom Up Pilot Pressure Sensor Voltage Low

11303.03 - Arm In Pilot Pressure Sensor Voltage High

11303.04 - Arm In Pilot Pressure Sensor Voltage Low

11304.03 - Travel Pilot Pressure Sensor Voltage High

11307.03 - Front Attachment Pilot Pressure Sensor Voltage High

11307.04 - Front Attachment Pilot Pressure Sensor Voltage Low

11400.02 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal

11400.03 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal

11400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Current Low

TM10076 - John Deere 200D & 200DLC Excavator Technical Manual - Operation and Test

TM10076 - John Deere 200D & 200DLC Excavator Technical Manual - Operation and Test

TM10076 - John Deere 200D & 200DLC Excavator Technical Manual - Operation and Test